Arctic Cat 250/300/400/500 ATV Service Manual – 2004, TBX & TRV (P/N 2256-958)

This Arctic Cat ATV service manual (P/N 2256-958) covers the 2004 250 2x4/4x4, 300 4x4, 400 2x4/4x4, and 500 4x4, including 400 TBX, 500 TBX, and 500 TRV. It provides maintenance, diagnosis, and component-level repair procedures for the covered manual- and automatic-transmission configurations.

Searchable Service Text and Bookmarked Chapters

Finding procedures and diagrams: Service text is searchable, and 13 bookmarks link to the main contents, chapters, and wiring diagrams. Labels within wiring diagrams are not searchable; small wire-color codes and connector labels require zooming.

Supplied as one printable PDF with 551 pages, including the contents pages and four notes pages.

Engine, Drivetrain, and Electrical Repair Coverage

Selected content: These highlights preview the manual’s repair coverage. Additional topics include storage preparation and headlight aiming.

• Engine and transmission repair: Engine/transmission removal and installation, top-side and side-cover disassembly, crankcase separation, valve and piston service, cylinder-head inspection, crankshaft work, oil-pump inspection, and reassembly.
• Fuel and lubrication: Keihin CVK carburetor schematics and service, throttle and idle adjustment, oil-flow diagnosis, and oil-pump pressure testing, supported by Oil Flow Charts.
• Drivetrain and suspension: Front differential and rear gear-case repair, drive-axle and CV-joint service, hub work, ACT swing-arm procedures, and FIS A-arm procedures.
• Steering and brakes: Steering-post repair, toe-in/toe-out measurement and adjustment, hydraulic-caliper replacement, brake bleeding, and pad burnishing.
• Electrical diagnosis: Tests for magneto, ignition coil, CDI, regulator/rectifier, starter motor, relays, electronic speedometer, temperature switches, neutral-start circuits, and the 400 FIS/500 front-drive selector switch and actuator.
• Reference data: Model-specific torque tables, fluid capacities, wear limits, shaft and gear clearances, valve and camshaft inspection specifications, oil-pressure data, resistance and peak-voltage values, maintenance schedules, and condition/remedy troubleshooting charts.

The component-level procedures, special-tool callouts, and measurement requirements suit professional technicians and experienced mechanics with appropriate lifting, measuring, and electrical test equipment.

Variant-Specific Engine and Cooling Procedures

The 250/300 engine and transmission form their own repair family. Separate 400 and 500 sections distinguish manual-transmission clutch, shaft, and shift-fork work from automatic-transmission starter-clutch, primary one-way drive, driven-pulley, and V-belt procedures.

The engine sections identify top-side and side-cover jobs that can be performed in the frame and central crankcase work requiring engine removal. This helps you plan the scope of disassembly before starting a repair.

Cooling and fuel systems: Oil-cooler procedures cover the 250, 300, and 400. The liquid-cooled 500 receives radiator, thermostat, cooling-fan, and separate manual- and automatic-transmission water-pump procedures. Fuel-system service is carburetor-based.

Chassis Schematics and TBX/TRV Body Work

The Rear Suspension/Axle Assembly – Fully Independent Suspension, Hydraulic Brake Assembly Schematics, and Body Panel Assembly Schematics show component relationships. Frame, exhaust, rack, fender, and footrest illustrations accompany removal and installation work.

TBX procedures address the side storage box and cargo box. The 500 TRV has separate coverage for its seat and backrest assembly.

Brake repair limits: The hydraulic brake caliper and master cylinder are identified as non-serviceable components to be replaced as assemblies.

Wiring Diagrams and Specified Test Equipment

Electrical sheets distinguish configurations, including 400 4x4 automatic STD/FIS and TBX/FIS harnesses, plus separate 500 automatic TBX/TRV and standard-model wiring diagrams.

Electrical instruments: Testing specifies the Fluke Model 73 Multimeter (P/N 0644-191) with Peak Voltage Reading Adapter (P/N 0644-307).

Mechanical tools: Callouts include the 250/300 Valve Gap Adjuster (P/N 0444-092), 400/500 Valve Clearance Adjuster (P/N 0444-078), Side Case Puller (P/N 0644-262), and Piston-Pin Puller (P/N 0644-328).

Manual-Specific Repair Cautions

The manual warns that misalignment between a manual-transmission driveshaft bushing’s oil-feed hole and the shaft passage can interrupt lubrication and damage the engine. Excessive removal of valve-cover sealing-surface material can reduce camshaft clearance and damage the camshaft.

Wheel-off, axle, suspension, and engine-removal work requires secure ATV support. The procedures include battery-isolation, hydraulic-brake, and pressurized cooling-system warnings, together with model- and transmission-specific torque and adjustment data.

Selected Valve and Piston-Ring Clearances

400 valve adjustment: Cold valve/tappet clearance is specified as 0.05–0.10 mm for intake and 0.22–0.27 mm for exhaust valves on both manual- and automatic-transmission models.

500 piston inspection: Installed piston-ring end gap is specified as 0.35–0.63 mm for both transmission versions. These selected specifications illustrate the dimensional checks included with the engine inspection and overhaul procedures.