Arctic Cat DVX 250 2007 Service Manual Download Page 122 | Manualshive

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8-1

8

SECTION 8 - STEERING/FRAME

TABLE OF

CONTENTS

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

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Summary of Contents for DVX 250 2007

Page 1: ......

Page 2: ...eword Click on the red text to go 1 General Information 2 Periodic Maintenance Tune Up 3 Engine Transmission 4 Fuel Lubrication Cooling 5 Electrical System 6 Drive System 7 Suspension 8 Steering Frame...

Page 3: ...TABLE OF CONTENTS General Specifications DVX Model 1 2 General Specifications Utility Model 1 3 Break In Procedure 1 4 Gasoline Oil Lubricant 1 4 Genuine Parts 1 5 Preparation For Storage 1 6 Prepara...

Page 4: ...C volts blue yellow to green white Magneto Output approx 220W 5000 RPM Stator Coil Output no load 40 60 AC volts 3000 RPM yellow to yellow CHASSIS Dry Weight approx 186 kg 410 lb Length overall 168 3...

Page 5: ...eto Output approx 220W 5000 RPM Stator Coil Output no load 40 60 AC volts 3000 RPM yellow to yellow CHASSIS Dry Weight approx 216 kg 477 lb Length overall 187 cm 73 6 in Height overall 111 8 cm 44 0 i...

Page 6: ...asoline to use is 87 minimum octane regular unleaded In many areas oxygenates either ethanol or MTBE are added to the gasoline Oxygenated gasolines containing up to 10 ethanol 5 methane or 5 MTBE are...

Page 7: ...m area Tighten the gas tank cap securely after filling the tank Genuine Parts When replacement of parts is necessary use only genuine Arctic Cat ATV parts They are precision made to ensure high qualit...

Page 8: ...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 prepar ing it will assure many miles a...

Page 9: ...ed 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 sp...

Page 10: ...Oil Filter 2 8 Rear Drive Lubricant Utility Model 2 8 Transmission Lubricant 2 9 Drive Chain DVX Model 2 9 Tires 2 11 Steering Components 2 11 Driveshaft Coupling Utility Model 2 11 Suspension Shock...

Page 11: ...Float Chamber D Engine RPM Idle I I A Engine Oil Level I A Engine Oil Filter R R R Drive Chain DVX Model I I C L Rear Drive Lubricant Utility Model I R R Transmission Lubricant I R Tires Air Pressure...

Page 12: ...e the battery hold down strap KM133A 2 Remove the negative battery cable then remove the positive cable Remove the battery from the ATV 3 Trickle charge the battery at 1 5 amps for 5 10 hours 4 Place...

Page 13: ...KM095A 3 Loosen the clamp then remove the filter AF640DA 4 Fill a wash pan larger than the filter with a non flammable cleaning solvent then dip the filter in the solvent and wash it NOTE Foam Filter...

Page 14: ...the jam nut then rotate the tappet adjuster screw clock wise until friction is felt 5 Align the valve adjuster handle with one of the marks on the valve adjuster dial 6 While holding the valve adjuste...

Page 15: ...white or dark insulator indicates that the engine may need to be serviced or the carburetor may need to be adjusted To maintain a hot strong spark keep the plug free of carbon ATV 0051 Adjust the gap...

Page 16: ...Turn the adjuster until the throttle cable 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...

Page 17: ...nd allow it to idle for a few min utes 8 Turn the engine off and wait approximately one minute Check the oil level in the engine oil inspection window The oil level should be visi ble through the wind...

Page 18: ...changing the lubricant use approved SAE 80W 90 hypoid gear lube To change the lubricant use the following proce dure 1 Place the ATV on level ground 2 Loosen the fill plug then remove the transmis si...

Page 19: ...for O ring type chains 1 Using a suitable nonflammable cleaning solu tion thoroughly wash the chain and sprockets 2 Allow the chain to dry then apply a dry graph ite based lubricant to the chain NOTE...

Page 20: ...aged G Cotter pins not damaged or missing Driveshaft Coupling Utility Model The following drive system components should be inspected periodically to ensure proper operation A Spline lateral movement...

Page 21: ...ed 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 pro cedure 1 Remove the boot fro...

Page 22: ...tion The neutral indicator light should illu minate NOTE If the neutral indicator light does not illu minate adjustment of the shift linkage will be required To adjust proceed to step 2 2 Loosen the j...

