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

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For Arctic Cat Parts Call 606-678-9623 or 606-561-4983
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
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.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
AT THIS POINT directs the technician to certain and specific procedures to promote
www.mymowerparts.com
Table of Contents
Manual
August 2010

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Summary of Contents for Arctic Cat ATV 300 Utility/DVX 300 2011

  • Page 1 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.
  • Page 2 Click on the blue text to go. For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 TABLE OF CONTENTS Service Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the Manual Table of Contents bookmarks on the left side of the screen, or click the blue text below. To return to this page, click the Manual Table of Contents button at the bottom of each page.

  • Page 3: General Information

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 General Information Torque Specifications  NOTE: Some photographs and illustrations used in STEERING COMPONENTS this manual are used for clarity purposes only and Torque Part Part Bolted To are not designed to depict actual conditions.

  • Page 4: Torque Conversions (Ft-Lb/N-M)

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ENGINE/TRANSMISSION Torque Conversions Torque (ft-lb/N-m) Part Part Bolted To ft-lb N-m Cylinder Head Cylinder Cylinder Nut Crankcase ft-lb ft-lb ft-lb ft-lb Camshaft Holder Cylinder Head Bevel Drive Gear (Utility) Driveshaft 35.4 69.4 103.4...

  • Page 5: Break-In Procedure

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil, which has been specifically Break-In Procedure formulated for use in this Arctic Cat engine. Although Arctic Cat ACX All Weather synthetic engine oil is the...

  • Page 6: Genuine Parts

    10. Store the ATV indoors in a level position. When replacement of parts is necessary, use only genuine CAUTION Arctic Cat ATV parts. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illus- Avoid storing outside in direct sunlight and avoid using...
  • Page 7 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 8. Tighten all nuts, bolts, cap screws, and screws mak- CAUTION ing sure all calibrated nuts, cap screws, and bolts are Connect the positive battery cable first; then the nega- tightened to specifications.

  • Page 8: Periodic Maintenance/Tune-Up

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Periodic Maintenance/ Description Compression Tester Kit 0444-213 Tune-Up Tappet Adjuster 0444-189  NOTE: Special tools are available from the Arctic SPECIAL TOOLS Cat Service Parts Department. A number of special tools must be available to the techni- cian when performing service procedures in this section.

  • Page 9: Lubrication Points

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

  • Page 10: Valve/Tappet Clearance

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Valve/Tappet Clearance Testing Engine Compression To check and adjust valve/tappet clearance, use the fol- lowing procedure. To test engine compression, use the following procedure.  NOTE: The seat assembly, side panels, and gas 1.

  • Page 11: Muffler/Spark Arrester

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ATV-0051 KM139A 2. Using a soft wire brush, clean the carbon from the CAUTION screen (3) taking care not to tear or damage the Before removing the spark plug, make sure to clean the screen.

  • Page 12: Transmission Lubricant

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 1. Remove the rear drive level plug; the lubricant level should be at the threads of the plug. DSC02248 4. Clean the screen/filter in parts-cleaning solvent; then inspect the O-ring and replace if damaged.

  • Page 13: Cleaning And Lubricating

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

  • Page 14: Nuts/Bolts/Cap Screws

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983  NOTE: Chain “slack” should be within a range of To replace the headlight bulb, use the following procedure. 30-40 mm (1.2-1.6 in.). 1. Remove the boot from the back of the headlight housing;...

  • Page 15: Checking Adjustment

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM124B KM179A CHECKING ADJUSTMENT Hydraulic Brake Systems Stop the ATV completely and shift the transmission into the R position. The reverse gear indicator light should be illuminated. CHECKING/BLEEDING ! WARNING The hydraulic brake systems have been filled and bled at Never shift the ATV into reverse gear when the ATV is the factory.

  • Page 16: Inspecting Hoses

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 A. Remove the cover and fill the reservoir with DOT 3. If thickness of either brake pad is less than 1.0 mm 4 Brake Fluid. (0.039 in.), the brake pad must be replaced.

