ARCTIC CAT SNOWMOBILE F7 EFI Replacement Parts Manual 2004
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A A RC CC T T I
®
Illustrated Parts Manual
2004
Firecat 700 EFI
™
Model Number S2004F7FEFUSG
Model Number S2004F7FEFUSB
Model Number S2004F7FEFUSR
Model Number S2004F7FEBUSG (EXT)
Model Number S2004F7FEBUSB (EXT)
Model Number S2004F7FEBUSR (EXT)
Model Number S2004F7FEBOSB (International)
TABLE OF CONTENTS
2004 Firecat 700 EFI
(Model No. S2004F7FEFUSG - Green) (Model No. S2004F7FEBUSG - EXT Green)
(Model No. S2004F7FEFUSB - Black) (Model No. S2004F7FEBUSB - EXT Black)
(Model No. S2004F7FEFUSR - Red) (Model No. S2004F7FEBUSR - EXT Red)
(Model No. S2004F7FEBOSB - Black - International)
NOTE: The illustrations used in this Parts Manual are for reference to replacement part numbers only and
are not to be used for assembly. For assembly procedures, use an Arctic Cat Service Manual. Underlined
part numbers are new for the 2004 model year.
2003 Arctic Cat Inc. Printed August 2003
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
SKI AND SPINDLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A-ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SHOCK ABSORBER AND SWAY BAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT SUSPENSION SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STEERING POST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TIE ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HANDLEBAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HYDRAULIC BRAKE CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DRIVE TRAIN SHAFTS AND BRAKE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DRIVE/DROPCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SLIDE RAIL AND TRACK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SLIDE RAIL AND TRACK ASSEMBLY (EXT/International) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
IDLER WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REAR SUSPENSION FRONT ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REAR SUSPENSION FRONT ARM SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REAR SUSPENSION REAR ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REAR SUSPENSION REAR ARM SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FRONT FRAME AND FOOTREST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
HOOD AND WINDSHIELD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
HEADLIGHT, INSTRUMENTS, AND WIRING ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . 21
CONSOLE AND SWITCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
BELLY PAN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BELT GUARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
GAS TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FUEL PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TUNNEL, REAR BUMPER, AND TAILLIGHT ASSEMBLY (EXT/International) . . . . . . . . . . . . 29
COOLING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGINE AND RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
EXHAUST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
AIR SILENCER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OIL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CYLINDER AND HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
PISTON AND CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REED VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
THROTTLE BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
WATER PUMP AND THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SERVOMOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
RELATED ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
2004 Firecat 700 EFI
1
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
SKI AND SPINDLE ASSEMBLY
