2004 Arctic Cat 250 300 400 500 ATV Repair Manual
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TABLE OF CONTENTS
1. General Information
2. Periodic Maintenance/Tune-Up
3. Engine/Transmission
4. Fuel/Lubrication/Cooling
5. Electrical System
6. Drive System
7. Suspension
8. Steering/Frame
9. Controls/Indicators
10. Aids for Maintenance
11. Troubleshooting
1
2
3
4
5
6
7
8
9
10
11
2004 ATV SERVICE MANUAL
SECTION
Click on the BLUE text to go!
1-1
1
SECTION 1 - GENERAL INFORMATION
TABLE OF
CONTENTS
General Specifications (250) ................................... 1-2
General Specifications (300) ................................... 1-3
General Specifications
(400/400 TBX - Automatic Transmission) ............. 1-4
General Specifications
(400 - Manual Transmission) ................................ 1-5
General Specifications
(500 - Manual Transmission) ................................ 1-6
General Specifications
(500/500 TBX/TRV - Automatic Transmission) ..... 1-7
Break-In Procedure ................................................. 1-8
Gasoline - Oil - Lubricant ........................................ 1-8
Genuine Parts ......................................................... 1-9
Preparation For Storage ........................................ 1-10
Preparation After Storage...................................... 1-10
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1-2
General Specifications*
(250)
* Specifications subject to change without notice.
** One inch below plug threads.
CARBURETOR
Type Keihin CVK32
Main Jet 138
Slow Jet 38
Low Speed Fuel Screw Setting
(turns)
1 3/4
Jet Needle N8TT
Needle Jet 4.0/3.4
Idle RPM 1300-1400
Starter Jet 60
Float Arm Height 17 mm (0.7 in.)
Throttle Cable Free-Play
(at lever)
3-6 mm
(1/8-1/4 in.)
ELECTRICAL
Ignition Timing 5° BTDC below 1800 RPM
35° BTDC above 3800 RPM
Spark Plug Type NGK DR7EA
Spark Plug Gap 0.6-0.7 mm (0.024-0.028 in.)
Spark Plug Cap 8000-12,000 ohms
Ignition Coil Resistance
(primary)
(secondary)
0.4-0.6 ohm
(terminal to ground)
5200-7800 ohms
(high tension - plug cap
removed - to ground)
Ignition Coil Peak (primary/CDI)
Voltage
98.3-147.5 volts
(terminal to ground)
Magneto Coil Resistance (trigger)
(charging)
84-126 ohms (black/yellow to
green/white)
0.44-0.66 ohm (yellow to
yellow)
Magneto Coil Peak (trigger)
Voltage
(charging)
3.12-4.68 volts (black/yellow
to green/white)
30-45 volts (yellow to yellow)
Magneto Output (approx) 220W @ 5000 RPM
CHASSIS
Dry Weight (approx) 2x4 - 245 kg (540 lb)
4x4 - 261 kg (575 lb)
Length (overall) 202 cm (79.5 in.)
Height (overall) 114 cm (45 in.)
Width (overall) 114 cm (45 in.)
Suspension Travel 16.5 cm (6.5 in.)
Ground Clearance 20.3 cm (8.0 in.)
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Wheelbase 127 cm (50 in.)
Tracking 89 cm (35 in.)
Tire Size Front - AT23 x 8-12
Rear - AT24 x 9-12
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
Turning Radius 3.0 m (9.85 ft)
MISCELLANY
Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.)
Reserve Capacity 2.46 L (0.65 U.S. gal.)
Engine Oil Capacity 3.5 L (3.7 U.S. qt)
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) SAE 10W-40
Differential Capacity (front - 4x4) 275 ml (9.3 fl oz)**
Differential Lubricant (front - 4x4) SAE Approved
80W-90 Hypoid
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/27W
Headlight 12V/27W (2)
Starting System Electric w/Manual Recoil
(Emergency)
Back to Table of Contents Back to Table of Contents Back to Section Table of Contents
1-3
1
General Specifications*
(300)
* Specifications subject to change without notice.
