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Arctic Cat ATV 300 Utility/DVX 300 2011, Service Manual

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Arctic Cat ATV 300 Utility/DVX 300 2011 Service Manual Download Page 115

114

KM800A

5. Fill the master cylinder with DOT 4 brake fluid; then

bleed the system (see Periodic Maintenance).

Auxiliary Brake Pedal/

Master Cylinder 

Assembly

NOTE: The auxiliary brake master cylinder is a non-

serviceable component; it must be replaced as an
assembly.

REMOVING

1. Connect a clear plastic hose to the appropriate bleed

screw on the rear brake caliper; then loosen the bleed

screw and pump the foot brake until the fluid is

pumped into a suitable container.

2. Compress the reservoir clamp and remove the reser-

voir hose; then remove the union bolt. Account for

and discard two crush washers.

KM801A

3. Remove the cotter pin from the clevis pin and

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.

INSTALLING

1. Install the jam nut; then install the clevis and adjuster

nut. Finger-tighten only at this time.

2. Secure the master cylinder to the frame with the two

cap screws and tighten securely.

3. Using two new crush washers, connect the brake

hose to the master cylinder with the union bolt; then

making sure the spring clamp is seated securely, con-

nect the reservoir hose to the master cylinder.

Tighten the union bolt to 25 ft-lb.

4. Making sure the brake pedal is fully released and

against the stop, turn the clevis and adjuster nut until

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).

CAUTION

Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the ATV.

Manual

Table of Contents

For Arctic Cat Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

Summary of Contents for ATV 300 Utility/DVX 300 2011

Page 1: ...e symbol WARNING identifies personal safety related information Be sure to fol low the directive because it deals with the possibility of severe personal injury or even death A CAUTION identi fies unsafe practices which may result in ATV related damage Follow the directive because it deals with the possibility of damaging part or parts of the ATV The symbol NOTE identifies supplementary informatio...

Page 2: ...Rectifier 80 Specifications 20 Start in Gear Relay 80 Removing Engine Transmission 21 Headlights 81 Top Side Components 26 Taillight Brakelight 81 Removing Top Side Components 26 Ignition Timing 81 Servicing Top Side Components 28 Troubleshooting 82 Installing Top Side Components 32 Drive System 84 Left Side Components 34 Rear Drive Assembly Schematics 84 Removing Left Side Components 34 Rear Driv...

Page 3: ... Nut Steering Post 50 68 Upper And Lower Ball Joint Nut Steering Knuckle 22 30 Tie Rod End Nut Steering Knuckle 15 20 Tie Rod Lock Nut Tie Rod 15 20 ELECTRICAL COMPONENTS Starter Motor Lead Cable Nut Starter 36 in lb 5 Starter Motor Mounting Bolt Crankcase 9 12 EXHAUST COMPONENTS Exhaust Pipe Engine 25 34 Muffler Mounting Bolt Frame 25 34 BRAKE COMPONENTS Brake Hose Union Bolt Master Cylinder Cali...

Page 4: ...t Crankshaft 72 98 Engine Oil Drain Plug Crankcase 21 29 Transmission Drain Plug Transmission 21 29 Transmission Case Cover Transmission 20 27 ft lb N m ft lb N m ft lb N m ft lb N m 1 1 4 26 35 4 51 69 4 76 103 4 2 2 7 27 36 7 52 70 7 77 104 7 3 4 1 28 38 1 53 72 1 78 106 1 4 5 4 29 39 4 54 73 4 79 107 4 5 6 8 30 40 8 55 74 8 80 108 8 6 8 2 31 42 2 56 76 2 81 110 2 7 9 5 32 43 5 57 77 5 82 111 5 ...

Page 5: ...ENDED 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 Cat ACX All Weather synthetic engine oil is the only oil recommended for use in this engine use of any API certified SM 5W 50 oil is acceptable OILCHARTI RECOMMENDED REAR DRIVE LUBRICANT Utility The recommended lubri...

Page 6: ...oolant 9 Disconnect the battery cables then remove the bat tery clean the battery posts and cables and store in a clean dry area 10 Store the ATV indoors in a level position Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble free riding Arctic Cat recommends the following procedure to pre pare the ATV 1 Clean the ATV thoro...

