Arctic Cat Firecat, Sabercat, Pantera, Z, Panther, Bearcat, and Mountain Cat 2004 Snowmobile Service Manual (P/N 2256-924, 2256-966)

• 644-page combined PDF of Arctic Cat's official 2004 factory service publication, Volumes 1 and 2, dated September 2003. In this file, Volume I: 300 pages (Sections 1–5) and Volume II: 344 pages (Sections 6–9), with Section 6 beginning on PDF page 301. Factory photographs, assembly drawings, specification charts, and wiring schematics support the procedures.
• Model coverage follows the factory wiring index: Bearcat 570; Panther 370 and 570; Pantera 550, 600 EFI, and 800 EFI; Z 370/370 LX, Z 440 LX, and Z 570/570 LX; Firecat 500/500 Sno Pro, 600/600 Sno Pro, 600 EFI (EB), 600 EFI EXT, 600 EFI/600 EFI Sno Pro, 700/700 Sno Pro, 700 EFI EXT, and 700 EFI/700 EFI Sno Pro; Sabercat 500/500 LX, 600/600 LX, 600 EFI EXT, 600 EFI/600 EFI LX, 700 EFI EXT, and 700 EFI/700 EFI LX; Mountain Cat 570, 600 EFI, 800 EFI, and 900; King Cat 900; and ZR 900/900 Sno Pro.
• Engine repair coverage includes model-specific removal, complete disassembly, top-side service, cleaning and inspection, critical measurement, reassembly, installation, pressure testing, and carbureted/EFI troubleshooting for 370/440, 550, 570, 600 standard, 800/900, and 500/600/700 "Laydown" engines.
• Carbureted fuel-system procedures are paired with batteryless EFI self-diagnostics, trouble codes, EFI Analyzer and Kokusan-mode testing, fuel-system checks, TPS adjustment, Arctic Power Valve (APV) and Exhaust Controlled Timing (ECT) service, ignition timing, peak-voltage and resistance tests, and electric-start fault tracing.
• Volume II separates AWS V and AWS VI steering and body repair, covering steering posts, tie rods, spindles, ski alignment, front suspension arms, ski shocks, sway bars, consoles, belly pans, gas tank/seat assemblies, heat exchangers, air silencers, headlights, warmer circuits, and main/hood wiring diagrams.
• Drive-train chapters detail drive belts, drive clutches, ACT roller driven pulleys, clutch center-to-center and offset setup, chain-and-sprocket service, reverse and non-reverse chaincase layouts, chain adjustment, hydraulic brakes, mechanical quick-adjust brakes, and dedicated clutch, belt, and brake troubleshooting.
• Track and rear-suspension material includes skid-frame setup and mounting locations, slide-rail/front-arm/rear-arm/idler-wheel schematics, drive-sprocket and track-selection charts, three factory repair-procedure groups, and rebuildable IFP, position-sensitive, and remote-reservoir shock service with valving, piston-depth, bleeding, and nitrogen-pressurizing data.

Engine, Fuel, and Electrical Service Coverage

The manual keeps the engine families separate instead of applying one generic procedure across every chassis. It distinguishes fan-cooled and liquid-cooled layouts and breaks out the 500, 600, and 700 cc Laydown designs, with APV and non-APV differences identified where required. Factory procedures cover engine removal, crankcase disassembly, cylinder and piston service, reed-valve inspection, crankshaft bearings and seals, water-pump and oil-injection drive work, cooling-system filling, final pressure testing, and complete installation. A dedicated Laydown top-side section documents major engine repair without full powerplant removal where the manual provides for it.

The carburetor material covers cleaning, float and fuel-level inspection, jetting, throttle and choke adjustment, oil-injection setup, and synchronization. Batteryless EFI follows its own diagnostic path with ECU trouble codes, sensor and injector checks, electric fuel-pump testing, throttle-body service, TPS setup, EFI Analyzer functions, and the recommended Kokusan troubleshooting sequence. Engine-electrical coverage adds ignition fault isolation for EFI, fan-cooled, and liquid-cooled models, along with ignition timing, charging and starter components, and harness-specific wiring diagrams.

Factory Specifications, Schematics, and Special Tools

Reference material is organized by engine family and chassis system. It includes engine assembly schematics, component-specific torque tables and tightening patterns, the piston-travel-versus-crank-angle chart, cylinder-head volume and squish specifications, crankshaft runout, cylinder trueness, piston-to-cylinder clearance, ring end gap, and electrical test values. Chassis data covers clutch setup, belt dimensions and replacement, track usage and lug patterns, shock valving and spring selection, plus approved fuel, oil, coolant, and lubricant guidance. The general-information section also distinguishes carbureted and EFI handling of oxygenated gasoline and specifies the applicable oil-injection formulations. Standard-to-metric, fraction-to-decimal, and drill-size charts round out the shop references.

Useful visual references include the engine torque-pattern sheets, displacement-specific assembly schematics, cooling-system schematics, ignition/main/hood wiring diagrams, reverse and non-reverse drive-train schematics, and the slide-rail, front-arm, rear-arm, and idler-wheel exploded views. Factory tool callouts include the Drive Clutch Puller P/N 0644-207, Flywheel Puller/Spanner Wrench P/N 0144-310, Piston-Pin Puller P/N 0644-328, EFI Analyzer P/N 0644-342, TPS Adjustment Tool P/N 0644-299, and Shock Inflation Needle P/N 0644-158.

Several assembly cautions are especially important during repair. Installing an APV exhaust valve backward can cause severe engine damage, while crankshaft bearings that miss their retaining pins can keep the crankcase halves from sealing. The oil-injection/water-pump driveshaft must align with the pump slot, and the impeller washer's sealing side must face the specified direction; otherwise the pump can be damaged or a coolant leak can result. Coverage is limited to the listed 370–900 cc two-stroke models; this PDF does not contain a four-stroke engine service section. Clutch, brake, track, engine, and nitrogen-charged shock work involves rotating parts, stored spring energy, and pressurized systems, so the factory warnings and specified service equipment should be followed throughout the repair.