Arctic Cat ATV 300 Utility/DVX 300 2011 User manual

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arctic Cat
ATV 300 Utility/DVX 300. This manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the
standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual
as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.
The service technician should become familiar with the operation and construction of each component or system by
carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient
with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize
important information. The 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 information worthy of particular
attention. The symbol AT THIS POINT directs the technician to certain and specific procedures to promote
efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic
Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2010 Arctic Cat Inc. August 2010
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Manual
Table of Contents
For Arctic Cat Parts Call 606-678-9623 or 606-561-4983
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2
011
ATV Service
Manual
DVX 300
300 Utility
TM
SHARE OUR PASSION.
1
TABLE OF CONTENTS
General Information........................................................... 2 Oil Flow Chart .............................................................69
General Specifications.................................................. 2 Oil Pump .....................................................................69
Torque Specifications.................................................... 2 Liquid Cooling System ................................................69
Torque Conversions (ft-lb/N-m)..................................... 3 Radiator.......................................................................69
Tightening Torque (General Bolts)................................ 3 Hoses/Thermostat.......................................................70
Break-In Procedure ...................................................... 4 Fan ..............................................................................71
Gasoline - Oil - Lubricant.............................................. 4 Water Pump ................................................................71
Genuine Parts............................................................... 5 Troubleshooting ...........................................................72
Preparation For Storage ............................................... 5 Electrical System..............................................................73
Preparation After Storage ............................................. 5 Specifications ..............................................................73
Periodic Maintenance/Tune-Up......................................... 7 RPM Limiter ................................................................73
Periodic Maintenance Chart ......................................... 7 Testing Electrical Components ....................................73
Lubrication Points ......................................................... 8 Electrical Connections.................................................73
Air Filter ........................................................................ 8 Switches ......................................................................73
Valve/Tappet Clearance................................................ 9 Battery.........................................................................73
Testing Engine Compression ........................................ 9 Brakelight Switch (Auxiliary)........................................74
Spark Plug .................................................................... 9 Brakelight Switch (Handlebar Control) ........................75
Muffler/Spark Arrester ................................................ 10 Coolant Temperature and Cooling Fan Switches ........75
Engine Oil - Filter........................................................ 10 Fan Motor ....................................................................75
Rear Drive Lubricant (Utility) ...................................... 11 Fuse Block...................................................................76
Transmission Lubricant............................................... 11 Fuses ..........................................................................76
Drive Chain (DVX) ...................................................... 12 Ignition Coil .................................................................76
Driveshaft/Coupling (Utility) ........................................ 13 Indicator Lights (DVX) .................................................77
Nuts/Bolts/Cap Screws ............................................... 13 LCD Gauge Assembly.................................................77
Headlight/Taillight- Brakelight ..................................... 13 Ignition Switch .............................................................78
Shift Lever................................................................... 13 Handlebar Control Switches........................................78
Hydraulic Brake Systems............................................ 14 Magneto Coils .............................................................79
Auxiliary/Rear Hydraulic Brake ................................... 16 Starter Motor ...............................................................79
Burnishing Brake Pads ............................................... 18 Starter Relay ...............................................................80
Checking/Replacing V-Belt ......................................... 18 CDI Unit.......................................................................80
Engine/Transmission....................................................... 20 Regulator/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 Drive Axle (DVX).................................................84
Servicing Left-Side Components ................................ 35 Rear Drive Axle (Utility)...............................................87
