Arctic Cat ATV 250 Utility 2009 Service Manual Download Page 117 | Manualshive

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8-1

8

SECTION 8 - STEERING/FRAME

TABLE OF

CONTENTS

Steering/Frame........................................................ 8-2
Steering Post/Tie Rods ........................................... 8-2
Measuring/Adjusting Toe-In/Toe-Out ....................... 8-4
Body ........................................................................ 8-4
Steering Post Cover/Instrument Pod ....................... 8-7
Troubleshooting ....................................................... 8-9

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Summary of Contents for ATV 250 Utility 2009

Page 1: ......

Page 2: ...VX 300 Manual Manual Service Service TABLE OF CONTENTS Foreword Click on the red text to go 1 General Information Specifications 2 Periodic Maintenance Tune Up 3 Engine Transmission 4 Fuel Lubrication...

Page 3: ...300 1 2 General Specifications 250 Utility 1 2 Torque Specifications 1 3 Torque Conversions ft lb N m 1 4 Tightening Torque General Bolts 1 4 Break In Procedure 1 4 Gasoline Oil Lubricant 1 4 Genuine...

Page 4: ...0 81 U S qt Brake Fluid DOT 4 Taillight Brakelight 12V 5W 21W Headlight 12V 35W 2 Starting System Electric CHASSIS Dry Weight approx 216 kg 477 lb Length overall 187 cm 73 6 in Height overall 111 8 c...

Page 5: ...Pivot Nut Frame 32 44 Front Shock Absorber Mounting Nut Upper Lower Frame 29 39 SUSPENSION COMPONENTS Rear Left Pivot Bolt Utility Swing Arm 36 in lb 5 Right Pivot Bolt Utility Swing Arm 82 112 Left...

Page 6: ...ubricant 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 conta...

Page 7: ...essary 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...

Page 8: ...the following proce dure to prepare the ATV 1 Clean the ATV thoroughly 2 Clean the engine Remove the cloth from the exhaust system 3 Check all control wires and cables for signs of wear or fraying Rep...

Page 9: ...ion 2 4 Spark Plug 2 5 Muffler Spark Arrester 2 5 Engine Oil Filter 2 6 Rear Drive Lubricant 250 Utility 2 6 Transmission Lubricant 2 7 Drive Chain DVX 300 2 7 Driveshaft Coupling 250 Utility 2 8 Nuts...

Page 10: ...er D Engine RPM Idle I I A Engine Oil Level I A Engine Oil Screen C C C Drive Chain DVX 300 I I C L Rear Drive Lubricant 250 Utility I I R A Transmission Lubricant I I R A Tires Air Pressure I I A R S...

Page 11: ...Pivot Clevis D Choke Cable Upper End E Shift Lever Ball Joints F Idle RPM Screw Carburetor Air Filter Use the following procedure to remove the filter and inspect and or clean it CLEANING AND INSPECT...

Page 12: ...screw clockwise until friction is felt 5 Align the adjuster handle with one of the marks on the adjuster dial 6 While holding the adjuster handle in place rotate the adjuster dial counterclockwise unt...

Page 13: ...Adjust the gap to 0 8 0 9 mm 0 032 0 036 in for proper ignition Use a wire feeler gauge to check the gap ATV0052B When installing the spark plug make sure to tighten it securely A new spark plug shou...

Page 14: ...ine while the ATV is outside on level ground and allow it to idle for a few minutes 8 Turn the engine off and wait approximately one minute Check the oil level in the engine oil inspection window The...

Page 15: ...e To change the lubricant use the following procedure 1 Place the ATV on level ground 2 Loosen the fill plug then remove the transmission drain plug and drain the transmission lubricant KM104A KM106A...

Page 16: ...a dry graphite based chain lubricant dirt build up on the drive chain will be minimized ADJUSTING TENSION To adjust the drive chain tension use the following procedure 1 Loosen the four cap screws 1 a...

Page 17: ...sing then secure with the spring clip 4 Connect the three wire connector to the bulb then install the boot TAILLIGHT BRAKELIGHT To replace the taillight brakelight bulb use the follow ing procedure 1...

Page 18: ...and bled at the factory To check and or bleed a hydraulic brake system use the following procedure 1 With the master cylinder in a level position check the fluid level in the reservoir If the level i...

