2002 Arctic Cat 120 cc, 370 cc, 440 cc, 500 cc, 550 cc, 570 cc, 600 cc, 800 cc, and 1000 cc Snowmobile Service Manual (P/N 0734-451)

• Document identity and model coverage: 711-page PDF combining Volumes I and II of the 2002 Arctic Cat Service Manual (P/N 0734-451). Model-indexed charts cover Bearcat W/T; Mountain Cat 500, 570, 600 EFI, 800/800 EFI, and 1000; Pantera 550/600 EFI/800 EFI; Panther 440/570; Thundercat; Z 370/440/570; ZL 500/550/600 EFI/800 EFI; ZR 120/500/600/800; and ZRT 600, including the listed es, esr, LE, SS, CC, r, and EB variants.
• Engine repair coverage: Covers removal, disassembly, cleaning and inspection, critical measurement, reassembly, installation, and troubleshooting for 120 cc, 370 cc, 440 cc, 500 cc, 550 cc, 570 cc, 600 cc, 800 cc, and 1000 cc engines. Tables separate the 600 EFI, 600 carbureted twin and triple, and 800 carbureted and EFI configurations.
• Fuel, cooling, and APV systems: Details BV-, VM-, and TM-style carburetor service; batteryless EFI diagnostics; oil-injection synchronization, bleeding, and testing; water-pump repair; engine pressure testing; cooling-system service; and Arctic Power Valve adjustment and repair.
• Electrical diagnosis and schematics: Includes resistance, peak-voltage, ignition-timing, electric-start, sensor, gauge, warmer, switch, lighting, and harness tests, supported by 11 ignition-harness diagrams, 27 main-harness diagrams, five hood-harness diagrams, and separate EFI wiring diagrams.
• Drive train, brake, steering, and body repair: Covers clutch and driven-pulley service, belt deflection and alignment, chaincases with and without reverse, hydraulic and mechanical brakes, AWS III and AWS V steering, ski alignment, front suspension, body components, and one- and three-bulb headlight aiming.
• Track, rear suspension, and rebuildable shocks: Provides model-to-schematic charts for skid frames, slide rails, arms, idler wheels, wear strips, track setup, and the Bearcat articulating skid frame, plus IFP, quick-adjust, and remote-reservoir shock repair data.

Technical Documentation Details

General information covers VIN and engine serial-number identification, fuel and oil requirements, break-in, high-altitude operation, storage preparation, the after-break-in checklist, torque conversions, and metric/SAE reference charts.

The engine section follows the progression used for a major shop repair. It starts with removal and installation by chassis and engine family, then provides separate teardown and assembly coverage for the 120, 370/440, 550, 570, 500/600 twin, 800, 600 triple, and 1000 cc engines. Eight engine-family assembly-schematic sets show factory symbols for torque control, threadlockers, sealants, and lubrication.

The 120 cc chapter covers its four-stroke valve train, camshaft, tappets, piston, connecting rod, oil-level sensor, and lubrication components. The two-stroke chapters address cylinders, pistons, crankshafts, reed assemblies, balancer shafts where used, oil-injection drives, and water-pump drives.

The engine specification matrix identifies the individual engine models and distinguishes fan-cooled from liquid-cooled builds, carbureted from EFI versions, and twins from triples. Reference categories include bore and stroke, compression ratio, ignition and lighting data, piston-to-cylinder and ring limits, piston-pin and connecting-rod dimensions, crankshaft runout and end play, and reed-stopper specifications. Related pages provide component-specific torque tables and patterns, piston replacement guides, piston-travel and crank-angle charts, cylinder-head volume tests, crankshaft inspection and repair data, and exhaust-temperature probe-location charts.

Carburetor coverage includes main-jet replacement, BV/VM/TM schematics, component disassembly and inspection, cable adjustment, 2002 production specifications, Mikuni tuning components, and fault charts. Fuel guidance distinguishes oxygenated-gasoline setup by system: carbureted models use a main-jet change, while EFI models use the Fuel Designation Connector.

The covered EFI systems are batteryless. The manual explains ECU trouble codes, the recommended Kokusan-mode diagnostic sequence, throttle-position-sensor and throttle-body testing, peak-voltage checks, and air- and water-temperature voltage/resistance charts. Separate EPROM charts and EFI wiring diagrams support model-specific fault isolation.

The Arctic Power Valve chapter separates flat-style valves used on 500 and 800 engines from the round-style valves used on 600 engines. It covers cable adjustment, valve cleaning and inspection, assembly, and carbureted and EFI troubleshooting. EFI diagnosis identifies Analyzer p/n 0644-212, or p/n 0644-342 for APV EFI, together with Fuel Pressure Tester p/n 0644-203. Internal engine and clutch procedures identify tools such as Piston-Pin Puller p/n 0644-328 and Drive Clutch Puller p/n 0644-207.

Specification Previews

The wiring indexes map each listed model and trim to the correct ignition, main, and hood harness rather than relying on one generic schematic. Diagnostic sections cover Digital 3-D Ignition for 500, 600, 800, and 1000 cc models; model-specific ignition timing; electric-start fault isolation; low-oil and high-temperature circuits; fuel-gauge and sender checks; electric fuel-pump testing; brake-light switches; hand, thumb, and passenger warmers; and headlight circuits.

Drive-system sections document clutch and driven-pulley inspection, belt deflection, offset, parallelism, center-to-center distance, reverse and non-reverse chaincases, brake systems, and master-cylinder service. Production charts cover cam arms, chains and sprockets, drive-belt dimensions and replacement applications, and model-specific drive settings.

Rear-suspension material includes mounting-location drawings, four model-assigned repair procedures, track and skid-frame service, shock and spring application charts, valve stacks, rebuild kits, required tools, piston-depth data, and shock pressurization procedures. Suspension schematics cover slide rails, front and rear arms, idler-wheel arrangements, articulating skid frames, and the model-specific placement of drive sprockets and related hardware.

Several cautions address damage that can result from incorrect repair methods. Separating crankcase halves with a wedge can ruin the sealing surfaces. Misaligning the oil-injection pump drive can damage the pump, while incorrect water-pump washer orientation can cause coolant leakage. Gas shocks must be depressurized and held in the specified retaining blocks because improvised clamping can deform the shock body.

Before clutch, track, brake, or suspension work, secure the snowmobile and isolate the ignition or electric-start power. Rebuildable shocks must be fully depressurized before they are opened.

Detailed engine-overhaul coverage is provided for the 120 cc engine and the listed 370–1000 cc two-stroke engine families. The 4-Stroke Touring and 4-Stroke Trail models appear in general maintenance information, but their engine does not have a dedicated overhaul chapter in this publication. Historical piston and drive-belt replacement charts are supplementary and do not expand the primary service coverage beyond the 2002 models.