Arctic Cat 2002 Snowmobile Service Manual Set — Volumes I & II

Together, the volumes connect engine and fuel-system diagnosis with the matching chassis wiring, drive-train settings, and suspension procedures.

Engine-overhaul coverage is provided for the 120 cc four-stroke engine and the listed 370–1000 cc two-stroke families. 4-Stroke Touring and 4-Stroke Trail appear in general maintenance information but do not have a dedicated engine-overhaul chapter. Historical piston, drive-belt, and EPROM application charts do not extend the primary service coverage beyond the 2002 models.

Searchable Service Text and Detailed Wiring Pages

Search and diagram detail: Service text supports PDF search, and embedded bookmarks open the nine main sections. Many wiring-diagram labels are outside the searchable text layer. Small labels on the checked EFI, ignition, and chassis diagrams require zooming.

The ZIP download contains one printable, English-language 711-page PDF, combining both volumes and including four CD-ROM cover/navigation pages.

Engine Overhaul, EFI Diagnosis, and Chassis Repair

The following selected contents highlight the workshop coverage rather than reproduce the full contents list. Other topics include storage preparation and high-altitude operation.

• Engine repair: Step-by-step removal, disassembly, inspection, measurement, reassembly, and installation procedures, with separate engine-family sections and troubleshooting charts.

• Fuel and EFI: BV-, VM-, and TM-style carburetor service, batteryless EFI diagnostics, throttle-body testing, and oil-injection synchronization, bleeding, and testing.

• Cooling and APV: Water-pump repair, engine pressure testing, cooling-system service, and Arctic Power Valve cable adjustment, cleaning, inspection, and troubleshooting.

• Electrical diagnosis: Resistance and peak-voltage tests, ignition timing, electric-start fault isolation, sensor checks, and model-indexed ignition, main, hood, and EFI wiring diagrams.

• Drive train and brakes: Clutch and driven-pulley service, belt alignment, reverse and non-reverse chaincases, hydraulic and mechanical brakes, and master-cylinder service.

• Steering and body: AWS III and AWS V steering, ski alignment, front suspension, body-component replacement, and single- and three-bulb headlight aiming.

• Track and shocks: Model-assigned skid-frame repair, track setup, articulating suspension, and IFP, quick-adjust, and remote-reservoir shock service.

Suited to technicians and experienced snowmobile owners who can take precision measurements and use the specified pullers, electrical meters, and EFI test equipment.

Engine Families and Model Fit

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; and Thundercat.

They also identify Z 370/440/570, ZL 500/550/600 EFI/800 EFI, ZR 120/500/600/800, and ZRT 600, with the applicable es, esr, LE, SS, CC, r, and EB variants assigned in the individual charts.

The overhaul sections distinguish 370/440, 550, 570, 500/600 twin, 800, 600 triple, and 1000 cc engines. The 120 cc chapter covers its valve train, camshaft, tappets, piston, connecting rod, oil-level sensor, and lubrication components. Two-stroke sections address cylinders, pistons, crankshafts, reed assemblies, and balancer, oil-injection, and water-pump drives where fitted.

Eight engine-family assembly-schematic sets mark torque control, threadlockers, sealants, and lubrication points. Reference material includes bore and stroke, compression ratios, piston and ring limits, pin and connecting-rod dimensions, crankshaft runout and end play, and reed-stopper specifications.

Component torque tables and patterns accompany piston replacement guides, piston-travel/crank-angle charts, cylinder-head volume tests, crankshaft repair data, and exhaust-temperature probe-location charts. Tools include Piston-Pin Puller p/n 0644-328 and Clutch Puller p/n 0644-207.

Crankcase cautions address sealing-surface damage from wedging the halves apart; other assembly notes explain how oil-pump-drive misalignment can damage the pump and incorrect water-pump washer orientation can cause coolant leakage.

Carburetors, Batteryless EFI, and Oil Injection

Carburetor material includes main-jet replacement, component schematics, cable adjustment, production settings, Mikuni tuning components, and fault charts. Fuel guidance distinguishes oxygenated-gasoline setup for carbureted models from the EFI Fuel Designation Connector.

Batteryless EFI coverage explains ECU trouble codes, Kokusan-mode diagnosis, throttle-position-sensor and throttle-body testing, and air- and water-temperature voltage/resistance charts. The analyzer does not test every component: separate meter and fuel-pressure checks cover the remaining circuits and fuel-delivery components.

The manual identifies EFI Analyzer p/n 0644-212 with the applicable updates, APV EFI Analyzer p/n 0644-342, and Fuel Pressure Tester p/n 0644-203. Its historical EPROM charts are reference material; the EPROM chip on 2002 models is not replaceable.

Oil-injection coverage extends to pump synchronization, bleeding, output testing, and check-valve testing. The pump-output chart does not supply a consumption specification for the 570 cc engine.

Cooling Systems and Arctic Power Valves

Water-pump sections separate twin, 600 cc triple, and 1000 cc arrangements. Cooling System Schematics show heat exchangers, hose routing, and coolant flow with the thermostat open or closed. Related procedures cover cooling-system filling and thermostat inspection, engine air-leak testing, axial-fan/belt service, and recoil-starter repair.

APV coverage distinguishes flat-style valves on 500 and 800 cc engines from round-style valves on 600 cc engines, with separate carbureted and EFI troubleshooting.

Model-Matched Electrical Troubleshooting

The wiring indexes assign each model and trim to the appropriate diagram: 11 ignition harnesses, 27 main harnesses, five hood harnesses, and separate EFI diagrams. This lets a technician select the matching harness before tracing a fault across the engine and chassis connections.

Diagnostic coverage includes Digital 3-D Ignition, model-specific timing, electric-start components, low-oil and high-temperature circuits, fuel gauges and senders, electric fuel pumps, brake-light switches, hand/thumb/passenger warmers, and headlight circuits. Wire-color/function descriptions explain the circuit connections.

Clutches, Chaincases, Brakes, and Steering

Drive-system reference material covers belt deflection, offset, parallelism, center-to-center distance, cam arms, chains and sprockets, and belt dimensions and replacement applications. Drive Train Schematics distinguish reverse and non-reverse assemblies; production charts assign clutch components and settings by model.

Hydraulic-brake troubleshooting accompanies caliper and master-cylinder service. Mechanical and quick-adjust brakes have their own procedures. Steering and body sections distinguish AWS III/AWS V arrangements and cover ski wear bars, tie rods, spindles, suspension arms, sway bars, consoles, belly pans, seats, windshields, and lighting assemblies.

Skid Frames and Rebuildable Shocks

A servicing chart assigns models to four rear-suspension repair procedures and their slide-rail, arm, and idler-wheel schematics. The Bearcat has a separate Articulating Skid Frame Schematic. Supporting charts cover mounting locations, drive-sprocket placement, track applications, shock and spring selection, valve stacks, rebuild kits, and piston depths.

Shock procedures include IFP, front-arm quick-adjust, and remote-reservoir/clicker designs, internal travel-limiting spacers, seals, and pressurization. Improvised clamping can deform the shock body, so the manual specifies retaining blocks.

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.

Selected EFI Pressure and Throttle-Sensor Values

Regulated fuel pressure is specified at 37.9 ± 2.2 psi for 600 cc batteryless EFI models and 48 ± 2.2 psi for 800 cc batteryless EFI models.

For the 600 cc EFI throttle-valve-angle test, the idle-position sensor reading is 0.625–0.647 V with the engine off.