Page 19: ...d automatically as the brake pads wear The only maintenance that is required is replacement of the brake pads when they show excessive wear Check the thickness of each of the brake pads as follows 1 R...

Page 20: ...KE PADS 250 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 Remov...

Page 21: ...the brake pad retaining pin out of the caliper 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 Insp...

Page 22: ...uxiliary brake if necessary 5 Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed Checking Replacing V Belt REMOVING 1 On the 250 Utility remove th...

Page 23: ...he crankshaft splines should be visible and the stepped washer should sit over the splines KM263A 4 Secure the movable drive face to the crankshaft with the drive pulley nut and tighten to 72 ft lb 5...

Page 24: ...3 1 3 SECTION 3 ENGINE TRANSMISSION TABLE OF CONTENTS Engine Transmission 3 2 Specifications 3 2 Table of Contents 3 3 Troubleshooting 3 43 Back to TOC...

Page 25: ...e Tappet Clearance intake exhaust cold engine 0 1 mm Valve Guide Stem Clearance max intake exhaust 0 06 mm 0 08 mm Valve Spring Free Length min inner outer 29 4 mm 39 0 mm Valve Spring Tension 18 0 mm...

Page 26: ...DVX 300 1 Remove the seat 2 Remove the negative cable from the battery then remove the positive cable Remove the battery hold down strap then remove the battery 3 Remove the reinstallable rivet from...

Page 27: ...ll the drain plugs KM314A KM147A KM106A 14 Loosen the clamps then remove the front and rear V belt cooling boots from the V belt housing KM359A KM360A 15 Loosen the clamps then disconnect the coolant...

Page 28: ...M332 20 Raise the engine lift to take the slack out of the sling then remove the upper rear and lower rear engine through bolts KM333A KM325A 21 Raise the front of the engine sufficiently to allow the...

Page 29: ...5 Remove the side panels then remove the front rack and front fenders see Section 8 6 Remove the air filter housing see Section 4 7 Remove the gas tank see Section 4 8 Remove the muffler assembly see...

Page 30: ...M315A 15 Disconnect the shift linkage from the transmission shift arm then swing the shift linkage forward and out of the way 16 Remove the front engine through bolt then remove the two engine mountin...

Page 31: ...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 transmission doe...

Page 32: ...s and two alignment pins KM706A KM707A 4 Remove the camshaft gear from the cam chain then secure the timing chain so it will not fall into the engine Remove the camshaft 5 Remove the two external cap...

Page 33: ...essary VALVE ASSEMBLY When servicing valve assembly inspect valve seats valve stems valve faces and valve stem ends for pits discoloration or other signs of abnormal wear NOTE Whenever a valve is out...

Page 34: ...carbon removal tool remove any carbon build up from the combustion chamber making sure not to nick scrape or damage the combustion chamber or the sealing surface 2 Inspect the spark plug hole for any...

Page 35: ...and install the valve cotters KM717A PISTON ASSEMBLY NOTE Whenever a piston rings or pin are out of tolerance they must be replaced Cleaning Inspecting Piston 1 Using a non metallic carbon removal too...

Page 36: ...into the piston pin bore The diameter must not exceed specifications Take two measurements to ensure accuracy ATV 1069 Measuring Piston Skirt Cylinder Clearance 1 Measure the cylinder front to back i...

Page 37: ...be replaced Honing Cylinder 1 Using a slide gauge and a dial indicator or a snap gauge measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90 from...

Page 38: ...NOTE Steps 1 4 in the preceding sub section must precede this procedure 5 While keeping tension on the cam chain place the front cam chain guide into the cylinder 6 Place the head gasket into position...

Page 39: ...le 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 remove...

Page 40: ...ve face taking care not to loose the rollers Servicing Left Side Components RECOIL STARTER 250 Utility Removing Disassembling 1 Remove the cap screws securing the recoil starter assembly to the V belt...

Page 41: ...the springs and ratchet for wear or damage 3 Inspect the reel 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...

Page 42: ...cap screw coated with blue Loctite 243 Tighten securely 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 ro...

Page 43: ...r damage or excessive wear KM256 2 Inspect the face surfaces of the fixed and movable drive faces for grooving nicks or discoloration KM394A 3 Inspect the drive pulley collar for wear or damage Measur...