** One inch below plug threads.
CARBURETOR
Type Keihin CVK32
Main Jet 135
Slow Jet 38
Low Speed Fuel Screw Setting
(turns)
2 1/4
Jet Needle N8TT
Needle Jet 4.0/3.4
Idle RPM 1300-1400
Starter Jet 65
Float Arm Height 17 mm (0.7 in.)
Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.)
ELECTRICAL
Ignition Timing 5° BTDC @ 1800 RPM
30° BTDC @ 3800 RPM
Spark Plug Type NGK DR7EA
Spark Plug Gap 0.6-0.7 mm (0.024-0.028 in.)
Spark Plug Cap 8000-12,000 ohms
Ignition Coil Resistance (primary)
(secondary)
0.4-0.6 ohm
(terminal to ground)
5200-7800 ohms
(high tension - plug cap
removed - to ground)
Ignition Coil Peak (primary/CDI)
Voltage
98.3-147.5 volts
(terminal to ground)
Magneto Coil Resistance (trigger)
(charging)
84-126 ohms
(black/yellow to green/white)
0.44-0.66 ohm
(yellow to yellow)
Magneto Coil Peak (trigger)
Voltage (charging)
3.12-4.68 volts (black/yellow
to green/white)
30-45 volts (yellow to yellow)
Magneto Output (approx) 220W @ 5000 RPM
CHASSIS
Dry Weight (approx) 263 kg (580 lb)
Length (overall) 202 cm (79.5 in.)
Height (overall) 114 cm (45 in.)
Width (overall) 114 cm (45 in.)
Suspension Travel 16.5 cm (6.5 in.)
Ground Clearance 20.3 cm (8.0 in.)
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Wheelbase 127 cm (50 in.)
Tracking 89 cm (35 in.)
Tire Size Front - AT24 x 9-12
Rear - AT25 x 10-12
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
Turning Radius 2.7 m (8.9 ft)
MISCELLANY
Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.)
Reserve Capacity 2.46 L (0.65 U.S. gal.)
Differential Capacity (front) 275 ml (9.3 fl oz)**
Engine Oil Capacity 3.5 L (3.7 U.S. qt)
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) SAE 10W-40
Differential Lubricant (front) SAE Approved
80W-90 Hypoid
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/27W
Headlight 12V/27W (2)
Starting System Electric w/Manual Recoil
(Emergency)
Back to Table of Contents Back to Table of Contents Back to Section Table of Contents
1-4
General Specifications*
(400/400 TBX - Automatic
Transmission)
* Specifications subject to change without notice.
** One inch below plug threads.
*** At the plug threads.
CARBURETOR
Type Keihin CVK34
Main Jet 150
Slow Jet 38
Low Speed Fuel Screw Setting
(turns)
2 1/8
Jet Needle N8TV
Needle Jet 4.0/3.4
Idle RPM 1250-1350
Starter Jet 60
Float Arm Height 17 mm (0.7 in.)
Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.)
ELECTRICAL
Ignition Timing 10° BTDC @ 1500 RPM
Spark Plug Type NGK CR7E
Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.)
Spark Plug Cap 8000-12,000 ohms
Ignition Coil Resistance (primary)
(secondary)
0.4-0.6 ohm
(terminal to ground)
5200-7800 ohms
(high tension - plug cap
removed - to ground)
Ignition Coil Peak (primary/CDI)
Voltage
160.8-241.2 volts
(terminal to ground)
Magneto Coil Resistance (trigger)
(source)
(charging)
160-240 ohms
(green to blue)
0.08-0.12 ohm
(yellow to white)
0.32-0.48 ohm
(black to black)
Magneto Coil Peak (trigger)
Voltage (source)
(charging)
5.04-7.56 volts (green to
blue)
0.7-1.05 volts (yellow to
white)
12.5-18.6 volts (black to black
#1) (black to black #2)
Magneto Output (approx) 220W @ 5000 RPM
CHASSIS
Dry Weight (approx) 2x4 - 268 kg (590 lb)
4x4 - 282 kg (622 lb) - ACT
4x4 - 286 kg (630 lb) - FIS
4x4 - 323.5 kg (713 lb) - TBX
Length (overall) 2x4 - 202 cm (79.5 in.)
4x4 - 205 cm (81 in.)