Installing Left-Side Components................................. 41 Troubleshooting Drive System.....................................96
Right-Side Components ............................................. 42 Troubleshooting Brake System....................................96
Removing Right-Side Components ............................ 42 Suspension .......................................................................97
Servicing Right-Side Components.............................. 48 Front and Rear Suspension Assembly Schematics ....97
Installing Right-Side Components .............................. 54 Front Shock Absorbers................................................97
Center Crankcase Components ................................. 54 Rear Shock Absorber..................................................98
Separating Crankcase Halves .................................... 54 Swing Arm...................................................................99
Disassembling Crankcase Half................................... 55 Front A-Arms .............................................................102
Servicing Center Crankcase Components ................. 55 Wheels and Tires ......................................................104
Assembling Crankcase Half........................................ 56 Troubleshooting .........................................................105
Joining Crankcase Halves .......................................... 56 Steering/Frame ...............................................................106
Installing Engine/Transmission ................................... 57 Steering Post/Tie Rods .............................................106
Troubleshooting .......................................................... 60 Measuring/Adjusting Toe-In/Toe-Out .........................108
Fuel/Lubrication/Cooling................................................. 63 Body ..........................................................................108
Carburetor Specifications ........................................... 63 Steering Post Cover/Instrument Pod .........................111
Carburetor................................................................... 63 Troubleshooting .........................................................112
Throttle Cable Free-Play............................................. 67 Controls/Indicators.........................................................113
Engine RPM (Idle) ...................................................... 67 Front Brake Lever/Master Cylinder Assembly ...........113
Gas Tank..................................................................... 68 Auxiliary Brake Pedal/Master Cylinder Assembly......114
Gas Tank Valve........................................................... 68 Throttle Control .........................................................115
Gas/Vent Hoses.......................................................... 68
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2
General Information
NOTE: Some photographs and illustrations used in
this manual are used for clarity purposes only and
are not designed to depict actual conditions.
General Specifications
Specifications subject to change without notice.
Torque Specifications
*w/Red Loctite #271
CHASSIS DVX Utility
Dry Weight (approx) 177.3 kg
(391 lb)
216 kg
(477 lb)
Length (overall) 171.9 cm
(67.7 in.)
187 cm
(73.6 in.)
Height (overall) 113.5 cm
(44.7 in.)
111.8 cm
(44.0 in.)
Width (overall) 113.5 cm
(44.7 in.)
105.1 cm
(41.40 in.)
Suspension Travel (Front)
(Rear)
15.5 cm (6.1 in.)
16.5 cm (6.5 in.)
12.7 cm (5.0 in.)
Brake Type Hydraulic w/Brake Lever Lock and
Auxiliary Brake
Tire Size (Front)
(Rear)
AT21 x 7-10
AT20 x 11-9
AT22 x 7-10
AT22 x 10-10
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.)
13 L
(3.43 U.S. gal.)
Reserve Capacity N/A 4.54 L
(1.2 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)
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 1.4 L (1.5 U.S. qt)
Rear Drive Capacity N/A 150 ml (5 fl oz)
Rear Drive Lubricant N/A SAE Approved
80W-90 Hypoid
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/21W
Headlight 12V/35W (2)
Starting System Electric Electric w/Manual
Recoil (Emergency)
STEERING COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
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
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/
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
DRIVE TRAIN COMPONENTS
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
Pinion Nut Shaft 72 98
Gear Case Cover (8mm)
(10 mm)
Gear Case 19
36
26
49
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
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3
* w/Red Loctite #271
Torque Conversions
(ft-lb/N-m)
Tightening Torque
(General Bolts)
ENGINE/TRANSMISSION
Part Part Bolted To Torque
ft-lb N-m
Cylinder Head Cylinder 7 10
Cylinder Nut Crankcase 7 10
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 8 11
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
Cam Chain Tensioner Cover Bolt Tensioner 24
in.-lb
3
Starter Ratchet Crankshaft 68 92
Camshaft Chain Tensioner Mount Cylinder Head 9 12
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
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
11.4 26 35.4 51 69.4 76 103.4
22.7 27 36.7 52 70.7 77 104.7
34.1 28 38.1 53 72.1 78 106.1
45.4 29 39.4 54 73.4 79 107.4
56.8 30 40.8 55 74.8 80 108.8
68.2 31 42.2 56 76.2 81 110.2
79.5 32 43.5 57 77.5 82 111.5
810.9 33 44.9 58 78.9 83 112.9
912.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
Type of Bolt
Thread
Diameter A
(mm)
Tightening
Torque
(Conventional or 4 Marked Bolt) 5 12-36 in.-lb
6 36-60 in.-lb
8 7-11 ft-lb
10 16-25 ft-lb
(7 Marked Bolt) 5 24-48 in.-lb
6 6-8 ft-lb
8 13-20 ft-lb
10 29-43 ft-lb
Manual
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4
Break-In Procedure
A new ATV and an overhauled ATV engine require a
“break-in” period. The first 10 hours (or 200 miles) are
most critical to the life of this ATV. Proper operation dur-
ing this break-in period will help assure maximum life
and performance from the ATV.
