Arctic Cat Snowmobile 2004 Service Manual Set (370–900 cc)

The two volumes bring engine and fuel-system repairs together with drivetrain and chassis work. Model-specific wiring indexes and the rear-suspension servicing chart help match each snowmobile to the appropriate harness diagrams and skid-frame repair procedure.

Coverage distinguishes fan- and liquid-cooled engines, Standard and Laydown layouts, carbureted and batteryless EFI systems, APV applications, and LX, EXT and Sno Pro configurations. The 120 and separate four-stroke models are outside this manual set.

PDF Text Search and Wiring Detail

Search and diagram labels: Service text is searchable across the chapter files, but many wiring labels in Sections 5 and 6 are embedded in images and cannot be found with text search. There are no embedded PDF bookmarks. Small wiring labels require zooming for comfortable reading.

The ZIP contains 12 printable PDFs: nine section files plus separate one-page cover, foreword and master contents files. The 644-page total includes those three introductory pages and five notes pages within the chapters.

Engine, Electrical and Chassis Service

The following is a selection of covered work, rather than a complete contents list. Other topics include storage preparation and after-break-in checks.

• Engine repair: Step-by-step engine removal and installation, disassembly and reassembly, Laydown top-side service, critical-component measurement and crankshaft inspection.

• Cooling and exhaust controls: Axial fan and belt service, Standard and Laydown water-pump repair, engine pressure testing, APV cleaning and adjustment, and the 500 cc ECT system.

• Carburetors and EFI: VM-style, Standard TM-style and Laydown TM-style carburetor overhaul, synchronization and tuning; batteryless EFI fault codes, sensor checks and analyzer routines.

• Electrical diagnosis: Ignition, resistance and peak-voltage tests, TPS adjustment, electric-start repair, warning and accessory circuits, and model-specific ignition, main and hood wiring diagrams.

• Drive and brakes: Drive-clutch and ACT roller driven-pulley repair, clutch alignment, belt setup, chain-case service, reverse-linkage adjustment, and hydraulic and mechanical brake work.

• Steering and suspension: AWS V and AWS VI steering and body procedures, track removal, tension and alignment, skid-frame repair and rebuildable-shock service.

Designed for service personnel, this set is suited to technicians and experienced mechanics equipped for precision measurement, electrical testing, clutch and brake work, and nitrogen-charged shock service.

Engine Service and Component Overhaul

Internal repair procedures are separated for the 370/440, 550, 570, 600 Standard, 800/900 and 500/600/700 Laydown engine groups. Inspection covers cylinder heads, cylinders, pistons and rings, reed assemblies, crankcases, crankshaft bearings, connecting-rod small ends and sealing surfaces.

Engine assembly schematics, torque-pattern views, piston-travel charts, cylinder-head volume tests, piston replacement data and crankshaft repair dimensions support rebuild and machine-shop evaluation. Named equipment includes the Pressure Testing Kit P/N 0144-127 and V Blocks P/N 0644-022.

Related procedures cover cooling-system filling, thermostat inspection, recoil-starter overhaul, and oil-injection pump synchronization and bleeding.

The Laydown APV instructions flag incorrect exhaust-valve orientation as a cause of severe engine damage. Crankshaft assembly cautions also link misaligned bearing locating holes and retaining pins to poor crankcase sealing and engine damage.

Fuel-System Testing and ECU Diagnosis

Carburetor references include model- and altitude-specific specifications, main-jet selection, choke and throttle cable adjustment, and fuel-system troubleshooting. Batteryless EFI coverage explains fail-safe operation, fuel-pressure and injector checks, ECU memory functions and the Kokusan troubleshooting sequence.

Current-fault and memory-diagnosis routines help investigate intermittent sensor complaints. The EFI Analyzer P/N 0644-342, Update Harness Kit P/N 0644-341 and Laydown EFI Analyzer Update Kit P/N 0637-243 are identified, with separate component tests and air- and water-temperature voltage/resistance charts.

ECU coverage concerns diagnosis and replacement, rather than internal ECU repair. On EFI models, the TPS is not a separate service part; the throttle body and sensor are replaced together.

Starting, Warning Circuits and Harness Diagrams

Electric-start material includes starter-motor disassembly, inspection and reassembly. Additional tests address low-oil and high-temperature warnings, fuel gauges and senders, electric fuel pumps, brake-light switches, handlebar and thumb warmers, and passenger handwarmers.

The wiring indexes identify the appropriate ignition, main and hood harness diagrams, including dedicated Firecat 600 EFI (EB) drawings.

Drivetrain, Brake and Suspension References

Drive-system references cover altitude calibration, clutch offset and center distance, chains and sprockets, belt specifications and component torque tables. Drivetrain schematics distinguish arrangements with and without reverse; hydraulic caliper and master-cylinder repair, brake bleeding and mechanical quick-adjust brake service have dedicated procedures.

Clutch tool references include the Drive Clutch Puller P/N 0644-207 and Drive Clutch Spanner Wrench P/N 0644-136.

Suspension references include slide-rail, front-arm, rear-arm and idler-wheel schematics, track setup, shock valve stacks and piston-depth charts. IFP, position-sensitive and remote-reservoir shock procedures include pressurization information and the Shock Inflation Needle P/N 0644-158.

The manual's safety coverage addresses ignition sources during fuel-system repair, pressure discharge before gas-shock service, approved brake-fluid handling, secure support for raised machines, and moving-track precautions.

APV Cable and Handwarmer Test Examples

APV cable data gives a center length of 30.1 mm ±1 mm for the 600 cc Standard engine and 34.5 mm ±1 mm for APV-equipped 500/600/700 cc Laydown engines. Separate adjustment procedures address cable routing and matched cable lengths.

The passenger handwarmer element test specifies 7.6–9.2 ohms at a room temperature of 20°C (68°F), tying the resistance check to a defined test temperature.