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Arctic Cat 300 Utility, Service Manual, Page: 103 / 118

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Arctic Cat 300 Utility Service Manual Download Page 103

100

KM927

KM928

5. Heat the gear case to approximately 180° F and using

a blind-bushing puller, remove the pinion needle
bearing.

CLEANING AND INSPECTING

1. Clean all components in parts cleaning solvent and

dry with compressed air.

2. Inspect all bearings for excessive wear, discolor-

ation, roughness in turning, or flaking.

3. Inspect gears for excessive wear, chipped teeth, flak-

ing, or discoloration.

4. Inspect the gear case and cover for cracks, warpage,

or scoring of bearing bores.

5. If seals have not been removed and will be reused,

inspect for nicks, tears, missing tension springs, or
excessive wear on lips.

ASSEMBLING

1. Drive the bearings into the gear case and gear case

cover using an appropriate bearing driver. Make sure
the bearing is firmly seated.

KM926

KM928

2. Apply grease to the seal lips; then using a seal driver,

drive the seals into the gear case and cover (flat side
out) until flush with the seal bore.

KM927A

KM925A

3. Drive a new pinion needle bearing into the gear case;

then apply molybdenum disulfide grease to the nee-
dle bearing. Secure with the snap ring.

Summary of Contents for 300 Utility

Page 1: ...300 UTILITY DVX 300 ATV SERVICE MANUAL 2014 ...

Page 2: ...ications and decals display the words Warning Caution Note and At This Point to emphasize important information The symbol WARNING identifies personal safety related information Be sure to fol low the directive because it deals with the possibility of serious injury or even death A CAUTION identifies unsafe practices which may result in ATV related damage Follow the directive because it deals with...

Page 3: ......

Page 4: ...s 51 Removing Right Side Components 52 Servicing Right Side Components 57 Installing Right Side Components 64 Center Crankcase Components 65 Separating Crankcase Halves 65 Disassembling Crankcase Half 65 Servicing Center Crankcase Components 65 Assembling Crankcase Half 66 Joining Crankcase Halves 67 Installing Engine Transmission 67 Troubleshooting 70 Fuel Lubrication Cooling 73 Carburetor 73 Thr...

Page 5: ...on Coil Resistance primary secondary 2 4 3 0 ohms 12 300 16 600 ohms Ignition Coil Peak Voltage primary CDI 9 6 16 4 DC volts Magneto Coil Resistance trigger charging 105 110 ohms Less than 1 ohm Stator Coil Peak Voltage trigger 1 1 1 4 DC volts Magneto Output approx 220W 5000 RPM Stator Coil Output no load 40 60 AC volts 3500 RPM CAMSHAFT AND CYLINDER HEAD Cam Lobe Height min intake exhaust 34 15...

Page 6: ...ase 40 54 Axle Housing Cap Screw DVX Swing Arm 29 39 DRIVE TRAIN COMPONENTS Engine Mounting Through Bolt Frame 29 39 Engine Mounting Bracket Cap Screw Frame 16 22 Rear Axle Housing Utility Swing Arm 40 54 Rear Axle Housing DVX Tube 29 39 Gear Case Swing Arm 50 68 Pinion Nut Shaft 72 98 Gear Case Cover 8 mm 10 mm Gear Case 19 36 26 49 Hub Nut Front Front Spindle 50 68 Wheel Lug Nut Hub 40 54 Hub Nu...

Page 7: ... 10 ethanol or 5 methane are acceptable gasolines When using ethanol blended gasoline it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system RECOMMENDED ENGINE OIL The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil which has been specifically formulated for use in this Arctic Cat engine Although Arctic ...

Page 8: ...the air filter housing cover and air filter Start the engine and allow it to idle then using Arctic Cat Engine Storage Preserver slowly inject the preserver into the air filter opening for a period of 10 to 20 seconds then stop the engine Install the air filter and housing cover 4 Drain the carburetor float chamber 5 Plug the exhaust hole in the exhaust system with a clean cloth 6 Apply light oil ...

Page 9: ...brake systems fluid level pads etc all controls headlights taillight brakelight and headlight aim adjust or replace as necessary 8 Tighten all nuts bolts cap screws and screws mak ing sure all calibrated nuts cap screws and bolts are tightened to specifications 9 Check tire pressure Inflate to recommended pressure as necessary 10 Make sure the steering moves freely and does not bind 11 Check the s...

Page 10: ... or Every 500 Miles EveryYear or Every 1500 Miles As Needed Battery I I C Air Filter Drain Tube I I C R Valve Tappet Clearance I I A Spark Plug I I R 4000 Mi or 18 Mo Muffler Spark Arrester C R Gas Vent Hoses I I R 2 Yrs Gas Tank Valve I C Throttle Cable I I C L A R Carb Float Chamber D Engine RPM Idle I I A Engine Oil Level I A Engine Oil Screen C C C Drive Chain DVX I I C L Rear Drive Lubricant ...

Page 11: ...d secure with the clamp 9 Install the air filter housing cover and secure with the retaining clips then install the seat making sure it locks securely CHECKING DRAINING DRAIN TUBE Periodically check the drain tube for gasoline or oil accu mulation If noticed remove the drain tube cap from beneath the housing and drain the gasoline or oil into a suitable container then install and secure the tube c...

Page 12: ...ay from the spark plug hole 4 Attach the gauge from Compression Tester Kit NOTE The engine must be warm and the battery must be fully charged for this test 5 While holding the throttle lever in the full open posi tion crank the engine over with the electric starter until the gauge shows a peak reading five to 10 compression strokes NOTE The compression should be within a range of 210 230 psi in th...

