2004 Arctic Cat ATV Service Manual | 250, 300, 400, 500, TBX & TRV Models

Arctic Cat ATV 250, 300, 400, 500, TBX, and TRV — troubleshooting and repair reference for engine, transmission, chassis, and electrical systems. PN 0436-005

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Document Details

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Document Number / Seller:
27515 / Nancy Hicks
File Size:
132.80 MB
File Type:
PDF
Language:
English
Pages:
551
Printable:
Yes
Category:
ATV
Last updated / verified
Dec 16, 2025

Models Covered & Key Technical Specifications

2004 Arctic Cat ATV Service Manual | 250, 300, 400, 500, TBX & TRV Models | Technical Reference Arctic Cat ATV Integrated Reference Hydraulic Manual: Arctic Cat ATV Official Arctic Cat ATV 250, 300, 400, 500, TBX, and TRV Factory Service and Repair Manual, 2004 Engine-Compendium | Official Handbook Suite

  • Dry Weight (approx): 2x4 - 245 kg (540 lb) / 4x4 - 261 kg (575 lb)
  • Length (overall): 202 cm (79.5 in.)
  • Height (overall): 114 cm (45 in.)
  • Width (overall): 114 cm (45 in.)
  • Suspension Travel: 16.5 cm (6.5 in.)
  • Ground Clearance: 20.3 cm (8.0 in.)

Professional Workshop Service Manual & Technical Specifications

Integrated Reference Hydraulic Manual: Arctic Cat ATV Official Arctic Cat ATV 250, 300, 400, 500, TBX, and TRV Factory Service and Repair Manual, 2004 Engine-Compendium

Serial-Range: 250-500 // Diagnostic-Area: Engine & Transmission Logic // Technical-Scope: Complete Operation Data.

Component Rating Context
Drive Belt 10.4-11.8 kg-m Primary Gear Assembly Installation
Carburetor Free-Play 3-6 mm Throttle Lever Operation
Ignition Timing 10° BTDC @ 1500 RPM Engine Timing Accuracy
Tire Inflation Pressure 0.35 kg/cm² Tire Performance
Gas Tank Capacity 17.98 L Fuel Storage Volume
Engine Oil Capacity 3.08 L Lubrication Volume

Technical chapters are organized around engine, transmission, and electrical systems, covering diagnostics, maintenance, and repair procedures.

FAQ

Specify the **lubrication** requirements for the engine oil? keyboard_arrow_down

SAE 10W-40 is the recommended engine oil viscosity for the Arctic Cat ATV engine.

What is the **exact** torque specification for the drive belt? keyboard_arrow_down

10.4-11.8 kg-m (75-85 ft-lb) is the specified torque for the drive belt nut.

Calculate the **specific** idle RPM for the 400/500 models? keyboard_arrow_down

1250-1350 RPM is the specified idle range for the 400/500 models.

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Reviews (4)

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I reached out for support and received a quick reply. The manual covers everything you need to know about servicing my Arctic Cat. Highly recommend!
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This manual is a lifesaver for maintaining my ATV. The instructions are clear and easy to follow, making repairs a breeze!
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The download process was quick and the manual is very detailed. I love the wiring diagrams; they made troubleshooting so much easier!
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Rated 4 out of 5 stars