🏷️ Basic Information Identification Make: Arctic Cat Model: 250, 300, 400, 500 Utility ATV Year: 2004 Product Type: Repair Service Manual Format: PDF Download 👋 Introduction Market Position Segment: Utility ATV (All-Terrain Vehicle) Target User: Owners, DIY mechanics, and professional repair shops seeking detailed repair information. Competitive Analysis Key Competitors 2004: Honda FourTrax, Polaris Sportsman, Yamaha Wolverine/Grizzly, Kawasaki Bayou/Prairie. Key Features Manual Benefit: Enables users to perform maintenance, diagnose issues, and complete repairs efficiently and correctly, saving on labor costs. Illustration Quality: Illustrated with clear, step-by-step instructions and diagrams. 📋 Manual Details Coverage Areas Included Models: Arctic Cat 250, 300, 400, 500 Utility ATVs Applicable Years: 2004 Page Count Estimated Pages: Varies by specific model (typically 300-600 pages for a comprehensive service manual) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine overhaul, disassembly, assembly, tuning, lubrication, cooling system, fuel system (carburetor/injection), exhaust system, ignition system. Transmission: Clutch operation, gearbox service, drive shafts, final drive, belt drive maintenance (CVT). Brakes: Hydraulic brake system service, caliper and master cylinder repair, fluid bleeding, brake pad replacement, parking brake adjustment. Electrical: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starting system, lighting, ignition system components, CDI unit, fuses, relays. Chassis And Suspension: Frame inspection, front and rear suspension geometry, shock absorber service, steering system, wheel bearings, A-arms, ball joints. Bodywork And Trim: Body panel removal and installation, seat, fenders, racks, lighting fixtures, graphics. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air), spark plug service, chain/belt adjustment, lubrication points. Troubleshooting: Diagnostic flowcharts for common problems, symptom-based troubleshooting guides for engine, electrical, and drivetrain issues. Repair And Rebuild: Detailed instructions for component disassembly, inspection, repair, and reassembly for all major systems. Specifications And Torques: Precise torque values for critical fasteners, critical measurements, and assembly specifications. Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds, detailed electrical diagnostics). 📊 Manual Specifications File Format Digital Format: Portable Document Format (PDF) Print Quality Image Resolution: High-resolution scanned images for clear diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, SOHC (Single Overhead Camshaft) for 300/400/500 models; likely carbureted. Displacement 250: Approximately 239cc (Specific model variant applies) Displacement 300: Approximately 283cc (Specific model variant applies) Displacement 400: Approximately 375cc (Specific model variant applies) Displacement 500: Approximately 499cc (Specific model variant applies) Performance Horsepower Range: Estimated 15-30 HP depending on model displacement and tuning (specifications vary significantly by model). Fuel System Fuel Delivery: Carburetor (e.g., Mikuni) for most 2004 utility models, though some higher displacement models might have fuel injection options depending on sub-trim. Fuel Type: Unleaded gasoline (octane rating as specified in the manual). 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) with high/low range and reverse. Optional Optional Gearbox: N/A for this utility segment in 2004. Features Drive Modes: 2WD/4WD selectable, often with locking front differential (on 400/500 models). Clutch Type: Automatic centrifugal clutch with drive belt. 📐 Dimensions Exterior Dimensions Overall: Varies by model (typically around 80-85 inches L x 45-50 inches W x 45-50 inches H). Weights Dry Weight: Varies by model (typically 500-700 lbs). Towing Capacity: Typically 500-1000 lbs (varies by model). Cargo Capacity Rack: Front and rear racks with substantial weight limits (e.g., 50-100 lbs front, 100-200 lbs rear). 🛡️ Safety Features Ratings Safety Standards: Meets ANSI standards for ATVs. (No specific crash test ratings like cars). Active Features Braking System: Hydraulic disc brakes on all wheels, often with sealed parking brake. Suspension Stability: Independent front suspension (IFS) on most models for improved handling and stability, rear swingarm or independent suspension depending on model. Passive Features Lighting: Headlights, taillight, brake light for visibility and signaling. Hand Grips And Levers: Ergonomically designed controls for safe operation. 💡 Technology Features Infotainment Infotainment System: N/A (Basic utility ATVs of this era typically did not feature advanced infotainment systems beyond essential controls). Driver Assistance Driver Assistance Features: N/A (Focus on mechanical systems and basic controls, no electronic driver aids). Connectivity Connectivity Options: N/A 🔧 Maintenance Service Intervals Engine Oil Change: Typically every 50-100 hours or annually (refer to specific manual for exact intervals and conditions). Air Filter Cleaning Replacement: Inspect every 20 hours, clean or replace as needed, more frequently in dusty conditions. Spark Plug Service: Inspect annually or as recommended, replace as needed (typically based on mileage/hours). Fluid Specifications Engine Oil Type: API SG or higher, SAE 10W-40 or 20W-50 motorcycle/ATV specific oil recommended. (Manual will specify exact viscosity and API rating). Transmission Oil Type: Specific Arctic Cat synthetic gear oil or equivalent is often recommended for the CVT and final drive. (Refer to manual for exact part number and type). Coolant Type: Ethylene glycol-based antifreeze mixed...