Page 13: ...ark arrester KM139A 2 Using a soft wire brush clean the carbon from the screen 3 taking care not to tear or damage the screen KM140B 3 Install the spark arrester and secure with the cap screw Tighten securely Engine Oil Filter Replace the engine oil and clean the screen filter at the scheduled intervals The engine should always be warm when the oil is changed so the oil will drain easily and compl...

Page 14: ... fill plug 3 Remove the cap screws securing the rear drive gear guard then remove the guard 4 Drain the lubricant into a drain pan by removing the drain plug from the bottom of the rear drive NOTE If the rear drive lubricant is contaminated with water inspect the drain plug fill plug and or bladder 5 After all the lubricant has been drained install the drain plug and tighten securely Install the r...

Page 15: ... with an O ring type roller chain Each link incorporates small O rings to seal out water and dirt Care should be taken to choose cleaning solutions and lubricants that are suitable for O ring type chains 1 Using a suitable nonflammable cleaning solution thoroughly wash the chain and sprockets 2 Allow the chain to dry then apply a dry graphite based lubricant to the chain NOTE The drive chain shoul...

Page 16: ...ass portion of the bulb If the glass is touched it must be cleaned with a dry cloth before installing Skin oil residue on the bulb will shorten the life of the bulb To replace the headlight bulb use the following procedure 1 Remove the boot from the back of the headlight housing then remove the three wire connector from the bulb 2 Using care not to bend or deform the spring clip release the two en...

Page 17: ...oth ends of the shift rod and turn the shift rod until the neutral light illuminates Tighten the jam nuts securely KM313 NOTE On the DVX the neutral position in the trans mission is indexed by passing a Phillips screwdriver through the transmission shift arm and into the index hole in the transmission cover KM179A Hydraulic Brake Systems CHECKING BLEEDING The hydraulic brake systems have been fill...

Page 18: ...caps are installed and no leakage is present INSPECTING HOSES Carefully inspect the hydraulic brake hoses for cracks or other damage If found the brake hoses must be replaced CHECKING REPLACING FRONT PADS The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear The only maintenance that is required is replacement of the brake pads when they show excessi...

Page 19: ...s section MEASURING REPLACING REAR BRAKE PADS Utility Removing 1 Support the ATV on a suitable support stand 2 Remove the left rear wheel 3 Remove the two brake pad alignment pins A then remove the mounting cap screws B KM273A 4 Remove the caliper from the disc then compress the caliper holder and remove the brake pads KM267 Inspecting and Measuring 1 Inspect the pads for gouges chips or wear 2 In...

Page 20: ...r KM902B KM244 2 Remove the brake spring plate then remove the brake pads KM905 Inspecting and Measuring 1 Inspect the pads for gouges chips or wear 2 Inspect the disc for gouges grooves cracks and warpage 3 Using a calipers measure the thickness of each brake pad 4 If the thickness of any brake pad is less than 1 0 mm 0 039 in the brake pad must be replaced NOTE The brake pads should be replaced ...

Page 21: ...ove the left footwell then remove the recoil starter assembly On the DVX proceed to step 2 KM279 2 Remove the front and rear V belt housing cooling ducts 3 Remove the cap screws securing the V belt cover noting the location of the different lengthed cap screws for installing purposes then using a rubber mallet gently tap on the cover tabs to loosen the cover Remove the cover Account for two alignm...

Page 22: ...e face to the crankshaft with the drive pulley nut and tighten to 72 ft lb 5 Install the V belt cover and tighten the cap screws securely then connect the cooling boots and tighten the clamps securely KM252A 6 Install the recoil starter and footwell assembly Util ity Tighten all hardware securely CAUTION If the splines are not protruding as shown the V belt may be too deep in the drive sheaves Thi...

Page 23: ...ts and missing components Body REMOVING DVX 1 Remove the seat then remove the battery hold down strap battery and starter relay Lay the relay aside without disconnecting the wiring NOTE Always remove the negative battery cable first then the positive cable SP107 2 Remove the CDI start in gear relay and fuse block and lay aside without disconnecting the wires then remove the shift knob 3 Remove the...

Page 24: ...d rear fenders then remove the cap screws securing the mud guards to the front rests and remove the mud guards KM789A 6 Remove the side panels then remove the cap screws and flange nuts securing the front and rear fenders to the frame and fender supports KM799B 7 Disconnect the left and right headlight connectors then disconnect the taillight 8 Remove the gas tank cover then remove the shift knob ...

Page 25: ...propriately engaged with the fenders and side panels KM789A KM788A 5 Install the front center cover then install the front and rear racks Tighten all fasteners securely 6 Install the battery then connect the positive battery cable negative battery cable and battery hold down strap NOTE Always install the positive cable first then install the negative cable 7 Install the battery cover then install ...

Page 26: ... Remove the steering post cover DVX or the instru ment pod Utility then remove the cap screws securing the handlebar to the steering post Account for two handlebar holders KM189A 3 Lift the handlebar out of the lower handlebar holders and lay the handlebar forward 4 Remove the cotter pins and slotted nuts securing the tie rod ends to the steering post arm then disconnect the tie rods from the arm ...

Page 27: ...y a thin coat of grease to the lips of the lower steering post seals then lower the steering post into position in the lower steering post bearings KM593 2 Apply a thin coat of grease to the upper steering post bushing then secure the steering post with the support blocks and existing hardware Tighten to 17 ft lb KM589 KM595 3 Install the slotted nut on the lower steering post and tighten to 50 ft...

