Arctic Cat ATV 250 Utility 2009 Service Manual
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Arctic Cat ATV 250 Utility 2009 Service Manual

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For Arctic Cat Discount Parts Call 606-678-9623 or 606-561-4983
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2009 Arctic
Cat ATV 250 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. The symbol
! CAUTION identifies 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
mation worthy of particular attention. The symbol
cific 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.
© 2008 Arctic Cat Inc.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
AT THIS POINT directs the technician to certain and spe-
Back to TOC
www.mymowerparts.com
NOTE: identifies supplementary infor-
July 2008

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  • 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 2009 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 TABLE OF CONTENTS SHARE OUR PASSION.

  • Page 3: Table Of Contents

    SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications (DVX 300)......1-2 General Specifications (250 Utility) ......1-2 Torque Specifications ..........1-3 Torque Conversions (ft-lb/N-m) ....... 1-4 Tightening Torque (General Bolts) ......1-4 Break-In Procedure ..........1-4 Gasoline - Oil - Lubricant ........1-4 Genuine Parts ............

  • Page 4: General Specifications (Dvx 300)

    500 ml (16.9 fl/oz) Gasoline (recommended) 87 Octane Regular Unleaded Gasoline (recommended) 87 Octane Regular Engine Oil (recommended) Arctic Cat ACX All Weather Unleaded (Synthetic) Engine Oil (recommended) Arctic Cat ACX All Weather Cooling System Capacity 0.776 L (0.81 U.S. qt)

  • Page 5: Torque Specifications

    Torque Specifications ENGINE/TRANSMISSION Torque Part Part Bolted To ft-lb N-m Cylinder Head Cylinder DRIVE TRAIN COMPONENTS Cylinder Nut Crankcase Torque Camshaft Holder Cylinder Head Part Part Bolted To ft-lb N-m Bevel Drive Gear (Utility) Driveshaft Engine Mounting Through-Bolt Frame Magneto Rotor/Flywheel Crankshaft Engine Mounting Bracket Cap Screw Frame Bevel Driven Gear (Utility)

  • Page 6: Torque Conversions (Ft-Lb/N-M)

    7-11 ft-lb ! CAUTION 16-25 ft-lb (7 Marked Bolt) 24-48 in.-lb Do not use white gas. Only Arctic Cat approved gaso- 6-8 ft-lb line additives should be used. 13-20 ft-lb 29-43 ft-lb Next...

  • Page 7: Genuine Parts

    Since gasoline expands as its temperature rises, the gas tor-based oils. tank must be filled to its rated capacity only. Expan- The recommended oil to use is Arctic Cat ACX All sion room must be maintained in the tank particularly Weather synthetic engine oil, which has been specifi- if the tank is filled with cold gasoline and then moved cally formulated for use in this Arctic Cat engine.

  • Page 8: Preparation After Storage

    Start the engine and allow it it will assure many miles and hours of trouble-free to idle; then using Arctic Cat Engine Storage Pre- riding. Arctic Cat recommends the following proce- server, slowly inject the preserver into the air filter dure to prepare the ATV.
  • Page 9 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart........2-2 Periodic Maintenance..........2-3 Lubrication Points............ 2-3 Air Filter..............2-3 Valve/Tappet Clearance .......... 2-4 Testing Engine Compression ........2-4 Spark Plug............... 2-5 Muffler/Spark Arrester ..........2-5 Engine Oil - Filter ............ 2-6 Rear Drive Lubricant (250 Utility) ......

  • Page 10: Periodic Maintenance Chart

    A = Adjust I = Inspect Periodic Maintenance C = Clean L = Lubricate Chart D = Drain R = Replace T = Tighten Initial Service Every Month Every 3 Every 6 Every Year or After Break-In Every Months or Months or Item Every 1500...

  • Page 11: Periodic Maintenance

    Arctic Cat ATV. 1. Remove the seat. NOTE: Arctic Cat recommends the use of new 2. Remove the air filter housing cover from the gaskets, lock nuts, and seals and lubricating all retaining clips.

  • Page 12: Valve/Tappet Clearance

    8. Place the filter in the air filter housing making sure 6. While holding the adjuster handle in place, rotate it is properly seated and secure with the clamp. the adjuster dial counterclockwise until proper valve/tappet clearance is attained. 9. Install the air filter housing cover and secure with the retaining clips;...

