2002 Arctic Cat ATV Service Manual
Technician-level documentation for Arctic Cat 250, 300, 375, 400 & 500 ATV Models 2002. PN 0436-005.
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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
Build 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
Technical Scope and Coverage for the 2002 Arctic Cat ATV
- Covers the 2002 Arctic Cat ATV 250, 300, 375, 400, and 500 models, including 2x4, 4x4, manual, and automatic transmission variants
- Original OEM publication with factory-specified dimensions, capacities, and torque values for engine, transmission, and chassis components
- Documents maintenance procedures, service intervals, and component removal for engine/transmission, top-side, left-side, and right-side assemblies
- Delivered as a direct download the moment payment clears
- Stored against your account so you can retrieve it after a hard-drive loss
- Full-text search finds any part number in seconds
- Suitable for printing individual sections for shop-floor use
- This 2002 factory publication serves as the primary technical reference for the entire 2002 Arctic Cat ATV lineup including all drivetrain configurations
Engine and Transmission Walkthrough
The 2002 Arctic Cat ATV service manual details the complete service progression for the 250, 300, 375, 400, and 500 engines. Sections cover the removal and installation of the engine/transmission from the frame, alongside extensive procedures for dismantling top-side, left-side, and right-side components. The text outlines the disassembly of crankcase halves, center crankcase component inspection, and the systematic assembly of shifting cams, gear dogs, and drive assemblies.
Guidance is provided for managing the carburetor, recoil starter, stator assembly, and transmission-specific components. The content covers the removal of magneto rotors, idler gear assemblies, and gear shifting arms, ensuring technicians have the correct sequence for internal component access. Procedures for cylinder head maintenance, piston removal, and valve-tappet clearance adjustment are provided for all documented engine sizes.
Specification Highlights
Engine oil capacity for the 2002 Arctic Cat ATV 250 is documented at 3.9 liters. The 2002 Arctic Cat ATV 400 engine oil capacity is specified at 3.08 liters. Spark plug gap for the 2002 Arctic Cat ATV 500 is documented at 0.7–0.8 mm. This official factory manual also provides detailed charts for load capacity ratings, viscosity requirements, and ignition timing specifications across all engine variants. Detailed torque values and fluid capacity tables assist in identifying exact service requirements for each variant.
Reference only — always consult a certified technician before performing service on this equipment. An official factory publication covering the 2002 Arctic Cat ATV 250–500, documenting detailed engine, chassis, electrical, and transmission service specifications for the 2002 model year.
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