During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the engine
RPM during the break-in period allows the components
to “load” (aiding the mating process) and then “unload”
(allowing components to cool). Although it is essential to
place some stress on the engine components during
break-in, care should be taken not to overload the engine
too often. Do not pull a trailer or carry heavy loads dur-
ing the 10-hour break-in period.
When the engine starts, allow it to warm up properly. Idle
the engine several minutes until the engine has reached
normal operating temperature. Do not idle the engine for
excessively long periods of time.
During the break-in period, a maximum of 1/2 throttle is
recommended; however, brief full-throttle accelerations
and variations in driving speeds contribute to good
engine break-in.
After the completion of the break-in period, the engine
oil and oil filter should be changed. Other maintenance
after break-in should include checking of all prescribed
adjustments and tightening of all fasteners.
Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum octane
regular unleaded. In many areas, oxygenates (either etha-
nol or MTBE) are added to the gasoline. Oxygenated
gasolines containing up to 10% ethanol, 5% methane, or
5% MTBE are acceptable gasolines.
When using ethanol blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.
RECOMMENDED 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 lubricant is Arctic Cat Gear Lube or
an equivalent gear lube which is SAE approved 80W-90
hypoid. This lubricant meets all of the lubrication
requirements of the Arctic Cat ATV rear drive.
RECOMMENDED TRANSMISSION
LUBRICANT
The recommended lubricant is Arctic Cat Gear Lube or an
equivalent gear lube which is SAE approved 80W-90
hypoid. This lubricant meets all the lubrication requirements
of the Arctic Cat ATV front differential and rear drive.
FILLING GAS TANK
Since gasoline expands as its temperature rises, the gas
tank must be filled to its rated capacity only. Expansion
room must be maintained in the tank particularly if the
tank is filled with cold gasoline and then moved to a
warm area.
CAUTION
Do not use white gas. Only Arctic Cat approved gaso-
line additives should be used.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.
CAUTION
Any lubricant used in place of the recommended lubri-
cant could cause serious rear drive damage.
CAUTION
Any lubricant used in place of the recommended lubri-
cant could cause serious front differential/rear drive
damage.
! WARNING
Always fill the gas tank in a well-ventilated area. Never
add fuel to the ATV gas tank near any open flames or
with the engine running. DO NOT SMOKE while filling
the gas tank.
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5
ATV0049B
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 quality and correct fit. Refer to the appropriate Illus-
trated Parts Manual for the correct part number, quantity,
and description.
Preparation For Storage
Arctic Cat recommends the following procedure to pre-
pare the ATV for storage.
1. Clean the seat cushion (cover and base) with a damp
cloth and allow it to dry.
2. Clean the ATV thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire ATV.
Allow the ATV to dry thoroughly. DO NOT get
water into any part of the engine or air intake.
3. Either drain the gas tank or add Fuel Stabilizer to the
gas in the gas tank. Remove the air filter housing
cover and air filter. Start the engine and allow it to
idle; then using Arctic Cat Engine Storage Preserver,
slowly inject the preserver into the air filter opening
for a period of 10 to 20 seconds; then stop the
engine. Install the air filter and housing cover.
4. Drain the carburetor float chamber.
5. Plug the exhaust hole in the exhaust system with a
clean cloth.
