🏷️ Basic Information

Make:

Arctic Cat

Model:

Snowmobile (2004 Model Year)

Model Variants Covered:

AC 440 SNO PRO, BEARCAT 570, BEARCAT WIDE TRACK, FIRECAT 500, FIRECAT 600, FIRECAT 600 EFI, FIRECAT 700, FIRECAT 700 EFI, KING CAT 900, MOUNTAIN CAT 570, MOUNTAIN CAT 600 EFI, MOUNTAIN CAT 800 EFI, MOUNTAIN CAT 900, MOUNTAIN CAT 900 EFI, PANTERA 550, PANTERA 600 EFI, PANTERA 800 EFI, PANTHER 370, PANTHER 570, SABERCAT 500, SABERCAT 600, SABERCAT 600 EFI, SABERCAT 700 EFI, T660, T660 TURBO, Z 370, Z 440, Z 570, ZR 120, ZR 900, ZR 900 EFI

Year:

2004

👋 Introduction

Purpose:

To provide comprehensive technical guidance for servicing, repairing, and maintaining 2004 Arctic Cat snowmobiles, aimed at both DIY enthusiasts and professional mechanics.

Value Proposition:

Offers dealership-level technical information at an economical price, enabling owners to perform a wide range of maintenance and repairs, thus reducing reliance on costly dealership services.

Content Highlight:

Includes hundreds of photos and wiring diagrams for clear procedural guidance, covering all systems from engine to bodywork.

Document Origin:

This is the same manual utilized by Arctic Cat dealer technicians.

📋 Manual Details

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF Download

Target Audience:

Do-it-yourselfer and Experienced Mechanic

Coverage Level:

Complete Service, Repair, and Maintenance

📖 Manual Coverage

Engine Systems:

2-Stroke Engine Variants (Carbureted & EFI), 4-Stroke Engine Variants, Engine Disassembly/Reassembly, Cooling Systems (Liquid), Oil Systems, Arctic Power Valve (APV) System, Exhaust Controlled Timing (ECT) System, Turbocharger/Intercooler Systems, Water Pump, Recoil Starter, Air Intake Assembly

Fuel Systems:

Carbureted Fuel Systems, EFI Fuel Systems, Fuel Pump, Fuel Tank

Electrical Systems:

Ignition Systems (Transistorized, 2-Stroke), Throttle Position Sensor, Wiring Harnesses, Voltage Regulators, Chassis Control Units, Servomotors, Potentiometers, Low-Oil Light Sensor, Coolant Temperature Sensor, Fuel Gauge, Electric Fuel Pump, Ignition Key Switch, Starter Motor, Magneto, Brakelight Switch, Headlight Dimmer Switch, Handlebar/Thumb Warmers, Passenger Handwarmers, Seat Heater, Speedometer Sensor, Reverse Alarm Switch, Shift Actuator

Drivetrain And Suspension:

Drive Chain, Drive Sprockets, Driveshaft, Drive Clutch, Driven Pulley, Drive Belt, Gear Cases, Rear Suspension (Skid Frame, ACT Shocks, Fox Air Shocks, Fox Zero Pro Shocks), Front Suspension (Skis, Tie Rods, Spindles, Shock Absorbers, Sway Bars), Track Systems (Tension, Alignment)

Braking System:

Hydraulic Brake System, Brake Lever, Master Cylinder Assembly, Brake Disc

Bodywork And Controls:

Steering Post, Ski Alignment, Console, Belly Pan, Front Bumper, Gas Tank, Seat Assembly, Taillight/Brakelight, Windshield, Backrest/Rack, Tunnel, Rear Bumper, Snowflap, Headlight Assembly

General Specifications:

Includes general specifications like snowmobile identification, recommended gasoline and oil, break-in procedures, high altitude operation, and torque conversions.

Efi Components:

Detailed coverage of EFI systems including throttle valve angle specifications, fuel pump specifications, and troubleshooting for EFI related components.

Turbocharger:

Specific section dedicated to Turbocharger and Intercooler systems for models equipped with this technology (e.g., T660 TURBO).

Maintenance Procedures:

General Maintenance, Break-In Procedures, Drive Chain Lubrication, Preparation for Storage, Preparation after Storage, After Break-In Checkups (100/600 Miles), Oil Changes, Spark Plug Removal/Installation, Compression Checks, Valve Servicing, Cooling System Maintenance, Track Tensioning and Alignment

Repair Procedures:

Complete Engine Disassembly and Reassembly, Carburetor Service, EFI System Diagnosis and Repair, Turbocharger Servicing, Water Pump Repair, Starter Motor Repair, Ignition System Repair, Suspension Component Rebuilding (Shocks, Springs), Brake System Overhaul, Drive Clutch/Driven Pulley Service, Track Troubleshooting and Repair

Troubleshooting:

Engine Troubleshooting (2-Stroke Carbureted, 2-Stroke EFI, 4-Stroke), Electrical System Troubleshooting, Drive Train Troubleshooting, Track Troubleshooting, Hydraulic Brake System Troubleshooting, Drive Clutch/Driven Pulley Troubleshooting, Drive Belt Troubleshooting, Servomotor Troubleshooting

Assembly Schematics:

Includes assembly schematics with torque specifications for general bolts and specific components.

Suspension Servicing:

Detailed procedures for servicing rear suspension components, including ACT shocks, and rebuilding/recharging Fox Air Shocks and Fox Zero Pro Shock Absorbers.

Electrical Testing:

Extensive electrical testing procedures for various sensors, switches, actuators, and components, including handlebar and thumb warmer elements.

Depth Of Information:

Detailed step-by-step instructions for complete disassembly and reassembly, including hundreds of illustrations, diagrams, and schematics.

