Systems:
• General Information
• Periodic Maintenance / Tune-Up
• Engine
• Transmission
• Fuel System
• Lubrication System
• Cooling System
• Electrical System
• Drive System
• Suspension System
• Steering System
• Frame
• Controls
• Indicators
• Aids for Maintenance
• Troubleshooting
Electrical System Details:
Includes wiring diagrams, starter system, charging system (magneto, stator, rectifier, regulator), battery maintenance, lighting system, ignition system, and switch operation.
Suspension Steering Frame Coverage:
Includes front and rear suspension component inspection, repair, and adjustment, including struts, swingarms, and linkages. Steering system components, frame inspection, and wheel alignment procedures are also covered.
Controls Indicators Coverage:
Detailed information on throttle control, brake levers, gear shift mechanisms, dashboard indicators, and electrical switches.
Bodywork Plastics Coverage:
Information on fender removal and installation, plastic panel repair, and seat maintenance.
Frame And Chassis Coverage:
Includes inspection of frame welds, steering head bearing service, and handlebar mounting.
Procedures:
• Diagnosis
• Repair
• Rebuilding
• Refurbishing
• Restoration
• Routine Maintenance
• Tune-ups
• Component Overhauls
• Component Installation
• Troubleshooting and Problem Solving
• Fluid Changes
• Component Adjustments
Engine Procedures:
• Cylinder head removal and installation
• Piston and connecting rod service
• Crankshaft inspection and overhaul
• Valve clearance adjustment
• Camshaft timing
• Carburetor overhaul and jetting adjustments (main jet, pilot jet, slow jet)
• Fuel pump testing
• Cooling system service (radiator, hoses, pump)
• Lubrication system checks and oil pump service
Brake System Procedures:
Hydraulic brake system overhaul, pad replacement, caliper service, rotor inspection, and bleeding procedures.
Fuel Lubrication Cooling Procedures:
Procedures for fuel filter replacement, fuel line inspection, carburetor cleaning and adjustment, lubrication of pivot points, and coolant system flushing.
Electrical System Procedures:
Includes starter motor testing, battery charging system checks, light bulb replacement, ignition coil testing, and switch troubleshooting.
Suspension Procedures:
Includes front and rear shock absorber service, spring replacement, and linkage lubrication.
Depth:
Comprehensive. Covers all diagnostic and repair procedures in great detail. Suitable for DIY enthusiasts and professional technicians. Provides high-quality illustrations and step-by-step instructions.
Drive System Coverage:
Detailed information on drive shafts, CV boots, axle maintenance, differential service, and wheel bearing replacement.
Troubleshooting Depth:
Extensive troubleshooting section with common problems, symptom-based diagnostics, and step-by-step solutions for electrical, mechanical, and fuel system issues. Includes diagnostic error codes if applicable.
Frame Steering Coverage:
Includes frame inspection for damage, steering column and handlebar service, tie rod end adjustment, and wheel alignment specifications.
Transmission Overhaul Depth:
Detailed procedures for CVT clutch assembly disassembly, inspection, and reassembly, including variator weights and spring inspection.
Wheel And Tire Coverage:
Covers tire pressure specifications, wheel bearing maintenance, and lug nut torque specifications.
Engine Type:
Single-cylinder, 4-stroke (specific engine types vary by model, e.g., OHV, SOHC).
Displacement Range:
Approximately 249cc to 500cc (exact displacement for 250, 300, 375, 400, 500 models are detailed within the manual).
Power Torque Note:
Specific horsepower and torque figures for each engine displacement are detailed within the manual's specifications sections.
Fuel Delivery:
Carburetor (specific carburetor models and tuning instructions covered) and potentially Fuel Injection (EFI) on some higher-end models, as indicated by the 'efi' tag.
Efi Mention:
The inclusion of 'efi' in tags suggests that some models within the range may feature electronic fuel injection, with specific troubleshooting and service for EFI systems covered.
Oil Type:
Manual specifies recommended engine oil viscosity and specifications (e.g., SAE 10W-40, API SG or higher).
Cooling Method:
Liquid-cooled (radiator, coolant specifications, and flush procedures are covered).
Intervals:
Comprehensive service schedule detailing recommended intervals for oil changes, filter replacements, spark plug checks, valve adjustments, lubrication points, and general inspections.
Filter Replacement Intervals:
Recommended intervals for air filter cleaning/replacement and oil filter replacement.
Fluids:
• Engine Oil (viscosity, API rating)
• Coolant (type, mixture ratio)
• Brake Fluid (DOT specification)
• Gearcase Oil / Differential Oil (viscosity, type)
• CVT Belt Lube (if applicable)
Lubrication Capacities:
Fluid capacities for engine oil, coolant, and gearcases are provided for each model variant.
Common Problems:
The manual would address common wear items and potential issues for this model year, such as CVT belt wear, carburetor tuning difficulties, suspension component wear, and electrical system checks.
Carburetor Issues:
Specific guidance on common carburetor issues such as pilot jet clogging, mixture screw adjustment for optimal idle, and float bowl level settings.
Tune Up:
Detailed procedures for tune-ups including spark plug replacement, air filter cleaning/replacement, carburetor adjustment (idle speed, mixture screw), and ignition timing checks.
Brand Focus:
Arctic Cat has a long-standing history in powersports, particularly with snowmobiles and ATVs, known for ruggedness and off-road capability.
Model Lineup:
The 2002 lineup represents a significant period for Arctic Cat ATVs, with these displacements offering a range of power and capability for various utility and recreational purposes. The inclusion of 2x4 and 4x4 variants, along with different suspension types (FIS, ACT), highlights the model diversification.
Production Context:
Manufactured by Arctic Cat Inc. during a period of strong growth in the ATV market.