6. Apply light oil to the upper steering post bushing and
plungers of the shock absorbers.
7. Tighten all nuts, bolts, cap screws, and screws. Make
sure rivets holding components together are tight.
Replace all loose rivets. Care must be taken that all
calibrated nuts, cap screws, and bolts are tightened to
specifications.
8. Fill the cooling system to the FULL line in the cool-
ing system reservoir with properly mixed coolant.
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 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. Replace if necessary.
4. Change the engine oil and filter.
5. Check the coolant level and add properly mixed
coolant as necessary.
6. Charge the battery; then install. Connect the battery
cables.
! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the engine to
cool before filling the gas tank.
! WARNING
Do not over-fill the gas tank.
CAUTION
Prior to storing the ATV, it must be properly serviced to
prevent rusting and component deterioration.
CAUTION
Rapid induction of oil or any liquid into a four-cycle
engine can cause “hydraulic-lock” resulting in severe
engine damage.
CAUTION
If the interior of the air filter housing is dirty, clean the
area before starting the engine.
CAUTION
This maintenance-free battery should be charged at the
recommended rate every 30 days or permanent damage
may occur if the battery completely discharges.
CAUTION
Avoid storing outside in direct sunlight and avoid using
a plastic cover as moisture will collect on the ATV caus-
ing rusting.
CAUTION
The ignition switch must be in the OFF position prior to
installing the battery or damage may occur to the igni-
tion system.
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6
7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight,
and headlight aim; adjust or replace as necessary.
8. Tighten all nuts, bolts, cap screws, and screws mak-
ing sure all 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
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7
Periodic Maintenance/
Tune-Up
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appro-
priate tool description.
NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
Periodic Maintenance
Chart
A = Adjust I = Inspect C = Clean L = Lubricate D = Drain R = Replace T = Tighten
Description p/n
Compression Tester Kit 0444-213
Tappet Adjuster 0444-189
Item
Initial Service After
Break-In (First
Month or 100 Miles)
Every
Day
Every Month or
Every 100 Miles
Every 3 Months
or Every 300
Miles
Every 6 Months
or Every 500
Miles
Every Year
or Every
1500 Miles
As
Needed
Battery I I C
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Spark Plug I I R (4000 Mi
or 18 Mo)
Muffler/Spark Arrester CR
Gas/Vent Hoses I I R (2 Yrs)
Gas Tank Valve IC
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 IR
Suspension (Ball joint boots, tie
rods, differential and rear drive
bellows)
II l* R
Nuts/Cap Screws/Screws I I T
Ignition Timing I
Headlight/Taillight-Brakelight I I R
Switches I I R
Shift Lever IA-L
Choke Cable I C-L R
Recoil Starter (Utility) I C-R
Handlebar Grips I R
Handlebars I I R
Gauges/Indicators I I R
Frame/Welds/Racks I I l
Electrical Connections lC
Complete Brake System (Hydraulic
and Auxiliary)
II C L-R
Brake Pads I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Coolant/Cooling System I I R (2 Yrs)
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8
* Service/Inspect more frequently when operating in adverse conditions.
Lubrication Points
It is advisable to lubricate certain components periodi-
cally to ensure free movement. Apply light oil to the
components using the following list as reference.
A. Throttle Lever Pivot/Cable Ends
B. Brake Lever Pivot
C. Auxiliary Brake 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 INSPECTING
FILTER
1. Remove the seat.
2. Remove the air filter housing cover from the retain-
ing clips.
KM095A
3. Loosen the clamp; then remove the filter.
KM097B
4. Fill a wash pan larger than the filter with a non-flam-
mable cleaning solvent; then dip the filter in the sol-
vent and wash it.
NOTE: Foam Filter Cleaner and Foam Filter Oil are
available from Arctic Cat.