Page 7: ...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 spark plug Clean or replace as necessary CAUTION Connect the positive battery cable first then the nega tive Manual Table of Contents For Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www m...

Page 8: ...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 Utility I I R A Transmission Lubricant I I R A Tires Air Pressure I I A R Steering Components I I I R V Belt I I R Suspension Ball joint boots tie...

Page 9: ...stic bag then pour in air filter oil and work the filter 7 Clean any dirt or debris from inside the air cleaner Make sure no dirt enters the carburetor 8 Place the filter in the air filter housing making sure it is properly seated and 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 DRAININ...

Page 10: ...703 9 Install the timing inspection plug Testing Engine Compression To test engine compression use the following procedure 1 Remove the high tension lead from the spark plug 2 Using compressed air blow any debris from around the spark plug 3 Remove the spark plug then attach the high tension lead to the plug and ground the plug on the cylinder head well away from the spark plug hole 4 Attach the g...

Page 11: ...9A 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 completely 1 Park the ...

Page 12: ...sen the 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 Instal...

Page 13: ...lowing procedure to clean and lubricate the chain NOTE This ATV is equipped 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 a...

Page 14: ... CARE When replacing the headlight bulb do not touch the glass 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 ca...

Page 15: ...ntil 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 filled and bled at the factory To check and or bleed a...

Page 16: ...NG 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 excessive wear Check the thick ness of each of the brake pad...

Page 17: ... 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 Inspect the disc for gouges grooves cracks and warpage 3 Using a...

Page 18: ...e 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 as a set 5 Using a calipers measure the thick...

Page 19: ...nd 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 alignment pins and one gasket KM253 4 Remove the nut securing the movable drive face then remove the face Account for the s...

Page 20: ...ly 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 This would cause the drive pulley to be under tightened and severe drive sheave or crankshaft damage could occur CAUTION On the DVX the re...

Page 21: ...pring Free Length min inner outer 29 4 mm 39 0 mm Valve Spring Tension 18 0 mm intake 10 2 11 8 kg 22 5 26 0 lb Valve Spring Tension 21 5 mm exhaust 19 05 22 0 kg 42 0 48 5 lb CAMSHAFT AND CYLINDER HEAD Cam Lobe Height min intake exhaust 34 15 mm 34 05 mm Rocker Arm Shaft Clearance max 0 1 mm Cylinder Head Cover Distortion max 0 05 mm CYLINDER PISTON AND RINGS Piston Skirt Cylinder Clearance max 0...

Page 22: ...brication Cooling 7 Remove the gas tank see Fuel Lubrication Cooling 8 Remove the muffler assembly see Steering Frame 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 positive wire then remove the engine ground wire KM319A 13 D...

Page 23: ... 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 Manual Table of Contents For Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 24: ... lower rear engine through bolts KM333A KM325A 21 Raise 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 batter...

Page 25: ...ve 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 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 starte...

Page 26: ...ough bolt then remove 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 sufficie...

Page 27: ...over 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 Remove the cap screws securing the cylinder head cover Account for the O ring KM703 NOTE Keep the mounting hardware with the cover for assembly purposes 2 Remove the plug from the cam chain tensioner then turn the cam chain tensioner screw clockwise...

Page 28: ...e and remove the cylinder Support the piston with rubber bands or other suitable supports Account for two dowel pins and the cylinder gasket KM450 C Cylinder D Piston NOTE Steps 1 6 in the preceding sub section must precede this procedure 7 Using a needle nose pliers remove one piston pin circlip Take care not to drop it into the crankcase AT THIS POINT To service valves and cylinder head see Serv...

Page 29: ...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 Inspect the rocker arms for excessive wear loose adjusters or score...

Page 30: ...ing to move the cylinder head in a fig ure eight motion until a uniform bright metallic finish is attained Measuring Cylinder Head Distortion 1 Remove any carbon buildup in the combustion chamber 2 Lay a straightedge across the cylinder head then using a feeler gauge check the distortion factor between the head and the straightedge 3 Maximum distortion must not exceed specifications CC141D Measuri...

