Arctic Cat Dvx 300 and 300 Utility - Workshop Manual / Repair Manual

ARCTIC CAT DVX 300 AND 300 UTILITY - WORKSHOP, REPAIR, SERVICE MANUAL

- Workshop Manual, to Arctic Cat Dvx 300 and 300 Utility.



INDEX:


2011 SERVICE MANUAL



FOREWORD
TABLE OF CONTENTS

GENERAL INFORMATION
- General Specifications
- Torque Specifications
- Torque Conversions (ft-lb/N-m)
- Tightening Torque (General Bolts)
- Break-In Procedure
- Gasoline - Oil - Lubricant
- Recommended Gasoline
- Recommended Engine Oil
- Recommended Rear Drive Lubricant (Utility)
- Recommended Transmission Lubricant
- Filling Gas Tank
- Genuine Parts
- Preparation For Storage
- Preparation After Storage

PERIODIC MAINTENANCE/ TUNE-UP
- SPECIAL TOOLS
- Periodic Maintenance Chart
- Lubrication Points
- Air Filter
- Cleaning And Inspecting Filter
- Checking/Draining Drain Tube
- Valve/Tappet Clearance
- Testing Engine Compression
- Spark Plug
- Muffler/Spark Arrester
- Engine Oil - Filter
- Rear Drive Lubricant (Utility)
- Transmission Lubricant
- Drive Chain (DVX)
- Inspecting
- Cleaning And Lubricating
- Adjusting Tension
- Driveshaft/Coupling (Utility)
- Nuts/Bolts/Cap Screws
- Headlight/Taillight- Brakelight
- Shift Lever
- Checking Adjustment
- Adjusting Shift Lever
- Hydraulic Brake Systems
- Checking/Bleeding
- Inspecting Hoses
- Checking/Replacing Front Pads
- Auxiliary/Rear Hydraulic Brake
- Checking
- Bleeding
- Measuring/Replacing Rear Brake Pads (Utility)
- Removing
- Inspecting And Measuring
- Installing
- Measuring/Replacing Rear/ Auxiliary Brake Pads (Dvx)
- Removing
- Inspecting And Measuring
- Installing
- Burnishing Brake Pads
- Checking/Replacing V-Belt
- Removing
- Installing

ENGINE/TRANSMISSION
- SPECIAL TOOLS
- Specifications

REMOVING ENGINE/ TRANSMISSION
- DVX
- Utility
- Top-Side Components
- Removing Top-Side Components
- A. Valve Cover B. Cylinder Head
- C. Cylinder D. Piston
- Servicing Top-Side Components
- Valve Assembly

- Cleaning/Inspecting Camshaft Holder
- Removing Valves
- Measuring Valve Stem/Valve Guide Clearance
- Inspecting Valve Face
- Cylinder Head Assembly
- Cleaning/Inspecting Cylinder Head
- Measuring Cylinder Head Distortion
- Measuring Camshaft Lobe Height
- Inspecting Camshaft Bearing Journal
- Measuring Rocker Arm/ Shaft Clearance
- Installing Valves
- Piston Assembly
- Cleaning/Inspecting Piston
- Removing Piston Rings
- Cleaning/Inspecting Piston Rings
- Measuring Piston-Ring End Gap (Installed)
- Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore
- Measuring Piston Skirt/ Cylinder Clearance
- Installing Piston Rings
- Cylinder Assembly
- Cleaning/Inspecting Cylinder
- Inspecting Cam Chain Guide