Page 23: ...ll one end of a clear hose onto one FRONT bleed screw and direct the other end into a container then while holding slight pressure on the brake lever open the bleed screw and watch for air bubbles Clo...

Page 24: ...place the brake pads use the following pro cedure A With the wheel removed remove the brake pad alignment pins from the caliper then remove the mounting cap screws KM265A KM266A B Remove the caliper f...

Page 25: ...aliper from the disc then com press 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...

Page 26: ...nd 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 b...

Page 27: ...ntifreeze 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 cooling system reservoir un...

Page 28: ...ng nut Tighten to specifications KM276 3 Install the movable drive face onto the crank shaft making sure to bottom the sheave out against the center bushing The crankshaft splines should be visible an...

Page 29: ...2 20 KM252A 5 Install the recoil starter and footwell assembly Utility model Tighten all hardware securely Back to TOC Back to Section TOC Back...

Page 30: ...3 1 3 SECTION 3 ENGINE TRANSMISSION TABLE OF CONTENTS Engine Transmission 3 2 Specifications 3 2 Table of Contents 3 4 Back to TOC...

Page 31: ...Deflection wobble deflection max 0 35 mm 0 014 in Valve Guide Inside Diameter 5 500 5 512 mm 0 2165 0 2170 in Valve Stem Outside Diameter intake exhaust 5 475 5 490 mm 0 2156 0 2161 in 5 455 5 470 mm...

Page 32: ...M above below 0 3 kg cm 4 3 psi 0 7 kg cm 10 psi CLUTCH Clutch Release Screw 1 8 turn back Drive Plate fiber Thickness min 2 4 mm 0 094 in Drive Plate fiber Tab min 11 mm 0 43 in Driven Plate warpage...

Page 33: ...m the battery then remove the positive cable Remove the bat tery hold down strap then remove the battery 3 Remove the reinstallable rivet from the bottom of the electrical tray then remove and lay the...

Page 34: ...ission gear lubricant then install the drain plugs and tighten to specifications KM314A KM147A KM106A 14 Loosen the clamps then remove the front and rear V belt cooling boots from the V belt hous ing...

Page 35: ...d engine lift to the front engine mounting boss KM332 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...

Page 36: ...KM106A 4 Remove the gas tank cover panel and gas tank vent hose 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 Rem...

Page 37: ...g boots from the V belt housing then remove the cool ant hoses from the engine KM359A KM360A KM323 KM314 14 Loosen the output drive boot clamp then slide the boot off the output housing KM315A 15 Disc...

Page 38: ...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 39: ...TE 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 clock wise to release the chain tension KM704A...

Page 40: ...eplacing with new rings replace as a complete set only If the piston rings must be removed remove them in this sequence A Starting with the top ring slide one end of the ring out of the ring groove B...

Page 41: ...ection 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 R...

Page 42: ...all the drain plug and tighten to specifications 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 KM344...

Page 43: ...ift cam stopper ball 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...

Page 44: ...n remove the cover Account for a gasket KM648A 4 Remove the speedometer gear retainer nut washer and speedometer gear KM649 5 Using a Spanner Wrench p n 0444 153 to hold the centrifugal clutch housing...

Page 45: ...de shaft then remove the upper shift fork and shift cam KM679A 9 Remove the lower shift fork KM680 10 Remove the countershaft and driveshaft as an assembly KM681 11 To disassemble the countershaft use...

Page 46: ...bevel gear assembly use the following 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...

Page 47: ...tor flywheel Account for a key and the starter one way clutch bearing KM775 KM766A NOTE The starter one way clutch bearing is direction oriented and will only function if installed properly Note the m...

Page 48: ...for Top Side Left Side and Right Side must precede this procedure NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only th...

Page 49: ...Crankcase Components 3 33 Crankshaft Assembly 3 33 Crank Balancer Shaft 3 34 Servicing Right Side Components 3 34 Transmission DVX Model 3 34 Transmission Utility Model 3 36 Servicing Top Side Compone...

Page 50: ...ngs and remove the valve cotters Account for an upper spring retainer KM717A 2 Remove the valve seal valve springs and the lower remaining spring seat Discard the valve seal NOTE The valve seals must...

