🏷️ Basic Information Identification Make: Arctic Cat Model: ATV Year: 2004 Generation Generation Designation: First Generation (Pre-2006 Redesign) 👋 Introduction Market Position Target Audience: Owners of 2004 Arctic Cat 250, 300, 400, and 500 series ATVs seeking to perform their own maintenance, repairs, and diagnostics. Competitive Analysis Manual Advantage: Offers comprehensive coverage for multiple ATV models within a single, easily accessible digital format, unlike fragmented or proprietary service information. Key Features Delivery Method: Instant download post-payment, eliminating shipping delays and costs. Usability: Designed for ease of use on various devices (computers, tablets, smartphones) for on-the-trail or workshop reference. Support: Includes a lifetime protection policy for lost or damaged files. 📋 Manual Details Coverage Areas Covered Models: 250 4x2, 250 4x4, 300 4x4, 400 4x2, 400 4x2 AUTO, 400 4x4 (ATC), 400 4x4, 400 4x4 AUTO (ACT), 400 4x4 AUTO, 400 4x4 AUTO TBX, 500 4x4, 500 4x4 AUTO, 500 4x4 AUTO TBX, 500 4x4 AUTO TRV Manual Type Type: Repair Manual / Service Manual / Workshop Manual Format Format Type: Downloadable PDF Language Language: English 📖 Manual Coverage Systems Covered Engine: Detailed coverage of engine removal, installation, tuning, and internal component overhaul (pistons, rings, valves, crankshaft, etc.). Includes specific torque values and clearances. Fuel System: Carburetor adjustment, cleaning, and rebuilding. Fuel pump operation, fuel filter replacement, and fuel line maintenance. Lubrication And Cooling: Oil change procedures, fluid specifications, oil filter replacement. Radiator maintenance, fan operation, thermostat testing, and coolant flush. Transmission Drivetrain: Manual and Automatic transmission service, including fluid checks, changes, and internal repairs. Drive chain inspection, adjustment, and replacement. CV joint maintenance and boot replacement. Steering: Steering column maintenance, tie rod end replacement, steering linkage adjustments, and troubleshooting steering play. Shocks Suspension: Front and rear shock absorber inspection, service, and replacement. Suspension arm bushings and ball joint checks and replacement. Bodywork: Panel removal and installation, fender repairs, and cosmetic maintenance. Seat and rack installation/removal. Intake Exhaust: Air filter inspection and replacement. Exhaust system inspection for leaks and damage. Muffler and pipe maintenance. Electrical System: Battery testing and maintenance, charging system (stator, regulator/rectifier) diagnostics. Starter motor and solenoid testing. Lighting system troubleshooting. Ignition system components (spark plug, coil). Wiring diagrams for all electrical circuits. Procedures Included Maintenance: Routine maintenance schedules, lubrication points, filter replacement intervals (oil, air), spark plug maintenance, and general cleaning procedures. Troubleshooting: Comprehensive diagnostic procedures for common and complex issues across all systems. Symptom-based troubleshooting guides. Repair Rebuild: Detailed step-by-step instructions for disassembling, inspecting, repairing, and reassembling major components and systems, including engine internals, transmissions, and suspension. Diagnostics: Fault finding, testing procedures for electrical components, fuel system diagnostics, and mechanical system checks. Technical Depth Depth Level: Advanced diagnostics, complete engine and transmission rebuilds, detailed electrical system troubleshooting, and component-level repair. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Fully searchable text for quick access to information. Print Quality Print Readability: Optimized for clear printing, allowing users to print specific pages for workshop use. