Basic Information Identification Make: Arctic Cat Model: ATV 250/300/400/500 Year: 2004 Product Type: Repair Service Manual Product Format: PDF Download Introduction Market Position Target User: Arctic Cat ATV owners, independent repair shops, and DIY enthusiasts seeking comprehensive service information for 2004 models. Competitive Analysis Value Proposition: Provides factory-level repair and maintenance data, essential for accurate servicing and troubleshooting, offering significant cost savings compared to dealership labor rates. Key Features Manual Utility: Empowers owners to perform their own maintenance and repairs, understand their ATV better, and extend its lifespan through proper care and timely interventions. Manual Details Coverage Areas Covered Models: 2004 Arctic Cat ATV 250, 2004 Arctic Cat ATV 300, 2004 Arctic Cat ATV 400, 2004 Arctic Cat ATV 400 TBX, 2004 Arctic Cat ATV 500, 2004 Arctic Cat ATV 500 TBX, 2004 Arctic Cat ATV 500 TRV Transmission Coverage: Manual and Automatic Transmissions Page Count Total Pages: 550 Manual Type Manual Classification: Original Factory Service Manual Language Language Of Publication: English Format Download Format: PDF Manual Coverage Systems Covered Engine Systems: Engine overhaul, cooling system, lubrication system, fuel system, ignition system, starting system, exhaust system, engine diagnostics, troubleshooting. Drivetrain Systems: Transmission (manual and automatic), drive shafts, differential, clutches, gearboxes, lubrication, maintenance, and repair. Chassis Systems: Frame, suspension (front and rear), steering system, wheels, tires, brakes (hydraulic disc), maintenance, and repair. Electrical Systems: Wiring diagrams, lighting, ignition, charging system, battery, starter motor, electrical component testing, troubleshooting, and repair. Bodywork And Plastics: Body panel removal and installation, fenders, racks, seat, storage compartments, graphics, and basic trim repair. Procedures Included Maintenance Procedures: Regular maintenance checks, oil changes, filter replacements, spark plug service, brake fluid flush, coolant replacement, chain adjustment (if applicable), battery maintenance. Troubleshooting Guides: Diagnostic charts for common problems, symptom-based troubleshooting, electrical system fault finding, engine performance issues, transmission operation faults. Repair And Rebuild Procedures: Detailed step-by-step instructions for engine disassembly and reassembly, transmission overhaul, brake caliper rebuild, suspension component replacement, carburetor tuning, electrical component replacement. Technical Specifications And Data: Torque specifications for all fasteners, engine timing, valve clearances, fluid capacities, electrical system voltages, tire pressures, dimensional data. Technical Depth Depth Of Coverage: Comprehensive, covering all aspects from routine maintenance and adjustments to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and repair strategies. Manual Specifications File Format Digital Format: PDF Print Quality Digital Image Quality: High-resolution scans, ensuring clarity of diagrams, illustrations, and text. Searchable text for easy navigation. Binding Type Physical Binding Analogue: N/A (Digital PDF) Paper Type Physical Paper Analogue: N/A (Digital PDF) Engine Specifications Primary Engine Engine Displacement Options: 250cc, 300cc, 400cc, 500cc Engine Type: Single-cylinder, liquid-cooled, 4-stroke (specific configurations vary by model, details within manual) Performance Horsepower And Torque: Specific figures vary by engine size and tuning; detailed performance data and curves are within the manual. Fuel System Carburetion Type: Mikuni carburetors (specific models vary by engine size, details provided in manual) Fuel Type Recommendation: Unleaded gasoline (octane rating specified in manual) Transmission Standard Transmission Type Standard: Manual (clutch lever operation) Optional Transmission Type Optional: Automatic (CVT - Continuously Variable Transmission) Features Drive Modes: 2WD/4WD engagement, potentially with locking differentials on certain models (e.g., 400/500 series). Transmission Fluid Type: Specific gear oil and CVT fluid types and capacities detailed in manual. Dimensions Exterior Wheelbase Range: Varies by model; specific dimensions for each ATV variant are present in the manual. Weights Dry Weight Range: Approximate dry weights range from 500 lbs (227 kg) for smaller models to over 650 lbs (295 kg) for larger 500cc variants. Exact figures in manual. Safety Features Ratings Atv Safety Standards: Adherence to ANSI/SVIA standards for ATV safety (where applicable for the era). Active Features Braking System: Hydraulic disc brakes (front and rear) with specific service procedures and fluid types. Passive Features Operator Safety Considerations: Guidance on safe operation, rider training, protective gear, and machine limitations as per factory recommendations. Technology Features Infotainment Instrument Panel Features: Digital odometer, trip meter, hour meter, neutral indicator, reverse indicator, high beam indicator, oil pressure warning light, engine temperature warning light (if equipped). Driver Assistance Electronic Aids: Limited to engine management and ignition systems. No advanced electronic driver assistance systems typical of modern vehicles. Maintenance Service Intervals Oil Change Interval: Typically every 100 hours or annually, whichever comes first. Exact interval in manual. Air Filter Cleaning Interval: Recommended cleaning or replacement every 20-40 hours of operation, or more frequently in dusty conditions. Specific guidance in manual. Spark Plug Replacement Interval: Generally recommended every 100-200 hours or annually. Manual provides specific plug type and gap. Example: NGK DPR7EA-9. Fluid Specifications Engine Oil Type: API SG or higher, SAE 10W-40 or 20W-50 (depending on ambient temperature). Manual specifies exact grades and capacities. Coolant Type: Ethylene glycol-based antifreeze/coolant (50/50 mix with distilled water). Manual specifies capacity and type. Brake Fluid Type: DOT 3 or DOT 4 hydraulic brake...