🏷️ Basic Information

Make:

Arctic Cat

Product Type:

Snowmobile Repair Manual

Product Format:

Downloadable PDF

Model Year:

2002

👋 Introduction

Market Niche:

Essential resource for owners and service centers of 2002 Arctic Cat snowmobiles, offering factory-level repair and maintenance data.

Competitor Alternatives:

Third-party aftermarket manuals may exist but often lack the precision and completeness of OEM factory documentation. This manual aims to replicate the original factory service manual.

Digital Access:

Instant download provides immediate access to repair information, eliminating shipping delays and the risk of damaging physical manuals in the field.

Lifetime Policy:

Lifetime Protection Policy ensures replacement of the manual if lost or damaged, offering long-term value.

Original Equipment Manufacturer:

This manual is presented as an OEM manual or factory authorized reprint, ensuring the highest level of accuracy and detail as originally provided by Arctic Cat.

Diy Benefit:

Empowers snowmobile owners to perform their own maintenance and repairs, saving money on labor costs and gaining a deeper understanding of their machine.

📋 Manual Details

Covered Models:

Bearcat 550, Mountain Cat 1000, Mountain Cat 500, Mountain Cat 570, Mountain Cat 600, Mountain Cat 800, Pantera 550, Pantera 600, Pantera 800, Panther 440, Panther 570, Thundercat, Z 370, Z 440, Z 570, ZL 500, ZL 550, ZL 600, ZL 800, ZR 120, ZR 500, ZR 600, ZR 800, ZRT 600

Estimated Page Count:

Highly variable per model, estimated 400-700 pages total for comprehensive coverage

Manual Type:

OEM Shop / Service / Repair Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Engine:

General Information, Engine Removal and Installation, Engine Specifications, Fuel System, Lubrication and Cooling System, Intake & Exhaust

Drivetrain:

Transmission, Drive Chain & Sprockets

Chassis And Suspension:

Steering System, Shocks, Body Work

Electrical:

Electrical System

Fuel System Details:

Carburetor jetting, float bowl adjustment, fuel pump testing, fuel line routing and inspection, fuel filter replacement. Specific procedures for Mikuni TM40, VM34, or similar carburetors used by Arctic Cat.

Cooling System Details:

Radiator inspection and cleaning, coolant flush and replacement, water pump seal inspection and replacement, thermostat testing and replacement, fan operation (if applicable).

Electrical System Details:

Stator and flywheel testing, ignition coil testing, CDI unit function, lighting circuits, starter motor operation, battery maintenance, wiring diagrams for all models covered.

Track And Suspension Maintenance:

Track alignment and tension adjustment, lubrication of suspension pivot points, inspection of track lugs and studs for damage.

Maintenance:

Routine Maintenance, Service Intervals

Repair:

Component Repair, System Troubleshooting

Diagnostics:

Advanced Troubleshooting

Engine Rebuild:

Complete engine disassembly, inspection of pistons, rings, cylinders, crankshaft, connecting rods, bearings. Reassembly with torque specifications and clearances.

Suspension Repair:

Front and rear suspension component inspection (shocks, trailing arms, skis, torsion springs, sway bars), shock absorber rebuilding or replacement, and alignment adjustments.

Steering System Repair:

Steering post lubrication and adjustment, tie rod end replacement, spindle inspection, ski alignment procedures.

Bodywork And Plastics:

Installation and removal of body panels, snow flaps, seat, windshields. Repair of plastic components.

Depth:

Comprehensive factory-level repair and maintenance procedures suitable for professional technicians and experienced DIY enthusiasts.

Diagnostic Charts:

Includes symptom-based troubleshooting charts to help diagnose common problems related to starting, running quality, power loss, and electrical issues.

Torque Specifications:

Precise torque values for all critical fasteners throughout the vehicle, ensuring correct assembly and preventing component failure.

Special Tools:

Lists any specialized tools recommended or required for specific repair procedures, such as clutch holding tools, piston ring compressors, or flywheel pullers.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Searchability:

The PDF is designed to be text-searchable, allowing users to quickly find specific terms, part numbers, or procedures.

Print Quality:

High-resolution scans, suitable for printing individual pages or the entire manual. Text is searchable within the PDF.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Family 2002 Arctic Cat:

Arctic Cat engines utilized a range of displacements, including but not limited to: 544cc (Suzuki-based), 600cc (Rotax-based and Arctic Cat's own designs), 800cc, 1000cc, and potentially smaller 370/440cc variants. Specific engine types (carbureted, EFI, 2-stroke, 4-stroke where applicable) are detailed within the manual for each model.

Engine Types Covered:

Primarily 2-stroke twin-cylinder engines, including carbureted and potentially early EFI systems. Some models might feature larger displacement 2-stroke triples or twins, or potentially 4-stroke engines depending on the specific model within the 2002 lineup.

