2004 Arctic Cat Snowmobile 370 cc, 440 cc, 500 cc, 550 cc, 570 cc, 600 cc, 700 cc, 800 cc, 900 cc Factory Service Manual (P/N 2256-932)

• Model and engine coverage: Covers 2004 two-stroke Bearcat, Firecat, King Cat, Mountain Cat, Pantera, Panther, Sabercat, Z, and ZR snowmobiles from 370 cc through 900 cc. The set includes fan- and liquid-cooled engines, Standard and Laydown layouts, carbureted and batteryless EFI systems, APV applications, and LX, EXT, and Sno Pro packages, plus separate Firecat 600 EFI early-build electrical diagrams. The 120 and separate four-stroke models are outside this manual.

• Engine repair: Provides configuration-specific engine removal and installation, complete disassembly and reassembly, top-side service, critical-component inspection and measurement, crankshaft runout checks, engine pressure testing, water-pump repair, cooling-system service, and APV adjustment.

• Fuel and electrical diagnosis: Distinguishes VM-style, Standard TM-style, and Laydown TM-style carburetors, with overhaul, synchronization, and tuning procedures. Batteryless EFI coverage includes self-diagnostic codes, ECU and sensor tests, EFI Analyzer routines, TPS checks, ignition diagnosis, and resistance and peak-voltage testing.

• Drive and brake work: Details drive-clutch and ACT roller driven-pulley repair, clutch alignment and belt setup, chain cases with and without reverse, reverse-linkage adjustment, driven-shaft service, hydraulic caliper and master-cylinder repair, brake bleeding, and mechanical quick-adjust brake service.

• Chassis and suspension repair: Separates AWS V and AWS VI steering and body procedures, maps each model to the correct skid-frame schematic and rear-suspension repair procedure, and covers track removal, tension and alignment, shock rebuilding, IFP and position-sensitive shocks, remote reservoirs, and shock pressurization.

Issued in September 2003, this 644-page PDF set contains Arctic Cat's two-volume service manual in nine numbered sections. The foreword states that the manual was designed for service personnel. Its depth is best 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

The engine section divides removal, teardown, assembly, and installation by twin fan-cooled, Standard liquid-cooled, and Laydown configurations. Internal repair procedures are further separated for the 370/440, 550, 570, 600 Standard, 800/900, and 500/600/700 Laydown groups. Inspection material addresses cylinder heads, cylinders, pistons and rings, reed assemblies, crankcases, crankshaft bearings, connecting-rod small ends, and sealing surfaces. Cylinder-head volume tests, piston replacement data, piston-travel charts, and crankshaft repair dimensions support rebuild and machine-shop evaluation.

Related systems receive their own factory procedures. These include axial fan and belt service, Standard and Laydown water-pump repair, cooling-system filling and thermostat inspection, recoil-starter overhaul, oil-injection pump synchronization and bleeding, APV cable adjustment and valve cleaning, and the 500 cc Exhaust Controlled Timing system.

On Laydown engines, reversing an APV exhaust valve can cause severe engine damage; its long side must face the cylinder head. Crankshaft bearing locating holes must also seat over the retaining pins, or the crankcase halves will not seal correctly and engine damage may result.

Fuel, EFI, and Electrical Systems

Carburetor content includes model- and altitude-based specifications, main-jet selection, removal, disassembly, cleaning, inspection, assembly, cable adjustment, throttle-valve synchronization, and fuel-system troubleshooting. The EFI section explains the batteryless system, flash-code diagnosis, fail-safe operation, fuel-pressure and injector checks, ECU memory functions, and the Kokusan troubleshooting sequence. Named diagnostic equipment includes the EFI Analyzer P/N 0644-342, its update harness and Laydown-engine update kit, the engine Pressure Testing Kit P/N 0144-127, and V Blocks P/N 0644-022 for crankshaft runout measurement.

Engine and chassis electrical chapters add ignition-timing procedures, throttle-position sensor adjustment, electric-start repair, low-oil and high-temperature warning circuits, fuel-gauge and electric-fuel-pump tests, brake-light switches, handlebar and thumb warmers, and passenger handwarmers. Separate ignition, main, and hood harness diagrams identify the correct circuit drawing by model, including dedicated Firecat 600 EFI early-build coverage.

Technical Specifications and Data

Factory reference material includes engine and torque specifications, tightening patterns, clearances and inspection limits, carburetor and EFI data, and ignition and electrical test values. Separate drivetrain and suspension references cover altitude calibration, clutch offset and center distance, chains and sprockets, track setup, shock valve stacks, piston-depth charts, and model-specific torque tables.

The drawing set includes engine assembly schematics and torque-pattern views, cooling-system schematics, model-specific ignition/main/hood wiring diagrams, drive-train schematics with and without reverse, and slide-rail, front-arm, rear-arm, and idler-wheel schematics. Additional named tools include the Drive Clutch Puller P/N 0644-207, Drive Clutch Spanner Wrench P/N 0644-136, and 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.