Page 31: ... 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 for proper installation When installing new rings install as a complete set only Cleaning Inspecting Piston Rings 1 Take an old piston ring and snap it into two pieces then grind the end o...

Page 32: ...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 the top surface of each ring faces the dome of the piston Rotate the rin...

Page 33: ...ghly 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 rod making sure there is a circlip on each side an...

Page 34: ...ay 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 18 ft lb KM707A KM706A 10 Install the cam chain ten...

Page 35: ...n of the recoil cover gasket Replace if damaged B V Belt Cover C Drive Pulley D Driven Pulley Centrifugal Clutch Assembly NOTE On the Utility step 1 in the preceding sub section must precede this procedure 2 Remove the ten cap screws securing the V belt cover then remove the cover noting the location of the two dowel pins Note the condition of the V belt cover gasket Replace if damaged KM253 3 On ...

Page 36: ...the ratchet guide spacer and spring KM411 4 Carefully lift the reel free of the case making sure the spiral spring does not accidentally disengage from the case KM402A 5 Remove the protective cover from the starter handle and pull the rope out of the handle then untie the knot in the rope and remove the handle Account for a flat washer WARNING Always wear safety glasses when servicing the recoil s...

Page 37: ...or 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 it in a counterclockwise direc tion until the complete spring is installed NOTE The spiral spring must seat evenly in the recoil case KM402 2 Inse...

Page 38: ...rom 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 assembly into position on the left side cover then tighten the cap screws to securely V BELT COVER 1 Inspect the bearing for excessive wear rough or binding when...

Page 39: ...ol 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 assembling KM374A 2 Secure the centrifugal clutch with the spring com pressor then remove the drive plate nut KM373 3 Release the spring pressure a...

Page 40: ...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 KM382A 4 Inspect the pins and bushings for wear flat spots looseness or cracking KM379 Manual Table of Contents For Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 41: ...ompressor 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 on the fixed face making sure the alignment marks are properly aligned KM374A 3 Install the pins and spacers into the fixed face hub then pack the cam slots in the movable fa...

Page 42: ... the faces of the driven pulley then insert a suitable wedge between the faces to hold them apart 3 Place the V belt around the pulley and push the belt down between the pulley faces then install the driven pulley centrifugal clutch assembly onto the driveshaft Loop the V belt over the drive pulley col lar KM262 KM369 4 Place the fixed drive face into position on the crank shaft and engage the spl...

Page 43: ...rom the frame for this procedure Removing Right Side Components A Transmission DVX 1 Drain the transmission lubricant into a suitable con tainer then install the drain plug and tighten to 21 ft lb KM106 2 Remove the drive sprocket cover then remove the cap screws and lock plate securing the sprocket to the driveshaft and remove the sprocket KM344A 3 Remove the cap screws securing the transmission ...

Page 44: ...all spring and seal washer KM677A KM619A 6 Remove the shift fork guide shaft then hold the shift fork away from the shift cam and remove the shift cam KM620A KM621 7 Remove the shift fork then remove the main shaft assembly KM622A 8 Remove the countershaft then remove the primary drive axle KM627B Manual Table of Contents For Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 45: ... gear retainer nut washer and speedometer gear KM649 5 Using a Spanner Wrench to hold the centrifugal clutch housing remove the nut securing the second ary drive bevel gear to the driveshaft KM650 NOTE If the engine has been removed and the left side components are removed install the centrifugal clutch housing on the driveshaft If the left side com ponents have not been removed see Removing Left ...

Page 46: ...e the lower shift fork KM680 10 Remove the countershaft and driveshaft as an assembly KM681 11 To disassemble the countershaft use the following procedure A Remove the thrust washer and high gear clutch dog KM684 B Remove the high drive gear circlip and washer then remove the high drive gear and thrust washer Manual Table of Contents For Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymow...

Page 47: ...ollowing procedure A Secure the universal joint using a suitable vise then engage the output end of the shaft with the universal joint KM653 B Remove the nut securing the driven bevel gear then remove the gear Account for a washer KM654 C Remove the shaft and housing from the universal joint and remove the shaft from the housing NOTE If left side components are still attached remove the centrifuga...