  • Page 17: Auxiliary/Rear Hydraulic Brake

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Remove the two brake pad alignment pins (A); then remove the mounting cap screws (B). KM268 D. Spread the brake pads and place the brake caliper over the disc. Secure with the mounting cap KM273A screws.

  • Page 18: Measuring/Replacing Rear/ Auxiliary Brake Pads (Dvx)

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM273A KM905 3. Install the wheel and secure. Tighten to 32 ft-lb. Inspecting and Measuring 4. Remove the ATV from the support stand. 1. Inspect the pads for gouges, chips, or wear.

  • Page 19: Burnishing Brake Pads

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 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.
  • Page 20 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 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.

  • Page 21: Specifications

    Valve Spring Tension @ 21.5 mm (exhaust) 19.05-22.0 kg (42.0-48.5 lb)  NOTE: Arctic Cat recommends the use of new gas- CAMSHAFT AND CYLINDER HEAD kets, lock nuts, and seals and lubricating all internal Cam Lobe Height (min) (intake) 34.15 mm...

  • Page 22: Removing Engine/Transmission

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 11. Disconnect the stator connector, shift position con- nector, and coolant temperature sensor. Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information.
  • Page 23 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM314A KM360A 15. Loosen the clamps; then disconnect the coolant hoses from the engine. KM147A KM323 KM106A 14. Loosen the clamps; then remove the front and rear V- belt cooling boots from the V-belt housing.
  • Page 24 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM313 KM325A 18. Remove the front engine mounting through-bolt; 21. Raise the front of the engine sufficiently to allow the then remove the left and right engine mounting engine assembly to be moved forward enough to clear brackets from the frame.
  • Page 25 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 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 Steering/Frame). 6. Remove the air filter housing (see Fuel/Lubrication/ Cooling.
  • Page 26 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 13. Remove the front and rear V-belt cooling boots from the V-belt housing; then remove the coolant hoses from the engine. KM315A 15. Disconnect the shift linkage from the transmission shift arm; then swing the shift linkage forward and out of the way.

  • Page 27: Removing Top-Side Components

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Top-Side Components  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment.
  • Page 28 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM704A KM718A 3. Using a crisscross pattern, loosen the four nuts secur- 6. Remove the cam chain guide; then disconnect the ing the camshaft holder to the cylinder head. Use 2-3 coolant hose and remove the cylinder. Support the steps until the nuts are all free;...

  • Page 29: Servicing Top-Side Components

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983  NOTE: Whenever a valve is out of tolerance, it must be replaced. Cleaning/Inspecting Camshaft Holder 1. Remove the rocker arm shafts, rocker arms, and stop plate from the camshaft holder. KM451 8.

  • Page 30: Cylinder Head Assembly

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion factor between the head and the straightedge. 3. Maximum distortion must not exceed specifications. KM717A 2. Remove the valve seal, valve springs, and the lower remaining spring seat.
  • Page 31 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ATV-1011A CC400D 4. Place a spring retainer over the valve springs; then 2. Remove each ring by working it toward the dome of using the valve spring compressor, compress the the piston while rotating it out of the groove.
  • Page 32 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Measuring Piston Pin (Outside Installing Piston Rings Diameter) and Piston-Pin Bore 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the 1.

  • Page 33: Inspecting Cam Chain Guide

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect the sealing surface for any indication of high spots.
  • Page 34 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 C. Cylinder Head D. Valve Cover  NOTE: Steps 1-4 in the preceding sub-section must precede this procedure. 5. While keeping tension on the cam chain, place the front cam chain guide into the cylinder.

  • Page 35: Removing Left-Side Components

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Removing Left-Side Components A. Recoil Starter (Utility) 1. Remove the five recoil starter cover cap screws. Remove the recoil starter assembly noting the loca- tion of the dowel pins. Note the condition of the recoil cover gasket.

