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

2004 Arctic Cat ATV Technical Service Documentation

• Covers 2004 Arctic Cat ATV models including 250, 300, 400, 400 TBX, 500, 500 TBX, and 500 TRV, documenting both 2x4 and 4x4 variants with manual or automatic transmission
• Official Arctic Cat factory publication, 551 pages
• Includes 11 comprehensive sections covering engine, transmission, electrical, fuel, cooling, and chassis systems with over 100 exploded-view diagrams and assembly schematics
• File delivered as a direct download the moment payment clears
• Stored against your account so you can retrieve it after a hard-drive loss
• Full-text search finds any part number in seconds
• Laid out for standard letter and A4 printing
• This 2004 service manual is the definitive OEM reference for the 250 through 500 engine-series lineup, documenting critical specifications for the TBX and TRV utility configurations.

Contents Overview

This 2004 Arctic Cat ATV service manual provides the complete technical scope for the 250, 300, 400, and 500 engine platforms. The document structure mirrors the factory service workflow, detailing the disassembly and assembly of the top-side, left-side, and right-side engine components. Core sections cover the engine/transmission, fuel/lubrication/cooling systems, electrical system, drive system, steering, and suspension, supported by a dedicated maintenance chart and troubleshooting index.

Technical data is provided for individual engine displacement tiers, with specific chapters for the 250/300 class and separate reference tables for the 400 and 500 automatic and manual transmissions. The documentation includes precise clearance values for intake/exhaust valves, camshaft bearing journals, piston rings, and crankshaft assemblies. Electrical reference data is provided for ignition timing, spark plug gaps, and magneto resistance values across all 2004 model variants.

Technical Data Preview

Engine oil capacity for the 2004 Arctic Cat 500 is documented at 3.4 liters. Piston ring end gap for the 500 series is listed at 0.35–0.63 mm. The 400 Automatic Transmission final reduction ratio is 3.090 for the front drive. All specifications within this 551-page factory publication serve as the baseline for the 2004 model year, covering maintenance schedules and tolerance limits for the complete ATV range, from the entry-level 250 to the heavy-duty TBX and TRV utility units.