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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.