- Honing Cylinder
- Installing Top-Side Components
- A. Piston B. Cylinder
- C. Cylinder Head D. Valve Cover
- Left-Side Components
- Removing Left-Side Components
- A. Recoil Starter (Utility)
- B. V-Belt Cover C. Drive Pulley D. Driven Pulley/Centrifugal Clutch Assembly
- Servicing Left-Side Components
- Recoil Starter (Utility)
- Removing/Disassembling
- Cleaning and Inspecting
- Assembling/Installing
- V-Belt Cover
- Drive Pulley
- Driven Pulley/Centrifugal Clutch Assembly
- Disassembling
- Inspecting
- Assembling
- Installing Left-Side Components
- A. Drive Pulley B. Driven Pulley/Centrifugal Clutch Assembly C. V-Belt Cover
- Right-Side Components
- Removing Right-Side Components
- A. Transmission (Dvx)
- A. Transmission (Utility)
- B. Water Pump C. Trigger Coil D. Stator Coil E. Rotor/Flywheel
- F. Oil Pump
- Servicing Right-Side Components
- Transmission (Dvx)
- Inspecting
- Assembling
- Transmission (Utility)
- Inspecting
- Assembling
- Installing Right-Side Components
- A. Oil Pump
- B. Rotor/Flywheel C. Trigger Coil D. Stator Coil
- E. Water Pump F. Transmission
- Center Crankcase Components
- Separating Crankcase Halves
- Disassembling Crankcase Half
- Servicing Center Crankcase Components
- Crankshaft Assembly
- Measuring Connecting Rod (Small End Inside Diameter)
- Measuring Connecting Rod (Small End Deflection)
- Measuring Connecting Rod (Big End Side-to-Side)
- Measuring Crankshaft (Runout)

- Measuring Crankshaft (Web-to- Web)
- Crank Balancer Shaft
- Inspecting
- Assembling Crankcase Half
- Joining Crankcase Halves
- Installing Engine/ Transmission
- Dvx
- Utility
- Troubleshooting

FUEL/LUBRICATION/COOLING
- Carburetor Specifications
- Carburetor
- Removing
- Disassembling
- Cleaning And Inspecting
- Assembling
- Installing
- Throttle Cable Free-Play
- Engine RPM (Idle)
- Gas Tank
- Removing
- Cleaning And Inspecting
- Installing
- Gas Tank Valve
- Removing/Inspecting
- Installing
- Gas/Vent Hoses
- Oil Flow Chart
- Oil Pump
- Removing/Disassembling
- Cleaning And Inspecting
- Assembling/Installing
- Liquid Cooling System
- Radiator
- Removing
- Cleaning And Inspecting
- Installing
- Hoses/Thermostat
- Removing
- Inspecting
- Installing
- Fan
- Removing
- Installing
- Water Pump
- Removing/Disassembling
- Cleaning And Inspecting
- Assembling/Installing
- Troubleshooting

ELECTRICAL SYSTEM
- SPECIAL TOOLS
- Specifications
- RPM Limiter
- Testing Electrical Components
- Electrical Connections
- Switches
- Battery
- Brakelight Switch (Auxiliary)
- Voltage (Wiring Harness Side)
- Resistance (Switch Connector)
- Brakelight Switch (Handlebar Control)
- Voltage (Wiring Harness Connector)
- Resistance (Switch)
- Coolant Temperature and Cooling Fan Switches
- Fan Motor
- Voltage (Main Harness Connector To Fan Motor)
- Resistance (Fan Motor Connector)
- Fuse Block
- Fuses
- Ignition Coil
- Peak Voltage (Primary/Cdi Side)
- Resistance
- Primary Winding
- Secondary Winding
- Spark Plug Cap
- Indicator Lights (DVX)
- LCD Gauge Assembly
- Removing
- Testing
- Installing
- Ignition Switch
- Voltage
- Resistance
- Handlebar Control Switches
- Resistance (Hi Beam)
- Resistance (Lo Beam)
- Resistance (Starter Button)
- Resistance (Emergency Stop)
- Resistance (Reverse Override)
- Magneto Coils
- Voltage (Charging Coil - Output)
- Voltage (Stator Coil - No Load)
- Resistance (Charging Coil)
- Resistance (Trigger Coil)
- Peak Voltage
- Stator Coil (Trigger)
- Starter Motor
- Removing/Installing
- Starter Relay
- Voltage
- CDI Unit
- Regulator/Rectifier
- Testing
- Start-in-Gear Relay
- Testing
- Headlights
- Bulb Verification (Lo And Hi Beam)
- Voltage
- Taillight - Brakelight
- Bulb Verification
- Voltage (Taillight)
- Voltage (Brakelight)
- Ignition Timing
- Troubleshooting