  • Page 13: Spark Plug

    NOTE: The compression should be within a range of 200-215 psi (250 Utility) or 210-230 psi (DVX 300) in the full-open throttle position. 6. If compression is abnormally low, verify the fol- lowing items. A. Starter cranks engine over. B. Gauge functions properly. C.

  • Page 14: Engine Oil - Filter

    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.

  • Page 15: Transmission Lubricant

    KM131A KM104A 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;...

  • Page 16: Driveshaft/Coupling (250 Utility)

    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.

  • Page 17: Headlight/Taillight-Brakelight

    2. Push the bulb in and turn it counterclockwise. Headlight/Taillight- 3. Install the new bulb by turning it clockwise while pushing in. Brakelight 4. Install the lens cover. ! CAUTION Each time the ATV is used, lights should be checked for proper function.

  • Page 18: Hydraulic Brake Systems

    ADJUSTING SHIFT LEVER 1. With the master cylinder in a level position, check the fluid level in the reservoir. If the level in the 1. Place the shift lever in the N (neutral) position; reservoir is not visible in the sight glass, add DOT then set the engine stop switch to the STOP posi- 4 brake fluid.
  • Page 19 KM116A KM265A 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.

  • Page 20: Auxiliary/Rear Hydraulic Brake

    D. Spread the brake pads and place the brake cali- per 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. KM273A 4. Remove the caliper from the disc; then compress the caliper holder and remove the brake pads.
  • Page 21 KM273A KM244 3. Install the wheel and secure. Tighten to 32 ft-lb. 2. Remove the brake spring plate; then remove the brake pads. 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).

  • Page 22: Burnishing Brake Pads

    Checking/Replacing V-Belt REMOVING 1. On the 250 Utility, remove the left footwell; then remove the recoil starter assembly. On the DVX 300, proceed to step 2. KM245 2. Install the brake pad retaining pin and secure with the clip pin; then install the dust cover. KM279 2.
  • Page 23 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 visible and the stepped washer should sit over the splines. KM276 5. Remove the nut securing the driven pulley; then remove the splined bushing, centrifugal clutch, pulley, and V-belt.
  • Page 24 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 Table of Contents ............ 3-3 Troubleshooting ............. 3-43 Back to TOC...
  • Page 25 Valve Spring Tension @ 21.5 mm (exhaust) 19.05-22.0 kg removed from the frame. (42.0-48.5 lb) CAMSHAFT AND CYLINDER HEAD NOTE: Arctic Cat recommends the use of new Cam Lobe Height (min) (intake) 34.15 mm gaskets, lock nuts, and seals and lubricating all (exhaust) 34.05 mm...
  • Page 26 3. Remove the reinstallable rivet from the bottom of the electrical tray; then remove and lay the tray Table of Contents forward. Leave the starter relay, fuse block, and CDI attached. Removing Engine/Transmission......3-3 Top-Side Components..........3-8 Removing Top-Side Components ......3-8 Servicing Top-Side Components......
  • Page 27 12. Remove the starter positive wire; then remove the engine ground wire. KM359A KM319A 13. Drain the coolant, engine oil, and transmission gear lubricant; then install the drain plugs. KM360A 15. Loosen the clamps; then disconnect the coolant hoses from the engine. KM314A KM323 KM147A...
  • Page 28 KM344A KM333A 17. Disconnect the shift linkage from the transmission shift arm. KM325A 21. Raise the front of the engine sufficiently to allow the engine assembly to be moved forward enough to clear the rear mounting brackets (approximately 6 in.). KM313 18.
  • Page 29 250 Utility 1. Remove the seat; then remove the battery box cover. KM106A 4. Remove the gas tank cover panel and gas tank vent hose. 5. Remove the side panels; then remove the front KM133A rack and front fenders (see Section 8). 2.
  • Page 30 KM319A KM314 13. Remove the front and rear V-belt cooling boots 14. Loosen the output drive boot clamp; then slide the from the V-belt housing; then remove the coolant boot off the output housing. hoses from the engine. KM315A 15. Disconnect the shift linkage from the transmission KM359A shift arm;...