Page 44: ...ollar KM385 5 Remove four pins and bushings from the fixed face hub then remove the movable face KM384 KM380 Inspecting 1 Inspect the pulley faces for wear galling or grooving KM394A 2 Inspect the O r...

Page 45: ...shoe lining The minimum service limit for the lin ing 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 pul...

Page 46: ...all the nut lightly coated with red Loctite 271 KM373 7 Using a suitable holding fixture tighten the drive plate nut to 43 ft lb Installing Left Side Components A Drive Pulley B Driven Pulley Centrifu...

Page 47: ...e with the cap screws Tighten securely 8 On the 250 Utility install the recoil starter and secure with the cap screws Tighten securely Right Side Components NOTE For efficiency it is preferable to rem...

Page 48: ...move 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 d...

Page 49: ...he engine has not been removed remove the swing arm assembly see Section 7 2 Using a crisscross pattern remove four cap screws securing the secondary driven bevel gear assembly to the transmission cas...

Page 50: ...ing Left Side Components in this section Remove only the V belt cover 6 Remove the eight cap screws securing the trans mission case cover to the transmission case then remove the cover Account for a g...

Page 51: ...rive gear circlip and washer then remove the high drive gear and thrust washer KM685 12 To disassemble the driveshaft use the following procedure A Remove the thrust washer then remove the reverse gea...

Page 52: ...Stator Coil E Rotor Flywheel 14 Remove the right crankcase cover see Section 4 Water Pump 15 Remove the trigger coil mounting screws then remove the wire set plate KM772A 16 Remove the three cap scre...

Page 53: ...gether with the rotor flywheel to keep the one way clutch bearing intact KM767A KM766A 21 Remove the two cap screws securing the oil baffle to the crankcase and remove the baffle then remove the snap...

Page 54: ...d shift shaft gear for exces sive wear KM626 5 Inspect all gear teeth for chipping discoloration pitting or excessive wear Replace as required 6 Inspect clutch dogs and mating surfaces for chip ping r...

Page 55: ...stall the seal into the gear case 5 Install the countershaft then making sure the main shaft thrust washer is in place install the main shaft assembly into the gear case KM613A 6 Install the shift sha...

Page 56: ...as required 8 Inspect transmission housing and cover for cracks scoring or galling of bearing bores or case discol oration 9 Inspect the drive and driven bevel gears for chip ping flaking or excessiv...

Page 57: ...425 5 Use a center punch to stake the nut to the driven shaft KM426A 6 Install the high drive gear thrust washer on the countershaft then install the high drive gear and secure with a circlip KM685A 7...

Page 58: ...shift fork pawl in the appropriate shift cam groove KM700 12 Install the high shift fork into the high clutch dog then engage the shift fork pawl into the appropri ate shift cam groove 13 Install the...

Page 59: ...gear assembly using the four cap screws then using a crisscross pattern tighten the cap screws until fully seated in the transmission housing KM646A Installing Right Side Components A Oil Pump 1 Inst...

Page 60: ...ts NOTE This procedure cannot be done with the engine transmission in the frame Complete Removing procedures for Top Side Left Side and Right Side must precede this procedure NOTE For efficiency it is...

Page 61: ...indicator contact point against the center of the connecting rod small end journal 2 Zero the indicator and push the small end of the connecting rod away from the dial indicator 3 Maximum deflection m...

Page 62: ...embling install compo nents on the left side crankcase half To assemble center crankcase components install the balancer shaft into the left side crankcase half then align the timing mark on the balan...

Page 63: ...and install the lower rear and upper rear through bolts and nuts Finger tighten only 4 Remove the engine lift from the front mounting boss then install the left and right engine mount ing brackets and...

Page 64: ...mount and grade of engine coolant engine oil and transmission lubri cant 23 Install the seat 250 Utility 1 Attach a suitable engine lift to the front engine mounting boss then lift the engine transmis...

Page 65: ...11 Connect the coolant temperature sensor then con nect the trigger coil connector shift position con nector and stator connector KM324A KM347A 12 Install the coil see Section 5 13 Install the carbur...

Page 66: ...structed 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...