4x4 - 244.5 cm (96 in.) - TBX
Height (overall) 122 cm (48 in.) - ACT
125 cm (49.3 in.) - FIS
Width (overall) 112 cm (44.25 in.) - ACT
121 cm (47.5 in.) - FIS
CHASSIS (Cont)
Suspension Travel (front) 21.5 cm (8.45 in.) - ACT
25 cm (10 in.) - FIS
Suspension Travel (rear) 18.2 cm (7.2 in.) - ACT
25 cm (10 in.) - FIS
Ground Clearance 20.3 cm (8 in.)
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Wheelbase 127 cm (50 in.)
Wheel Stance 89 cm (35 in.)
Tire Size Front - 25 x 8-12
Rear - 25 x 10-12 - ACT
Rear - 25 x 10-12 - FIS
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
Turning Radius 2.7 m (8.9 ft)
MISCELLANY
Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.)
Reserve Capacity 2.46 L (0.65 U.S. gal.)
Rear Drive Capacity 275 ml (9.3 fl oz) - ACT***
250 ml (8.5 fl oz) - FIS**
Differential Capacity (front - 4x4) 275 ml (9.3 fl oz)**
Engine Oil Capacity 3.08 L (3.25 U.S. qt)
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) SAE 10W-40
Differential/Rear Drive Lubricant SAE Approved
80W-90 Hypoid
Drive Belt Width 30.3 mm (1.19 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/27W
Headlight 12V/27W (2)
Starting System Electric w/Manual Recoil
(Emergency)
Back to Table of Contents Back to Table of Contents Back to Section Table of Contents
1-5
1
General Specifications*
(400 - Manual Transmission)
* Specifications subject to change without notice.
** One inch below plug threads.
*** At the plug threads.
CARBURETOR
Type Keihin CVK34
Main Jet 150
Slow Jet 38
Low Speed Fuel Screw Setting
(turns)
2 1/8
Jet Needle N8TV
Needle Jet 4.0/3.4
Idle RPM 1250-1350
Starter Jet 60
Float Arm Height 17 mm (0.7 in.)
Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.)
ELECTRICAL
Ignition Timing 10° BTDC @ 1500 RPM
Spark Plug Type NGK CR7E
Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.)
Spark Plug Cap 8000-12,000 ohms
Ignition Coil Resistance (primary)
(secondary)
0.4-0.6 ohm
(terminal to ground)
5200-7800 ohms
(high tension - plug cap
removed - to ground)
Igniton Coil Peak (primary/CDI)
Voltage
160.8-241.2 volts
(terminal to ground)
Magneto Coil Resistance (trigger)
(source)
(charging)
160-240 ohms
(green to blue)
0.08-0.12 ohm
(yellow to white)
0.32-0.48 ohm
(black to black)
Magneto Coil Peak (trigger)
Voltage (source)
(charging)
5.04-7.56 volts (green to blue)
0.7-1.05 volts
(yellow to white)
12.5-18.6 volts
(black to black #1)
(black to black #2)
Magneto Output (approx) 220 W @ 5000 RPM
CHASSIS
Dry Weight (approx) 2x4 - 261 kg (577 lb)
4x4 - 276 kg (609 lb) - ACT
4x4 - 280 kg (617 lb) - FIS
Length (overall) 2x4 - 202 cm (79.5 in.)
4x4 - 205 cm (81 in.)
Height (overall) 122 cm (48 in.) - ACT
125 cm (49.3 in.) - FIS
Width (overall) 112 cm (44.25 in.) - ACT
121 cm (47.5 in.) - FIS
Suspension Travel (front) 21.5 cm (8.45 in.) - ACT
25 cm (10 in.) - FIS
CHASSIS (Cont)
Suspension Travel (rear) 18.2 cm (7.2 in.) - ACT
25 cm (10 in.) - FIS
Ground Clearance 20.3 cm (8 in.)
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Wheelbase 127 cm (50 in.)
Wheel Stance 89 cm (35 in.)
Tire Size Front - 25 x 8-12
Rear - 25 x 10-12 - ACT
Rear - 25 x 10-12 - FIS
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
Turning Radius 2.7 m (8.9 ft)
MISCELLANY
Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.)
Reserve Capacity 2.46 L (0.65 U.S. gal.)