  • Page 36: Servicing Left-Side Components

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ! WARNING During the disassembling procedure, continuous back- ward pressure must be exerted on the reel so it does not accidentally unwind and cause injury. 2. Rotate the reel clockwise until the notch of the reel is near the rope guide in the case.
  • Page 37 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM408 KM402 2. Insert the rope through the hole in the reel and tie a  NOTE: Do not remove the spiral spring unless knot in the end; then wrap the rope clockwise around replacement is necessary.

  • Page 38: V-Belt Cover

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM402A KM410 6. Install the ratchets making sure the ends are properly 9. With the 50 cm (20 in.) of rope exposed, hook the oriented on the reel. rope in the notch of the reel.

  • Page 39: Drive Pulley

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DRIVEN PULLEY/CENTRIFUGAL 2. Inspect the V-belt cover for cracks, distortion, and loose alignment pins. CLUTCH ASSEMBLY  NOTE: If the V-belt cover is cracked or distorted or if Disassembling the bearing is loose in the cover, the cover must be ! WARNING replaced.
  • Page 40 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Inspect the O-rings on the movable face for nicks, tears, or swelling. KM385 5. Remove four pins and bushings from the fixed face hub; then remove the movable face. KM380A 3. Inspect two grease seals in the movable face for nicks, cuts, or damage.
  • Page 41 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 5. Measure the driven face spring free length. If the free 2. Apply multi-purpose grease to the O-rings and length is less than 131 mm, the spring must be grease seals on the movable face; then install on the replaced.

  • Page 42: Installing Left-Side Components

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM386 KM262 6. Place the centrifugal clutch assembly, drive plate nut, and clutch compressor adapter in position; then using the clutch compressor wing nut, compress the clutch spring and install the nut (lightly coated with red Loctite #271).

  • Page 43: Removing Right-Side Components

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AT THIS POINT  To service any one specific component, only limited dis- assembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  NOTE: The engine/transmission does not have to be removed from the frame for this procedure.
  • Page 44 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. Remove the shift fork guide shaft; then hold the shift fork away from the shift cam and remove the shift cam. KM609A 4. Remove the output driveshaft circlip; then remove the driveshaft from the transmission case cover.
  • Page 45 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 A. Transmission (Utility) 1. Drain the transmission lubricant into a suitable con- tainer; then install the drain plug and tighten to 21 ft- KM649 5. Using a Spanner Wrench to hold the centrifugal clutch housing, remove the nut securing the second- ary drive bevel gear to the driveshaft.
  • Page 46 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM652A KM680 7. Remove the shift shaft; then remove plug, seal/ 10. Remove the countershaft and driveshaft as an assembly. washer, spring, and shift cam stopper ball. KM681 11. To disassemble the countershaft, use the following KM677A procedure.
  • Page 47 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM685 KM692A 12. To disassemble the driveshaft, use the following pro- 13. To disassemble the secondary driven bevel gear cedure. assembly, use the following procedure. A. Remove the thrust washer; then remove the A.
  • Page 48 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 B. Water Pump C. Trigger Coil D. Stator Coil E. Rotor/Flywheel AT THIS POINT  To remove/service the water pump, see Fuel/Lubrica- tion/Cooling. 14. Remove the right crankcase cover (see Fuel/Lubrica- tion/Cooling - Water Pump).

  • Page 49: Servicing Right-Side Components

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 TRANSMISSION (DVX) Inspecting 1. Measure the shift fork guide shaft runout. If runout exceeds 0.03 mm, the shaft must be replaced. KM766A 21. Remove the two cap screws securing the oil baffle to the crankcase and remove the baffle;...
  • Page 50 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM628 KM628 7. Inspect all bearings, bushings, seals, and shafts for 3. Install the drive axle into the transmission housing; proper fit, surface mating, or discoloration. Replace then secure with the circlip.
  • Page 51 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM617A KM624 7. Install the shift cam stopper ball, spring, seal/washer, 4. Inspect the shift shaft and gear for excessive wear. and plug (threads coated with red Loctite #271). Check that the spring is not broken.
  • Page 52 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 11. Inspect the driven shaft for scoring, discoloration, or worn splines. KM420 4. Install the flat thrust washer and driven bevel gear on the driven shaft; then using the universal joint and...
  • Page 53 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM685A KM690A 7. Install the high gear clutch dog and flat washer. At 10. Apply clean engine oil to the assembled shafts and this point, the countershaft is ready for installation. gears; then install the countershaft and driveshaft simultaneously into the transmission case.
  • Page 54 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM619A KM650 14. Install the shift shaft making sure to align the timing 17. Use a center punch to stake the nut to the driveshaft. mark between the two marks on the shift cam.