5. Dry the filter.
6. Put the filter in a plastic 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/DRAINING DRAIN TUBE
Periodically check the drain tube for gasoline or oil accu-
mulation. If noticed, remove the drain tube cap from
beneath the housing and drain the gasoline or oil into a
suitable container; then install and secure the tube cap.
KM114
CAUTION
Failure to inspect the air filter frequently if the vehicle is
used in dusty, wet, or muddy conditions can damage
the engine.
CAUTION
A torn air filter can cause damage to the ATV engine. Dirt
and dust may get inside the engine if the element is torn.
Carefully examine the element for tears before and after
cleaning it. Replace the element with a new one if it is torn.
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9
Valve/Tappet Clearance
To check and adjust valve/tappet clearance, use the fol-
lowing procedure.
NOTE: The seat assembly, side panels, and gas
tank must be removed for this procedure.
1. Remove the timing inspection plug; then remove the
cylinder head cover (see Engine/Transmission -
Removing Top-Side Components).
2. Rotate the crankshaft so the “T” mark on the fly-
wheel aligns with the index mark on the right-side
crankcase cover.
NOTE: At this point, the round hole in the camshaft
gear should be up.
3. Place Tappet Adjuster onto the jam nut securing the
tappet adjuster screw; then rotate the adjuster dial
clockwise until the end is seated in the tappet
adjuster screw.
4. While holding the adjuster dial in place, use the
adjuster handle and loosen the jam nut; then rotate
the tappet adjuster 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 until proper valve/
tappet clearance is attained.
NOTE: Refer to the appropriate specifications in
Engine/Transmission for the proper valve/tappet
clearance.
NOTE: Rotating the adjuster dial counterclockwise
will open the valve/tappet clearance by 0.05 mm
(0.002 in.) per mark.
7. While holding the adjuster dial at the proper clear-
ance setting, tighten the jam nut securely with the
valve adjuster handle.
8. Place the cylinder head cover with a new O-ring into
position; then tighten the cover securely.
KM703
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 gauge from Compression Tester Kit.
NOTE: The engine must be warm and the battery
must be fully charged for this test.
5. While holding the throttle lever in the full-open posi-
tion, crank the engine over with the electric starter
until the gauge shows a peak reading (five to 10
compression strokes).
NOTE: The compression should be within a range
of 210-230 psi in the full-open throttle position.
6. If compression is abnormally low, verify the follow-
ing items.
A. Starter cranks engine over.
B. Gauge functions properly.
C. Throttle lever in the full-open position.
D. Valve/tappet clearance correct.
E. Valve not bent or discolored.
F. Valve seat not discolored.
NOTE: To service valves, see Engine/Transmission.
7. Pour 29.5 ml (1 fl oz) of oil into the spark plug hole,
attach the gauge, and test compression.
8. If compression is now evident, service the piston
rings (see Engine/Transmission).
Spark Plug
A light brown insulator indicates that the plug is correct.
A 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.
! WARNING
Always wear safety glasses when using compressed
air.
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ATV-0051
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 should be tightened 1/2 turn
once the washer contacts the cylinder head. A used spark
plug should be tightened 1/8-1/4 turn once the washer
contacts the cylinder head.
Muffler/Spark Arrester
The muffler has a spark arrester which must be periodi-
cally cleaned. At the intervals shown in the Periodic
Maintenance Chart, clean the spark arrester using the fol-
lowing procedure.
1. Remove the cap screw (1) securing the spark arrester
(2) to the muffler assembly; then carefully remove
the spark arrester.
KM139A
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 ATV on level ground.
2. Loosen the oil fill plug.
KM126A
3. Remove the screen/filter cap from the bottom of the
engine and drain the oil into a drain pan. Account for
a spring, O-ring, and screen/filter.
CAUTION
Before removing the spark plug, make sure to clean the
area around the spark plug. Dirt could enter engine
when removing or installing the spark plug.
! WARNING
Wait until the muffler cools to avoid burns.
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DSC02248
4. Clean the screen/filter in parts-cleaning solvent; then
inspect the O-ring and replace if damaged.