DRIVE SYSTEM
- SPECIAL TOOLS
- Rear Drive Assembly Schematics
- Rear Drive Axle (DVX)
- Removing
- Cleaning And Inspecting
- Removing Bearings
- Installing Bearings
- Installing
- Rear Drive Axle (Utility)
- Removing
- Cleaning And Inspecting
- Disassembling
- Cleaning And Inspecting
- Assembling
- Checking Tooth Contact
- Correcting Tooth Contact
- Checking Backlash
- Replacing Swing Arm Seals And Bearings
- Installing
- Troubleshooting Drive System
- Troubleshooting Brake System

SUSPENSION
- Front and Rear Suspension Assembly Schematics
- Front Shock Absorbers
- Removing
- Cleaning And Inspecting
- Installing
- Rear Shock Absorber
- Removing
- Cleaning And Inspecting
- Installing
- Adjusting Spring Preload
- Swing Arm
- Removing And Disassembling
- Cleaning And Inspecting
- Assembling And Installing
- Front A-Arms
- Removing
- Cleaning And Inspecting
- Installing
- Wheels and Tires
- Tire Size
- Tire Inflation Pressure
- Removing
- Cleaning And Inspecting
- Installing
- Checking/Inflating
- Troubleshooting

STEERING/FRAME
- Steering Post/Tie Rods
- Removing
- Cleaning And Inspecting
- Installing
- Measuring/Adjusting Toe-In/Toe-Out
- Body
- Removing (Dvx)
- Removing (Utility)
- Cleaning And Inspecting
- Installing (Dvx)
- Installing (Utility)
- Steering Post Cover/ Instrument Pod
- Removing (Dvx)
- Removing (Utility)
- Inspecting/Servicing (Dvx)
- Inspecting (Utility)
- Installing (Dvx)
- Installing (Utility)
- Troubleshooting

CONTROLS/INDICATORS
- Front Brake Lever/Master Cylinder Assembly
- Removing
- Inspecting
- Installing
- Auxiliary Brake Pedal/ Master Cylinder Assembly
- Removing
- Installing
- Throttle Control
- Removing
- Installing

BACK COVER




2012 SERVICE MANUAL




FOREWORD
TABLE OF CONTENTS

GENERAL INFORMATION
- General Specifications
- Torque Specifications
- Torque Conversions (ft-lb/N-m)
- Break-In Procedure
- Gasoline - Oil - Lubricant
- Recommended Gasoline
- Recommended Engine Oil
- Recommended Rear Drive Lubricant (Utility)
- Recommended Transmission Lubricant
- Filling Gas Tank
- Genuine Parts
- Preparation For Storage
- Preparation After Storage

PERIODIC MAINTENANCE/ TUNE-UP
- SPECIAL TOOLS
- Periodic Maintenance Chart
- Lubrication Points
- Air Filter
- Cleaning And Inspecting Filter
- Checking/Draining Drain Tube
- Valve/Tappet Clearance
- Testing Engine Compression
- Spark Plug
- Muffler/Spark Arrester
- Engine Oil - Filter
- Rear Drive Lubricant (Utility)
- Transmission Lubricant
- Drive Chain (DVX)
- Inspecting
- Cleaning And Lubricating
- Adjusting Tension
- Driveshaft/Coupling (Utility)
- Nuts/Bolts/Cap Screws
- Headlight/Taillight- Brakelight
- Shift Lever
- Checking Adjustment
- Adjusting Shift Lever
- Hydraulic Brake Systems
- Checking/Bleeding
- Inspecting Hoses
- Checking/Replacing Front Pads
- Auxiliary/Rear Hydraulic Brake
- Checking
- Bleeding
- Measuring/Replacing Rear Brake Pads (Utility)
- Removing
- Inspecting and Measuring
- Installing
- Measuring/Replacing Rear/ Auxiliary Brake Pads (Dvx)
- Removing
- Inspecting and Measuring
- Installing
- Burnishing Brake Pads
- Checking/Replacing V-Belt
- Removing
- Installing