Page 51: ...tion 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 assembly by continuing to move the cylinder head in...

Page 52: ...d valve guide seal over each valve guide 2 Insert each valve into its original valve location 3 Install the valve springs with the closest coils toward the cylinder head ATV 1011A 4 Place a spring ret...

Page 53: ...tapered side up Measuring Piston Ring End Gap Installed 1 Place each piston ring in the wear portion of the cylinder Use the piston to position each ring squarely in the cylinder 2 Using a feeler gau...

Page 54: ...ation 726 306A CYLINDER ASSEMBLY NOTE If the cylinder cannot be trued it must be replaced Cleaning Inspecting Cylinder 1 Wash the cylinder in parts cleaning solvent 2 Inspect the cylinder for pitting...

Page 55: ...air then immedi ately 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 Servicing Left S...

Page 56: ...y cracked or damaged in any way replacement is necessary 1 Clean all components 2 Inspect the springs and ratchet for wear or dam age 3 Inspect the reel and case for cracks or damage 4 Inspect the sha...

Page 57: ...roperly oriented on the reel KM397A 7 Install the spacer spring and the ratchet guide making sure the ratchet pins engage the guide B603D 8 Hold the ratchet guide down in place on the ratchet pins and...

Page 58: ...ct the V belt cover for cracks distortion and loose alignment pins NOTE If the V belt cover is cracked or distorted or if the bearing is loose in the cover the cover must be replaced DRIVE PULLEY 1 Re...

Page 59: ...then remove the clutch nut KM373 3 Release the spring pressure and remove the cen trifugal clutch assembly from the driven pulley KM375 4 Remove the spring and spring seat then remove the hub collar...

Page 60: ...ble face for nicks cuts or damage KM380B KM382A 4 Inspect the pins and bushings for wear flat spots looseness or cracking KM379 5 Measure the driven face spring free length If the free length is less...

Page 61: ...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 t...

Page 62: ...enter 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 must not exceed specifica tions Measur...

Page 63: ...d bearing surfaces for chips discoloration or excessive wear KM724 Servicing Right Side Components NOTE Whenever a part is worn excessively cracked damaged in any way or out of tolerance replacement i...

Page 64: ...gear and splined retainer onto the main shaft then secure with the circlip KM631A 2 Install the clutch dog splined washer bushing and primary driven gear onto the main shaft then install the second sp...

Page 65: ...exceeds 0 03 mm 0 0012 in the shaft must be replaced KM623 2 Inspect the shift forks for distortion discolora tion or excessive wear 3 Inspect the shift cam groove and shift cam gear for excessive we...

Page 66: ...scolora tion or worn splines KM421 Assembling 1 Using the appropriate bearing and seal drivers install any required bearings and seals in the transmission case and case cover KM696 2 Replace any requi...

Page 67: ...on KM684 8 Install the low driven gear washer on the drive shaft then install the low driven gear and thrust washer Secure with a circlip KM692A 9 Install the low reverse clutch dog and spacer washer...

Page 68: ...KM619A 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 trans mission case cover and secure wi...

Page 69: ...ves 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 mallet lightl...

Page 70: ...n gear oil on the crankshaft KM767 NOTE Make sure the crankshaft and rotor fly wheel contact surfaces are clean and dry before installing the flywheel 5 Install the key in the crankshaft then with the...

Page 71: ...ulley centrifugal clutch assembly onto the driveshaft Loop the V belt over the drive pulley collar KM262 KM369 4 Place the fixed drive face into position on the crankshaft and engage the splines makin...

Page 72: ...the direction of the exhaust side of the piston 5 for correct ring end gap orientation B Install the compression rings 1 and 2 so the letter on the top surface of each ring faces the dome of the pist...

Page 73: ...routed through the chain cavity KM718A 7 Turn the crankshaft as required to align the T mark on the rotor flywheel with the index mark on the right side crankcase cover KM779A 8 With the index hole in...

Page 74: ...ft 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 eng...

Page 75: ...Install the gas tank see Section 4 18 Install the air filter housing see Section 8 19 Install the body see Section 8 20 Install the gas tank cover panel 21 Install the electrical tray Install the batt...

Page 76: ...ar and one front through bolt 7 Connect the shift linkage using the existing hardware 8 Install the output drive boot onto the bevel driven gear housing and secure with the existing clamp KM315A 9 Con...