0738-641
1 0703-900 2 Ski, Plastic - Green
1703-109 2 Ski, Plastic - Black (Black/International)
1703-500 2 Ski, Plastic - Red (Red)
2 1603-248 2 Handle, Plastic - Green
1603-897 2 Handle, Plastic - Yellow
(Black/International)
1603-395 2 Handle, Plastic - Red (Red)
3 1703-472 1 Wearbar - Right
1703-473 1 Wearbar - Left
4 1703-501 2 Saddle, Ski - Platinum (inc. 5)
5 0603-621 4 ² Insert, Ski Saddle
6 1703-370 1 Spindle, Steering - Right - Platinum
(inc. 7-14)
1703-371 1 Spindle, Steering - Left - Platinum
(inc. 7-14)
7 0603-158 4 ² Bearing
8 0603-083 4 ² Bearing
9 1623-010 2 ² Fitting, Grease
10 0603-647 4 ² Insert, Spindle
11 8005-584 2 ² Screw, Cap
12 0623-796 2 ² Ring, Retaining
13 1603-203 6 ² Washer, Thrust
14 1703-413 2 ² Arm, Steering
15 0603-034 2 Axle, Spindle
16 5611-384 2 Decal, “AWS” - Spindle
17 0623-831 2 Cap, Spindle
18 8048-366 4 Nut, Lock
19 8017-581 4 Screw, Machine
20 0603-036 2 Damper, Ski
21 0623-552 2 Screw, Cap
22 0123-458 2 Pin, Cotter
23 0623-728 4 Washer
24 0123-296 2 Nut, Lock
25 8048-486 8 Nut, Lock
26 8048-426 4 Nut, Lock
27 8020-143 2 Screw, Cap
28 8020-135 2 Screw, Cap
2004 Firecat 700 EFI
2
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
A-ARM ASSEMBLY
0738-642
1 1703-245 1 A-Arm, Lower - Right - Platinum (inc. 2)
1703-246 1 A-Arm, Lower - Left - Platinum (inc. 2)
2 1603-895 8 ² Bearing
3 1703-094 2 A-Arm, Upper - Platinum (inc. 4)
4 0603-083 8 ² Bearing
5 0623-952 2 Screw, Cap
6 0623-664 4 Washer
7 1603-563 2 Axle, Inner - Upper Arm
8 8048-486 8 Nut, Lock
9 0603-864 2 Tube, Axle
10 8020-230 4 Screw, Cap
11 2603-179 4 Axle, Inner - Lower Arm
12 2606-886 1 Brace, Lower A-Arm
13 1623-009 2 Screw, Cap
14 8040-546 2 Nut, Lock
15 1603-616 4 Axle, Powder Metal
16 8026-232 2 Screw, Cap
2004 Firecat 700 EFI
3
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
SHOCK ABSORBER AND SWAY BAR ASSEMBLY
0738-643
1 1703-449 2 Shock, Ski
2 1603-890 2 Retainer, Spring
3 8048-486 8 Nut, Lock
4 1603-023 4 Sleeve, Shock
5 0623-991 2 Washer
6 8020-232 2 Screw, Cap
7 0603-648 2 Spacer, Shock Mount
8 1703-201 2 Spring, Compression - Yellow
9 1703-144 1 Sway Bar
10 1603-211 2 Bearing
11 0603-558 2 Arm, Sway Bar
12 8020-225 2 Screw, Cap
13 8020-224 2 Screw, Cap
14 1603-002 2 Link, Sway Bar
15 8048-426 4 Nut, Lock
16 8020-137 4 Screw, Cap
2004 Firecat 700 EFI
4
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
FRONT SUSPENSION SHOCK ABSORBER
(Complete Shock Absorber p/n 1703-449 )
0738-644
1 2603-262 1 Body, Shock
2 1603-501 1 Eyelet, Shock
3 1603-995 1 Rod, Shock
4 0603-991 1 Bumper, Shock
5 1703-452 1 Cap, Shock (inc. 6)
6 1604-271 1 ² O-Ring
7 1603-996 1 Piston, 0.120 in. - Orifice
8 1604-274 1 Strap, Piston - Teflon
9 1604-272 1 Washer, Top Out
10 2603-055 2 Valve, 0.800 x 0.010 in.
11 2603-065 2 Valve, 0.900 x 0.010 in.
12 2603-075 2 Valve, 1.000 x 0.010 in.
13 2603-095 2 Valve, 1.100 x 0.010 in.
14 2603-124 1 Valve, 1.250 x 0.008 in.
15 2603-047 1 Valve, 0.700 x 0.015 in.
16 2603-052 1 Valve, 0.800 x 0.006 in.
17 2603-132 1 Valve, 1.300 x 0.006 in.
18 2603-122 2 Valve, 1.250 x 0.006 in.
19 2603-062 1 Valve, 0.900 x 0.006 in.
20 2603-125 1 Valve, 1.250 x 0.010 in.
21 1604-273 1 Washer, Backup
22 0623-696 1 Nut, Lock
23 1603-911 1 Nut, Adjuster
24 0704-791 1 Piston, Floating (inc. 25-26)
25 2604-153 1 ² Strap, Piston - Teflon
26 2604-152 1 ² O-Ring
27 2603-012 1 Sleeve, Protector
28 1603-209 2 Sleeve, Eyelet
29 1603-914 2 Bushing, Shock
30 0624-546 1 Screw, Valve
31 0704-796 1 Valve, Pressure (inc. 32)
32 2604-162 1 ² O-Ring, Valve
33 0603-955 2 Bushing, Shock
34 2639-151 AR Oil, Gas Shock - 6 qt Case
2004 Firecat 700 EFI
5
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
STEERING POST ASSEMBLY
0738-645 *Optional
1 0705-961 1 Post, Steering
2 0605-513 1 Riser, Handlebar - 4.44 in.
