3-3
3
Table of Contents
Removing Engine/Transmission.............................. 3-3
Top-Side Components............................................. 3-8
Removing Top-Side Components ........................... 3-8
Servicing Top-Side Components........................... 3-10
Installing Top-Side Components ........................... 3-15
Left-Side Components .......................................... 3-16
Removing Left-Side Components ......................... 3-16
Servicing Left-Side Components .......................... 3-17
Installing Left-Side Components ........................... 3-23
Right-Side Components ........................................ 3-24
Removing Right-Side Components....................... 3-25
Servicing Right-Side Components ........................ 3-31
Installing Right-Side Components......................... 3-36
Center Crankcase Components............................ 3-37
Separating Crankcase Halves............................... 3-37
Disassembling Crankcase Half ............................. 3-37
Servicing Center Crankcase Components............ 3-38
Assembling Crankcase Half .................................. 3-39
Joining Crankcase Halves..................................... 3-39
Installing Engine/Transmission ............................. 3-40
Removing Engine/
Transmission
Many service procedures can be performed without
removing the engine/transmission from the frame.
Closely observe the note introducing each sub-section
for this important information.
Secure the ATV on a support stand to elevate the
wheels.
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 the bottom of
the electrical tray; then remove and lay the tray
forward. Leave the starter relay, fuse block, and
CDI attached.
KM357
4. Remove the gas tank cover panel; then install the
gas tank cap and remove the gas tank vent hose.
5. Remove the body (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 Section 8).
9. Remove the carburetor (see Section 4).
10. Remove the coil (see Section 5).
11. Disconnect the stator connector, shift position con-
nector, and coolant temperature sensor.
KM348A
KM324A
AT THIS POINT
If the technician’s objective is to service/replace
left-side cover oil seals, the engine/transmission does
not have to be removed from the frame.
! WARNING
Make sure the ATV is solidly supported on the support
stand to avoid injury.
! WARNING
Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a bat-
tery.
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Summary of Contents for ATV 250 Utility 2009
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