Arctic Cat ATV 250 Utility 2009 User manual

2009
TM
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250 UTILITY
DVX 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/Cooling
5. Electrical System
6. Drive System
7. Suspension
8. Steering/Frame
9. Controls/Indicators
1
2
3
4
5
6
7
8
9

1-1
1
SECTION 1 - GENERAL INFORMATION
TABLE OF
CONTENTS
General Specifications (DVX 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 Parts ......................................................... 1-5
Preparation For Storage.......................................... 1-5
Preparation After Storage........................................ 1-6
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1-2
General Specifications*
(DVX 300)
* Specifications subject to change without notice.
General Specifications*
(250 Utility)
* Specifications subject to change without notice.
CHASSIS
Dry Weight (approx) 177.3 kg (391 lb)
Length (overall) 171.9 cm (67.7 in.)
Height (overall) 113.5 cm (44.7 in.)
Width (overall) 113.5 cm (44.7 in.)
Suspension Travel (Front)
(Rear)
15.5 cm (6.1 in.)
16.5 cm (6.5 in.)
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Tire Size (Front)
(Rear)
AT21 x 7-10
AT 2 0 x 1 1 - 9
Tire Inflation Pressure2(Front)
2(Rear)
0.28 kg/cm2(4 psi)
0.25 kg/cm2(3.5 psi)
MISCELLANY
Gas Tank Capacity (rated) 12.5 L (3.3 U.S. gal.)
Engine Oil Capacity 1.6 L (1.7 U.S. qt)
Transmission (Overhaul)
Lubricant Capacity (Change)
400 ml (13.5 fl/oz)
300 ml (10.1 fl/oz)
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather
(Synthetic)
Cooling System Capacity 0.776 L (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 cm (44.0 in.)
Width (overall) 105.1 cm (41.40 in.)
Suspension Travel 12.7 cm (5.0 in.)
Brake Type Hydraulic w/Brake Lever
Lock and Auxiliary Brake
Tire Size (Front)
(Rear)
AT2 2 x 7 -1 0
AT22 x 10-10
Tire Inflation Pressure 2(Front)
2(Rear)
0.28 kg/cm2(4 psi)
0.25 kg/cm2(3.5 psi)
MISCELLANY
Gas Tank Capacity (rated) 13 L (3.43 U.S. gal.)
Reserve Capacity 4.54 L (1.2 U.S. gal.)
Engine Oil Capacity 1.6 L (1.7 U.S. qt)
Transmission (Overhaul)
Lubricant Capacity (Change)
600 ml (20.3 fl/oz)
500 ml (16.9 fl/oz)
Gasoline (recommended) 87 Octane Regular
Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather
(Synthetic)
Cooling System Capacity 1.6 L (1.7 U.S. qt)
Rear Drive Capacity 150 ml (5 fl oz)
Rear Drive Lubricant SAE Approved
80W-90 Hypoid
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/21W
Headlight 12V/35W (2)
Starting System Electric w/Manual Recoil
(Emergency)
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1-3
1
Torque Specifications
* w/Red Loctite #271
DRIVE TRAIN COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Engine Mounting Through-Bolt Frame 29 39
Engine Mounting Bracket Cap Screw Frame 16 22
Rear Axle Housing (Utility) Swing Arm 40 54
Rear Axle Housing (DVX) Tube 29 39
Gear Case Swing Arm 50 68
Hub Nut (Front) Front/Spindle 50 68
Wheel Lug Nut Hub 32 44
Hub Nut (Rear) Axle 72 98
Rear Axle Nut* (Utility) Axle 72 98
Rear Axle Nut* (DVX) Axle 86 117
EXHAUST COMPONENTS
Exhaust Pipe Engine 25 34
Muffler Mounting Bolt Frame 25 34
ELECTRICAL COMPONENTS
Starter Motor Lead Cable
Nut
Starter 36
in.-lb
5
Starter Motor Mounting Bolt Crankcase 912
STEERING COMPONENTS
Handlebar Clamp Cap Screw Steering Head 18 24
Steering Post Support Block Frame 17 23
Steering Post 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
BRAKE COMPONENTS
Brake Hose Union Bolt Master Cylinder/
Caliper
25 34
Brake Bleed Screw Caliper 56
in.-lb
5
Brake Caliper Mounting Cap Screw Steering Knuckle/
Swing Arm
25 34
Master Cylinder (Front) Handlebar 13 18
Brake Pad Mounting Pin (Front/Rear) Brake Caliper 13 18
Brake Caliper Slide Pin (Front/Rear) Brake Caliper 25 34
Front Brake Line Nut Brake Line/Junction
Block
25 34
Brake Caliper (Rear) Swing Arm Housing 25 34
SUSPENSION COMPONENTS (Front)
A-Arm 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 Pivot Lock Nut (Utility) Left Pivot Bolt 82 112
Swing Arm Pivot Nut (DVX) Frame 50 68
Rear Shock Absorber Mounting Nut
(Upper/Lower)
Frame/Swing Arm 29 39
Axle Housing Cap Screw (Utility) Final Drive Gear
Case
40 54
Axle Housing Cap Screw (DVX) Swing Arm 29 39
ENGINE/TRANSMISSION
Part Part Bolted To Torque
ft-lb N-m
Cylinder Head Cylinder 710
Cylinder Nut Crankcase 710
Camshaft Holder Cylinder Head 18 24
Bevel Drive Gear (Utility) Driveshaft 72 98
Magneto Rotor/Flywheel Crankshaft 47 64
Bevel Driven Gear (Utility) Driven Shaft 72 98
Output Drive Sprocket Lock Plate
(DVX)
Driveshaft 43 59
Crankcase Cap Screw Crankcase 811
Engine Oil Screen/Filter Cap Crankcase 11 15
Shift Cam Stopper Plug* (Utility) Left Case 20 27
Shift Cam Stopper Plug* (DVX) Transmission Case 35 48
Camshaft Chain Tensioner Adjuster Cam Chain
Tensioner
912
Camshaft Chain Tensioner Mount Cylinder Head 912
Camshaft Chain Tension Spring Holder
Plug
Cam Chain
Tensioner
36
in.-lb
4
Starter Ratchet Crankshaft 68 93
Centrifugal Clutch Housing Driveshaft 40 54
Timing Plug Right Case 16 22
Driven Pulley Retaining Nut Driven Shaft
(Transmission)
43 59
Drive Plate Nut* Fixed Driven Face 43 59
Drive Pulley Nut Crankshaft 72 98
Engine Oil Drain Plug Crankcase 21 29
Transmission Drain Plug Transmission 21 29
Transmission Case Cover Transmission 20 27
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