  • Page 55: Installing Right-Side Components

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Installing Right-Side Components A. Oil Pump 1. Install the oil pump with the arrow on the pump body directed upward; then secure with the two cap screws and tighten securely. Make sure the shaft turns freely after installing.

  • Page 56: Disassembling Crankcase Half

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Using Crankcase Separator/Crankshaft Remover and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins and a gasket. Disassembling Crankcase Half 1. Remove the crankshaft from the left crankcase half.

  • Page 57: Assembling Crankcase Half

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ATV-1074 KM724 3. Zero the indicator and rotate the crankshaft slowly. Assembling Crankcase CAUTION Half Care should be taken to support the connecting rod when rotating the crankshaft. 4. Maximum runout must not exceed specifications.

  • Page 58: Installing Engine/Transmission

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Lower the engine/transmission and install the lower rear and upper rear through-bolts and nuts. Finger tighten only. 4. Remove the engine lift from the front mounting boss; then install the left and right engine mounting brack- ets and attach with the existing hardware.
  • Page 59 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM324A KM328 14. Install the coil (see Electrical System). 3. Slide the engine/transmission rearward into the rear engine mounts; then install the rear through-bolts 15. Install the carburetor (see Fuel/Lubrication/Cooling). and nuts. Do not tighten at this time.
  • Page 60 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 11. Connect the coolant temperature sensor; then con- nect the trigger coil connector, shift position connec- tor, and stator connector. KM315A 9. Connect the V-belt cooling boots to the V-belt hous- ing and secure with the existing hose clamps.

  • Page 61: Troubleshooting

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn - seated poorly 2.
  • Page 62 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Problem: Engine noisy (Noise seems to come from secondary-transmission/right-side cover) Condition Remedy 1. Gears - shaft(s) worn 1. Replace gears - shafts 2. Bearing(s)/bushing(s) damaged 2. Replace bearing(s)/bushing(s) Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)
  • Page 63 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Problem: Engine lacks power Condition Remedy 1. Valve clearance incorrect 1. Adjust clearance 2. Valve springs weak 2. Replace springs 3. Valve timing out of adjustment 3. Adjust timing 4. Piston ring(s) - cylinder worn 4.

  • Page 64: Carburetor Specifications

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Remove the cap screws securing the air filter hous- ing to the frame; then loosen the clamp securing air Fuel/Lubrication/Cooling inlet boot to the carburetor and remove the air filter. Carburetor...
  • Page 65 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 PR162C KC0021A 6. Loosen the outer jam nut securing the throttle cable 3. Remove the Phillips-head screws securing the float to the carburetor body; then route the cable out of the chamber; then remove the chamber. Account for the way.

  • Page 66: Cleaning And Inspecting

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CC753 CC758  NOTE: Note the locations of the jets, pilot screw, CLEANING AND INSPECTING and holder for disassembling procedures.  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary.
  • Page 67 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 5. Place the float chamber into position making sure the O-ring is properly positioned; then secure with the Phillips-head screws. CC758  NOTE: Turn the pilot screw clockwise until it is lightly seated; then turn it counterclockwise the rec- ommended number of turns as an initial setting.

  • Page 68: Engine Rpm (Idle)

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 PR162B KM111A 3. Connect the throttle cable to the actuator arm. 2. Turn the adjuster until the throttle cable has proper free-play of 1-4 mm (1/16-3/16 in.) at the lever. PR162C 4. Place the throttle actuator cover into position on the ATV-0047B carburetor;...