ENGINE/TRANSMISSION
- SPECIAL TOOLS
- Removing Engine/ Transmission
- Dvx
- Utility
- Top-Side Components
- Removing Top-Side Components
- A. Valve Cover B. Cylinder Head
- C. Cylinder D. Piston
- Servicing Top-Side Components
- Valve Assembly
- Cleaning/Inspecting Camshaft Holder
- Removing Valves
- Measuring Valve Stem/Valve Guide Clearance
- Inspecting Valve Face
- Cylinder Head Assembly
- Cleaning/Inspecting Cylinder Head
- Measuring Cylinder Head Distortion
- Measuring Camshaft Lobe Height
- Inspecting Camshaft Bearing Journal
- Measuring Rocker Arm/ Shaft Clearance
- Installing Valves
- Piston Assembly
- Cleaning/Inspecting Piston
- Removing Piston Rings
- Cleaning/Inspecting Piston Rings
- Measuring Piston-Ring End Gap (Installed)
- Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore
- Measuring Piston Skirt/ Cylinder Clearance
- Installing Piston Rings
- Cylinder Assembly
- Cleaning/Inspecting Cylinder
- Inspecting Cam Chain Guide
- Honing Cylinder
- Installing Top-Side Components
- A. Piston B. Cylinder
- C. Cylinder Head D. Valve Cover
- Left-Side Components
- Removing Left-Side Components
- A. Recoil Starter (Utility)
- B. V-Belt Cover C. Drive Pulley D. Driven Pulley/Centrifugal Clutch Assembly
- Servicing Left-Side Components
- Recoil Starter (Utility)
- Removing/Disassembling
- Cleaning and Inspecting
- Assembling/Installing
- V-Belt Cover
- Drive Pulley
- Driven Pulley/Centrifugal Clutch Assembly
- Disassembling
- Inspecting
- Assembling
- Installing Left-Side Components
- A. Drive Pulley B. Driven Pulley/Centrifugal Clutch Assembly C. V-Belt Cover
- Right-Side Components
- Removing Right-Side Components
- A. Transmission (Dvx)
- A. Transmission (Utility)
- B. Water Pump C. Trigger Coil D. Stator Coil E. Rotor/Flywheel
- F. Oil Pump
- Servicing Right-Side Components
- Transmission (Dvx)
- Inspecting
- Assembling
- Transmission (Utility)
- Inspecting
- Secondary Gears
- Checking Backlash
- Correcting Backlash
- Checking Tooth Contact
- Correcting Tooth Contact
- Assembling
- Installing Right-Side Components
- A. Oil Pump
- B. Rotor/Flywheel C. Trigger Coil D. Stator Coil
- E. Water Pump F. Transmission
- Center Crankcase Components
- Separating Crankcase Halves
- Disassembling Crankcase Half
- Servicing Center Crankcase Components
- Crankshaft Assembly
- Measuring Connecting Rod (Small End Inside Diameter)
- Measuring Connecting Rod (Small End Deflection)
- Measuring Connecting Rod (Big End Side-to-Side)
- Measuring Crankshaft (Runout)
- Measuring Crankshaft (Web-to- Web)
- Crank Balancer Shaft
- Inspecting
- Assembling Crankcase Half
- Joining Crankcase Halves
- Installing Engine/ Transmission
- Dvx
- Utility
- Troubleshooting

FUEL/LUBRICATION/COOLING
- Carburetor
- Removing
- Disassembling
- Cleaning And Inspecting
- Assembling
- Installing
- Throttle Cable Free-Play
- Engine RPM (Idle)
- Gas Tank
- Removing
- Cleaning And Inspecting
- Installing
- Gas Tank Valve
- Removing/Inspecting
- Installing
- Gas/Vent Hoses
- Oil Flow Chart
- Oil Pump
- Removing/Disassembling
- Cleaning And Inspecting
- Assembling/Installing
- Liquid Cooling System
- Radiator
- Removing
- Cleaning And Inspecting
- Installing
- Hoses/Thermostat
- Removing
- Inspecting
- Installing
- Fan
- Removing
- Installing
- Water Pump
- Removing/Disassembling
- Cleaning And Inspecting
- Assembling/Installing
- Troubleshooting