Rear Drive Capacity 275 ml (9.3 fl oz) - ACT***
250 ml (8.5 fl oz) - FIS**
Differential Capacity (front - 4x4) 275 ml (9.3 fl oz)**
Engine Oil Capacity 3.08 L (3.25 U.S. qt)
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) SAE 10W-40
Differential/Rear Drive Lubricant SAE Approved
80W-90 Hypoid
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/27W
Headlight 12V/27W (2)
Starting System Electric w/Manual Recoil
(Emergency)
Back to Table of Contents Back to Table of Contents Back to Section Table of Contents
1-6
General Specifications*
(500 - Manual Transmission)
* Specifications subject to change without notice.
** One inch below plug threads.
*** At the plug threads.
CARBURETOR
Type Keihin CVK36
Main Jet 148
Slow Jet 75
Low Speed Fuel Screw Setting
(turns)
1 7/8
Jet Needle N3RS
Needle Jet 6.0/4.0
Idle RPM 1250-1350
Starter Jet 90
Float Arm Height 17 mm (0.7 in.)
Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.)
ELECTRICAL
Ignition Timing 10° BTDC @ 1500 RPM
Spark Plug Type NGK CR6E
Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.)
Spark Plug Cap 8000-12,000 ohms
Ignition Coil Resistance (primary)
(secondary)
0.4-0.6 ohm
(terminal to ground)
5200-7800 ohms
(high tension - plug cap
removed - to ground)
Igniton Coil Peak (primary/CDI)
Voltage
142.4-213.6 volts
(terminal to ground)
Magneto Coil Resistance (trigger)
(source)
(charging)
160-240 ohms
(green to blue)
0.08-0.12 ohm
(yellow to white)
0.32-0.48 ohm
(black to black)
Magneto Coil Peak (trigger)
Voltage (source)
(charging)
4.2-6.3 volts (green to blue)
0.40-0.62 volt
(yellow to white)
9.44-14.2 volts
(black to black #1)
(black to black #2)
Magneto Output (approx) 325W @ 5000 RPM
CHASSIS
Dry Weight (approx) 288.5 kg (636 lb)
Length (overall) 205 cm (81 in.)
Height (overall) 125 cm (49.3 in.)
Width (overall) 120.7 cm (47.5 in.)
Suspension Travel (front) 25 cm (10 in.)
Suspension Travel (rear) 25 cm (10 in.)
Ground Clearance 20.3 cm (8 in.)
CHASSIS (Cont)
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Wheelbase 127 cm (50 in.)
Tracking 89 cm (35 in.)
Tire Size Front - 25 x 8-12
Rear - 25 x 11-12
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
Turning Radius 2.7 m (8.9 ft)
MISCELLANY
Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.)
Reserve Capacity 2.46 L (0.65 U.S. gal.)
Coolant Capacity 2.9 L (3.0 U.S. qt)
Differential Capacity 275 ml (9.3 fl oz)**
Rear Drive Capacity 250 ml (8.5 fl oz)***
Engine Oil Capacity 3.4 L (3.5 U.S. qt)
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) SAE 10W-40
Differential/Rear Drive Lubricant SAE Approved
80W-90 Hypoid
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/27W
Headlight 12V/27W (2)
Starting System Electric w/Manual Recoil
(Emergency)
Back to Table of Contents Back to Table of Contents Back to Section Table of Contents
1-7
1
General Specifications*
(500/500 TBX/TRV - Automatic
Transmission)
* Specifications subject to change without notice.
** One inch below plug threads.
*** At the plug threads.
CARBURETOR
Type Keihin CVK36
Main Jet 148
Slow Jet 75
Low Speed Fuel Screw Setting
(turns)
1 7/8
Jet Needle N3RS
Needle Jet 6.0/4.0
Idle RPM 1250-1350
Starter Jet 90
Float Arm Height 17 mm (0.7 in.)
Throttle Cable Free-Play (at lever) 3 -6 mm (1/8-1/4 in.)
ELECTRICAL
Ignition Timing 10° BTDC @ 1500 RPM
Spark Plug Type NGK CR6E
Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.)