  • Page 69: Gas Tank Valve

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Gas Tank Gas Tank Valve The ATV has a valve attached to the gas tank. There are ! WARNING three positions: ON, RES, and OFF. Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc.,...

  • Page 70: Oil Flow Chart

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Install the oil pump into the engine (see Right-Side Components in Engine/Transmission). Oil Flow Chart Liquid Cooling System When filling the cooling system, use pre-mixed Arctic Cat Antifreeze. While the cooling system is being filled, air pockets may develop;...
  • Page 71 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 5. Disconnect the fan wiring from the main wiring har- ness; then remove the radiator/fan assembly and account for the grommets and collars. 6. Remove the fan/fan shroud assembly from the radiator.

  • Page 72: Water Pump

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CLEANING AND INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. REMOVING 1. Clean all pump components in parts-cleaning sol- vent. 1. Remove the radiator (see Radiator in this section).
  • Page 73 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Troubleshooting Problem: Starting impaired Condition Remedy 1. Starter jet obstructed 1. Clean jet 2. Starter jet passage obstructed 2. Clean passage 3. Starter body - carburetor leaking air 3. Tighten - adjust - replace gasket 4.
  • Page 74 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Electrical System Testing Electrical Components This section has been organized into sub-sections which show procedures for the complete servicing of the Arctic All of the electrical tests should be made using the Fluke Cat ATV electrical system.

  • Page 75: Brakelight Switch (Auxiliary)

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 1. Remove the battery hold-down; then disconnect the 6. After charging the battery for the specified time, battery cables (negative cable first). remove the battery charger and allow the battery to sit for 1-2 hours.

  • Page 76: Brakelight Switch (Handlebar Control)

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Brakelight Switch (Handlebar Control) The switch has spade-type connectors which engage the harness connectors at the switch.  NOTE: The ignition switch must be in the ON position. VOLTAGE (Wiring Harness Connector) 1.

  • Page 77: Fuse Block

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. The meter must show 50-60 ohms. Fuses  NOTE: If the meter does not show as specified, trou- bleshoot or replace the connector or the fan.  NOTE: To determine if the fan motor is good, con- 1.

  • Page 78: Indicator Lights (Dvx)

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Primary Winding TESTING 1. Remove the two spade connectors from the coil; then  NOTE: If any functions (segments or displays) are connect the red tester lead to either terminal and the not normal or do not display as indicated, the LCD black tester lead to the other terminal.

  • Page 79: Ignition Switch

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 10. Connect the red MaxiClip to the brown/black wire. 4. The meter must show less than 1 ohm. The tester must read battery voltage and the speed- 5. Turn the ignition switch to the LIGHTS position.

  • Page 80: Magneto Coils

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Connect the red tester lead to the brown/blue wire;  NOTE: If both voltage tests failed, check all connec- then connect the black tester lead to the black/white tions, etc., and test again. If no voltage is present, wire.

  • Page 81: Starter Relay

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983  NOTE: Prior to replacing the CDI unit to assure the CDI unit is defective, it is advisable to perform a CDI Starter Relay peak voltage test (see Ignition Coil in this section) and/or perform a continuity test of the wiring harness from the CDI connector to the CDI unit.

  • Page 82: Taillight - Brakelight

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the green wire; then connect the black tester lead to the white wire. 3. With the dimmer switch in the LO position (LO beam), the meter must show battery voltage.
  • Page 83 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 1. Attach the Timing Light to the spark plug high ten- 3. Install the timing inspection plug. sion lead; then remove the timing inspection plug If ignition timing cannot be verified, the rotor may be from the left-side crankcase cover.
  • Page 84 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Problem: Starter button not effective Condition Remedy 1. Battery charge low 1. Recharge - replace battery 2. Switch contacts defective 2. Replace switch 3. Starter motor brushes not seating 3. Repair - replace brushes 4.