Page 28: ...ie rod lock nuts to 15 ft lb NOTE Prior to locking the jam nuts make sure the ball joints are at the center of their normal range of motion and at the correct angle NOTE The front wheels do not have to be removed to adjust the tie rod Also care should be taken not to disturb the handlebar position Front Brake Lever Master Cylinder Assembly NOTE The master cylinder is a non serviceable component it...

Page 29: ...re with the master cylinder clamp and two cap screws Make sure the UP arrow on the clamp is directed upward KM800B 3 Tighten the cap screw 1 to 13 ft lb then tighten the cap screw 2 to 13 ft lb KM800B 4 Using new crush washers secure the brake hose to the master cylinder with the brake hose union bolt Tighten to 25 ft lb KM800A 5 Fill the master cylinder with DOT 4 brake fluid then bleed the syste...

Page 30: ...the hole in the clevis is aligned with the hole in the brake pedal lever then tighten the jam nut securely CD476 KM801C 5 Fill the master cylinder reservoir with DOT 4 brake fluid and bleed the system see Periodic Mainte nance Tune Up Hydraulic Brake Systems Throttle Control REMOVING 1 Remove the boot from the throttle cable adjuster then loosen the jam nut and turn the adjuster com pletely in to ...

Page 31: ...d 8 Bolts nuts frame loose 1 Adjust pressure 2 Replace wheel s 3 Tighten replace cap screws 4 Replace bearing 5 Replace tighten tie rod ends 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts Problem Steering pulling to one side Condition Remedy 1 Tires inflated unequally 2 Front wheel alignment incorrect 3 Wheel hub bearings worn broken 4 Frame distorted 5 Shock absorber defective 1 Adjust p...

Page 32: ... and seals and lubricating all internal components when servicing the engine transmission SPECIAL TOOLS A number of special tools must be available to the techni cian when performing service procedures in this section Refer to the current Special Tools Catalog for the appro priate tool description NOTE Special tools are available from the Arctic Cat Service Parts Department Description p n Crankca...

Page 33: ...ols 6 Remove the air filter housing see Fuel Lubrication Cooling 7 Remove the gas tank see Fuel Lubrication Cooling 8 Remove the muffler assembly see Steering Frame Controls 9 Remove the carburetor see Fuel Lubrication Cooling 10 Remove the coil see Electrical System 11 Disconnect the stator connector shift position con nector and coolant temperature sensor KM348A KM324A 12 Remove the starter posi...

Page 34: ... boots from the V belt housing KM359A KM360A 15 Loosen the clamps then disconnect the coolant hoses from the engine KM323 KM314 16 Remove the output drive sprocket cover then remove the output drive sprocket KM344A 17 Disconnect the shift linkage from the transmission shift arm KM313 ...

Page 35: ...ise the front of the engine sufficiently to allow the engine assembly to be moved forward enough to clear the rear mounting brackets approximately 6 in 22 Lower the front of the engine slowly swing the rear of the engine to the left and slide the engine out of the left side of the frame KM330 KM331 Utility 1 Remove the seat then remove the battery box cover KM133A 2 Remove the negative cable from ...

Page 36: ...e the muffler assembly see Steering Frame Controls 9 Remove the carburetor see Fuel Lubrication Cool ing 10 Remove the coil see Electrical System 11 Disconnect the stator connector shift position con nector trigger coil connector and coolant tempera ture sensor KM347A KM324A 12 Remove the starter positive wire then remove the engine ground wire from the crankcase KM319A 13 Remove the front and rea...

Page 37: ...move the two engine mounting brackets from the frame KM414A 17 Attach a suitable lifting sling and engine lift to the front engine mounting boss then using an engine lift apply slight upward pressure on the engine transmission KM332A 18 Remove the upper rear and lower rear engine through bolts to free the engine transmission then raise the front of the engine transmission sufficiently to allow the...

Page 38: ...procedure Removing Top Side Components A Valve Cover B Cylinder Head NOTE Remove the spark plug and timing inspec tion plug then rotate the crankshaft to top dead cen ter of the compression stroke 1 On the right side remove the air hose from the cylin der head cover Retain the hose clamp KM941A 2 Remove the vent hose from the top of the cylinder head cover Retain the hose clamp 3 Remove the cap sc...

Page 39: ...ns KM706A KM707A 7 Remove the camshaft gear from the cam chain then secure the timing chain so it will not fall into the engine Remove the camshaft 8 Remove the two external cap screws securing the cylinder head to the cylinder then remove the cylin der head Account for two alignment pins and a cyl inder head gasket KM718A 9 Remove the cam chain guide then disconnect the coolant hose and remove th...

Page 40: ... faces and valve stem ends for pits discoloration or other signs of abnormal wear NOTE Whenever a valve is out of tolerance it must be replaced Cleaning Inspecting Camshaft Holder 1 Remove the rocker arm shafts rocker arms and stop plate from the camshaft holder KM708A 2 Inspect the camshaft holder for cracks distortion or galling 3 Inspect the rocker arm shafts for blue discoloration or scoring 4...

Page 41: ...et or dry sandpaper Using light pressure move the cylinder head in a figure eight motion Inspect the sealing surface for any indication of high spots A high spot can be noted by a bright metallic finish Correct any high spots before assem bly by continuing to move the cylinder head in a fig ure eight motion until a uniform bright metallic finish is attained Measuring Cylinder Head Distortion 1 Rem...

Page 42: ...or signs of excessive blowby Excessive blowby indicates worn piston rings or an out of round cylinder Removing Piston Rings 1 Starting with the top ring slide one end of the ring out of the ring groove CC400D 2 Remove each ring by working it toward the dome of the piston while rotating it out of the groove NOTE If the existing rings will not be replaced with new ones note the location of each ring...

