Complete Service Repair Manual
Arctic Cat Snowmobile 2004

This Manual is specifically written for the do-it-yourselfer as well as the experienced mechanic. Using this repair manual is an inexpensive way to keep you vehicle working properly. Each manual provides step-by-step instructions based on the complete disassembly of the machine. The high level of detail, along with hundreds of illustrations and details guide the reader through each service and repair procedure.
This is the same manual used by dealer technicians to service, repair and mantain your Arctic Cat Snowmobile 2004.

Models covered:
AC 440 SNO PRO
BEARCAT 570
BEARCAT WIDE TRACK
FIRECAT 500
FIRECAT 600
FIRECAT 600 EFI
FIRECAT 700
FIRECAT 700 EFI
KING CAT 900
MOUNTAIN CAT 570
MOUNTAIN CAT 600 EFI
MOUNTAIN CAT 800 EFI
MOUNTAIN CAT 900
MOUNTAIN CAT 900 EFI
PANTERA 550
PANTERA 600 EFI
PANTERA 800 EFI
PANTHER 370
PANTHER 570
SABERCAT 500
SABERCAT 600
SABERCAT 600 EFI
SABERCAT 700 EFI
T660
T660 TURBO
Z 370
Z 440
Z 570
ZR 120
ZR 900
ZR 900 EFI

Typical Index of Contents:
1 - General Specifications
Snowmobile Identification
Recommended Gasoline and Oil
Break-In Procedure
Genuine Parts
High Altitude Operation
Drive Chain Lubrication
Low Oil Pressure Warning Light
Preparation For Storage
Preparation After Storage
After Break-In Checkup (100 Miles - 2-Stroke/600 Miles - 4-Stroke)
After Break-In Checkup Checklist
Engine Specifications (2-Stroke)
Engine Specifications (4-Stroke)
Cylinder Head Volume Specifications (2-Stroke)
Engine Piston Travel Versus
Crank Angle Chart (2-Stroke)
Crankshaft Runout/Repair Specifications(2-Stroke)
Fraction/Decimal Conversions
MM/IN. Conversions
Torque Conversions (ft-lb/N-m)
Tightening Torque (General Bolts)
Assembly Schematics/Torque Specifications
(Table of Contents)
Engine Torque Patterns
Arctic Power Valve (APV) System
Specifications (2-Stroke)
Oil Consumption Specifications (2-Stroke)
EFI Specifications
Throttle Valve Angle Specifications
Fuel Pump Specifications
Carburetor Specifications
Electrical Specifications
Ignition Timing Specifications (2-Stroke)
Steering/Body Torque Specifications
Drive System Specifications
Drive Clutch/Driven Pulley-Related
Specifications
Arctic Cat Drive Belt Dimensions
Drive System Components
Gear Case Performance Calibrations
Drive System Torque Specifications
Rear Suspension Torque Specifications
Track Warranty Guidelines
Track Specifications
Front Suspension Specifications
Rear Suspension Specifications
Shock Absorber Specifications
Idler Wheel Dimensions
2 - Engine
Engine - 120
Engine - 570/F 570/T570
Engine - 500/600
Engine - 700/800/1000
Engine - 370/440/550/570
Engine - 900/1000
Engine - 660/660 T
Troubleshooting Engine (2-Stroke Carbureted Models)
Troubleshooting Engine (2-Stroke EFI Models)
Troubleshooting Engine (4-Stroke)
3 - Engine-Related Items
Water Pump
Pressure Testing Engine (2-Stroke)
Removing Spark Plugs
Checking Compression
Servicing Valves
Installing Spark Plugs
Changing Oil/Filter
Changing Oil
Testing Oil Pressure
Oil Flow Chart
Liquid Cooling System
Cooling System Schematics
Recoil Starter
Air Silencer
Air Intake Assembly
Turbocharger/Intercooler
Arctic Power Valve (APV) System (2-Stroke)
Exhaust Controlled Timing (ECT) System (2-Stroke)
4 - Fuel Systems
Fuel System (Carbureted)
Fuel System (EFI)
Fuel System (Related Items)
5 - Electrical Systems
Testing Components
Transistorized Ignition System (120)
Ignition System (2-Stroke)
Throttle Position Sensor (2-Stroke EFI Models)
Testing Main Wiring Harness (120 cc)
Testing Electrical Resistances
Voltage Regulator Test
Chassis Control Unit
Servomotor/Potentiometer Test
Peak Voltage Tests
Testing Low-Oil Light Sensor
Testing Coolant Temperature Sensor
Testing Coolant Temperature Warning Light
Testing Fuel Gauge
Testing Fuel Gauge Sender
Testing Electric Fuel Pump
Testing Ignition Key Switch
Testing Ignition Components
Emergency Stop Switch
Solenoid (Electric Start Models)
Fuse
Ignition Switch - Electric Start Function
Starter Motor
Magneto
Troubleshooting Electric Start
Ignition Timing
Brakelight Switch
Headlight Dimmer Switch
Testing Handlebar Warmer Elements
Testing Thumb Warmer Element
Testing Handlebar Warmer/Thumb Warmer/Switch
Testing Passenger Handwarmer Switch
Testing Passenger Handwarmer Elements
Testing Seat Heater Harness/Switches
Testing Speedometer Sensor
Testing Reverse Alarm Switch
Testing Shift Actuator Switch
Testing Shift Actuator
Troubleshooting Servomotor
6 - Drive Train/Track/Brake Systems
Drive Chain and Sprockets and Driveshaft
Brake System
Drive Belt
Drive Clutch
Driven Pulley
Drive Clutch/Driven Pulley
Drive Train/Brake Disc
Drive Sprockets
Track Tension
Track Alignment
Brake System (Hydraulic)
Brake Lever/Master Cylinder Assembly
Troubleshooting Track
Troubleshooting Hydraulic Brake System
Troubleshooting Drive Clutch/Driven Pulley
Troubleshooting Drive Belt
7 - Rear Suspension
Understanding the Suspension
Suspension Setup Basics
Chassis and Skid Frame Mounting Locations
Servicing Rear Suspension
Servicing ACT Shock
Rebuilding/Recharging Fox Air Shocks
Servicing Fox Zero Pro Shock Absorbers
Shaft Eyelet
Pressurizing Rebuildable Shocks
8 - Steering and Body
Steering Post
Ski
Drag Link
Tie Rods
Spindle
Steering Tie Rod
Ski Alignment
Front Suspension - Shock Absorber
Sway Bar
Front Suspension Mounting Bracket
Console
Belly Pan
Front Bumper/Belly Pan Assembly
Gas Tank/Seat Assembly
Seat/Cushion/Taillight Housing
Taillight/Brakelight Assembly
Windshield
Backrest/Rack Assembly
Tunnel/Rear Bumper/Snowflap
Tunnel/Chassis/Rear Bumper/Snowflap
Rear Storage Compartment
Headlight Assembly
Adjusting Headlight Aim

Snowmobile Wiring Diagrams 2004


Language: ENG
File Format: PDF
Requirements: Adobe PDF Reader
Specifications: High quality - Fully Bookmarked - Printable
Compatible: All Windows and Mac Computers

All systems, maintenance and repairs are covered.
Hundreds of photos & Wiring diagrams showing complete procedures of disassembly and reassembly.