  • Page 31: Top-Side Components

    KM332A KM329 18. Remove the upper rear and lower rear engine through-bolts to free the engine/transmission; then raise the front of the engine/transmission suffi- ciently to allow the engine assembly to be moved forward enough to disengage the driveshaft. KM331 Top-Side Components KM333A NOTE: For efficiency, it is preferable to remove...
  • Page 32 1. Remove the cap screws securing the cylinder head cover. Account for the O-ring. KM707A 4. Remove the camshaft gear from the cam chain; then secure the timing chain so it will not fall into KM703 the engine. Remove the camshaft. NOTE: Keep the mounting hardware with the 5.

  • Page 33: Servicing Top-Side Components

    B. Remove each ring by working it toward the AT THIS POINT dome of the piston while rotating it out of the To inspect cam chain guide, see Servicing Top-Side groove. Components sub-section. AT THIS POINT C. Cylinder D. Piston To service piston, see Servicing Top-Side Compo- nents sub-section.

  • Page 34: Cylinder Head Assembly

    Cleaning/Inspecting Cylinder Head 1. Using a non-metallic carbon removal tool, remove any carbon build-up from the combustion chamber making sure not to nick, scrape, or damage the combustion chamber or the sealing surface. 2. Inspect the spark plug hole for any damaged threads.
  • Page 35 ATV1013A KM717A 2. The lobe heights must not be less than minimum PISTON ASSEMBLY specifications. NOTE: Whenever a piston, rings, or pin are out of Inspecting Camshaft Bearing tolerance, they must be replaced. Journal Cleaning/Inspecting Piston 1. Inspect the bearing journal for scoring, seizure marks, or pitting.
  • Page 36 Cleaning/Inspecting Piston Rings 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45° angle and to a sharp edge. 2. Using the sharpened ring as a tool, clean carbon from the ring-grooves.

  • Page 37: Cylinder Assembly

    Honing Cylinder 2. Install the compression rings (1 and 2) so the letter on the top surface of each ring faces the dome of 1. Using a slide gauge and a dial indicator or a snap the piston. Rotate the rings until the ring end gaps gauge, measure the cylinder bore diameter in three are on directly opposite sides of the piston accord- locations from top to bottom and again from top to...

  • Page 38: Installing Top-Side Components

    6. Place the head gasket into position on the cylinder. Place the alignment pins into position; then place Installing Top-Side the head assembly into position on the cylinder Components making sure the cam chain is routed through the chain cavity. ! CAUTION A.

  • Page 39: Left-Side Components

    9. Install the two alignment pins; then install the camshaft holder and secure with the four cylinder head nuts and washer. Using a crisscross pattern, tighten to 18 ft-lb. KM703 Left-Side Components KM707A NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components.

  • Page 40: Servicing Left-Side Components

    2. Remove the ten cap screws securing the V-belt cover; then remove the cover noting the location of the two dowel pins. Note the condition of the V-belt cover gasket. Replace if damaged. KM369 6. Remove the drive pulley collar and the movable drive face taking care not to loose the rollers.
  • Page 41 3. Remove the cap screw. Account for the ratchet 6. Remove the spiral spring from the case by lifting guide, spacer, and spring. the spring end up and out. Hold the remainder of the spring with thumbs and alternately release each thumb to allow the spring to gradually release from the case.
  • Page 42 KM400 KM401 8. Hold the ratchet guide down in place on the ratchet pins and secure with the cap screw coated with blue Loctite #243. Tighten securely. KM405 5. Align the inner hook of the spiral spring with the notch in the reel spacer. KM410 9.

  • Page 43: Drive Pulley

    V-BELT COVER 1. Inspect the bearing for excessive wear, rough or binding when turning, seal condition, and secure mounting in the V-belt cover. NOTE: If the bearing is worn excessively, turns roughly, or bearing seals are loose, the bearings must be replaced. KM394A 3.
  • Page 44 KM373 KM380 3. Release the spring pressure and remove the cen- Inspecting trifugal clutch assembly from the driven pulley. 1. Inspect the pulley faces for wear, galling, or grooving. KM375 4. Remove the spring and spring seat; then remove the hub collar. KM394A 2.
  • Page 45 6. Measure the driven fixed face hub using a calipers. The minimum service limit is 39.93 mm. KM380B KM378 7. Measure the thickness of the centrifugal clutch shoe lining. The minimum service limit for the lin- ing is 0.5 mm. NOTE: If any shoe lining is below the service limit, the complete set must be replaced.