Spark Plug Cap 8000-12,000 ohms
Ignition Coil Resistance (primary)
(secondary)
0.4-0.6 ohm
(terminal to ground)
5200-7800 ohms
(high tension - plug cap
removed - to ground)
Igniton Coil Peak (primary/CDI)
Voltage
142.4-213.6 volts
(terminal to ground)
Magneto Coil Resistance (trigger)
(source)
(charging)
160-240 ohms
(green to blue)
0.08-0.12 ohm
(yellow to white)
0.32-0.48 ohm
(black to black)
Magneto Coil Peak (trigger)
Voltage (source)
(charging)
4.2-6.3 volts (green to blue)
0.40-0.62 volt
(yellow to white)
9.44-14.2 volts
(black to black #1)
(black to black #2)
Magneto Output (approx) 325W @ 5000 RPM
CHASSIS
Dry Weight (approx) 293 kg (646 lb)
331.5 kg (731 lb) - TBX
339 kg (748 lb) - TRV
Length (overall) 205 cm (81 in.)
244.5 cm (96 in.) - TBX/TRV
Height (overall) 125 cm (49.3 in.)
128 cm (50.5 in.) - TRV
Width (overall) 120.7 cm (47.5 in.)
Suspension Travel (front) 25 cm (10 in.)
Suspension Travel (rear) 25 cm (10 in.)
Ground Clearance 20.3 cm (8 in.)
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Wheelbase 127 cm (50 in.)
147 cm (58 in.) - TRV
Tracking 89 cm (35 in.)
Tire Size Front - 25 x 8-12
Rear - 25 x 11-12
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
Turning Radius 2.7 m (8.9 ft)
MISCELLANY
Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.)
Reserve Capacity 2.46 L (0.65 U.S. gal.)
Coolant Capacity 2.9 L (3.0 U.S. qt)
Differential Capacity 275 ml (9.3 fl oz)**
Rear Drive Capacity 250 ml (8.5 fl oz)***
Engine Oil Capacity 2.5 L (2.6 U.S. qt)
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) SAE 10W-40
Differential/Rear Drive Lubricant SAE Approved
80W-90 Hypoid
Drive Belt Width 36.7 mm (1.44 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/27W
Headlight 12V/27W (2)
Starting System Electric w/Manual Recoil
(Emergency)
Back to Table of Contents Back to Table of Contents Back to Section Table of Contents
1-8
Break-In Procedure
A new ATV and an overhauled ATV engine require a
“break-in” period. The first 10 hours (or 200 miles) are
most critical to the life of this ATV. Proper operation
during this break-in period will help assure maximum
life and performance from the ATV.
During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the engine
RPM during the break-in period allows the compo-
nents to “load” (aiding the mating process) and then
“unload” (allowing components to cool). Although it
is essential to place some stress on the engine compo-
nents during break-in, care should be taken not to
overload the engine too often. Do not pull a trailer or
carry heavy loads during the 10-hour break-in period.
When the engine starts, allow it to warm up properly.
Idle the engine several minutes until the engine has
reached normal operating temperature. Do not idle the
engine for excessively long periods of time.
During the break-in period, a maximum of 1/2 throttle
is recommended; however, brief full-throttle accelera-
tions and variations in driving speeds contribute to
good engine break-in.
During the break-in period (or whenever the brake
pads are replaced), the hydraulic brake pads must be
burnished. Slow disc-speed hydraulic brakes must be
properly burnished in order to achieve maximum stop-
ping power.
NOTE: Do not be reluctant to heat up the brake
pads during the burnishing procedure.
After the completion of the break-in period, the engine
oil and oil filter should be changed. Other maintenance
after break-in should include checking of all pre-
scribed adjustments and tightening of all fasteners.
Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum
octane regular unleaded. In many areas, oxygenates
(either ethanol or MTBE) are added to the gasoline.
Oxygenated gasolines containing up to 10% ethanol,
5% methane, or 5% MTBE are acceptable gasolines.
When using ethanol blended gasoline, it is not neces-
sary to add a gasoline antifreeze since ethanol will pre-
vent the accumulation of moisture in the fuel system.
RECOMMENDED ENGINE/
TRANSMISSION OIL
The recommended oil to use is Arctic Cat 4-Cycle
Engine Oil (p/n 0436-005) or an equivalent oil which
is rated SE, SF, or SG under API service classification.