Page 48: ...ter one way clutch bearing KM775 KM766A NOTE The starter one way clutch bearing is direc tion oriented and will only function if installed prop erly Note the markings or arrows when removed F Oil Pump NOTE Steps 14 18 in the preceding sub section must precede this procedure 19 Remove the rotor flywheel see Rotor Flywheel in this sub section 20 Remove the starter drive gear and place together with ...

Page 49: ...s necessary TRANSMISSION DVX Inspecting 1 Measure the shift fork guide shaft runout If runout exceeds 0 03 mm the shaft must be replaced KM623 2 Inspect the shift forks for distortion discoloration scoring or excessive wear 3 Inspect the shift cam groove and shift cam gear for excessive wear KM625 4 Inspect shift shaft and shift shaft gear for excessive wear KM626 5 Inspect all gear teeth for chip...

Page 50: ...llar and thrust washer The main shaft is now assembled and can be installed KM629A KM628 3 Install the drive axle into the transmission housing then secure with the circlip KM611A 4 Apply multi purpose grease to the lip of the main drive seal then using a suitable driver install the seal into the gear case 5 Install the countershaft then making sure the main shaft thrust washer is in place install...

Page 51: ...ping discoloration pit ting or excessive wear Replace as required 6 Inspect clutch dogs and mating surfaces for chip ping rounding or excessive wear Replace as required 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 case discolor ation 9 In...

Page 52: ...il to the secondary driven bevel gear shaft then install the bearing into the case KM420 4 Install the flat thrust washer and driven bevel gear on the driven shaft then using the universal joint and vise to hold the shaft install a new nut and tighten to 72 ft lb KM425 5 Use a center punch to stake the nut to the driven shaft KM426A 6 Install the high drive gear thrust washer on the coun tershaft ...

Page 53: ...tershaft and driveshaft simultaneously into the transmission case KM699 11 Install the low reverse shift fork into the low reverse clutch dog then install the shift cam into the trans mission case and engage the 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 appropriate shift cam groove 13 I...

Page 54: ...bevel gear with a new nut and tighten to 72 ft lb KM650 17 Use a center punch to stake the nut to the driveshaft 18 Apply clean engine oil to a new O ring and install in the groove of the secondary driven bevel gear hous ing then with the index marks aligned install the secondary driven bevel gear assembly in the trans mission case KM673 19 Loosely secure the secondary driven bevel gear assembly u...

Page 55: ... the crankshaft with the nut and tighten to 47 ft lb then install the spring and oil through in the crankshaft KM773A 7 Install the trigger coil and stator coil in the right side crankcase cover then secure with the existing hard ware and tighten securely E Water Pump F Transmission See Servicing Right Side Components in this sub section Center Crankcase Components NOTE This procedure cannot be do...

Page 56: ...on a set of V blocks and mount a dial indicator and base on the surface plate Position the indicator contact point against the center of the connecting rod small end journal 2 Zero the indicator and push the small end of the con necting rod away from the dial indicator 3 Maximum deflection must not exceed specifications Measuring Connecting Rod Big End Side to Side 1 Push the lower end of the conn...

Page 57: ... components install the balancer shaft into the left side crankcase half then align the timing mark on the balancer shaft with the timing mark on the crankshaft Install the crankshaft KM728A Joining Crankcase Halves 1 Verify that the alignment pins and a new gasket are in place and that both case halves are clean and grease free Place the right side half onto the left side half 2 Using a plastic m...

Page 58: ...re Finger tighten only 5 Install the front engine through bolt and nut then tighten the engine mounting bracket cap screws to 16 ft lb 6 Tighten the engine through bolt nuts to 29 ft lb 7 Connect the shift linkage to the shift arm and tighten the nut securely 8 Install the output drive sprocket and drive chain then secure with the lock plate and two cap screws Tighten to 43 ft lb and bend the tabs...

Page 59: ...ine transmission should go in first KM331 2 Lifting the front of the engine transmission move the assembly forward sufficiently to clear the rear engine mounts then engage the secondary bevel driveshaft into the universal joint splines KM328 3 Slide the engine transmission rearward into the rear engine mounts then install the rear through bolts and nuts Do not tighten at this time 4 Remove the eng...