  • Page 46: Installing Left-Side Components

    3. Install the pins and spacers into the fixed face hub; then pack the cam slots in the movable face with multi-purpose grease. KM373 7. Using a suitable holding fixture, tighten the drive plate nut to 43 ft-lb. KM384 4. Install the spring seat over the hub and movable Installing Left-Side face hub.

  • Page 47: Right-Side Components

    6. Install the centrifugal clutch housing and clutch collar; then secure with the flange nut and tighten to 40 ft-lb. KM369 4. Place the fixed drive face into position on the crankshaft and engage the splines making sure the splines extend beyond the pulley face hub. KM253 KM263A KM368...

  • Page 48: Removing Right-Side Components

    Removing Right-Side Components A. Transmission (DVX 300) 1. Drain the transmission lubricant into a suitable container; then install the drain plug and tighten to 21 ft-lb. KM611A 5. Remove the shift shaft; then remove the plug. Account for one shift cam stopper ball, spring, and seal/washer.
  • Page 49 KM621 KM106 7. Remove the shift fork; then remove the main shaft NOTE: If the engine has not been removed, assembly. remove the swing arm assembly (see Section 7). 2. Using a crisscross pattern, remove four cap screws securing the secondary driven bevel gear assembly to the transmission case cover;...
  • Page 50 KM649 KM652A 5. Using a Spanner Wrench to hold the centrifugal 7. Remove the shift shaft; then remove plug, clutch housing, remove the nut securing the sec- seal/washer, spring, and shift cam stopper ball. ondary drive bevel gear to the driveshaft. KM677A KM650 NOTE: If the engine has been removed and the...
  • Page 51 KM680 KM685 10. Remove the countershaft and driveshaft as an 12. To disassemble the driveshaft, use the following assembly. procedure. A. Remove the thrust washer; then remove the reverse gear. KM681 11. To disassemble the countershaft, use the following procedure. KM689A A.
  • Page 52 B. Water Pump C. Trigger Coil D. Stator Coil E. Rotor/Flywheel AT THIS POINT To remove/service the water pump, see section 4. 14. Remove the right crankcase cover (see Section 4 - Water Pump). 15. Remove the trigger coil mounting screws; then remove the wire set plate.
  • Page 53 KM775 KM766A 21. Remove the two cap screws securing the oil baffle to the crankcase and remove the baffle; then remove the snap ring securing the oil pump driven sprocket. KM766A NOTE: The starter one-way clutch bearing is direction oriented and will only function if installed properly.

  • Page 54: Servicing Right-Side Components

    Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. TRANSMISSION (DVX 300) Inspecting KM626 1. Measure the shift fork guide shaft runout. If runout 5. Inspect all gear teeth for chipping, discoloration, exceeds 0.03 mm, the shaft must be replaced.
  • Page 55 2. Install the clutch dog, splined washer, bushing, and primary driven gear onto the main shaft; then install the second splined washer, spacer collar, and thrust washer. The main shaft is now assem- bled and can be installed. KM613A 6. Install the shift shaft making sure the pin in the gear position switch engages the slot in the shift shaft and the shift shaft gear is correctly timed to the shift cam.
  • Page 56 9. Inspect the drive and driven bevel gears for chip- ping, flaking, or excessive wear in the splines. Replace as required. KM623 2. Inspect the shift forks for distortion, discoloration, or excessive wear. 3. Inspect the shift cam groove and shift cam gear for KM422 excessive wear.
  • Page 57 KM695 KM426A 3. Apply oil to the secondary driven bevel gear shaft; 6. Install the high drive gear thrust washer on the then install the bearing into the case. countershaft; then install the high drive gear and secure with a circlip. KM420 4.
  • Page 58 KM692A KM700 9. Install the low/reverse clutch dog and spacer 12. Install the high shift fork into the high clutch dog; washer; then install the reverse gear and reverse then engage the shift fork pawl into the appropri- gear thrust washer. At this point, the driveshaft is ate shift cam groove.

  • Page 59: Installing Right-Side Components

    KM651A KM646A 16. Install a spacer washer and the drive bevel gear on the driveshaft; then while holding the centrifugal Installing Right-Side clutch housing with an appropriate holder, secure the bevel gear with a new nut and tighten to 72 Components ft-lb.

  • Page 60: Center Crankcase Components

    Center Crankcase Components NOTE: This procedure cannot be done with the engine/transmission frame. Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure. NOTE: For efficiency, it is preferable to remove and disassemble only those components which KM767 need to be addressed and to service only those NOTE: Make sure the crankshaft and rotor/fly- components.