ELECTRICAL SYSTEM
- SPECIAL TOOLS
- RPM Limiter
- Testing Electrical Components
- Electrical Connections
- Switches
- Battery
- Brakelight Switch (Auxiliary)
- Voltage (Wiring Harness Side)
- Resistance (Switch Connector)
- Brakelight Switch (Handlebar Control)
- Voltage (Wiring Harness Connector)
- Resistance (Switch)
- Coolant Temperature and Cooling Fan Switches
- Fan Motor
- Voltage (Main Harness Connector To Fan Motor)
- Resistance (Fan Motor Connector)
- Fuse Block
- Fuses
- Ignition Coil
- Peak Voltage (Primary/Cdi Side)
- Resistance
- Primary Winding
- Secondary Winding
- Spark Plug Cap
- Indicator Lights (DVX)
- LCD Gauge Assembly
- Removing
- Testing
- Installing
- Ignition Switch
- Voltage
- Resistance
- Handlebar Control Switches
- Resistance (Hi Beam)
- Resistance (Lo Beam)
- Resistance (Starter Button)
- Resistance (Emergency Stop)
- Resistance (Reverse Override)
- Magneto Coils
- Voltage (Charging Coil - Output)
- Voltage (Stator Coil - No Load)
- Resistance (Charging Coil)
- Resistance (Trigger Coil)
- Peak Voltage
- Stator Coil (Trigger)
- Starter Motor
- Removing/Installing
- Starter Relay
- Voltage
- CDI Unit
- Regulator/Rectifier
- Testing
- Start-in-Gear Relay
- Testing
- Headlights
- Bulb Verification (Lo And Hi Beam)
- Voltage
- Taillight - Brakelight
- Bulb Verification
- Voltage (Taillight)
- Voltage (Brakelight)
- Ignition Timing
- Troubleshooting

DRIVE SYSTEM
- SPECIAL TOOLS
- Rear Drive Assembly Schematics
- Rear Drive Axle (DVX)
- Removing
- Cleaning And Inspecting
- Removing Bearings
- Installing Bearings
- Installing
- Rear Drive Axle (Utility)
- Removing
- Cleaning And Inspecting
- Disassembling
- Cleaning And Inspecting
- Assembling
- Checking Tooth Contact
- Correcting Tooth Contact
- Checking Backlash
- Replacing Swing Arm Seals And Bearings
- Installing
- Troubleshooting Drive System
- Troubleshooting Brake System

SUSPENSION
- Front and Rear Suspension Assembly Schematics
- Front Shock Absorbers
- Removing
- Cleaning And Inspecting
- Installing
- Rear Shock Absorber
- Removing
- Cleaning And Inspecting
- Installing
- Adjusting Spring Preload
- Swing Arm
- Removing And Disassembling
- Cleaning And Inspecting
- Assembling And Installing
- Front A-Arms
- Removing
- Cleaning And Inspecting
- Installing
- Wheels and Tires
- Tire Size
- Tire Inflation Pressure
- Removing
- Cleaning And Inspecting
- Installing
- Checking/Inflating
- Troubleshooting

STEERING/FRAME/CONTROLS
- Steering Post/Tie Rods
- Removing
- Cleaning And Inspecting
- Installing
- Measuring/Adjusting Toe-In/Toe-Out
- Body
- Removing (Dvx)
- Removing (Utility)
- Cleaning And Inspecting
- Installing (Dvx)
- Installing (Utility)
- Steering Post Cover/ Instrument Pod
- Removing (Dvx)
- Removing (Utility)
- Inspecting/Servicing (Dvx)
- Inspecting (Utility)
- Installing (Dvx)
- Installing (Utility)
- Front Brake Lever/Master Cylinder Assembly
- Removing
- Inspecting
- Installing
- Auxiliary Brake Pedal/ Master Cylinder Assembly
- Removing
- Installing
- Throttle Control
- Removing
- Installing
- Troubleshooting