Page 60: ...rical System 13 Install the carburetor see Fuel Lubrication Cooling 14 Install the muffler assembly see Steering Frame 15 Install the gas tank and air filter see Fuel Lubrica tion Cooling 16 Install the fenders and front rack then install the side panels see Steering Frame 17 Install the battery then connect the positive and neg ative battery cables 18 Pour in the recommended amount and grade of e...

Page 61: ...ve clearance out of adjustment 1 Clean plug 2 Replace magneto 3 Replace CDI unit 4 Clean jets 5 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance too large 2 Valve spring s weak broken 3 Rocker arm rocker arm shaft worn 4 Camshaft worn 1 Adjust clearance 2 Replace spring s 3 Replace arm shaft 4 Replace camshaft Problem Engine noisy Noise seems to come...

Page 62: ...ustment 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 obstructed 11 Pilot screw setting improper 1 Adjust clearance 2 Replace service seats valves 3 Replace guides 4 Replace arms shafts 5 Replace magneto 6 Replace CDI unit 7 Adjust gap r...

Page 63: ...ght 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 level low 9 Fan malfunctioning 10 Fan switch malfunc...

Page 64: ...4 Needle Jet 4 0 3 6 Jet Needle NLRA Idle RPM 1250 1350 Float Arm Height 17 0 mm 0 67 in Throttle Cable Free Play at lever 1 4 mm 1 16 3 16 in 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 Nee...

Page 65: ...ve the cover KC0019A 2 Remove the vacuum piston assembly 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 Manual Table of Contents For...

Page 66: ...dy for cracks nicks stripped threads and any imperfections in the cast ing 6 Inspect the vacuum piston for cracks imperfections in the casting or cracks and tears 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 mai...

Page 67: ...ht by placing the carbu retor on its side w float contacting the needle then measure with a caliper 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 va...

Page 68: ...le has proper free play of 1 4 mm 1 16 3 16 in at the lever ATV 0047B 3 Tighten the jam nut against the throttle cable adjuster securely then slide the rubber boot over the adjuster Engine RPM Idle To properly 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 transmi...

Page 69: ...operating position gasoline will flow from the tank to the carburetor In this position on the Utility 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 indicator is pointed directly at the position desired REMOVING ...

Page 70: ...LLING 1 Place the rotors into the pump housing making sure the alignment pin is in the groove of the rotor 2 Place the cover onto the pump housing 3 Secure the pump with the Phillips head screw coated with red Loctite 271 4 Install 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 ...

Page 71: ...s required to the appropriate lev els KM339A KM136A 8 On the Utility install the cover and rack see Steering Frame Hoses Thermostat REMOVING 1 Drain approximately one U S qt of coolant from the cooling system 2 Remove the two machine screws securing the ther mostat housing cover to the thermostat housing Account for an O ring and a thermostat INSPECTING NOTE Whenever a part is worn excessively cra...

Page 72: ... cleaning sol vent 2 Inspect the mechanical seal and pump drive seal for damage NOTE If the mechanical seal and or pump drive seal are damaged they must be replaced as a set 3 Inspect the impeller for corrosion or damage ASSEMBLING INSTALLING NOTE Treat seals and O rings with clean antifreeze for initial lubrication 1 Press the seal washer into the impeller by hand 2 Install the water pump drive s...

Page 73: ...eed 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 Filter obstructed 6 Float height incorrect 7 Starter valve not fully closed 1 Shift into higher gear decrease RPM speed 2 Clean main jet 3 Clean needle jet 4 Check piston operation 5 Clean filter 6 Adjust float height 7 Adjust valve Pr...

Page 74: ...art B Emergency stop switch engine will stop C Reverse switch reverse 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 performanc...

Page 75: ...a light coat of multi purpose grease 9 Connect the battery cables positive cable first then install the battery hold down Brakelight Switch Auxiliary The switch connector is the two prong white connector on the right side of the engine directly above the switch NOTE The ignition switch must be in the ON position VOLTAGE Wiring Harness Side 1 Set the meter selector to the DC Voltage position 2 Conn...

Page 76: ...tch and thermometer 733 554E 3 On the cooling fan switch when the temperature reaches 86 90 C 187 194 F the meter should read a closed circuit On the coolant temperature sen sor when the temperature reaches 120 C 218 F the meter should read 16 0 ohms 4 Allow the oil to cool On the cooling fan switch when the temperature is within a range of 80 85 C 176 185 F the meter should read an open circuit O...