Performance Details:

Horsepower and torque figures vary significantly across the listed models and engine displacements. The manual provides detailed specifications, including power curves and tuning parameters for each specific engine application.

Fuel System Components:

Covers carburetor specifications (Mikuni, Keihin), fuel pump operation, fuel filters, and potential fuel injection systems for applicable models. Includes adjustment procedures and troubleshooting.

Carburetor Rebuild:

Detailed instructions for carburetor disassembly, cleaning, inspection, and reassembly with new gaskets and O-rings. Jetting charts and adjustment procedures are included.

🔧 Transmission

Transmission Type:

CVT (Continuously Variable Transmission) with Arctic Cat's TEAM or Arctic Cat branded clutch systems. Includes primary and secondary clutch service, belt replacement, and calibration.

Optional Transmission Types:

N/A (CVT was standard for these models)

Clutch Service:

Detailed procedures for primary and secondary clutch disassembly, inspection, cleaning, spring replacement, weight adjustment, and belt inspection/replacement.

📐 Dimensions

Length Width Height:

Varies significantly by model (e.g., trail, mountain, crossover). Manual will contain specific dimensions for each model covered.

Dry Weight:

Varies by model, from approximately 450 lbs to over 600 lbs. Manual provides exact dry weights and Gross Vehicle Weight Ratings (GVWR).

🛡️ Safety Features

Safety Standards:

Covers safety-related components and their proper function, including braking systems, steering mechanisms, and emergency shut-off switches. No formal crash ratings apply to snowmobiles in the same way as automobiles.

Active Safety Features:

Focuses on the correct operation and maintenance of headlights, taillights, brake lights, and kill switches.

Passive Safety Features:

Manual covers proper operation of seat belts (if equipped on certain utility models), hand warmers, thumb warmers, and track/suspension integrity for stable operation.

💡 Technology Features

Infotainment Features:

Basic analog gauges (speedometer, tachometer, engine temp, fuel level), handlebar-mounted controls. Advanced infotainment systems were not typical for this era of snowmobiles.

Driver Assistance Features:

No electronic driver assistance systems. Focus is on mechanical integrity and rider skill.

Connectivity Features:

N/A

🔧 Maintenance

Initial Service:

Break-in service typically around 20-50 hours or 100-250 miles, involving clutch adjustment, track tension check, and coolant level verification.

Regular Maintenance Intervals:

Varies by component: Spark plugs every 2,000-3,000 miles, drive belt inspection every 500-1,000 miles (or annually), suspension lubrication every 500-1,000 miles, engine oil/filter changes (for 4-stroke models, if applicable) every 1,000-2,000 miles or annually. Two-stroke specific maintenance includes exhaust port cleaning and checking crank seals.

Chaincase Lubrication:

Gearcase oil change recommended annually or every 1,000-2,000 miles. Inspection for leaks and proper level.

Engine Oil:

For 2-stroke engines: Pre-mix or injection oil meeting API-TC or JASO FD/FB specifications (e.g., Arctic Cat APV Synthetic 2-Stroke Oil, or equivalent). For 4-stroke engines (if applicable): SAE 0W-40 or 5W-30 synthetic engine oil meeting API SJ or higher, and JASO MA standards.

Coolant:

Ethylene glycol-based antifreeze with corrosion inhibitors, mixed at a 50/50 ratio with distilled water. Capacity varies by model, typically 1.5-2.5 liters.

Gearcase Oil:

Arctic Cat Gearcase Lubricant or equivalent SAE 80W-90 hypoid gear lubricant. Capacity typically around 250-350 ml.

Brake Fluid:

DOT 3 or DOT 4 brake fluid, depending on the specific hydraulic brake system used by Arctic Cat for 2002 models. Manual will specify.

Common Wear Items:

Drive belts (prone to wear and breakage), clutch rollers and buttons, hyfax (wear on the runners), shock seals, and headlight bulbs are common wear items requiring regular inspection and replacement.

Engine Specific Considerations:

For early 2-stroke Arctic Cat engines, ensuring proper oil injection function and avoiding lean conditions is critical to prevent piston damage. Exhaust power valve function can also be a maintenance point.

📚 Vehicle History

Arctic Cat Heritage:

Arctic Cat has a long-standing history in snowmobile manufacturing, known for performance-oriented machines and innovation in suspension and engine technology.

2002 Lineup Context:

The 2002 model year represented a period where Arctic Cat offered diverse platforms for various riding styles, from dedicated mountain sleds (Mountain Cat) to versatile crossover and trail machines (Bearcat, Pantera, ZR, ZL, Z). The Thundercat was a hallmark of high-performance, with large displacement engines.

Manufacturing Location:

Arctic Cat snowmobiles are historically manufactured in Thief River Falls, Minnesota, USA.