5. Install the screen/filter, spring, and screen/filter cap
into the bottom of the engine and tighten to 11 ft-lb.
6. Remove the oil fill plug and pour in 1.6 L (1.7 U.S.
qt) of the recommended oil into the fill hole; then
install the oil fill plug.
7. Start the engine (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 oil level should be visible through the window. If
oil is not visible, add recommended oil until the oil
level is visible between the lines of the window.
KM127A
9. Inspect the area around the screen/filter cap for leaks.
Rear Drive Lubricant
(Utility)
Check and change the lubricant according to the Periodic
Maintenance Chart. When changing the lubricant, use
approved SAE 80W-90 hypoid gear lube. To check lubri-
cant, use the following procedure.
1. Remove the rear drive level plug; the lubricant level
should be at the threads of the plug.
KM131A
2. If low, add SAE approved 80W-90 hypoid gear lube
as necessary.
To change the lubricant, use the following procedure.
1. Place the ATV on level ground.
2. Loosen 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. Install the rear drive
gear guard and tighten the cap screws securely.
6. Pour the appropriate amount of recommended lubri-
cant into the fill hole. Remove the level plug and
check for appropriate level.
7. Install the fill plug.
Transmission Lubricant
Change the lubricant according to the Periodic Mainte-
nance Chart. When changing the lubricant, use approved
SAE 80W-90 hypoid gear lube.
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.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.
CAUTION
Water entering the outer end of the axle will not be able
to enter the rear drive unless the seals are damaged.
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KM104A
KM106A
3. Install the drain plug and tighten securely.
4. Remove the fill plug and pour the appropriate
amount of recommended lubricant into the fill hole.
5. Install the fill plug and tighten securely.
6. Check the area around the drain plug for leakage.
Drive Chain (DVX)
Drive chain condition and adjustment should be
inspected each day before the ATV is operated. Always
follow the following guidelines for inspecting and servic-
ing the drive chain.
INSPECTING
Inspect the drive chain for any of the following conditions.
A. Loose pins.
B. Loose or cracked rollers.
C. Dry or rusted links.
D. Kinked or binding links.
E. Excessive wear.
The presence of any of the conditions requires drive
chain replacement.
NOTE: If the drive chain is worn or damaged, the
sprockets may also be worn or damaged. Inspect the
sprockets for worn, broken, or damaged teeth.
Always inspect the sprockets when a new drive chain
is being installed.
CLEANING AND LUBRICATING
The drive chain should be cleaned and lubricated fre-
quently to prolong chain and sprocket life. Use the fol-
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 apply a dry, graphite-
based lubricant to the chain.
NOTE: The drive chain should be lubricated with a
dry, graphite-based chain lubricant. By using a dry,
graphite-based chain lubricant, dirt build-up on the
drive chain will be minimized.
ADJUSTING TENSION
1. Loosen the four cap screws (1) at the rear of the axle
housing; then loosen the cap screw (2) on the front of
the brake caliper.
KM902A
2. Install an appropriate pin through the axle hub and
rear sprocket.
KM158A
3. With a person seated on the ATV, check chain ten-
sion at the mid-point of the chain.
! WARNING
Failure to inspect and maintain the drive chain can be
hazardous. Operating the ATV with the drive chain in
poor condition or improperly adjusted can cause an
accident resulting in possible injury.
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NOTE: Chain “slack” should be within a range of
30-40 mm (1.2-1.6 in.).
4. Push the ATV forward to tighten chain tension; push
the ATV backward to loosen chain tension.
5. Tighten the four cap screws (1) to 29 ft-lb; then
tighten the cap screw (2) to 29 ft-lb.
KM902A
Driveshaft/Coupling
(Utility)
The following drive system components should be
inspected periodically to ensure proper operation.