Page 43: ...ng expander 4 in the bottom groove of the piston then install the thin oil rings 3 over the expander making sure the expander ends do not overlap Stagger the end gaps of the upper and lower thin oil rings according to the illustration NOTE Note the direction of the exhaust side of the piston 5 for correct ring end gap orientation ATV 1085B 2 Install the compression rings 1 and 2 so the letter on t...

Page 44: ...lable use a lightweight petroleum based oil Thoroughly clean cylinder after honing using soap and hot water Dry with compressed air then immediately apply oil to the cylinder bore If the bore is severely damaged or gouged replace the cylinder CC390D 4 If any measurement exceeds the limit replace the cylinder Installing Top Side Components A Piston B Cylinder 1 Install the piston on the connecting ...

Page 45: ...ith the index hole in the camshaft gear directed away from the cylinder head and the two punch marks aligned with the cylinder head surface install the timing gear into the cam chain and seat the cam shaft into the camshaft journals KM715A 9 Install the two alignment pins then install the cam shaft holder and secure with the four cylinder head nuts and washer Using a crisscross pattern tighten to ...

Page 46: ...emble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to be removed from the frame for this procedure Removing Left Side Components A Recoil Starter Utility 1 Remove the five recoil starter cover cap screws Remove the recoil starter assembly noting the loca tion ...

Page 47: ...belt KM369 6 Remove the drive pulley collar and the movable drive face taking care not to loose the rollers Servicing Left Side Components RECOIL STARTER Utility Removing Disassembling 1 Remove the cap screws securing the recoil starter assembly to the V belt cover then remove the starter Account for two alignment pins KM413A 2 Rotate the reel clockwise until the notch of the reel is near the rope...

Page 48: ... and case for cracks or damage 4 Inspect the shaft for wear cracks or damage 5 Inspect the rope for breaks or fraying 6 Inspect the spiral spring for cracks crystallization or abnormal bends 7 Inspect the handle for damage cracks or deteriora tion Assembling Installing 1 If removed insert the spiral spring into the case with the outer end of the spring around the mounting lug in the case then wind...

Page 49: ...curely KM410 9 With the 50 cm 20 in of rope exposed hook the rope in the notch of the reel 10 Rotate the reel four turns clockwise then release the rope from the notch and allow the rope to retract 11 Pull the rope out two or three times to check for cor rect tension and ratchet extender KM412 NOTE Increasing the rotations in step 10 will increase spring tension 12 Place the recoil starter assembl...

Page 50: ... grooving nicks or discoloration KM394A 3 Inspect the drive pulley collar for wear or damage Measure the outside diameter of the drive pulley col lar sliding surface The minimum service limit is 26 94 mm KM389 DRIVEN PULLEY CENTRIFUGAL CLUTCH ASSEMBLY Disassembling 1 Place the driven pulley on a suitable spring compres sor then mark the pulley faces and centrifugal clutch for alignment during asse...

Page 51: ...ushings from the fixed face hub then remove the movable face KM384 KM380 Inspecting 1 Inspect the pulley faces for wear galling or groov ing KM394A 2 Inspect the O rings on the movable face for nicks tears or swelling KM380A 3 Inspect two grease seals in the movable face for nicks cuts or damage KM380B ...

Page 52: ... lining is 0 5 mm NOTE If any shoe lining is below the service limit the complete set must be replaced Assembling 1 Place the fixed face of the driven pulley on the pulley compressor base NOTE Make sure the spacer is on the base or dam age to the fixed face will occur when the spring is compressed KX571 2 Apply multi purpose grease to the O rings and grease seals on the movable face then install o...

Page 53: ...Using a suitable holding fixture tighten the drive plate nut coated with red Loctite 271 to 43 ft lb Installing Left Side Components A Drive Pulley B Driven Pulley Centrifugal Clutch Assembly C V Belt Cover 1 Install the movable drive face and drive pulley collar on the crankshaft 2 Open the faces of the driven pulley then insert a suitable wedge between the faces to hold them apart 3 Place the V ...

Page 54: ...V belt cover and secure with the cap screws Tighten securely 8 On the Utility install the recoil starter and secure with the cap screws Tighten securely Right Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine tran...

Page 55: ...procket KM344A 3 Remove the cap screws securing the transmission case cover to the transmission then remove the cover Account for the dowel pins and gasket KM609A 4 Remove the output driveshaft circlip then remove the driveshaft from the transmission case cover KM611A 5 Remove the shift shaft then remove the plug Account for one shift cam stopper ball spring and seal washer KM677A KM619A 6 Remove ...

Page 56: ...M106 NOTE If the engine has not been removed remove the swing arm assembly see Suspension Swing Arm 2 Using a crisscross pattern remove four cap screws securing the secondary driven bevel gear assembly to the transmission case cover then remove the assem bly Account for an O ring KM646A 3 Remove the three cap screws securing the secondary drive bevel gear cover then remove the cover Account for a ...

Page 57: ...en removed see Removing Left Side Components in this section Remove only the V belt cover 6 Remove the eight cap screws securing the transmis sion case cover to the transmission case then remove the cover Account for a gasket A the secondary drive bevel gear washer B and two alignment pins C KM651A KM652A 7 Remove the shift shaft then remove plug seal washer spring and shift cam stopper ball KM677...

Page 58: ...4 B Remove the high drive gear circlip and washer then remove the high drive gear and thrust washer KM685 12 To disassemble the driveshaft use the following pro cedure A Remove the thrust washer then remove the reverse gear KM689A B Remove a thrust washer and the low reverse clutch dog KM690A C Remove the low driven gear snap ring and washer then remove the low driven gear and thrust washer ...