Page 67: ...6 Replace shaft s 7 Replace thrust washer s Problem Centrifugal clutch slipping Condition Remedy 1 Clutch shoes worn 2 Clutch housing excessively worn 3 Drive belt slipping worn 1 Replace shoes 2 Repl...

Page 68: ...ring s cylinder worn 5 Valve seating poor 6 Spark plug fouled 7 Rocker arms shafts worn 8 Spark plug gap incorrect 9 Carburetor jets obstructed 10 Float level out of adjustment 11 Air cleaner element...

Page 69: ...cations 4 2 Carburetor 4 2 Throttle Cable Free Play 4 6 Engine RPM Idle 4 7 Gas Tank 4 7 Gas Tank Valve 4 7 Gas Vent Hoses 4 8 Oil Flow Chart 4 8 Oil Pump 4 8 Liquid Cooling System 4 9 Radiator 4 9 Ho...

Page 70: ...1 4 1 3 4 Needle Jet 4 0 3 4 4 0 3 6 Jet Needle N8TY NLRA Idle RPM 1250 1350 1250 1350 Float Arm Height 17 0 mm 0 67 in 17 0 mm 0 67 in Throttle Cable Free Play at lever 1 4 mm 1 16 3 16 in 1 4 mm 1 1...

Page 71: ...curing the top cover then remove the cover KC0019A 2 Remove the vacuum piston assembly from the car buretor body Account for a spring spring seat and the jet needle KC0021A 3 Remove the Phillips head...

Page 72: ...nly making sure all holes orifices and channels are unobstructed 5 Inspect the carburetor body for cracks nicks stripped threads and any imperfections in the casting 6 Inspect the vacuum piston for cr...

Page 73: ...bu retor and tighten securely 4 Place the float assembly with float valve into posi tion and secure to the carburetor with the float pin CC753 NOTE Check float arm height by placing the car buretor on...

Page 74: ...r 6 Install the air filter then tighten the clamp secur ing the air inlet boot to the carburetor Secure the air filter housing to the frame with the cap screws 7 Install the gas tank then install the...

Page 75: ...NSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all gas tank components with parts cleaning solvent 2 Inspect all hoses for cracks or...

Page 76: ...bstruct the routing of the carburetor vent hose Make sure the vent hose is securely connected to the carbure tor and the opposite end is always open Oil Flow Chart KM427A Oil Pump NOTE Whenever intern...

Page 77: ...never a part is worn excessively cracked or damaged in any way replacement is necessary 1 Flush the radiator with water to remove any con taminants 2 Inspect the radiator for leaks and damage 3 Inspec...

Page 78: ...ks and wear NOTE All coolant hoses and clamps should be replaced every four years or 4000 miles INSTALLING 1 Place the thermostat and O ring into the thermo stat housing then secure the thermostat hou...

Page 79: ...Press the seal washer into the impeller by hand 2 Install the water pump drive seal then drive the mechanical seal into the crankcase cover using an appropriate seal driver 3 Install the impeller wit...

Page 80: ...height Problem Medium or high speed impaired Condition Remedy 1 High RPM cut out against RPM limiter 2 Main jet obstructed 3 Needle jet obstructed 4 Throttle vacuum piston not operating properly 5 Fil...

Page 81: ...Handlebar Control 5 4 Coolant Temperature and Cooling Fan Switches 5 4 Fan Motor 5 5 Fuse Block 5 5 Fuses 5 6 Ignition Coil 5 6 Indicator Lights DVX 300 5 7 LCD Gauge Assembly 5 7 Ignition Switch 5 8...

Page 82: ...r absolute accuracy all tests should be made at room temperature of approximately 68 F Electrical Connections The electrical connections should be checked periodi cally for proper function In case of...

Page 83: ...d the charger should continue to charge If the charger cuts off replace the bat tery 6 After charging the battery for the specified time remove the battery charger and allow the battery to sit for 1 2...

Page 84: ...nect the red tester lead to the brown blue wire then connect the black tester lead to ground 3 The meter must show battery voltage NOTE If the meter shows no battery voltage troubleshoot the battery f...

Page 85: ...st show battery voltage NOTE If the meter shows no battery voltage troubleshoot the battery fuse or the main wiring harness NOTE If the meter shows battery voltage the main wiring harness is good The...

Page 86: ...t 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...