0605-491 1 Riser, Handlebar - 5.44 in.*
0605-512 1 Riser, Handlebar - 6.44 in.*
0605-514 1 Riser, Handlebar - 2.44 in.*
3 0705-355 2 Cap, Adjusting Block - Upper
4 0605-676 2 Cap, Adjusting Block - Lower
5 0623-872 8 Screw, Cap
6 0605-649 1 Plate, Retaining
7 0605-576 2 Block, Mounting - Steering Post
8 8017-579 2 Screw, Machine
9 8040-426 2 Nut, Lock
10 8048-366 4 Nut, Lock
11 8004-225 1 Screw, Cap
12 0623-025 3 Nut, Lock
13 0605-504 1 Ball Joint, Tie Rod - Right
14 0623-294 1 Nut, Hex - Right
15 0605-672 1 Tube, Tie Rod
16 0123-917 1 Nut, Hex - Left
17 0605-511 1 Ball Joint, Tie Rod - Left
18 0623-044 2 Washer
19 0705-947 1 Stop, Steering Post
20 8017-402 2 Screw, Machine
2004 Firecat 700 EFI
6
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
TIE ROD ASSEMBLY
0737-862
1 0705-397 1 Shaft, Steering
2 0623-954 4 Washer, Thrust
3 0623-955 2 Washer, Thrust
4 0605-635 2 Arm, Shaft
5 0623-956 2 Snap Ring
6 8005-584 2 Screw, Cap
7 0705-890 1 Shaft, Idler
8 0605-607 2 Ball Joint, Tie Rod - Left
9 1623-176 2 Screw, Cap
10 0605-673 2 Tube, Tie Rod - Spindle
11 0123-917 3 Nut, Hex - Left
12 0623-294 3 Nut, Hex - Right
13 0605-608 2 Ball Joint, Tie Rod - Right
14 0623-957 2 Screw, Cap
15 0605-605 1 Ball Joint, Tie Rod - Left
16 0605-312 1 Tube, Tie Rod
17 0605-606 1 Ball Joint, Tie Rod - Right
18 1606-079 2 Plug
2004 Firecat 700 EFI
7
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
CONTROL ASSEMBLY
0737-973 *Not a Service Part
1 0609-632 1 Control, Throttle - Assembly
(inc. 2-6 and two No. 7)
2 0609-576 1 ² Control, Housing Half (inc. 3-5)
3 0609-611 1 ² ² Clip, Retaining
4 0609-615 1 ² ² Plate
5 0609-612 2 ² ² Screw, Self-Tapping
6 0609-633 1 ² Control, Switch Half
7 0609-604 4 ² Screw, Machine
8 0609-501 2 Seal, Throttle Lever
9 0609-036 2 Washer
10 0609-040 1 E-Ring
11 0609-577 1 Axle, Lever - Throttle
12 0609-565 1 Lever, Throttle
13 0609-595 1 Clip, Retaining
14 1639-963 1 Tool, Removal - Kit - Throttle Cable
15 0609-623 1 Element, Thumbwarmer
16 0617-248 1 Pad, Insulator
17 0609-628 1 Control, Stop Switch/Warmer - Assembly
(inc. two No. 7 and 18-25)
18 0609-636 1 ² Control, Warmer Half (inc. 19-22)
19 0609-605 1 ² ² Screw, Machine
20 0609-573 1 ² ² Knob, Handwarmer
21 0609-606 1 ² ² Screw, Machine
22 0609-572 1 ² ² Knob, Thumbwarmer
23 0609-635 1 ² Control, Stop Switch Half (inc. 24-25)
24 0609-607 2 ² ² Screw, Machine
25 * 1 ² ² Switch, Stop
26 0123-788 AR Cable Tie - 8 in.
27 0687-155 1 Cable, Throttle (inc. 28)
28 0623-464 1 ² Nut, Locking - Throttle Cable
2004 Firecat 700 EFI
8
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
HANDLEBAR ASSEMBLY
0737-720
1 0705-417 1 Handlebar
2 1606-442 1 Grip, Handlebar - Right
2606-400 1 Grip, Handlebar - Left
3 0609-626 1 Element, Handwarmer - Right
0609-627 1 Element, Handwarmer - Left
4 0705-927 1 Wrap, Handlebar Pad (inc. 5)
5 0619-797 1 ² Foam, Handlebar Pad
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This Parts Manual is a comprehensive resource, featuring illustrated Exploded Parts Diagrams that provide a detailed overview of all the parts in your vehicle. It is an invaluable tool for disassembly, repair, and reassembly, with all part numbers conveniently listed in sections.
The manual is designed to be clear and easily understandable, making it suitable for both professional mechanics and DIY enthusiasts. It includes illustrations, part numbers, and descriptions to help you accurately identify the right part for your needs.
With the ability to print any necessary page, you can conveniently obtain the replacement part you require without incurring the high costs associated with dealership prices. This manual is compatible with all PC and MAC computers, and is instantly accessible upon payment, eliminating the need for shipping costs.
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