  • Page 85: Drive System

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ! WARNING Drive System Make sure the ATV is solidly supported on the support stand to avoid injury. SPECIAL TOOLS 2. Engage the brake lever lock; then remove the wheels. A number of special tools must be available to the techni- cian when performing service procedures in this section.

  • Page 86: Cleaning And Inspecting

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 7. Loosen the drive chain (see Periodic Maintenance); then slip the chain off the sprocket and remove the axle assembly from the right side. KM477 CLEANING AND INSPECTING 1. Inspect the sprocket teeth for wear. If they are worn...

  • Page 87: Removing Bearings

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 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. Account for one spacer.  NOTE: Do not reuse bearings after removal.

  • Page 88: Rear Drive Axle (Utility)

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. Coat the axle threads with red Loctite #271 and 10. Install the rear wheels and tighten to 32 ft-lb. install one axle nut (left-hand threads); then using the Rear Axle Nut Wrench, tighten the inner axle nut to calculated specification.
  • Page 89 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM508 KM505 11. Disengage the universal joint from the transmission 8. Remove the left and right pivot caps; then remove output shaft splines and set the driveshaft aside. the right-side pivot bolt.
  • Page 90 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM537 KM539 14. Place the right end (shorter length) of the axle on a wood block; then using a rubber mallet, drive the gear case from the axle. KM540 4. Check that all bearings turn freely and smoothly and are not worn, discolored, or missing dust seals.
  • Page 91 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM918 KM922 KM919A KM923 2. Remove the oil seal from the front of the gear case; then using the Pinion Gear Bearing Nut Wrench, remove the pinion nut. KM924A 4. Remove the oil seals from the case and cover; then drive the bearings out of the case.
  • Page 92 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ASSEMBLING 1. Drive the bearings into the gear case and gear case cover using an appropriate bearing driver. Make sure the bearing is firmly seated. KM926 KM926 KM927 KM928 2. Apply grease to the seal lips; then using a seal driver, drive the seals into the gear case and cover (flat side out) until flush with the seal bore.

  • Page 93: Checking Tooth Contact

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM925A KM920A 3. Drive a new pinion needle bearing into the gear case; then apply molybdenum disulfide grease to the nee- dle bearing. Secure with the snap ring. 4. If the pinion bearing was removed from the pinion,...

  • Page 94: Correcting Tooth Contact

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. While locking the pinion shaft to prevent it from turning, rock the ring gear back and forth and record the measurement. Standard backlash should be 0.05- 0.25 mm (0.002-0.010 in.). Maximum service limit is 0.4 mm (0.016 in.).
  • Page 95 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM522 KM528A 3. Remove the three cap screws, the dust plate, and one 3. Apply grease to the universal joint splines and drive- O-ring from the left axle housing on the swing arm;...
  • Page 96 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM531 KM505A 6. Align the swing arm assembly in the frame and 10. Tighten the final drive gear case drain plug securely; engage the universal joint onto the splines of the sec- then remove the fill plug and level plug.

  • Page 97: Troubleshooting Drive System

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 16. Install the rear hub caps; then install the rear wheels and tighten to 32 ft-lb. 17. Remove the ATV from the support stand. KM469 15. Install the rear brake calipers and tighten to 25 ft-lb.

  • Page 98: Front And Rear Suspension Assembly Schematics

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Suspension The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods not bent, pitted, or damaged. B. Rubber damper not cracked, broken, or missing. C. Shock absorber body not damaged, punctured, or leaking.

  • Page 99: Rear Shock Absorber

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Remove the ATV from the support stand. Rear Shock Absorber REMOVING 1. Secure the ATV on a support stand to elevate the wheels and to release load on the suspension. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.

