Arctic Cat 250 2x4 / 300 2x4 / 300 4x4 / 400 4x4 / 500 2000 4x4 Factory Service Manual (PN 2256-223)

• 318 PDF pages across 11 files — a 2-page electronic index plus Sections 1–7 and 9–11 of Arctic Cat’s factory service manual, dated July 1999. The supplied set does not include Section 8, Steering/Frame, and printed engine pages 3-36 through 3-42 are absent.
• Model-specific material covers the 250 2x4, 300 2x4 and 4x4, 400 2x4 and 4x4, and 500 4x4 configurations through dedicated specifications, wiring diagrams, brake schematics, and driveline assemblies. The factory load chart specifically notes that there is no 500 2x4 model.
• Major engine and transmission repair content covers removal and installation, cylinder-head and valve work, piston and cylinder inspection, recoil-starter service, clutch and shift mechanisms, oil-pump and cam-chain work, crankcase separation, transmission shafts and gears, and final assembly checks.
• Fuel, lubrication, cooling, and electrical chapters detail carburetor overhaul, fuel-tank and valve service, oil-pump testing, 250/300 oil-cooler work, 400/500 liquid-cooling service, starter-motor repair, charging and ignition tests, and system-specific fault tracing.
• Driveline, suspension, and brake procedures include front-differential setup, drive-axle and CV-boot service, rear-gear and axle work, wheel hubs, hydraulic calipers, shocks, A-arms, swing arms, wheels, tires, and control adjustments.
• Workshop reference material includes model-specific wiring diagrams, oil-flow charts, exploded assembly views, condition/remedy troubleshooting charts, torque tables, fluid-capacity data, wear limits, clearances, adjustment specifications, and electrical test values.

Factory Repair Depth

This is shop-level service material, not an operator’s guide with a few maintenance pages added. The periodic-maintenance section covers valve/tappet adjustment, compression testing, engine oil, filter and strainer service, clutch adjustment, brake inspection and bleeding, coolant work, ignition timing, steering checks, and electrical-connection inspection. The engine section moves into major repair work by displacement group, including top-side disassembly, valve and piston inspection, left- and right-side component service, clutch inspection, shift-fork and groove measurement, crankshaft and transmission work, and crankcase reassembly.

The transmission material is built around the clutch, gearshift pedal, reverse-shift mechanism, shift forks, shafts, and internal gears. No separate automatic-transmission repair chapter or supplement is included in this file set.

Diagnosis, Diagrams, and Assembly Views

The electrical section provides separate wiring diagrams for the 250, 300 2x4, 300 4x4, and 400/500 configurations. It also covers the battery, RPM limiter, brake-light and gear-position switches, magneto, ignition coil, starter motor and relays, CDI unit, regulator/rectifier, lighting, and ignition-timing checks.

Other useful graphics include the 250/300 and 400/500 oil-flow charts, 300 4x4 front-gear and front-lock exploded assemblies, 400/500 front and rear gear and axle views, hydraulic-brake assembly schematics, and the 400/500 cooling-system layout. These drawings are tied to inspection, testing, disassembly, setup, and reassembly procedures rather than presented only as parts illustrations.

Driveline Setup and Variant Control

The front-differential coverage goes beyond removal and replacement. It includes internal disassembly, seal and bearing inspection, shim selection, gear-backlash checks, and tooth-contact pattern evaluation. Rear-gear and rear-drive layouts are not treated as interchangeable; the manual directs the technician to identify which style is being serviced and use the matching assembly schematic. That distinction matters when locating variant-specific washers, shims, and internal parts during assembly.

Suspension and running-gear coverage includes front and rear shocks, A-arms, 400/500 swing arms, wheel hubs, tires, and wheel inspection. Section 9 adds hand-brake lever and master-cylinder removal and replacement—the master cylinder itself is identified as non-serviceable—plus mechanical foot-brake work, throttle control, gearshift pedal, the 300 4x4 drive selector, reverse-shift lever and cable, speedometer, and indicator-light service.

Factory Tool References and Specifications

The procedures call out named Arctic Cat tools where they matter. Examples include the Valve Gap Adjuster (p/n 0444-092) for 250/300 engines, Valve Clearance Adjuster (p/n 0444-078) for 400/500 engines, Compression Gauge (p/n 0444-096), Oil Pressure Gauge (p/n 0444-039), Fluke Model 73 Multimeter (p/n 0644-191), Side Case Puller (p/n 0644-262), and Crankcase Separator/Crankshaft Remover (p/n 0444-009).

The specification pages are divided by engine displacement, while Section 10 provides separate 250/300 and 400/500 torque tables plus unit-conversion references. Together, these sections support engine, clutch, transmission, carburetor, cooling, charging, ignition, drive, suspension, brake, and control repair. Section 11 closes the manual with condition/remedy charts for engine, drive, fuel, electrical, steering/suspension, and brake faults.

The engine chapter flags piston-ring installation and cylinder fitting as damage-critical; forcing the cylinder over incorrectly positioned rings can damage the piston, rings, cylinder, or crankshaft assembly. It also identifies the starter-clutch shoe nut as left-hand thread, an easy detail to miss during repair. Securely support the ATV before axle or suspension work, isolate the electrical system where required, and control brake-fluid and cooling-system hazards before service begins.