Page 87: ...the light green red wire then connect the jumper between the Maxi Clips and turn the ignition switch to the ON posi tion The neutral indicator light 9 must illuminate KM123D 4 Connect the red MaxiCli...

Page 88: ...n 2 Connect the red meter lead to the red white wire then connect the black meter lead to ground 3 The meter must show battery voltage NOTE If the meter shows no battery voltage troubleshoot the batte...

Page 89: ...ust show an open circuit 3 Depress and hold the reverse override button The meter must show less than 1 ohm of resistance NOTE If the meter does not show as specified replace the switch component or c...

Page 90: ...position 2 Connect the red tester lead to the battery supply terminal 1 then connect the black lead to the starter terminal 2 KM458A 3 Turn the ignition switch to the ON position The meter must read...

Page 91: ...y housing for testing continuity NOTE The module and wiring harness are not a serviceable component and must be replaced as an assembly TESTING The start in gear relay is located under the seat below...

Page 92: ...LIGHTS position 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the brown black wire then connect the black tester lead to the green wire 3 With the ignition key...

Page 93: ...lem Spark plug electrodes overheat or burn Condition Remedy 1 Spark plug incorrect too hot 2 Engine overheats 3 Spark plug loose 4 Mixture too lean 1 Replace plug 2 Service cooling system 3 Tighten pl...

Page 94: ...tch defective 1 Recharge replace battery 2 Replace switch 3 Repair replace brushes 4 Replace relay 5 Turn on switches 6 Connect tighten repair connections 7 Replace starter 8 Replace starter 9 Replace...

Page 95: ...VE SYSTEM TABLE OF CONTENTS Drive System 6 2 Rear Drive Assembly Schematics 6 2 Rear Drive Axle DVX 300 6 2 Rear Drive Axle 250 Utility 6 6 Troubleshooting Drive System 6 11 Troubleshooting Brake Syst...

Page 96: ...NG 1 Secure the ATV on a support stand to elevate the rear wheels 2 Engage the brake lever lock then remove the wheels 3 Remove the hub caps then remove and discard the cotter pins KM464 4 Remove the...

Page 97: ...ng KM481A 9 Remove the brake caliper holder and aligning col lar Account for the O ring KM483 10 Remove the four cap screws from the rear of the swing arm assembly then remove the rear axle housing fr...

Page 98: ...ng an appropriate driver drive the bearings out of the axle housing Account for one spacer NOTE Do not reuse bearings after removal KM486 2 Clean the axle housing and inspect for cracks elongated hole...

Page 99: ...ighten the axle nuts 6 Coat the axle threads with red Loctite 271 and install one axle nut left hand threads then using the Rear Axle Nut Wrench tighten the inner axle nut to calculated specification...

Page 100: ...e the rear drive gear case then drain the gear case 6 Loosen the clamp securing the joint boot to the swing arm then slip the boot off the swing arm KM504 7 Remove the clamp securing the brakeline hos...

Page 101: ...14 Place the right end shorter length of the axle on a wood block then using a rubber mallet drive the gear case from the axle KM538 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cr...

Page 102: ...ase assembly for smooth gear operation If gears are noisy or if there is any catching or binding the gear case assembly must be replaced REPLACING SWING ARM SEALS AND BEARINGS To replace damaged or wo...

Page 103: ...the universal joint splines and driveshaft splines then install the driveshaft spring into the driveshaft KM529 NOTE Apply a liberal amount of grease to the driveshaft splines and the driveshaft sprin...

Page 104: ...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 hol...

Page 105: ...djust 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...

Page 106: ...ION TABLE OF CONTENTS Suspension 7 2 Front and Rear Suspension Assembly Schematics 7 2 Front Shock Absorbers 7 2 Rear Shock Absorber 7 3 Swing Arm 7 4 Front A Arms 7 7 Wheels and Tires 7 10 Troublesho...

Page 107: ...Critical torque specifications are located in Section 1 REMOVING 1 Secure the ATV on a support stand to elevate the wheels and to release load on the suspension 2 Remove the cap screws and nuts securi...

Page 108: ...M555A 3 Remove the upper shock mounting nut and cap screw then remove the shock absorber from the frame KM554 CLEANING AND INSPECTING 1 Clean the shock absorber in parts cleaning sol vent 2 Inspect th...