  • Page 61: Servicing Center Crankcase Components

    KM721 CC290D 2. Remove the balancer shaft from the left crankcase 2. Maximum diameter must not exceed specifications. half. Measuring Connecting Rod (Small End Deflection) 1. Place the crankshaft on a set of V-blocks and mount a dial indicator and base on the surface plate.

  • Page 62: Assembling Crankcase Half

    ATV-1074 KM724 3. Zero the indicator and rotate the crankshaft slowly. Assembling ! CAUTION Crankcase Half Care should be taken to support the connecting rod when rotating the crankshaft. 4. Maximum runout must not exceed specifications. NOTE: For ease of assembling, install compo- NOTE: Proceed to check runout on the other end nents on the left-side crankcase half.

  • Page 63: Installing Engine/Transmission

    NOTE: Rotate the crankshaft back and forth to ensure no binding or sticking occurs while tighten- Installing ing the cap screws. Engine/Transmission DVX 300 1. Attach a suitable engine lift to the front engine mounting boss; then lift the engine/transmission into the frame from the left side.
  • Page 64 12. Connect the starter wire to the starter stud and secure with a washer and nut. Tighten securely. 13. Connect the stator connector, shift position con- nector, and the coolant temperature sensor; then secure the engine ground cable to the engine and tighten the cap screw securely.
  • Page 65 KM414A KM319A 6. Tighten the nuts on the two rear and one front 11. Connect the coolant temperature sensor; then con- through-bolt to 29 ft-lb. nect the trigger coil connector, shift position con- nector, and stator connector. 7. Connect the shift linkage using the existing hard- ware.
  • Page 66 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. Repair - replace guides 3. Valves mistimed 3.
  • Page 67 Problem: Engine noisy (Noise seems to come from crankshaft) Condition Remedy 1. Bearing worn - burned 1. Replace bearing 2. Lower rod-end bearing worn - burned 2. Replace bearing 3. Connecting rod side clearance too large 3. Replace thrust washer(s) Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy...
  • Page 68 Problem: Engine runs poorly at high speed Condition Remedy 1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease speed 2. Valve springs weak 2. Replace springs 3. Valve timing out of adjustment 3. Adjust timing 4.

  • Page 69: Fuel/Lubrication/Cooling

    SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Carburetor Specifications ........4-2 Carburetor ............... 4-2 Throttle Cable Free-Play ......... 4-6 Engine RPM (Idle)........... 4-7 Gas Tank ..............4-7 Gas Tank Valve ............4-7 Gas/Vent Hoses ............. 4-8 Oil Flow Chart ............4-8 Oil Pump ..............

  • Page 70: Carburetor Specifications

    2. Remove the cap screws securing the air filter housing to the frame; then loosen the clamp secur- Carburetor ing air inlet boot to the carburetor and remove the Specifications air filter. Type Keihin CVK32 Keihin CVK32 Main Jet Starter Jet Slow Jet Pilot Screw Setting 2 1/4...
  • Page 71 PR162C KC0021A 6. Loosen the outer jam nut securing the throttle 3. Remove the Phillips-head screws securing the cable to the carburetor body; then route the cable float chamber; then remove the chamber. Account out of the way. for the O-ring. PR162B KC0022A 7.
  • Page 72 CC753 CC758 CLEANING AND INSPECTING NOTE: Note the locations of the jets, pilot screw, and holder for disassembling procedures. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. ! WARNING When drying components with compressed air, always wear safety glasses.
  • Page 73 12. Inspect the carburetor mounting flange for damage and tightness. ASSEMBLING 1. Install the pilot screw, spring, washer, and O-ring. CC753 NOTE: Check float arm height by placing the car- buretor on its side w/float contacting the needle; then measure with a caliper the height when the float arm is in contact with the needle valve.

  • Page 74: Throttle Cable Free-Play

    KC0019A PR154B 5. Connect the choke assembly to the carburetor. INSTALLING 6. Install the air filter; then tighten the clamp secur- 1. Connect the vent hose onto the carburetor. ing the air inlet boot to the carburetor. Secure the air filter housing to the frame with the cap screws. 2.