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Quality: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine 250 Engine Type: Single-cylinder, 4-stroke Displacement Cc 250: Approximately 248.9 cc (specific variants may differ slightly) Primary Engine 300 Engine Type: Single-cylinder, 4-stroke Displacement Cc 300: Approximately 287 cc Primary Engine 400 Engine Type: Single-cylinder, 4-stroke, SOHC Displacement Cc 400: Approximately 375 cc Primary Engine 500 Engine Type: Single-cylinder, 4-stroke, SOHC Displacement Cc 500: Approximately 498.5 cc Performance Cooling System: Liquid-cooled (all covered models) Fuel System Carburetor Type: Mikuni (specific models vary, e.g., Mikuni BSR42/BSR40) Engine Specifications Ignition System: CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Transmission Type Manual: 5-speed manual with reverse (e.g., 250, 300, 400 models) Optional Transmission Type Automatic: CVT (Continuously Variable Transmission) with Hi/Low range and Reverse (e.g., 400 AUTO, 500 AUTO models) Features Drive System: 2WD or 4WD (selectable or automatic engagement depending on model) Final Drive: Shaft drive with enclosed U-joints and differentials. Fluid Specifications Cv Fluid: Specific CVT fluid required (refer to manual for exact type, often a proprietary blend or specified SAE grade). 📐 Dimensions Exterior Length Typical Length In: Approx. 78-82 inches (varies by model) Exterior Width Typical Width In: Approx. 46-48 inches (varies by model) Exterior Height Typical Height In: Approx. 45-48 inches (varies by model) Weights Typical Dry Weight Lbs: Approx. 550-650 lbs (varies significantly by model and configuration) Typical Ground Clearance In: Approx. 7-11 inches (varies by model) 🛡️ Safety Features Ratings Safety Standards: Manufactured to meet applicable industry safety standards for ATVs. Active Features Braking System: Hydraulic disc brakes (front and rear). Rear parking brake. Passive Features Lighting: Headlights, taillight, and brake light. 💡 Technology Features Infotainment Infotainment System: Not Applicable (Basic ATV controls, no digital infotainment system). Driver Assistance Driver Assistance Features: None (standard controls for throttle, brake, gear selection, 2WD/4WD). Connectivity Connectivity Options: None (standard...
Owners of 2004 Arctic Cat 250, 300, 400, and 500 series ATVs seeking to perform their own maintenance, repairs, and diagnostics.
Competitive Analysis
Manual Advantage:
Offers comprehensive coverage for multiple ATV models within a single, easily accessible digital format, unlike fragmented or proprietary service information.
Key Features
Delivery Method:
Instant download post-payment, eliminating shipping delays and costs.
Usability:
Designed for ease of use on various devices (computers, tablets, smartphones) for on-the-trail or workshop reference.
Support:
Includes a lifetime protection policy for lost or damaged files.
📋 Manual Details
Coverage Areas
Covered Models:
250 4x2, 250 4x4, 300 4x4, 400 4x2, 400 4x2 AUTO, 400 4x4 (ATC), 400 4x4, 400 4x4 AUTO (ACT), 400 4x4 AUTO, 400 4x4 AUTO TBX, 500 4x4, 500 4x4 AUTO, 500 4x4 AUTO TBX, 500 4x4 AUTO TRV
Manual Type
Type:
Repair Manual / Service Manual / Workshop Manual
Format
Format Type:
Downloadable PDF
Language
Language:
English
📖 Manual Coverage
Systems Covered
Engine:
Detailed coverage of engine removal, installation, tuning, and internal component overhaul (pistons, rings, valves, crankshaft, etc.). Includes specific torque values and clearances.
Fuel System:
Carburetor adjustment, cleaning, and rebuilding. Fuel pump operation, fuel filter replacement, and fuel line maintenance.
Lubrication And Cooling:
Oil change procedures, fluid specifications, oil filter replacement. Radiator maintenance, fan operation, thermostat testing, and coolant flush.
Transmission Drivetrain:
Manual and Automatic transmission service, including fluid checks, changes, and internal repairs. Drive chain inspection, adjustment, and replacement. CV joint maintenance and boot replacement.
Steering:
Steering column maintenance, tie rod end replacement, steering linkage adjustments, and troubleshooting steering play.
Shocks Suspension:
Front and rear shock absorber inspection, service, and replacement. Suspension arm bushings and ball joint checks and replacement.
Bodywork:
Panel removal and installation, fender repairs, and cosmetic maintenance. Seat and rack installation/removal.
Intake Exhaust:
Air filter inspection and replacement. Exhaust system inspection for leaks and damage. Muffler and pipe maintenance.
Electrical System:
Battery testing and maintenance, charging system (stator, regulator/rectifier) diagnostics. Starter motor and solenoid testing. Lighting system troubleshooting. Ignition system components (spark plug, coil). Wiring diagrams for all electrical circuits.
Procedures Included
Maintenance:
Routine maintenance schedules, lubrication points, filter replacement intervals (oil, air), spark plug maintenance, and general cleaning procedures.