These oils meet all of the lubrication requirements of
the Arctic Cat ATV engine. The recommended engine
oil viscosity is SAE 10W-40. Ambient temperature
should determine the correct weight of oil. See the
following viscosity chart for details.
VISCOSITY CHART
OILCHART
! CAUTION
BRAKE PADS MUST BE BURNISHED TO
ACHIEVE FULL BRAKING EFFECTIVENESS.
Braking distance will be extended until brake
pads are properly burnished.
TO PROPERLY BURNISH THE BRAKES, USE
FOLLOWING PROCEDURE:
Choose an area sufficiently large to safely
accelerate ATV to 30 mph and to brake to a stop.
Accelerate to 30 mph; then compress brake
lever to decelerate to 0-5 mph.
Repeat procedure five times until brakes are
burnished.
This procedure burnishes the brake pads,
stabilizes the pad material, and extends the life
of the brake pads.
! WARNING
Do not attempt sudden stops or put the ATV into
a situation where a sudden stop will be required
until the brake pads are properly burnished.
! CAUTION
Do not use white gas. Only Arctic Cat approved
gasoline additives should be used.
! CAUTION
Any oil used in place of the recommended oil
could cause serious engine damage. Do not use
oils which contain graphite or molybdenum
additives. These oils can adversely affect clutch
operation. Also, not recommended are racing,
vegetable, non-detergent, and castor-based oils.
Back to Section Table of Contents
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1-9
1
RECOMMENDED FRONT
DIFFERENTIAL/REAR DRIVE
LUBRICANT
The recommended lubricant is Arctic Cat Gear Lube
(p/n 0436-007) or an equivalent gear lube which is
SAE approved 80W-90 hypoid. This lubricant meets
all of the lubrication requirements of the Arctic Cat
ATV front differentials and rear drives.
FILLING GAS TANK
ATV0049B
Since gasoline expands as its temperature rises, the gas
tank must be filled to its rated capacity only. Expan-
sion room must be maintained in the tank particularly
if the tank is filled with cold gasoline and then moved
to a warm area.
Tighten the gas tank cap securely after filling the tank.
Genuine Parts
When replacement of parts is necessary, use only gen-
uine Arctic Cat ATV parts. They are precision-made to
ensure high quality and correct fit. Refer to the appro-
priate Illustrated Parts Manual for the correct part
number, quantity, and description.
! CAUTION
Any lubricant used in place of the recommended
lubricant could cause serious front differential/
rear drive damage.
! WARNING
Always fill the gas tank in a well-ventilated area.
Never add fuel to the ATV gas tank near any open
flames or with the engine running. DO NOT
SMOKE while filling the gas tank.
! WARNING
Do not overflow gasoline when filling the gas
tank. A fire hazard could materialize. Always
allow the engine to cool before filling the gas
tank.
! WARNING
Do not over-fill the gas tank.
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The manual covers the following models:
- 2004 ARCTIC CAT 250 4X2 ATV
- 2004 ARCTIC CAT 250 4X4 ATV
- 2004 ARCTIC CAT 300 4X4 ATV
- 2004 ARCTIC CAT 400 4X2 ATV
- 2004 ARCTIC CAT 400 4X2 AUTO ATV
- 2004 ARCTIC CAT 400 4X4 (ATC) ATV
- 2004 ARCTIC CAT 400 4X4 ATV
- 2004 ARCTIC CAT 400 4X4 AUTO (ACT) ATV
- 2004 ARCTIC CAT 400 4X4 AUTO ATV
- 2004 ARCTIC CAT 400 4X4 AUTO TBX ATV
- 2004 ARCTIC CAT 500 4X4 ATV
- 2004 ARCTIC CAT 500 4X4 AUTO ATV
- 2004 ARCTIC CAT 500 4X4 AUTO TBX ATV
- 2004 ARCTIC CAT 500 4X4 AUTO TRV ATV
Our informative shop, service, repair manual, owner's manuals, and parts catalogs contain all the information you'll need to perform repairs, look up parts, or do routine maintenance on your machine. They include topics such as:
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- Fuel System
- Lubrication and Cooling System
- Engine Specifications
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- Intake & Exhaust
- Electrical System
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