Page 109: ...EMBLING For the 250 Utility see Rear Drive Axle in Section 6 For the DVX 300 use the following procedure 1 Secure the ATV on a support stand to elevate the wheels and to release load on the suspension...

Page 110: ...arm and swing arm axle place the swing arm axle and bushings in the swing arm then using the flange bolt rock the bushings and axle from side to side and up and down If excessive play is noted the bus...

Page 111: ...nstall the new dust seals in the cushion arm then apply multi purpose grease to the bearings bushing and dust seal lips 4 Install the bushings in the cushion arm and cush ion link then connect the cus...

Page 112: ...tall the hub caps and rear wheels Tighten the lug nuts to 32 ft lb KM469 KM464 14 Remove the ATV from the support stand Front A Arms NOTE Critical torque specifications are located in Section 1 REMOVI...

Page 113: ...ively cracked or damaged in any way replacement is necessary 1 Clean the knuckle in parts cleaning solvent then dry with compressed air If any damage or exces sive wear is detected the knuckle must be...

Page 114: ...the ball joint nuts to 22 ft lb Install new cotter pins SP388A NOTE During assembly new cotter pins should be installed SP390 5 Install the arms to the frame with the pivot cap screws then tighten th...

Page 115: ...found on the tire repair kit or remove the wheel and have it repaired professionally NOTE Make sure all tires are the specified size and have identical tread pattern 3 Check the front wheel toe in and...

Page 116: ...n 1 Tighten cap screws 2 Replace bushings Problem Rear wheel oscillation Condition Remedy 1 Rear wheel hub bearings worn loose 2 Tires defective incorrect 3 Wheel rim distorted 4 Wheel hub cap screws...

Page 117: ...ECTION 8 STEERING FRAME TABLE OF CONTENTS Steering Frame 8 2 Steering Post Tie Rods 8 2 Measuring Adjusting Toe In Toe Out 8 4 Body 8 4 Steering Post Cover Instrument Pod 8 7 Troubleshooting 8 9 Back...

Page 118: ...ed in Section 1 KM598D REMOVING 1 On the 250 Utility remove the front rack and front center panel see Body in this section On the DVX 300 proceed to step 2 2 Remove the steering post cover DVX 300 or...

Page 119: ...andlebar clamps for cracks or wear 7 Inspect the handlebar for cracks wear or unusual bends 8 Inspect the handlebar grips for damage or wear 9 Inspect the lower steering post support bearing and seal...

Page 120: ...the wheels free to rotate then center and secure the handlebar 3 Measure the distance A and B between the front wheels then subtract distance B from A Distance A Distance B Toe In ATV2205 4 Adjust to...

Page 121: ...battery box KM782A KM790A 4 Remove four flange nuts and cap screws securing the rear fender support then remove the push nuts from the mounting studs at the front of the rear fenders KM785A KM784A 5...

Page 122: ...e the gas tank cover then remove the shift knob and front and rear fenders KM797 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary...

Page 123: ...ers securely 6 Install the battery then connect the positive bat tery cable negative battery cable and battery hold down strap NOTE Always install the positive cable first then install the negative ca...

Page 124: ...connectors then con nect the main harness connector to the ignition switch 2 Place the steering post cover onto the mounting bracket then secure with the reinstallable rivets INSTALLING 250 Utility 1...

Page 125: ...es 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 d...

Page 126: ...9 1 9 SECTION 9 CONTROLS INDICATORS TABLE OF CONTENTS Front Brake Lever Master Cylinder Assembly 9 2 Auxiliary Brake Pedal Master Cylinder Assembly 9 3 Throttle Control 9 4 Back to TOC...

Page 127: ...brake lever for wear 2 Inspect the brake lever for elongation of the pivot hole 3 Inspect the reservoir for cracks and leakage 4 Inspect the brake hose for cracks and deterioration and the condition...

Page 128: ...remove the clevis pin then remove the two cap screws securing the master cylinder to the frame and remove the master cylinder KM801B 4 Loosen the jam nut then remove the clevis and adjuster nut INSTAL...

Page 129: ...f the throttle control housing then remove the two machine screws securing the throttle control to the handlebar and remove the throttle control INSTALLING 1 Making sure the throttle housing upper fla...

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