Troubleshooting:
Comprehensive diagnostic procedures for common and complex issues across all systems. Symptom-based troubleshooting guides.
Repair Rebuild:
Detailed step-by-step instructions for disassembling, inspecting, repairing, and reassembling major components and systems, including engine internals, transmissions, and suspension.
Diagnostics:
Fault finding, testing procedures for electrical components, fuel system diagnostics, and mechanical system checks.
Technical Depth
Depth Level:
Advanced diagnostics, complete engine and transmission rebuilds, detailed electrical system troubleshooting, and component-level repair.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Fully searchable text for quick access to information.
Print Quality
Print Readability:
Optimized for clear printing, allowing users to print specific pages for workshop use.
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Quality:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine 250
Engine Type:
Single-cylinder, 4-stroke
Displacement Cc 250:
Approximately 248.9 cc (specific variants may differ slightly)
5-speed manual with reverse (e.g., 250, 300, 400 models)
Optional
Transmission Type Automatic:
CVT (Continuously Variable Transmission) with Hi/Low range and Reverse (e.g., 400 AUTO, 500 AUTO models)
Features
Drive System:
2WD or 4WD (selectable or automatic engagement depending on model)
Final Drive:
Shaft drive with enclosed U-joints and differentials.
Fluid Specifications
Cv Fluid:
Specific CVT fluid required (refer to manual for exact type, often a proprietary blend or specified SAE grade).
📐 Dimensions
Exterior Length
Typical Length In:
Approx. 78-82 inches (varies by model)
Exterior Width
Typical Width In:
Approx. 46-48 inches (varies by model)
Exterior Height
Typical Height In:
Approx. 45-48 inches (varies by model)
Weights
Typical Dry Weight Lbs:
Approx. 550-650 lbs (varies significantly by model and configuration)
Typical Ground Clearance In:
Approx. 7-11 inches (varies by model)
🛡️ Safety Features
Ratings
Safety Standards:
Manufactured to meet applicable industry safety standards for ATVs.
Active Features
Braking System:
Hydraulic disc brakes (front and rear). Rear parking brake.
Passive Features
Lighting:
Headlights, taillight, and brake light.
💡 Technology Features
Infotainment
Infotainment System:
Not Applicable (Basic ATV controls, no digital infotainment system).
Driver Assistance
Driver Assistance Features:
None (standard controls for throttle, brake, gear selection, 2WD/4WD).
Connectivity
Connectivity Options:
None (standard analog instrumentation).
🔧 Maintenance
Service Intervals
Oil Change Interval Hours:
Typically every 100 hours or annually (refer to specific model recommendations within the manual).
Air Filter Inspection:
Inspect every 20-40 hours or as needed based on operating conditions. Clean or replace as necessary.
Spark Plug Replacement:
Replace typically every 100-200 hours or as indicated by performance.
Fluid Specifications
Engine Oil Type:
SAE 10W-40 or 20W-50, API SG or higher (refer to manual for exact specification, e.g., Arctic Cat SYN-4 4-Stroke Oil).
Engine Oil Capacity Qts:
Approx. 2.0-2.5 quarts (varies by model, check dipstick).
Coolant Type:
Ethylene glycol-based antifreeze, compatible with aluminum engines (typically a 50/50 mix with distilled water).
Known Issues
Common Wear Items:
CV boots, tie rod ends, wheel bearings, brake pads, and drive belts (for CVT models) are common wear items.
Carburetor Issues:
Carburetor clogging due to fuel varnish or debris is a common maintenance point for older carbureted models.
📚 Vehicle History
Brand Heritage
Arctic Cat Atv History:
Arctic Cat has a long history in powersports, transitioning from snowmobiles to ATVs and UTVs, known for their utility and off-road capabilities.
Model Evolution
2004 Model Context:
The 2004 models represent a mature generation of Arctic Cat ATVs, incorporating improvements based on previous years of production. The 400 and 500 series were particularly popular for their performance and utility.
Production
Manufacturing Location:
Typically manufactured in Thief River Falls, Minnesota, USA.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Specific awards for the 2004 models are not prominently documented, but Arctic Cat ATVs from this era were generally well-regarded for their performance and utility in the utility ATV segment.