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 • Part #: 0638-313
Arctic Cat Models Covered & Key Technical Specifications
Models: 370 cc, 440 cc, 500 cc, 550 cc, 570 cc, 600 cc, 700 cc, 800 cc, 900 cc
Sub-models / Variants: Standard, Carbureted, EFI, APV, Laydown Engine Models, Mountain Cat, King Cat
Model Years: 2004
Technical Data:
- Engine Displacement: 367 cc through 862 cc
- Number of Cylinders: 2
- Cooling System: Fan Cooled, Liquid Cooled
- Fuel System: Oil Injection
- Spark Plug Gap: 0.7–0.8 mm (0.028–0.031 in.)
- Crankshaft Runout Limit: 0.05 mm (0.002 in.) to 0.15 mm (0.006 in.) depending on model
- Piston Skirt/Cylinder Clearance: 0.060–0.150 mm range
Arctic Cat Manual Features & Content Preview
2004 Arctic Cat Snowmobile Service Manual
- Covers the entire 370 cc through 900 cc engine range (Standard, Laydown, Carbureted, EFI, and APV configurations).
- Official 100-page OEM publication 0638-313 documenting engine, chassis, electrical, and fuel-injection specifications.
- Includes detailed engine torque patterns and conversion charts essential for a professional repair environment.
- Searchable instant download provides immediate access to critical part numbers and technical data.
Engine Service and Component Overhaul
This digital handbook provides in-depth technical references for the 2004 Arctic Cat lineup. Mechanics can quickly review structural layouts for the 370 to 900 cc engine classes. The text outlines detailed sequences for engine removal, disassembly, inspection, and assembly. You will find specific details on cylinder head configurations and crankshaft runout checks. It also covers baseline maintenance intervals, break-in protocols, and storage preparation guidelines. To ensure safety and prevent equipment damage, always verify technical values against the physical condition of the snowmobile and consult a certified technician before initiating any heavy mechanical work.
Technical Specifications and Data
Accurate data drives a successful rebuild. This manual delivers comprehensive specification tables required for complex diagnostics and every major repair. It documents precise cylinder head volumes to help prevent detonation issues. You get exact crankshaft runout specifications measured at points D, E, and F. Standardized factory metrics are clearly laid out. These include 42.5 mm travel rates, 65 mm bore diameters, and 185W lighting coil power ratings. Timing data is equally exhaustive. The guide pairs 0.024 mm piston pin diameter velocity specs with full piston travel versus crank angle charts. This keeps your shop working efficiently without second-guessing vital clearances.
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