Page 59: ...Flywheel 14 Remove the right crankcase cover see Fuel Lubrica tion Cooling Water Pump 15 Remove the trigger coil mounting screws then remove the wire set plate KM772A 16 Remove the three cap screws securing the stator coil to the crankcase cover then remove the stator coil and trigger coil 17 Remove the oil through and spring from the end of the crankshaft then hold the rotor flywheel with an appr...

Page 60: ...g intact KM767A KM766A 21 Remove the two cap screws securing the oil baffle to the crankcase and remove the baffle then remove the snap ring securing the oil pump driven sprocket KM428 KM429 22 Remove the oil pump drive chain and oil pump driven sprocket 23 Remove the two cap screws securing the oil pump to the crankcase and remove the oil pump Servicing Right Side Components TRANSMISSION DVX Insp...

Page 61: ...place as required KM628 7 Inspect all bearings bushings seals and shafts for proper fit surface mating or discoloration Replace as required 8 Inspect transmission housing and cover for cracks scoring or galling of bearing bores or discoloration of cases Assembling 1 Place the thrust washer needle bearing reverse gear and splined retainer onto the main shaft then secure with the circlip KM631A 2 In...

Page 62: ...tall the shift shaft making sure the pin in the gear position switch engages the slot in the shift shaft and the shift shaft gear is correctly timed to the shift cam KM617A 7 Install the shift cam stopper ball spring seal washer and plug threads coated with red Loctite 271 Tighten to 35 ft lb KM619A TRANSMISSION Utility Inspecting 1 Measure the shift fork guide shaft runout If runout exceeds 0 03 ...

Page 63: ...to con tact the secondary driven bevel gear 3 Mount the indicator tip of the dial indicator on the secondary driven bevel gear centered on the gear tooth 4 While rocking the driven bevel gear back and forth note the maximum backlash reading on the gauge 5 Acceptable backlash range is 0 03 0 15 mm 0 001 0 006 in Correcting Backlash NOTE If backlash measurement is within the acceptable range no corr...

Page 64: ...rease or decrease shims as necessary on both secondary drive and driven gears equally Use the Tooth Contact Shim Correction chart above for shim selections Assembling 1 Using the appropriate bearing and seal drivers install any required bearings and seals in the trans mission case and case cover KM696 2 Replace any required bearings and seals in the sec ondary driven bevel gear shaft case Apply oi...

Page 65: ...5A 7 Install the high gear clutch dog and flat washer At this point the countershaft is ready for installation KM684 8 Install the low driven gear washer on the driveshaft then install the low driven gear and thrust washer Secure with a snap ring KM692A 9 Install the low reverse clutch dog and spacer washer then install the reverse gear and reverse gear thrust washer At this point the driveshaft i...

Page 66: ...M619A 14 Install the shift shaft making sure to align the timing mark between the two marks on the shift cam KM702A 15 Install the two alignment pins gasket and transmis sion case cover and secure with eight cap screws Tighten in a crisscross pattern to 20 ft lb KM651A 16 Install a spacer washer and the drive bevel gear on the driveshaft then while holding the centrifugal clutch housing with an ap...

Page 67: ...all the starter idler shaft and gear in the crank case then install the starter driven gear on the crank shaft KM767 NOTE Make sure the crankshaft and rotor flywheel contact surfaces are clean and dry before installing the flywheel 5 Install the key in the crankshaft then with the starter one way bearing correctly installed place the rotor flywheel onto the crankshaft and position the align ing ke...

Page 68: ...erent sized cap screws for joining purposes KM720A 2 Using Crankcase Separator Crankshaft Remover and tapping lightly with a rubber mallet separate the crankcase halves Account for two alignment pins and a gasket Disassembling Crankcase Half 1 Remove the crankshaft from the left crankcase half KM721 2 Remove the balancer shaft from the left crankcase half KM722 Servicing Center Crankcase Component...

Page 69: ...contact at point 1 of the crank shaft ATV 1074 3 Zero the indicator and rotate the crankshaft slowly 4 Maximum runout must not exceed specifications NOTE Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 3 4 Measuring Crankshaft Web to Web 1 Using a calipers measure the distance from the out side edge of one web to the ou...

Page 70: ... a suitable engine lift to the front engine mounting boss then lift the engine transmission into the frame from the left side The front of the engine transmission should go in first 2 Lifting the front of the engine transmission move the assembly forward sufficiently to clear the rear engine mounts then slide the engine transmission into the rear mounts 3 Lower the engine transmission and install ...

Page 71: ... filter housing see Steering Frame 19 Install the body see Steering Frame 20 Install the gas tank cover panel 21 Install the electrical tray Install the battery and con nect the positive cable then connect the negative cable 22 Pour in the recommended amount and grade of engine coolant engine oil and transmission lubri cant 23 Install the seat Utility 1 Attach a suitable engine lift to the front e...

Page 72: ...o the bevel driven gear housing and secure with the existing clamp KM315A 9 Connect the V belt cooling boots to the V belt hous ing and secure with the existing hose clamps KM307A 10 Connect the engine ground wire to the engine then connect the starter positive wire to the starter using the existing hardware Tighten securely KM319A 11 Connect the coolant temperature sensor then con nect the trigge...

Page 73: ...ension lead Problem Engine will not start or is hard to start No fuel reaching the carburetor Condition Remedy 1 Gas tank vent hose obstructed 2 Carburetor inlet needle defective 3 Fuel hose obstructed 4 Fuel screens obstructed 1 Clean vent hose 2 Replace needle 3 Clean replace hose 4 Clean replace inlet screen valve screen Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magnet...