  • Page 100: Removing And Disassembling

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM551B KM568A 2. Tighten the lock nut securely. 5. Remove the axle housing (see Drive System). 6. Remove the brake hose guide clamp. Swing Arm REMOVING AND DISASSEMBLING For the Utility, see Rear Drive Axle in Drive System. For the DVX, use the following procedure.
  • Page 101 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Inspect the needle bearings for missing rollers, rust or corrosion, or flat rollers. Check for a tight fit in boss. Replace the arm if bearings are loose. KM499B KM565 5. Inspect all dust seals and replace if they are cracked, torn, dried out, or loose.

  • Page 102: Assembling And Installing

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ASSEMBLING AND INSTALLING 1. Remove any nicks or burrs from the bearing bosses in the cushion arm with fine emory cloth; then using a suitable bearing installer, press new needle bear- ings into the end bosses of the cushion arm.

  • Page 103: Front A-Arms

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM468 SP366 13. Install new cotter pins; then install the hub caps and 3. Remove the nut securing the hub. rear wheels. Tighten the lug nuts to 32 ft-lb. 4. Remove the cap screws securing the brake caliper;...
  • Page 104 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM573 SP382 7. Remove the brake hose clamp from the A-arm; then  NOTE: All bearings, bushings, and seals that are remove the cotter pins and slotted nuts securing the removed must be replaced with new ones.

  • Page 105: Wheels And Tires

    Wheels and Tires TIRE SIZE ! WARNING Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV operation. The ATV is equipped with low-pressure tubeless tires of the size and type listed. Do not under any circumstances substitute tires of a different type or size.

  • Page 106: Troubleshooting

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Inspect each wheel for cracks, dents, or bends. 2. Inspect the tires for damage, wear, or punctures. 4. Inspect each tire for cuts, wear, missing lugs, and ! WARNING leaks. Do not operate the ATV if tire damage exists.

  • Page 107: Steering Post/Tie Rods

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Steering/Frame The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent or cracked and has equal and complete full-left and full-right capability.
  • Page 108 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Apply a thin coat of grease to the upper steering post bushing; then secure the steering post with the sup- port blocks and existing hardware. Tighten to 17 ft- KM589 6. Remove the steering post from the ATV.

  • Page 109: Measuring/Adjusting Toe-In/Toe-Out

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Measure the distance (A) and (B) between the front wheels; then subtract distance (B) from (A). Distance A - Distance B = Toe-In. KM590 5. Install the handlebar and tighten the clamp cap screws to 18 ft-lb making sure to tighten the front cap screws first.
  • Page 110 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM782A KM352A 6. Turn the handlebar to the left; then raise the body turning it to the right and lift clear of the handlebar. REMOVING (Utility) 1. Remove the seat; then remove the battery box cover.

  • Page 111: Installing (Utility)

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 INSTALLING (DVX) 1. Fit the body over the handlebar and rotate into nor- mal mounting position. 2. Using the existing hardware, secure the front fenders to the fender supports; then connect the headlight.

  • Page 112: Steering Post Cover/Instrument Pod

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Disconnect the wire connectors from the indicator lights and from the ignition switch. REMOVING (Utility) 1. Remove the reinstallable rivet on the front of the instrument pod and the two cap screws on the rear;...
  • Page 113 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure incorrect 3. Adjust pressure 4.

  • Page 114: Front Brake Lever/Master Cylinder Assembly

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 INSPECTING Controls/Indicators  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. 1. Inspect the pivot bolt securing the brake lever for Front Brake Lever/Master wear.

  • Page 115: Auxiliary Brake Pedal/Master Cylinder Assembly

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KM800A KM801B 5. Fill the master cylinder with DOT 4 brake fluid; then 4. Loosen the jam nut; then remove the clevis and bleed the system (see Periodic Maintenance). adjuster nut. INSTALLING Auxiliary Brake Pedal/ 1.

  • Page 116: Throttle Control

    For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Throttle Control REMOVING 1. Remove the boot from the throttle cable adjuster; then loosen the jam nut and turn the adjuster com- pletely in to loosen the cable. 2. Remove the three machine screws securing the cover to the throttle control;...
  • Page 117 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2258-909 ®™...

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