A. Spline lateral movement (slop).
B. Coupling not cracked, damaged, or worn.
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure rivets
holding components together are tight. Replace all loose
rivets. Care must be taken that all calibrated nuts, bolts,
and cap screws are tightened to specifications.
Headlight/Taillight-
Brakelight
Each time the ATV is used, lights should be checked for
proper function. Turn the ignition switch to the LIGHTS
position; the headlights and taillight should illuminate.
Test the brakelight by compressing the brake lever. The
brakelight should illuminate.
NOTE: The bulb portion of the headlight is fragile.
HANDLE WITH 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 care not to bend or deform the spring clip,
release the two ends of the spring clip from the light
housing; then remove the bulb from the headlight
housing.
KM192A
3. Install the new bulb into the headlight housing; then
secure with the spring clip.
4. Connect the three-wire connector to the bulb; then
install the boot.
To replace the taillight-brakelight bulb, use the following
procedure.
1. Remove the two screws and remove the lens cover.
2. Push the bulb in and turn it counterclockwise.
3. Install the new bulb by turning it clockwise while
pushing in.
4. Install the lens cover.
Shift Lever
KM363A
! WARNING
Do not attempt to remove the bulb when it is hot. Severe
burns may result.
CAUTION
Tighten the lens cover screws only until they are snug.
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KM124B
CHECKING ADJUSTMENT
Stop the ATV completely and shift the transmission into
the R position. The reverse gear indicator light should be
illuminated.
If the reverse gear indicator light does not illuminate
when shifted to the reverse position, the switch may be
faulty, the fuse may be blown, the bulb may be faulty, a
connection may be loose or corroded, or the lever may
need adjusting. To adjust, proceed to Adjusting Shift
Lever.
ADJUSTING SHIFT LEVER
1. Place the shift lever in the N (neutral) position; then
set the engine stop switch to the STOP position and
turn the ignition switch to the RUN position. The
neutral indicator light should illuminate.
NOTE: If the neutral indicator light does not illumi-
nate, adjustment of the shift linkage will be required.
To adjust, proceed to step 2.
2. Loosen the jam nuts on both ends of the shift rod and
turn the shift rod until 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 hydraulic brake sys-
tem, use the following procedure.
1. With the master cylinder in a level position, check
the fluid level in the reservoir. If the level in the res-
ervoir is not visible in the sight glass, add DOT 4
brake fluid.
KM113
KM137
2. Compress the brake lever/pedal several times to
check for a firm brake. If the brake is not firm, the
system must be bled.
3. To bleed the brake system, use the following proce-
dure.
! WARNING
Never shift the ATV into reverse gear when the ATV is
moving as it could cause the ATV to stop suddenly
throwing the operator from the ATV.
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A. Remove the cover and fill the reservoir with DOT
4 Brake Fluid.
B. Install and secure the cover; then slowly compress
the brake lever several times.
C. Remove the protective cap, install 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. Close
the bleed screw before releasing the brake lever.
Repeat this procedure until no air bubbles are
present.
KM116A
NOTE: During the bleeding procedure, watch the
reservoir sight glass very closely to make sure there
is always a sufficient amount of brake fluid. Failure to
maintain a sufficient amount of fluid in the reservoir
will result in air in the system.
D. At this point, perform steps B and C on the other
FRONT bleed screw; then move to the REAR
bleed screw and follow the same procedure.
4. Carefully check the entire hydraulic brake system
that all hose connections are tight, the bleed screws
are tight, the protective caps are installed, and no
leakage is present.
INSPECTING 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 pads as follows.
1. Remove a front wheel.
2. Measure the thickness of each brake pad.
3. If thickness of either 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.
4. To replace the brake pads, use the following proce-
dure.
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 from the disc; then compress
the caliper holder and remove the brake pads.
KM267
C. Install new brake pads; then install the two brake
pad alignment pins.
CAUTION
This hydraulic brake system is designed to use DOT 4
brake fluid only. If brake fluid must be added, care must
be taken as brake fluid is very corrosive to painted sur-
faces.
