2004 Arctic Cat ATV Service Manual 250, 300, 400, 500, TBX & TRV Models (P/N 0436-005)

• Covers the complete 2004 Arctic Cat ATV lineup: 250, 300, 400, 400 TBX, 500, 500 TBX, and 500 TRV. Details both 2x4 and 4x4 drivetrains with manual or automatic transmissions.
• Official factory publication (P/N 0436-005) spanning 551 pages of OEM specifications.
• Breaks down 11 core systems—from engine and transmission to fuel, cooling, and electrical.
• Features over 100 exploded-view diagrams and clear assembly schematics for accurate component identification.
• Serves as the definitive OEM reference for the 250 through 500 engine-series, documenting critical specs for the heavy-duty TBX and TRV utility configurations.

Contents Overview

This factory manual delivers the exact technical specifications needed to maintain and overhaul the 250, 300, 400, and 500 engine platforms. It mirrors the standard workflow found in professional dealerships. You get a direct breakdown of top-end, left-side, and right-side engine components.

Working on ATVs involves significant mechanical forces and high-pressure fuel systems. Always refer to the factory torque values and safety procedures outlined in this guide before tearing down components or modifying fuel delivery setups.

Core chapters tackle the engine, transmission, electrical system, and drive assemblies. You will also find dedicated sections for suspension geometry and steering linkage, backed by a comprehensive maintenance chart and troubleshooting index. Clearances matter. The manual lists precise values for intake and exhaust valves, camshaft bearing journals, piston rings, and crankshaft assemblies. Technical data is categorized by displacement tiers, keeping the 250/300 class separate from the 400 and 500 tables to prevent cross-reference errors on the shop bench.

Technical Data Preview

Need quick reference numbers? The guide provides exact displacement tier data to baseline your repairs. For example, the engine oil capacity for the 500 series sits exactly at 3.4 liters. Piston ring end gap for that same 500 block requires a strict 0.35–0.63 mm tolerance. If you are servicing the 400 Automatic, the front drive final reduction ratio is 3.090.

Electrical testing is fully documented. You get complete reference tables for ignition timing, spark plug gaps, and magneto resistance values across every 2004 variant. From the entry-level 250 up to the heaviest 500 TRV, these specs dictate the exact tolerance limits for the entire model year.