Page 77: ...see Section 4 17 Install the fenders and front rack then install the side panels see Section 8 18 Install the battery then connect the positive and negative battery cables 19 Pour in the recommended...

Page 78: ...r Schematic 4 2 Carburetor 4 3 Cleaning and Inspecting Carburetor 4 5 Throttle Cable Free Play 4 6 Engine RPM Idle 4 6 Gas Tank 4 6 Gas Tank Valve 4 7 Gas Vent Hoses 4 7 Oil Flow Chart 4 7 Oil Pump 4...

Page 79: ...4 8 mm 0 58 in Throttle Cable Free Play at lever 1 4 mm 1 16 3 16 in KEY 1 Cover 2 Gasket 3 Spring 4 Needle Clip 5 E Clip 6 Jet Needle 7 Throttle Valve 8 Needle Jet 9 Adjuster Screw 10 Spring 11 Washe...

Page 80: ...sembly then remove the two carburetor mounting nuts and remove the carburetor DISASSEMBLING 1 Remove the Phillips head screws securing the float chamber then remove the chamber Account for the O ring...

Page 81: ...ring NOTE Turn the pilot screw clockwise until it is lightly seated then turn it counterclockwise the recommended number of turns as an initial set ting NOTE Note the locations of the jets and needle...

Page 82: ...the ON position Cleaning and Inspecting Carburetor NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Place all metallic components in a wire basket and...

Page 83: ...M327A 6 Remove the vent hose then remove the gas tank CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all gas tank compo...

Page 84: ...ING 1 Place the valve and gasket into position on the tank and secure with the machine screws Tighten securely 2 Install the gas hose onto the valve with the clamp Gas Vent Hoses Replace the gas hose...

Page 85: ...KM314A 2 On the Utility model remove the front rack then remove the front cover and fender assem bly see Section 8 3 Remove the upper and lower coolant hoses 4 Remove the cap screws and nuts securing...

Page 86: ...damage 2 Using the following procedure inspect the ther mostat for proper operation A Suspend the thermostat in a container filled with water B Heat the water and monitor the temperature with a thermo...

Page 87: ...anical 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 anti freeze f...

Page 88: ...Coolant Temperature and Cooling Fan Switches 5 3 Fan Motor 5 4 Fuse Block 5 4 Fuses 5 5 Ignition Coil 5 5 Indicator Lights DVX Model 5 6 LCD Gauge Assembly 5 6 Ignition Switch 5 7 Handlebar Control S...

Page 89: ...E The ignition switch must be in the ON position VOLTAGE Wiring Harness Side 1 Set the meter selector to the DC Voltage posi tion 2 Connect the red tester to the brown blue wire then connect the black...

Page 90: ...sistance RESISTANCE Switch NOTE The brake lever must be compressed for this test Also the ignition switch must be in the OFF position 1 Set the meter selector to the OHMS position 2 Connect the red te...

Page 91: ...the black tester lead to the black wire 3 The meter must show 50 60 ohms NOTE If the meter does not show as specified troubleshoot or replace the connector or the fan NOTE To determine if the fan moto...

Page 92: ...e for these tests NOTE The ignition switch must be in the ON position the emergency stop switch must be in the RUN position Also the white blue wire must be disconnected from the coil 1 Set the meter...

Page 93: ...then disconnect the speedometer cable Leave the gauge connected to the wiring harness NOTE To perform the following tests two Maxi Clips p n 0744 041 and one jumper wire will be required 2 Connect th...

Page 94: ...de the gauge will default to normal operation 10 seconds after the Mode Set buttons are released 15 With the ignition switch in the ON position use a small screwdriver or suitable tool to spin the inp...

Page 95: ...If the meter does not show as specified replace the switch component or connector RESISTANCE Emergency Stop 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the brown bl...

Page 96: ...these tests Stator Coil Trigger 1 Set the meter selector to the DC Voltage posi tion 2 Connect the red tester lead to the blue yellow wire then connect the black tester lead to the green white wire 3...

Page 97: ...able to perform a CDI peak voltage test see Ignition Coil in this section and or perform a continuity test of the wir ing harness from the CDI connector to the CDI unit Regulator Rectifier The regulat...

