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

This 551-page PDF is organized for component-level repair rather than basic owner maintenance. Its separate engine and transmission procedures, special-tool callouts, and measurement requirements make it best suited to professional technicians and experienced mechanics with normal shop lifting, measuring, and electrical test equipment.

• Model coverage: Covers the 2004 Arctic Cat 250 2x4 and 4x4; 300 4x4; 400 2x4 and 4x4 with manual or automatic transmission, ACT or FIS rear suspension, and 400 TBX; plus 500 4x4 manual and automatic models, 500 TBX, and 500 TRV. The 50, 90, 650 Twin, and DVX 400 require separate manuals.
• Engine and transmission repair: Details 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 final reassembly. Manual and automatic transmission procedures are kept in separate model-specific chapters.
• Fuel, lubrication, and cooling systems: Covers Keihin CVK carburetor schematics and service, throttle and idle adjustment, oil-flow diagnosis, oil-pump pressure testing, oil-cooler work for the 250/300/400, and liquid-cooling, radiator, thermostat, fan, and water-pump service for the 500.
• Drive, suspension, steering, and brakes: Includes front differential and rear gear-case repair, drive-axle and CV-joint service, ACT swing-arm and FIS A-arm procedures, hub and hydraulic-caliper work, brake bleeding and pad burnishing, steering-post repair, and toe-in/toe-out measurement and adjustment.
• Electrical diagnosis: Provides component tests for the magneto, ignition coil, CDI, regulator/rectifier, starter motor and relays, electronic speedometer, temperature switches, neutral-start circuits, and the 400 FIS/500 front-drive selector switch and actuator.
• Factory reference data: Supplies model-specific torque tables, fluid-capacity data, wear limits, shaft and gear clearances, valve and camshaft inspection specifications, oil-pressure test data, electrical resistance and peak-voltage values, maintenance schedules, and condition/remedy troubleshooting charts.

Variant-Specific Repair Depth

The 250/300 engine and transmission are handled as their own family. The 400 and 500 sections then split manual-transmission repair from automatic-transmission work so that clutch, shaft, shift-fork, and crankcase procedures are not mixed with the automatic models’ starter clutch, primary one-way drive, driven pulley, and V-belt systems.

Cooling coverage also follows the actual machine configuration. The 250, 300, and 400 chapters deal with their oil-cooler arrangements, while the liquid-cooled 500 receives radiator, thermostat, cooling-fan, and separate manual- and automatic-transmission water-pump procedures. Fuel-system work is carburetor-based; this manual does not cover EFI.

Utility-specific body work is included rather than treated as standard-model hardware. The TBX material covers the side storage box and cargo box, while the 500 TRV section identifies its separate seat and backrest assembly. Frame, exhaust, rack, fender, footrest, and body-panel schematics support the related removal and installation work.

Schematics, Testing, and Special Tools

Named diagrams include the Oil Flow Charts, Rear Suspension/Axle Assembly - Fully Independent Suspension, Hydraulic Brake Assembly Schematics, and Body Panel Assembly Schematics. Electrical sheets are separated by configuration, including the 400 4x4 automatic STD/FIS and TBX/FIS harnesses, plus distinct 500 automatic TBX/TRV and standard-model wiring diagrams.

Electrical testing specifies the Fluke Model 73 Multimeter (P/N 0644-191) with Peak Voltage Reading Adapter (P/N 0644-307). Other factory tool 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

On manual-transmission driveshaft work, the bushing oil-feed hole must align with the shaft passage; misalignment can interrupt lubrication and cause engine damage. The valve-cover service sections also warn that removing too much sealing-surface material can reduce camshaft clearance and damage the camshaft.

Wheel-off, axle, suspension, and engine-removal work requires the ATV to be securely supported. Follow the manual’s battery-isolation, hydraulic-brake, and pressurized cooling-system warnings, along with the correct model- and transmission-specific torque and adjustment data.