Page 74: ... 3 Adjust lever 4 Replace cam 5 Replace spring 6 Replace shaft 7 Adjust engine idle 8 Adjust shift linkage Problem Engine idles poorly Condition Remedy 1 Valve clearance out of adjustment 2 Valve seating poor 3 Valve guides defective 4 Rocker arms arm shaft worn 5 Magneto defective 6 CDI unit defective 7 Spark plug fouled gap too wide 8 Ignition coil defective 9 Float out of adjustment 10 Jets obs...

Page 75: ...t gap replace plug 9 Clean jets 10 Adjust float height 11 Clean element 12 Drain excess oil change oil 13 Tighten replace manifold 14 Replace cam chain Problem Engine overheats Condition Remedy 1 Carbon deposit piston crown excessive 2 Oil low 3 Octane low gasoline poor 4 Oil pump defective 5 Oil circuit obstructed 6 Gasoline level in float chamber too low 7 Intake manifold leaking air 8 Coolant l...

Page 76: ...arm PR162C 6 Loosen the outer jam nut securing the throttle cable to the carburetor body then route the cable out of the way WARNING Whenever any maintenance or inspection is performed on the fuel system during which there may be fuel leak age there should be no welding smoking open flames etc in the area KEY 1 Screw 2 Top 3 Spring 4 Seat Spring 5 Jet Needle 6 Vacuum Piston 7 Needle Jet 8 Needle J...

Page 77: ...from the carbu retor body Account for a spring spring seat and the jet needle KC0021A 3 Remove the Phillips head screws securing the float chamber then remove the chamber Account for the O ring KC0022A KC0063A 4 Remove the float pin KC0024A 5 Lift the float assembly from the carburetor Account for the float valve CC753 NOTE Note the locations of the jets pilot screw and holder for disassembling pr...

Page 78: ...rs in the rubber 7 Inspect float for damage 8 Inspect gasket and O rings for distortion tears or noticeable damage 9 Inspect tips of the jet needle pilot screw and the needle jet for wear damage or distortion 10 Inspect the slow jet and main jet for obstructions or damage NOTE If the slow jet is obstructed the mixture will be extremely lean at idle and part throttle operation 11 Inspect the float ...

Page 79: ...aliper the height when the float arm is in contact with the needle valve Float arm height should be 17 mm 5 Place the float chamber into position making sure the O ring is properly positioned then secure with the Phillips head screws KC0063A KC0022A 6 Place the jet needle spring seat and spring into the vacuum piston then place the assembly down into the carburetor 7 Place the top cover into posit...

Page 80: ... adjust the idle RPM a tachometer is neces sary To adjust idle RPM use the following procedure NOTE The idle adjustment screw is located on the right side of the carburetor 1 With the transmission in neutral start the engine and warm it up to normal operating temperature 2 Turn the idle adjustment screw clockwise one turn past the recommended RPM setting then turn it counterclockwise to the correc...

Page 81: ...e carburetor In this position 4 54 L 1 2 U S gal will remain in the tank as a reserve quantity Moving the valve to the RES position will allow the operator to use the remaining gasoline in the tank When turning the valve to any of the three positions make sure the indica tor is pointed directly at the position desired REMOVING INSPECTING 1 Remove the gas hose from the valve by releasing the clamp ...

Page 82: ... the oil pump into the engine see Right Side Components in Engine Transmission Liquid Cooling System When filling the cooling system use pre mixed Arctic Cat Antifreeze While the cooling system is being filled air pockets may develop therefore run the engine for five minutes after the initial fill shut the engine off and fill the coolant overflow tank under the seat to the FULL line KM136A Radiato...

Page 83: ...ainer filled with water B Heat the water and monitor the temperature with a thermometer C The thermostat should start to open at 78 82 C 172 179 F and should be full open at 90 C 194 F D If the thermostat does not open it must be replaced 3 Inspect all coolant hoses connections and clamps for deterioration cracks and wear NOTE All coolant hoses and clamps should be replaced every four years or 400...

Page 84: ...aired Condition Remedy 1 Starter jet obstructed 2 Starter jet passage obstructed 3 Starter body carburetor leaking air 4 Starter valve not operating properly 1 Clean jet 2 Clean passage 3 Tighten adjust replace gasket 4 Check adjust valve Problem Idling or low speed impaired Condition Remedy 1 Slow jet obstructed loose 2 Slow jet outlet obstructed 3 Low speed fuel screw setting incorrect 4 Starter...

Page 85: ... indicator light will illu minate D Hi Lo switch headlight high beam or low beam will illuminate E Brake switches rear brakelight will illuminate Battery The battery is located under the seat DVX or behind the seat Utility After being in service batteries require regular cleaning and recharging in order to deliver peak performance and maximum service life The following procedure is rec ommended fo...

Page 86: ...he battery fuse switch or the main wiring harness NOTE If the meter shows battery voltage the main wiring harness is good proceed to test the switch component the connector and the switch wiring har ness for resistance RESISTANCE Switch Connector 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the brown blue wire then connect the black tester lead to the green yellow...

Page 87: ...s are not as indicated the switch must be replaced 6 Install the switch and tighten securely 7 Connect the switch leads Fan Motor The fan motor connector is located directly above the fan To access the connector on the Utility the front rack and front center cover must be removed see Steering Frame NOTE The ignition switch must be in the ON position VOLTAGE Main Harness Connector to Fan Motor 1 Se...

Page 88: ...rame Body PEAK VOLTAGE Primary CDI Side NOTE All of the peak voltage tests should be made using the Fluke Model 77 Multimeter with Peak Volt age Reading Adapter If any other type of tester is used readings may vary due to internal circuitry NOTE The battery must be at full charge for these tests NOTE The ignition switch must be in the ON posi tion the emergency stop switch must be in the RUN posit...