Page 98: ...nectors are the two 3 prong ones secured to the front bumper supports one on each side with cable ties On the DVX model the connectors are the two 3 prong ones under the front fender BULB VERIFICATION...

Page 99: ...ignition switch should be in the ON position and the brake either foot pedal or hand lever must be applied 1 Set the meter selector to the DC Voltage posi tion 2 Connect the red tester lead to the gre...

Page 100: ...6 1 6 SECTION 6 DRIVE SYSTEM TABLE OF CONTENTS Drive System 6 2 General Information 6 2 Rear Drive Assembly Schematics 6 2 Rear Drive Axle DVX Model 6 2 Rear Drive Axle Utility Model 6 6 Back to TOC...

Page 101: ...REMOVING 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 Remo...

Page 102: ...r holder then remove the circlip securing the caliper holder to the axle housing KM481 9 Remove the brake caliper holder and aligning collar Account for the O ring KM483 10 Remove the two cap screws f...

Page 103: ...gs with a good quality wheel bearing grease Removing Bearings 1 Remove the dust seals using an appropriate seal removal tool then using an appropriate driver drive the bearings out of the axle housing...

Page 104: ...ghtening the axle nuts engage the brake lever lock NOTE It is necessary to calculate the torque value using the following formula due to the offset of the special tool used to tighten the axle nuts 6...

Page 105: ...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 will be pushed out and brake fluid wi...

Page 106: ...spring KM508 11 Disengage the universal joint from the transmis sion output shaft splines and set the driveshaft aside KM509 12 Remove the eight cap screws securing the swing arm to the final drive ge...

Page 107: ...ll bearings turn freely and smoothly and are not worn discolored or missing dust seals 5 Inspect brake components for leaks excessive wear or discoloration 6 Check the axle shaft for runout using a di...

Page 108: ...le bearing KM523A 4 Using a suitable bearing driver install the new axle bearing into the axle housing then install the O ring and dust plate Tighten the three cap screws securely INSTALLING 1 Install...

Page 109: ...of the secondary driven bevel gear shaft KM532 7 Install the right pivot bolt and left pivot adjust ing bolt and tighten securely then move the swing arm up and down to seat the bearings Tighten the...

Page 110: ...he cap screws securely 13 Apply grease to the brake disc hub and wheel hubs then install the disc and rear hubs KM502 14 Install the hub nuts and tighten to specifications then install new cotter pins...

Page 111: ...SECTION 7 SUSPENSION TABLE OF CONTENTS 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 Back to...

Page 112: ...er to the A arm and frame KM564 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 so...

Page 113: ...ew KM555A 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 Inspec...

Page 114: ...SEMBLING For the Utility model see Rear Drive Axle in Sec tion 6 For the DVX model use the following proce dure 1 Secure the ATV on a support stand to elevate the wheels and to release load on the sus...

Page 115: ...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 bu...

Page 116: ...ls can be properly installed 3 Using an appropriate seal driver install the new dust seals in the cushion arm then apply multi purpose grease to the bearings bushing and dust seal lips 4 Install the b...

Page 117: ...2 12 Apply grease to the axle splines then install the hubs and hub nuts Tighten to specifications KM468 13 Install new cotter pins then install the hub caps and rear wheels Tighten the lug nuts to s...

Page 118: ...ng cap screws then remove the shock absorber assem bly 9 Using a ball joint remover remove the ball joints from the knuckle then remove the front bumper CLEANING AND INSPECTING NOTE Whenever a part is...

Page 119: ...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 s...

Page 120: ...des SP054 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean the wheels and hubs with parts cleaning solvent 2 Clean the ti...

Page 121: ...and have identical tread pattern 3 Check the front wheel toe in and toe out and adjust as necessary see Section 8 4 Test drive the ATV on a dry level surface and note any pulling to the left or right...

Page 122: ...8 1 8 SECTION 8 STEERING FRAME TABLE OF CONTENTS Steering Post Tie Rods 8 2 Measuring Adjusting Toe In Toe Out 8 4 Body 8 4 Steering Post Cover Instrument Pod 8 7 Back to TOC...

Page 123: ...andlebar 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 s...

Page 124: ...ct 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...

Page 125: ...ract distance B from A Distance A Distance B Toe In ATV2205 4 Adjust toe in to 15 mm 0 60 in then measure distances C and D Distances C and D should be equal 5 After all the adjustments are to specifi...

