Target Audience:
DIY enthusiasts, independent repair shops, and owners of 2002 Arctic Cat 2-Stroke snowmobiles.
Value Proposition:
Offers unparalleled completeness for servicing a wide range of 2002 Arctic Cat 2-stroke models, providing significant cost savings over dealership service.
Completeness:
Described as the 'Most Complete Service Repair Manual ever compiled by mankind' for this specific model year and engine type, emphasizing its comprehensiveness.
Accessibility:
Instant download format allows immediate access to repair and maintenance information.
Primary Coverage:
Comprehensive service and repair for 2002 Arctic Cat 2-Stroke Snowmobiles
Model List:
Bearcat W/T, Mountain Cat 500, Mountain Cat 570, Mountain Cat 600 EFI, Mountain Cat 600 EFI LE, Mountain Cat 800, Mountain Cat 800 LE, Mountain Cat 800 EFI, Mountain Cat 800 EFI LE, Mountain Cat 1000, Pantera 550, Pantera 600 EFI, Pantera 800 EFI, Panther 440, Panther 570 ESR, Panther 570 R, Thundercat, Z 370, Z 370 ES, Z 440, Z 440 ES, Z 570, Z 570 ESR, Z 570 SS, ZL 500, ZL 550, ZL 550 ESR, ZL 600 EFI, ZL 600 EFI ESR, ZL 600 EFI SS, ZL 800 EFI ESR, ZL 800 EFI SS, ZR 120, ZR 500, ZR 500 LE, ZR 600, ZR EFI, ZR 800, ZR 800 EFI, ZRT 600
Estimated Page Count:
Likely extensive, covering all listed models and systems.
Type:
Service Repair Manual
Engine:
Complete engine overhaul, including diagnosis, disassembly, inspection, and reassembly of internal components. Covers cylinder, piston, crankshaft, connecting rods, seals, gaskets, and cooling systems.
Fuel System:
Detailed procedures for carburetor tuning, jetting, cleaning, and repair. Covers fuel pump, fuel lines, filters, and fuel injection (EFI) systems if applicable to specific models.
Engine Electrical:
Ignition system diagnostics, stator, flywheel, magneto, CDI unit, spark plugs, and wiring harnesses.
Chassis Electrical:
Headlights, taillights, brake lights, battery charging system (rectifier/regulator), starter motor, switches, and general wiring diagrams.
Steering Body:
Handlebar assembly, steering post, tie rods, skis, body panels, plastics, fenders, and seat removal/installation.
Drive Train Brakes:
Clutch service (primary and secondary), drive belt inspection and replacement, chaincase, differential (if applicable), and brake system service (pads, rotors, hydraulic lines, master cylinder).
Track Rear Suspension:
Track inspection, alignment, and replacement. Rear suspension components, including shocks, springs, bogey wheels, and adjusters.
Maintenance:
Scheduled maintenance, oil changes, lubrication points, filter replacements, and general upkeep.
Troubleshooting:
Diagnostic procedures for common problems, including no-spark issues, starting problems, engine misfires, and electrical faults.
Repair:
Step-by-step instructions for major component repairs and overhauls.
Installation:
Procedures for installing new components and accessories.
Depth:
Comprehensive, covering everything from basic adjustments and fluid changes to complete engine rebuilds and electrical system diagnostics. High-quality diagrams and detailed instructions suitable for DIY enthusiasts and professional mechanics.
Engine Configuration:
2-Stroke (various displacements including 370cc, 440cc, 500cc, 550cc, 570cc, 600cc, 800cc, 1000cc, 120cc - specific configurations vary by model).
Horsepower Range:
Varies significantly by model, typically ranging from approximately 60 HP for smaller displacement engines to over 130 HP for larger displacement, high-performance models.
Torque Characteristics:
Not explicitly detailed but crucial for clutch engagement and overall performance, covered within the manual's procedures.
Fuel Type:
High-octane gasoline (typically 91 octane or higher recommended for 2-stroke engines), mixed with appropriate 2-stroke oil.
Carburetor Details:
Details on specific carburetor models (e.g., Mikuni VM series) and their adjustment procedures (idle speed, mixture screw, pilot jet, main jet) will be covered.
Efi Systems:
For EFI models, the manual will cover fuel injectors, throttle body, ECU, sensors, and fuel pump operation.
Type:
CVT (Continuously Variable Transmission) with a primary clutch and secondary clutch.
Reverse:
Some models may feature a reverse gear, detailed within the drive train section.
Clutch Service:
In-depth instructions on clutch maintenance, roller replacement, spring replacement, and clutch alignment are a key component of this manual.
Length Width Height:
Varies significantly by model (e.g., utility vs. trail vs. mountain). Specific dimensions are not provided but are critical for trailering and storage, and will be found within the manual.
Dry Weight:
Varies by model. Ranges typically from under 500 lbs to over 600 lbs.
Estimated Loaded Weight:
Will increase with rider, fuel, and accessories. Manual may provide GVWR if applicable.
Crash Test Results:
Not applicable for snowmobiles in the same manner as automobiles. Safety focus is on operational safety and rider protection.
Braking System:
Hydraulic disc brakes (front and rear on most models) are standard. Manual details maintenance and troubleshooting for optimal performance.
Operator Safety:
Manual emphasizes safe operating practices, proper maintenance, and understanding of vehicle capabilities to prevent accidents.
Display Features:
Basic instrument cluster including speedometer, tachometer, odometer, and warning lights. No advanced infotainment systems expected for this era.
Efi Systems:
Electronic Fuel Injection (EFI) was available on some higher-end models, offering improved fuel efficiency, throttle response, and altitude compensation.
Diagnostic Ports:
Manual will cover diagnostic procedures, potentially involving basic electrical testing and visual inspections, rather than OBD-II style connectivity.
Oil Change:
Critical for 2-stroke engines, involves checking/topping up injection oil and proper fuel/oil mixture. Specific intervals depend on usage, detailed in manual.
Clutch Inspection:
Regular inspection of drive and driven clutches, belt condition, and alignment is recommended at intervals often tied to mileage or operating hours.
Spark Plug Maintenance:
Regular inspection and gap adjustment of spark plugs for optimal combustion.
Engine Oil Type:
High-quality, JASO FD certified 2-stroke synthetic or semi-synthetic oil is essential for the oil injection system and fuel mix. Specific viscosity and brand recommendations will be detailed.
Coolant Type:
For liquid-cooled models, a specific ethylene glycol-based antifreeze with corrosion inhibitors is required. Manual will specify type and capacity.
Gearcase Oil:
Specific gear oil for the drive train/chaincase will be specified, typically a multi-viscosity gear oil.
Carburetor Fouling:
Common in 2-stroke engines due to oil and fuel residue; requires periodic cleaning and adjustment.
Drive Belt Wear:
Drive belts can wear over time and require regular inspection for cracks, fraying, and proper tension.
Suspension Bushings:
Wear on suspension bushings and bearings can lead to looseness and reduced handling performance.
Arctic Cat Legacy:
Arctic Cat is a long-standing and reputable manufacturer in the snowmobile industry, known for performance and innovation.
2002 Model Year:
The 2002 model year represented a period of continued development in Arctic Cat's snowmobile lineup, featuring advancements in engine technology, suspension, and rider comfort.
Manufacturing Origin:
Arctic Cat snowmobiles are typically manufactured in North America.