Page 77: ... red tester lead to one spade end of the fuse then connect the black tester lead to the other spade end AR610D 3 The meter must show less than 1 ohm resistance If the meter reads open replace the fuse NOTE Make sure the fuses are returned to their proper position according to amperage Refer to the fuse block cover for fuse placement Ignition Coil The ignition coil is on the left side of the frame ...

Page 78: ...ted to the wiring harness NOTE To perform the following tests two MaxiClips and one jumper wire will be required 2 Connect the black MaxiClip to the green black wire 3 Connect the red MaxiClip to the light green red wire then connect the jumper between the MaxiClips and turn the ignition switch to the ON position The neu tral indicator light 9 must illuminate KM123D 4 Connect the red MaxiClip to t...

Page 79: ...itch to the ON position 2 Set the meter selector to the OHMS position 3 Connect the red tester lead to the red wire then con nect the black tester lead to the black wire 4 The meter must show less than 1 ohm 5 Turn the ignition switch to the LIGHTS position 6 Connect the red tester lead to the red wire then con nect the black tester lead to the brown wire 7 The meter must show less than 1 ohm NOTE...

Page 80: ... is present replace the stator assembly RESISTANCE Charging Coil 1 Set the meter selector to OHMS position 2 Test between the three yellow wires for a total of three tests 3 The meter reading must be within specification RESISTANCE Trigger 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 w...

Page 81: ...he CDI unit Regulator Rectifier The regulator rectifier is located 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 po...

Page 82: ...he HI position HI beam the meter must show battery voltage NOTE If battery voltage is not shown in any test inspect the fuses battery main wiring harness con nectors or the 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 Tailligh...

Page 83: ...eat 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 plug 4 Adjust carburetor Problem Magneto does not charge Condition Remedy 1 Lead wires connections shorted loose open 2 Magneto coils shorted grounded open 3 Regulator rectifier defective 1 Repair replace tighten lead wires 2 Replace...

Page 84: ...ry substance or spots on surfaces of cell plates Condition Remedy 1 Charging rate too low too high 2 Specific gravity too low 3 Battery run down damaged 4 Electrolyte contaminated 1 Replace battery 2 Charge battery 3 Replace battery 4 Replace battery Problem Battery discharges too rapidly Condition Remedy 1 Electrolyte contaminated 2 Specific gravity too high 3 Battery short circuited 4 Specific g...

Page 85: ...rd 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 disc assembly from the axle KM472 Description p n Pi...

Page 86: ...procket 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 seals for wear or damage If any defect is found replac...

Page 87: ...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 sprocket hub on the axle and secure with the snap rin...

Page 88: ...ity 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 apply the brakes with the calipers removed The brake pistons wil...

Page 89: ...iveshaft 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 two O rings KM536 Manual Table of Contents For Ar...

Page 90: ... brake 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...

Page 91: ...21 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 Manual Table of Contents For Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 92: ...he 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 s...

Page 93: ...nut and using the pinion lock 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 i...

Page 94: ... 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 7 Clean any oil from the mating surfaces th...

Page 95: ... secure the gear case 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...

Page 96: ... ware and tighten to 29 ft lb then install the brakeline hose clamp on the swing arm and tighten securely KM505A 10 Tighten the 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 secure...

Page 97: ...5 Master cylinder brake cylinder seal worn 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 ...

Page 98: ...cap screws and nuts securing each shock absorber to the A arm and frame KM573A CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 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 crack...

Page 99: ...e 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 skid plate an...

Page 100: ...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 see Drive System 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 chain guide...

Page 101: ...o side and up and down If excessive play is noted the bushings axle or swing arm must be replaced Check for cracks or broken 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 ...

Page 102: ...securely KM568 5 Install the swing arm axle and bushings then install the dust seals and lubricate the lips with grease 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 secu...