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KM268
D. Spread the brake pads and place the brake caliper
over the disc. Secure with the mounting cap
screws. Tighten the cap screws to 25 ft-lb; then
tighten the alignment pins to 13 ft-lb.
KM266A
5. Install the wheel. Tighten to 32 ft-lb.
6. Burnish the brake pads (see Burnishing Brake Pads
in this section).
Auxiliary/Rear Hydraulic
Brake
CHECKING
1. With the engine off, the transmission in neutral, and
the reverse lever in the forward position, press the
brake pedal and attempt to move the ATV.
2. If the rear wheels are locked, it is functioning prop-
erly.
3. If the rear wheels are not locked, it must be repaired
or bled.
BLEEDING
To bleed the auxiliary brake, see Hydraulic Brake Sys-
tems - CHECKING/BLEEDING in this section.
MEASURING/REPLACING REAR
BRAKE PADS (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. 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 calipers, measure the thickness of each brake
pad.
4. If the thickness of either 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.
Installing
1. Install new brake pads; then install the two brake pad
alignment pins.
2. Spread the brake pads and place the brake caliper
over the disc; then secure with the mounting cap
screws (B). Tighten the cap screws to 25 ft-lb; then
tighten the alignment pins (A) to 13 ft-lb.
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KM273A
3. Install the wheel and secure. Tighten to 32 ft-lb.
4. Remove the ATV from the support stand.
NOTE: Whenever installing new pads, the new pads
must be burnished (see Burnishing Brake Pads in
this section).
MEASURING/REPLACING REAR/
AUXILIARY BRAKE PADS (DVX)
Removing
NOTE: The brake caliper on the DVX contains two
sets of brake pads. The front pads are controlled by
the main brake lever and the rear pads are controlled
by the auxiliary brake pedal.
1. Remove the brake pad dust cover; then remove the
clip pin and pull 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. 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 thickness of the disc. If
any portion of the disc is less than 3.00 mm (0.12
in.), the disc must be replaced (see Drive System).
Installing
1. Install the brake pads in the caliper; then insert the
brake spring plate.
KM245
2. Install the brake pad retaining pin and secure with
the clip pin; then install the dust cover.
KM244
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3. Burnish the brake pads (see Burnishing Brake Pads
in this section).
Burnishing Brake Pads
Brake pads (both hydraulic and auxiliary) must be bur-
nished to achieve full braking effectiveness. Braking dis-
tance will be extended until brake pads are properly
burnished. To properly burnish the brake pads, use the
following procedure.
1. Choose an area large enough to safely accelerate the
ATV to 30 mph and to brake to a stop.
2. Accelerate to 30 mph; then compress brake lever or
apply the auxiliary brake to decelerate to 0-5 mph.
3. Repeat procedure on each brake system five times
until brake pads are burnished.
4. Adjust the auxiliary 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 Utility, remove the left footwell; then remove
the recoil starter assembly. On the DVX, proceed to
step 2.
KM279
2. Remove the front and 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 stepped
washer and spacer.
KM276
5. Remove the nut securing the driven pulley; then
remove the splined bushing, centrifugal clutch, pul-
ley, and V-belt.
INSTALLING
1. Using a rubber mallet, spread the driven pulley
sheaves by driving the V-belt down between the
sheaves; then slide the driven pulley and V-belt into
position.
KM262
2. Install the centrifugal clutch housing onto the driven
shaft; then install the splined bushing and secure
with the driven pulley retaining nut. Tighten to 40 ft-
lb.
! WARNING
Failure to properly burnish the brake pads could lead to
premature brake pad wear or brake loss. Brake loss can
result in severe injury.
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KM276
3. Install the movable drive face onto the crankshaft
making sure to “bottom” the sheave out against the
center bushing. The crankshaft splines should be vis-
ible 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. Install the V-belt cover and tighten the cap screws
securely; 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 rear boot clamp must be oriented as
shown or interference with heat shielding could occur.
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