  • Page 75: Engine Rpm (Idle)

    3. Tighten the jam nut against the throttle cable adjuster securely; then slide the rubber boot over the adjuster. Engine RPM (Idle) To properly adjust the idle RPM, a tachometer is nec- essary. To adjust idle RPM, use the following proce- dure.

  • Page 76: Gas/Vent Hoses

    Oil Flow Chart KM043A In the OFF position, the valve will not allow gasoline to flow to the carburetor. In the ON position (the nor- mal operating position), gasoline will flow from the tank to the carburetor. In this position 4.54 L (1.2 U.S. gal.) will remain in the tank as a reserve quantity.

  • Page 77: Liquid Cooling System

    2. Place the cover onto the pump housing. 2. On the 250 Utility, remove the front rack; then remove the front cover and fender assembly (see 3. Secure the pump with the Phillips-head screw Section 8). coated with red Loctite #271. 3.

  • Page 78: Hoses/Thermostat

    C. The thermostat should start to open at 78-82° C (172-179° F) and should be full-open at 90° C (194° F). D. If the thermostat does not open, it must be replaced. 3. Inspect all coolant hoses, connections, and clamps for deterioration, cracks, and wear.
  • Page 79 CLEANING AND INSPECTING 1. Press the seal washer into the impeller by hand. NOTE: Whenever a part is worn excessively, 2. Install the water pump drive seal; then drive the mechanical seal into the crankcase cover using an cracked, or damaged in any way, replacement is appropriate seal driver.

  • Page 80: Troubleshooting

    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. Starter valve not operating properly 4.
  • Page 81 SECTION 5 - ELECTRICA L SYSTEM TABLE OF CONTENTS Electrical System............. 5-2 Specifications ............5-2 RPM Limiter ............5-2 Testing Electrical Components........ 5-2 Electrical Connections..........5-2 Switches..............5-2 Battery..............5-3 Brakelight Switch (Auxiliary)........5-4 Brakelight Switch (Handlebar Control) ....5-4 Coolant Temperature and Cooling Fan Switches ..

  • Page 82: Electrical System

    NOTE: The ATV is equipped with a CDI unit that which show procedures for the complete servicing of retards ignition timing when maximum RPM is the Arctic Cat ATV electrical system. approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire.

  • Page 83: Battery

    B. When using a constant-current battery charger, use the following Battery Charging Chart. Battery ! CAUTION Never exceed the standard charging rate. The battery is located under the seat. ! WARNING After being in service, batteries require regular cleaning An overheated battery could explode causing severe and recharging in order to deliver peak performance and injury or death.

  • Page 84: Brakelight Switch (Auxiliary)

    VOLTAGE (Wiring Harness Connector) Brakelight Switch 1. Set the meter selector to the DC Voltage position. (Auxiliary) 2. Connect the red tester lead to the brown/blue wire; then connect the black tester lead to ground. The switch connector is the two-prong white connec- 3.

  • Page 85: Fan Motor

    NOTE: If the meter shows battery voltage, the main wiring harness is good. The connector should be checked for resistance. RESISTANCE (Fan Motor Connector) ! CAUTION Always disconnect the battery when performing resis- tance tests to avoid damaging the multimeter. 1.

  • Page 86: Fuses

    3. Connect the black tester lead to ground. Ignition Coil 4. Using the red tester lead, contact each end of the 30 amp fuse holder connector terminals individu- ally. The ignition coil is on the left side of the frame above 5.

  • Page 87: Indicator Lights (Dvx 300)

    Spark Plug Cap 1. Remove the instrument pod; then disconnect the speedometer cable. Leave the gauge connected to 1. Connect the red tester lead to one end of the cap; the wiring harness. then connect the black tester lead to the other end of the cap.

  • Page 88: Ignition Switch

    RESISTANCE 10. Connect the red MaxiClip to the brown/black wire. The tester must read battery voltage and the ! CAUTION speedometer backlight (5) must illuminate. If the tester does not read battery voltage, troubleshoot Always disconnect the battery when performing resis- the ignition switch or wiring harness connectors.

  • Page 89: Magneto Coils

    RESISTANCE (LO Beam) Magneto Coils 1. Connect the red tester lead to the white wire; then connect the black tester lead to the brown/black wire. 2. With the dimmer switch in the LO position, the VOLTAGE (Charging Coil - Output) meter must show less than 1 ohm.

