2002 Arctic Cat 250, 300, 375, 400, and 500 ATV Service & Repair Manual (P/N 0436-005)
Arctic Cat Models Covered & Key Technical Specifications
Models: Arctic Cat ATV 250, 300, 375, 400, 500
Sub-models / Variants: 2x4, 4x4, Manual Transmission, Automatic Transmission
Trade Names: Arctic Cat
Model Years: 2002
Technical Data:
- Engine oil capacity (250): 3.9 L (4.1 U.S. qt)
- Engine oil capacity (300): 3.4 L (3.5 U.S. qt)
- Engine oil capacity (400): 3.08 L (3.25 U.S. qt)
- Engine oil capacity (500 Manual): 3.4 L (3.5 U.S. qt)
- Engine oil capacity (500 Automatic): 2.5 L (2.6 U.S. qt)
- Gas tank capacity: 17.98 L (4.75 U.S. gal)
- Tire inflation pressure (250/300): 0.35 kg/cm² (5 psi)
- Tire inflation pressure (400/500 Front): 0.32 kg/cm² (4.5 psi)
- Tire inflation pressure (400/500 Rear): 0.25 kg/cm² (3.5 psi)
- Spark plug (250/300): NGK DR7EA
- Spark plug (400/500): NGK CR6E
Arctic Cat Manual Features & Content Preview
This original OEM factory publication (P/N 0436-005) serves as the primary technical reference for the entire 2002 Arctic Cat ATV lineup. It covers the 250, 300, 375, 400, and 500 models across all drivetrain configurations, including the 2x4, 4x4, manual, and automatic transmission variants. Whether you are running routine diagnostics or completely overhauling the chassis, this manual documents the exact factory specifications required for the job. Please note that servicing ATV powertrains involves handling heavy components and combustible fluids. Always ensure you follow standard shop safety practices and use appropriate lifting equipment when accessing these assemblies.
- Factory-specified dimensions, capacities, and torque values for all engine, transmission, and chassis components
- Complete documentation of maintenance procedures, service intervals, and component removal sequences
- Detailed teardown charts for engine/transmission, top-side, left-side, and right-side assemblies
Engine and Transmission Breakdown
The manual details the complete component layout for the 250 through 500 engine series. It outlines the exact sequence for removing the engine and transmission from the frame. You will find extensive diagrams and specifications for dismantling the top-side, left-side, and right-side components. The text maps out the crankcase halves, center crankcase inspection points, and the systematic assembly of shifting cams, gear dogs, and drive units.
Need to access internal components? The documentation covers the removal of magneto rotors, idler gear assemblies, and gear shifting arms. It provides the exact specifications needed for the carburetor, recoil starter, stator assembly, and transmission-specific hardware. Additionally, you get the necessary clearance data for cylinder head maintenance, piston removal, and valve-tappet adjustments across all documented engine sizes.
Specification Highlights
Accurate fluid capacities and clearances are critical on the shop floor. The engine oil capacity for the 250 model is documented at 3.9 liters, while the 400 engine requires 3.08 liters. If you are servicing the ignition system on the 500, the manual specifies a spark plug gap of 0.7 to 0.8 mm.
Beyond basic maintenance, the publication includes comprehensive charts for load capacity ratings, viscosity requirements, and ignition timing. Detailed torque values and fluid capacity tables help you quickly identify the exact service requirements for your specific variant, ensuring precision during every rebuild.
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