Page 103: ...m the nut SP366 3 Remove the nut securing the hub 4 Remove the cap screws securing the brake caliper then remove the caliper and lay aside KM266A 5 Remove the hub assembly then on the Utility remove the disc cover KM569 6 Remove the cotter pin and slotted nut securing the tie rod end to the knuckle then remove the tie rod end from the knuckle WARNING Make sure the ATV is solidly supported on the s...

Page 104: ...eal lips and spacers NOTE The pivots are equipped with roller bearings The bearing rollers may fall out when the spacers are removed 5 Check the bearings for excessive wear and replace them if worn 6 Using a suitable bearing remover remove the pivot bearings then clean all parts in parts cleaning sol vent SP382 NOTE All bearings bushings and seals that are removed must be replaced with new ones IN...

Page 105: ... Secure the ATV on a support stand to elevate the wheels 2 Remove the wheels NOTE Keep left side and right side wheels sepa rated for installing them on their proper sides CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary 1 Clean the wheels and hubs with parts cleaning sol vent 2 Clean the tires with soap and water WARNING Use ...

Page 106: ...ted during braking only check and adjust the brakes as necessary and recheck operation see Periodic Maintenance Tune Up 5 Increase the air pressure in the tires with the smallest circumference measurement until all tires are equal in circumference 6 Repeat steps 4 5 as necessary to ensure proper han dling Troubleshooting WARNING Do not operate the ATV if tire damage exists Problem Suspension too s...

Page 107: ... the front rack and front center panel see Body in this section On the DVX pro ceed to step 2 2 Remove the steering post cover DVX or the instru ment pod Utility see Steering Post Cover Instru ment Pod in this section 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 ha...

Page 108: ...pect the handlebar grips for damage or wear 9 Inspect the lower steering post support bearing and seal for wear or cracks INSTALLING 1 Apply 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 sup...

Page 109: ...C and D should be equal 5 After all the adjustments are to specifications tighten the tie 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 Body REMOVING ...

Page 110: ...ING Utility 1 Remove the seat then remove the battery box cover KM793A 2 Disconnect the negative battery cable first then the positive cable 3 Remove the battery hold down strap then remove the battery 4 Remove the front and rear racks then remove the cap screws securing the front center panel and remove the panel KM308A 5 Remove the cap screws and flange nuts securing the mud guards to the front ...

Page 111: ...crews and flange nuts Tighten securely 4 Install the six cap screws securing the body to the top of the frame Tighten securely 5 Install the fuse block start in gear relay and the CDI then install the body mounting cap screw into the bottom of the battery box 6 Install the battery and battery hold down strap then connect the positive battery cable and the negative battery cable NOTE Always install...

Page 112: ...ove the LCD gauge NOTE The LCD gauge is not a serviceable compo nent If any functions are incorrect or indicator lights do not illuminate the LCD gauge must be replaced INSPECTING SERVICING DVX 1 Remove the two self tapping screws securing the indicator lamp assembly in the steering post cover 2 Inspect the bulbs for blackening or burn out Replace as required 3 Inspect the indicator lamp holder fo...

Page 113: ...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 pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Replace shock absorber Problem Steering impaired Condition Remedy 1 Tire pressure too high 2 Steering linkage conne...

Page 114: ... the reservoir for cracks and leakage 4 Inspect the brake hose for cracks and deterioration and the condition of the fittings threaded and com pression 5 Inspect the brakelight switch for corrosion cracks missing or broken mounting tabs or broken and frayed wiring NOTE If the brakelight switch is determined to be not serviceable see Electrical System INSTALLING 1 Install the brakelight switch on t...

Page 115: ... then remove the clevis and adjuster nut INSTALLING 1 Install the jam nut then install the clevis and adjuster nut Finger tighten only at this time 2 Secure the master cylinder to the frame with the two cap screws and tighten securely 3 Using two new crush washers connect the brake hose to the master cylinder with the union bolt then making sure the spring clamp is seated securely con nect the res...

Page 116: ...rol to the handlebar and remove the throttle control INSTALLING 1 Making sure the throttle housing upper flat aligns with the alignment mark on the handlebar place the throttle control into position on the handlebar and secure with the two machine screws then tighten the machine screws securely KM122B 2 Thread the throttle cable into the throttle housing and turn the adjuster completely in then co...

Page 117: ... Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2258 909 For Arctic Cat Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

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