Page 89: ... The temperature indicator 4 must indicate hot all indicator segments visible and begin flashing The thermometer icon will also flash 7 Connect the red MaxiClip to the yellow white wire The fuel quantity indicator 8 must sequence one segment every 8 10 seconds until the bottom seg ment begins flashing After flashing for 8 10 sec onds the bottom segment will extinguish and the gas pump icon 7 will ...

Page 90: ...s Two white connectors join the handlebar control switch pigtails to the main harness To access the connectors on the Utility the front rack and front cover must be removed see Steering Frame Body NOTE These tests should be made on the switch side of the connectors with the connectors uncoupled RESISTANCE HI Beam 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the bl...

Page 91: ...igger Coil 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the blue yellow wire then connect the black tester lead to the green white wire The meter reading must be within specification PEAK VOLTAGE NOTE All of the peak voltage tests should be made using the Fluke Model 77 Multimeter with Peak Volt age Reading Adapter If any other type of tester is used readings may ...

Page 92: ... on the right side of the frame Verify all other charging system components before the regulator rectifier is replaced TESTING 1 Start the engine and warm up to normal operating temperature then connect a multimeter to the battery as follows 2 Select the DC Voltage position then connect the red tester lead to the positive battery post and the black tester lead to the negative battery post 3 Start ...

Page 93: ... left handlebar switch Taillight Brakelight The connector is the 3 prong one located under the rear fender assembly BULB VERIFICATION Visually inspect the bulb for broken filaments blacken ing or loose bulb base VOLTAGE Taillight NOTE Perform this test on the main harness side of the connector Also the ignition switch should be in the LIGHTS position 1 Set the meter selector to the DC Voltage posi...

Page 94: ... 2 Stator coils charging grounded open 3 Regulator rectifier defective 4 Cell plates battery defective 1 Repair tighten lead wires 2 Replace stator coils 3 Replace regulator rectifier 4 Replace battery Problem Magneto overcharges Condition Remedy 1 Internal battery short circuited 2 Regulator rectifier defective 3 Regulator rectifier poorly grounded 1 Replace battery 2 Replace regulator rectifier ...

Page 95: ...o high 3 Battery short circuited 4 Specific gravity too low 1 Replace battery 2 Check charging 3 Replace battery 4 Recharge battery Problem Battery polarity reversed Condition Remedy 1 Battery incorrectly connected 2 Electrical system damaged 1 Reverse connections replace battery 2 Replace damaged components ...

Page 96: ...wheels 3 Remove the hub caps then remove and discard the cotter pins KM464 4 Remove the rear wheel hubs then remove the brake caliper and lay aside NOTE Do not apply pressure to the brake pedal with the caliper removed The brake piston will be pushed out and brake fluid will be spilled 5 Remove the two axle nuts left hand threads Account for one flat washer and a spacer KM471 6 Remove the brake di...

Page 97: ...g the driven sprocket to the axle then remove the sprocket KM477 CLEANING AND INSPECTING 1 Inspect the sprocket teeth for wear If they are worn as shown replace the engine sprocket rear sprocket and drive chain as a set ATV2185 2 Measure the rear axle runout as shown using V blocks and a dial indicator If the axle runout exceeds 1 5 mm 0 06 in the axle must be replaced KM480 3 Inspect the dust sea...

Page 98: ...ly coat the lips with grease INSTALLING 1 Install the axle housing in the swing arm then install and finger tighten the two cap screws KM481A 2 Install the brake caliper holder then install the cir clip and cap screw and finger tighten only KM482 3 Slide the axle into the axle housing from the right side then apply multipurpose grease to all splined areas of the axle 4 Install the sprocket and spr...

Page 99: ...hten in a crisscross pat tern to 40 ft lb Rear Drive Axle Utility REMOVING 1 Secure the ATV on a support stand to elevate the rear wheels 2 Compress the brake lever and engage the brake lever lock then remove the rear wheels and hub caps 3 Remove the cotter pins and rear hub nuts then remove the hubs 4 Disengage the brake lever lock then remove the rear brake calipers and brake disc NOTE Do not ap...

Page 100: ...emove the swing arm assembly Account for the driveshaft spring KM508 11 Disengage the universal joint from the transmission output shaft splines and set the driveshaft aside KM509 12 Remove the eight cap screws securing the swing arm to the final drive gear case KM513 13 Support the swing arm from the right side then using a rubber mallet drive the axle shaft from the swing arm tube Account for tw...

Page 101: ...ke components for leaks excessive wear or discoloration 6 Check the axle shaft for runout using a dial indicator and suitable supports Maximum runout is 3 mm 0 12 in NOTE Axle runout is equal to 1 2 the total dial indi cator reading KM543 7 Check the final drive gear case assembly for smooth gear operation If gears are noisy or if there is any catching or binding the gear case assembly must be rep...

Page 102: ...g Nut Wrench remove the pinion nut KM920A KM921 3 Remove the pinion shaft using the pinion puller then using a three jaw puller remove the pinion bearing Account for the pinion shim KM922 KM923 KM924A 4 Remove the oil seals from the case and cover then drive the bearings out of the case KM925 KM926 ...

Page 103: ...cracks warpage or scoring of bearing bores 5 If seals have not been removed and will be reused inspect for nicks tears missing tension springs or excessive wear on lips ASSEMBLING 1 Drive the bearings into the gear case and gear case cover using an appropriate bearing driver Make sure the bearing is firmly seated KM926 KM928 2 Apply grease to the seal lips then using a seal driver drive the seals ...