Diagnostic Capabilities:

In-depth diagnostic procedures for various systems, including electrical component testing, fuel system testing, and engine performance checks.

Specific Data Provided:

Torque specifications, fluid capacities and specifications, engine specifications, electrical specifications, and dimensional data.

Diagnostic Tools:

References component testing procedures like peak voltage tests, electrical resistance tests, and voltage regulator tests, implying the use of standard automotive diagnostic tools.

Technical Conversions:

Includes useful conversion charts for Fractions/Decimals, MM/IN, and Torque (ft-lb/N-m) to facilitate accurate work.

📊 Manual Specifications

File Format:

PDF

Requirements:

Adobe PDF Reader

Searchability:

PDF format with bookmarking implies good navigability and potential for text search within the document.

Quality:

High quality

Features:

Fully Bookmarked, Printable

Binding:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

Operating Systems:

All Windows and Mac Computers

Completeness:

The manual is described as 'Complete Service Repair Manual' covering 'All systems, maintenance and repairs'.

⚙️ Engine Specifications

Engine Types:

Various 2-Stroke (Carbureted and EFI) and 4-Stroke engine displacements including 120cc, 370cc, 440cc, 500cc, 550cc, 570cc, 600cc, 660cc, 660cc Turbo, 700cc, 800cc, 900cc, 1000cc.

Performance Data Availability:

Detailed engine specifications, including cylinder head volume, piston travel charts, crankshaft runout/repair specifications for 2-stroke engines, and torque specifications for various engine components.

Ignition Timing:

Provides Ignition Timing Specifications for 2-stroke engines, crucial for optimal performance and engine health.

Fuel System Types:

Covers both Carbureted and Electronic Fuel Injection (EFI) systems, including fuel pump specifications and carburetor specifications.

Specific Engine Coverage:

Detailed sections for Engine - 120, Engine - 570/F 570/T570, Engine - 500/600, Engine - 700/800/1000, Engine - 370/440/550/570, Engine - 900/1000, Engine - 660/660 T.

🔧 Transmission

Transmission Type:

Continuously Variable Transmission (CVT) systems are standard on most models, utilizing drive and driven clutches.

Gear Reduction:

Manual covers gear case performance calibrations and drive system torque specifications.

Drive Belt Specifications:

Includes Arctic Cat drive belt dimensions and troubleshooting for drive belts.

📐 Dimensions

General Dimensions:

The manual provides specifications for various body components including skis, windshields, tunnels, and bumpers, but specific overall dimensions are model-dependent.

Dry Weight:

Dry weight varies significantly by model. Refer to individual model specifications within the manual for precise figures.

Towing Capacity:

N/A (Snowmobiles are not typically rated for towing capacity in the automotive sense).

🛡️ Safety Features

Crash Test Results:

N/A (Snowmobiles are not subject to automotive crash test ratings like NHTSA or IIHS).

Safety Systems:

Manual covers operation and troubleshooting of systems like the emergency stop switch, brake light switch, and ignition systems.

Component Safety:

Focuses on the safe servicing and operation of components such as the steering system, braking system, and body structure for rider protection.

💡 Technology Features

Instrumentation:

Covers speedometer sensor testing, indicating integrated electronic instrumentation for speed and potentially other vehicle data.

Control Systems:

Details systems like the Arctic Power Valve (APV) and Exhaust Controlled Timing (ECT) for optimized engine performance and emissions control.

Wiring Diagrams:

Includes comprehensive snowmobile wiring diagrams for 2004 models, crucial for diagnosing and repairing electrical systems.

🔧 Maintenance

Initial Service:

The manual details an 'After Break-In Checkup' at 100 miles for 2-stroke and 600 miles for 4-stroke engines.

Periodic Maintenance:

Covers regular maintenance items such as checking and topping off fluids, lubrication, inspection of drive belts, track tension, and suspension components.

Engine Oil 2 Stroke:

Recommends specific Arctic Cat 2-stroke oils and notes oil consumption specifications. Refer to specific model sections for exact oil mix ratios or injection oil types.

Engine Oil 4 Stroke:

Manual details oil change procedures and implies specific oil grades suitable for 4-stroke engines. Specific viscosity and API service classifications should be consulted from model-specific sections.

Gearcase Oil:

Covers drive system components including gear cases, implying specific lubricant requirements for optimal performance and longevity.

Coolant Specifications:

Manual includes information on the liquid cooling system, indicating the need for appropriate coolant types, which would typically be ethylene glycol-based antifreeze.

Brake Fluid:

The manual covers the hydraulic brake system, indicating the need for appropriate brake fluid (typically DOT 3 or DOT 4) for hydraulic brake systems.

Common Problems Addressed:

The manual's troubleshooting sections are designed to address common issues encountered with engine performance, electrical systems, drive train components, and suspension.

📚 Vehicle History

Manufacturer:

Arctic Cat is a long-standing American manufacturer of snowmobiles and ATVs, known for its performance-oriented designs and innovation in the powersports industry.

2004 Context:

The 2004 model year saw Arctic Cat offering a diverse range of snowmobiles, from lightweight trail sleds to powerful mountain and utility models, often featuring advanced technologies like EFI and independent front suspension.

Manufacturing Location:

Arctic Cat snowmobiles are historically manufactured in the United States.

🏆 Awards & Recognition

Industry Recognition:

While specific awards for the 2004 model year are not detailed in the product description, Arctic Cat has a history of receiving accolades for its snowmobile designs and performance.

Manual Quality Rating:

High (as indicated by 'High quality - Fully Bookmarked - Printable' and its use by dealer technicians).