Page 126: ...r flange nuts and cap screws secur ing the rear fender support then remove the push nuts from the mounting studs at the front of the rear fenders KM785A KM784A 5 Remove the hardware securing the front...

Page 127: ...nec tors then disconnect the taillight 8 Remove 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...

Page 128: ...ngaged 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 posit...

Page 129: ...ble component To inspect the LCD gauge see Section 5 INSTALLING DVX Model 1 Connect the indicator lamp connectors then connect the main harness connector to the igni tion switch 2 Place the steering p...

Page 130: ...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 131: ...spect 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 deteriora tion and the condition of the fittings threaded...

Page 132: ...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 cl...

Page 133: ...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 flat...

Page 134: ...10 SECTION 10 AIDS FOR MAINTENANCE TABLE OF CONTENTS Torque Specifications Utility Model 10 2 Torque Specifications DVX Model 10 3 Torque Conversions 10 4 Tightening Torque General Bolts 10 4 Back to...

Page 135: ...r Brake Caliper 1 8 13 0 Brake Caliper Slide Pin Front Rear Brake Caliper 3 5 25 0 Front Brake Line Nut Brake Line Junction Block 3 5 25 0 Brake Caliper Rear Swing Arm Housing 3 5 25 0 Brake Pad Mount...

Page 136: ...0 Master Cylinder Front Handlebar 1 8 13 0 Brake Caliper Holder Pin Front Rear Brake Caliper 1 8 13 0 Brake Caliper Slide Pin Front Rear Brake Caliper 3 5 25 0 Front Brake Line Nut Brake Line Junctio...

Page 137: ...1 5 31 4 3 51 7 1 71 9 8 91 12 6 12 1 7 32 4 4 52 7 2 72 10 0 92 12 8 13 1 8 33 4 6 53 7 3 73 10 1 93 12 9 14 1 9 34 4 7 54 7 5 74 10 2 94 13 0 15 2 1 35 4 8 55 7 6 75 10 4 95 13 1 16 2 2 36 5 0 56 7...

Page 138: ...11 1 11 SECTION 11 TROUBLESHOOTING TABLE OF CONTENTS Engine 11 2 Drive 11 5 Fuel System 11 5 Electrical 11 6 Steering Suspension 11 8 Brakes 11 9 Back to TOC...

Page 139: ...efective 2 Replace needle 3 Fuel hose obstructed 3 Clean replace hose 4 Fuel screens obstructed 4 Clean replace inlet screen valve screen Problem Engine stalls easily Condition Remedy 1 Spark plug fou...

Page 140: ...clearance too large 7 Replace thrust washer s Problem Centrifugal clutch slipping Condition Remedy 1 Clutch shoes worn 1 Replace shoes 2 Clutch housing excessively worn 2 Replace clutch housing 3 Driv...

Page 141: ...timing out of adjustment 3 Adjust timing 4 Piston ring s cylinder worn 4 Replace service rings cylinder 5 Valve seating poor 5 Repair seats 6 Spark plug fouled 6 Clean replace plug 7 Rocker arms shaft...

Page 142: ...closed 4 Adjust valve 5 Float height incorrect 5 Adjust float height Problem Medium or high speed impaired Condition Remedy 1 High RPM cut out against RPM limiter 1 Shift into higher gear decrease RP...

Page 143: ...not charge Condition Remedy 1 Lead wires connections shorted loose open 1 Repair replace tighten lead wires 2 Magneto coils shorted grounded open 2 Replace magneto coils 3 Regulator rectifier defecti...

Page 144: ...urfaces of cell plates Condition Remedy 1 Charging rate too low too high 1 Replace battery 2 Battery electrolyte insufficient 2 Keep electrolyte to prescribed level 3 Specific gravity too low 3 Charge...

Page 145: ...t 3 Wheel hub bearings worn broken 3 Replace bearings 4 Frame distorted 4 Repair replace frame 5 Shock absorber defective 5 Replace shock absorber Problem Steering impaired Condition Remedy 1 Tire pre...

Page 146: ...edy 1 Pad worn 1 Replace pads 2 Pedal free play excessive 2 Adjust free play 3 Brake fluid leaking 3 Repair replace hydraulic system 4 Air in hydraulic system 4 Bleed hydraulic system 5 Master cylinde...

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