Page 104: ... nut wrench tighten to 72 ft lb KM920A KM921 6 Apply grease to the pinion seal lips and install into the gear case until fully seated then apply a light coating of machinist s layout dye or paste to several ring gear teeth 7 Install the proper shims on the ring gear and install into the gear case then install the case cover and secure with the case cap screws Tighten in a criss cross pattern while...

Page 105: ...ays change both shims by the same amount on opposite sides If left shim is increased right shim must be decreased by the same amount 5 After backlash is corrected recheck gear tooth con tact Repeat Correcting Tooth Contact and Checking Backlash until both are within specifications 6 When tooth contact and backlash are within specifi cation remove the cap screws securing the cover to the gear case ...

Page 106: ...to the swing arm assembly with the eight cap screws Tighten to 50 ft lb KM528A 3 Apply grease to the universal joint splines and drive shaft splines then install the driveshaft spring into the driveshaft KM529 NOTE Apply a liberal amount of grease to the drive shaft splines and the driveshaft spring This will aid in keeping the spring in position while assembling 4 Insert the driveshaft assembly i...

Page 107: ...he final drive gear case drain plug securely then remove the fill plug and level plug KM131A 11 Pour the recommended gear lubricant into the fill hole until lubricant is visible on the threads of the level hole then install the level plug and the fill plug and tighten securely 12 Install the rear drive gear case guard and tighten the cap screws securely 13 Apply grease to the brake disc hub and wh...

Page 108: ...1 Replace pads 2 Adjust free play 3 Repair replace hydraulic system 4 Bleed hydraulic system 5 Replace appropriate cylinder Problem Brake lever travel excessive Condition Remedy 1 Hydraulic system entrapped air 2 Brake fluid low 3 Brake fluid incorrect 4 Piston seal cup worn 1 Bleed hydraulic system 2 Add fluid to proper level bleed system 3 Replace with correct fluid 4 Replace master cylinder Pro...

Page 109: ...stand to elevate the wheels and to release load on the suspension 2 Remove the cap screws and nuts securing each shock absorber to the A arm and frame KM573A CLEANING AND INSPECTING 1 Clean the shock absorbers in parts cleaning solvent 2 Inspect each shock rod for nicks pits bends and oily residue 3 Inspect the springs spring retainers shock rods shock bodies and eyelets for cracks leaks and bends...

Page 110: ... Inspect the spring spring seat and preload adjust ment nuts and threads for damage or corrosion If corrosion is present on the threads clean with a fine wire brush and oil lightly KM561A INSTALLING 1 Raise the swing arm and place the shock absorber in position then install the upper and lower cap screws and nuts 2 Tighten the upper nut and the lower nut to 29 ft lb 3 Install the rear swing arm sk...

Page 111: ...ove the cushion arm lock nut and cap screw then remove the lock nut and cap screw securing the cushion arm link to the swing arm Remove the cush ion arm link assembly Account for three bushings KM557A KM568A 5 Remove the axle housing 6 Remove the brake hose guide clamp KM495 7 Remove the swing arm pivot nut then remove the swing arm pivot flange bolt and remove the swing arm KM496 8 Remove the cha...

Page 112: ...ken welds 3 To inspect the cushion arm bushings install the bushings in the cushion arm then check for exces sive play by rocking the bushing KM564A 4 Inspect the needle bearings for missing rollers rust or corrosion or flat rollers Check for a tight fit in boss Replace the arm if bearings are loose KM565 5 Inspect all dust seals and replace if they are cracked torn dried out or loose KM499B KM564...

Page 113: ...e 6 Place the swing arm into position in the frame then install the swing arm pivot cap screw and lock nut Tighten to 50 ft lb KM496A 7 Apply grease to the swing arm pivot through the grease fitting KM501 8 Place the cushion arm and cushion arm link assem bly into position and secure with the flange cap screws and new lock nuts Tighten securely KM557A 9 Install the shock absorber and secure with t...

Page 114: ...ut securing the tie rod end to the knuckle then remove the tie rod end from the knuckle KM573 7 Remove the brake hose clamp from the A arm then remove the cotter pins and slotted nuts securing the upper and lower ball joints KM570 8 Remove the shock absorber mounting cap screws then remove the shock absorber assembly 9 Using a ball joint remover remove the ball joints from the knuckle then remove ...

Page 115: ...in the upper arm pivot to a depth of 13 6 mm 0 535 in with a bearing installer and suitable spacer ATV2196A 2 Coat the spacers and the lips of the dust seals with multi purpose grease then install them in the upper pivot 3 Repeat steps 1 and 2 for the lower A arm 4 Clean all grease from the ball joint tapers and the knuckle bores then install the arms to the steering knuckle and tighten the ball j...

Page 116: ...direction of rotation AF612D 2 Tighten in a crisscross pattern to 40 ft lb CHECKING INFLATING 1 Using an air pressure gauge measure the air pressure in each tire Adjust the air pressure as necessary to meet the recommended inflation pressure 2 Inspect the tires for damage wear or punctures NOTE If repair is needed follow the instructions found on the tire repair kit or remove the wheel and have it...

Page 117: ...m Suspension too soft Condition Remedy 1 Spring s weak 2 Shock absorber damaged 1 Replace spring s 2 Replace shock absorber Problem Suspension too stiff Condition Remedy 1 A arm related bushings worn or binding 1 Replace bushing Problem Suspension noisy Condition Remedy 1 Cap screws suspension system loose 2 A arm related bushings worn 1 Tighten cap screws 2 Replace bushings Problem Rear wheel osc...

Page 118: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2259 825 ...

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