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Manual Details
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Coverage Areas
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Primary Coverage:
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Comprehensive service and repair for 2002 Arctic Cat 2-Stroke Snowmobiles
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Model List:
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Bearcat W/T, Mountain Cat 500, Mountain Cat 570, Mountain Cat 600 EFI, Mountain Cat 600 EFI LE, Mountain Cat 800, Mountain Cat 800 LE, Mountain Cat 800 EFI, Mountain Cat 800 EFI LE, Mountain Cat 1000, Pantera 550, Pantera 600 EFI, Pantera 800 EFI, Panther 440, Panther 570 ESR, Panther 570 R, Thundercat, Z 370, Z 370 ES, Z 440, Z 440 ES, Z 570, Z 570 ESR, Z 570 SS, ZL 500, ZL 550, ZL 550 ESR, ZL 600 EFI, ZL 600 EFI ESR, ZL 600 EFI SS, ZL 800 EFI ESR, ZL 800 EFI SS, ZR 120, ZR 500, ZR 500 LE, ZR 600, ZR EFI, ZR 800, ZR 800 EFI, ZRT 600
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Page Count
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Estimated Page Count:
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Likely extensive, covering all listed models and systems.
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Manual Type
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Type:
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Service Repair Manual
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Language
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Language:
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English
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Format
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Format:
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PDF Download
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Manual Coverage
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Systems Covered
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Engine:
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Complete engine overhaul, including diagnosis, disassembly, inspection, and reassembly of internal components. Covers cylinder, piston, crankshaft, connecting rods, seals, gaskets, and cooling systems.
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Fuel System:
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Detailed procedures for carburetor tuning, jetting, cleaning, and repair. Covers fuel pump, fuel lines, filters, and fuel injection (EFI) systems if applicable to specific models.
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Engine Electrical:
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Ignition system diagnostics, stator, flywheel, magneto, CDI unit, spark plugs, and wiring harnesses.
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Chassis Electrical:
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Headlights, taillights, brake lights, battery charging system (rectifier/regulator), starter motor, switches, and general wiring diagrams.
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Steering Body:
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Handlebar assembly, steering post, tie rods, skis, body panels, plastics, fenders, and seat removal/installation.
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Drive Train Brakes:
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Clutch service (primary and secondary), drive belt inspection and replacement, chaincase, differential (if applicable), and brake system service (pads, rotors, hydraulic lines, master cylinder).
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Track Rear Suspension:
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Track inspection, alignment, and replacement. Rear suspension components, including shocks, springs, bogey wheels, and adjusters.
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Procedures Included
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Maintenance:
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Scheduled maintenance, oil changes, lubrication points, filter replacements, and general upkeep.
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Troubleshooting:
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Diagnostic procedures for common problems, including no-spark issues, starting problems, engine misfires, and electrical faults.
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Repair:
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Step-by-step instructions for major component repairs and overhauls.
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Installation:
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Procedures for installing new components and accessories.
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Technical Depth
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Depth:
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Comprehensive, covering everything from basic adjustments and fluid changes to complete engine rebuilds and electrical system diagnostics. High-quality diagrams and detailed instructions suitable for DIY enthusiasts and professional mechanics.
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Engine Specifications
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Primary Engine
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Engine Configuration:
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2-Stroke (various displacements including 370cc, 440cc, 500cc, 550cc, 570cc, 600cc, 800cc, 1000cc, 120cc - specific configurations vary by model).
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Performance
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Horsepower Range:
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Varies significantly by model, typically ranging from approximately 60 HP for smaller displacement engines to over 130 HP for larger displacement, high-performance models.
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Torque Characteristics:
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Not explicitly detailed but crucial for clutch engagement and overall performance, covered within the manual's procedures.
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Fuel System
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Fuel Type:
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High-octane gasoline (typically 91 octane or higher recommended for 2-stroke engines), mixed with appropriate 2-stroke oil.
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Carburetor Details:
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Details on specific carburetor models (e.g., Mikuni VM series) and their adjustment procedures (idle speed, mixture screw, pilot jet, main jet) will be covered.
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Efi Systems:
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For EFI models, the manual will cover fuel injectors, throttle body, ECU, sensors, and fuel pump operation.
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Maintenance
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Service Intervals
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Oil Change:
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Critical for 2-stroke engines, involves checking/topping up injection oil and proper fuel/oil mixture. Specific intervals depend on usage, detailed in manual.
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Clutch Inspection:
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Regular inspection of drive and driven clutches, belt condition, and alignment is recommended at intervals often tied to mileage or operating hours.
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Spark Plug Maintenance:
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Regular inspection and gap adjustment of spark plugs for optimal combustion.
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Fluid Specifications
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Engine Oil Type:
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High-quality, JASO FD certified 2-stroke synthetic or semi-synthetic oil is essential for the oil injection system and fuel mix. Specific viscosity and brand recommendations will be detailed.
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Coolant Type:
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For liquid-cooled models, a specific ethylene glycol-based antifreeze with corrosion inhibitors is required. Manual will specify type and capacity.
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Gearcase Oil:
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Specific gear oil for the drive train/chaincase will be specified, typically a multi-viscosity gear oil.
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Known Issues
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Carburetor Fouling:
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Common in 2-stroke engines due to oil and fuel residue; requires periodic cleaning and adjustment.
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Drive Belt Wear:
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Drive belts can wear over time and require regular inspection for cracks, fraying, and proper tension.
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Suspension Bushings:
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Wear on suspension bushings and bearings can lead to looseness and reduced handling performance.
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