  • Page 90: Starter Motor

    RESISTANCE (Trigger Coil) Starter Relay ! CAUTION Always disconnect the battery when performing resis- tance tests to avoid damaging the multimeter. VOLTAGE 1. Set the meter selector to the OHMS position. 1. Set the meter selector to the DC Voltage position. 2.

  • Page 91: Regulator/Rectifier

    The CDI is rarely the cause for electrical problems; NOTE: The brakelight should illuminate when- however, if the CDI is suspected, substitute another ever either brake is applied. If the brakelight does CDI unit to verify the suspected one is defective. not illuminate, troubleshoot the respective brake- light switch.

  • Page 92: Headlights

    1. Set the meter selector to the DC Voltage position. Headlights 2. Connect the red tester lead to the brown/black wire; then connect the black tester lead to the green wire. On the 250 Utility, the connectors are the two 3-prong 3.

  • Page 93: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace magneto 4. CDI unit defective 4. Replace CDI unit 5. Pick-up coil defective 5.
  • Page 94 Problem: Magneto overcharges Condition Remedy 1. Internal battery short circuited 1. Replace battery 2. Regulator/rectifier defective 2. Replace regulator/rectifier 3. Regulator/rectifier poorly grounded 3. Clean - tighten ground connection Problem: Charging unstable Condition Remedy 1. Lead wire intermittently shorting 1. Replace lead wire 2.
  • Page 95 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Rear Drive Assembly Schematics ......6-2 Rear Drive Axle (DVX 300)........6-2 Rear Drive Axle (250 Utility) ........6-6 Troubleshooting Drive System....... 6-11 Troubleshooting Brake System......6-11 Back to TOC...

  • Page 96: Drive System

    250 Utility Drive System NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. NOTE: Critical torque specifications are located in Section 1. SPECIAL TOOLS KM463 A number of special tools must be available to the techni- cian when performing service procedures in this section.
  • Page 97 KM471 KM481A 6. Remove the brake disc assembly from the axle. 9. Remove the brake caliper holder and aligning col- lar. Account for the O-ring. KM472 7. Loosen the drive chain (see Section 2); then slip KM483 the chain off the sprocket and remove the axle 10.
  • Page 98 ATV2185 KM486 2. Measure the rear axle runout as shown using V 2. Clean the axle housing and inspect for cracks, blocks and a dial indicator. If the axle runout elongated holes, and wear in bearing bores. exceeds 1.5 mm (0.06 in.), the axle must be Installing Bearings replaced.
  • Page 99 KM482 KM471 3. Slide the axle into the axle housing from the right L x Ts side; then apply multipurpose grease to all splined L + Ls areas of the axle. T: Torque wrench reading to be calculated 4. Install the sprocket and sprocket hub on the axle and Ts: Specified torque value (86 ft-lb) secure with the snap ring;...

  • Page 100: Rear Drive Axle (250 Utility)

    7. Remove the clamp securing the brakeline hose to the swing arm; then remove the lower rear shock Rear Drive Axle absorber mounting nut and bolt. (250 Utility) REMOVING 1. Secure the ATV on a support stand to elevate the rear wheels.
  • Page 101 KM508 KM536 11. Disengage the universal joint from the transmis- sion output shaft splines and set the driveshaft aside. KM537 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.
  • Page 102 KM519 KM543 3. Inspect all splines and hubs for excessive wear, 7. Check the final drive gear case assembly for chips, cracks, or distortion. smooth gear operation. If gears are noisy or if there is any catching or binding, the gear case assembly must be replaced.
  • Page 103 KM523A KM529 4. Using a suitable bearing driver, install the new NOTE: Apply a liberal amount of grease to the axle bearing into the axle housing; then install the driveshaft splines and the driveshaft spring. This O-ring and dust plate. Tighten the three cap screws will aid in keeping the spring in position while securely.
  • Page 104 KM532 KM131A 7. Install the right pivot bolt and left pivot adjusting 11. Pour the recommended gear lubricant into the fill bolt and tighten securely; then move the swing hole until lubricant is visible on the threads of the arm up and down to seat the bearings. Tighten the level hole;...

  • Page 105: Troubleshooting Drive System

    Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shaft serration worn - broken 1. Replace shaft Troubleshooting Brake System Problem: Braking poor Condition Remedy 1. Pad worn 1. Replace pads 2. Pedal free-play excessive 2.
  • Page 106 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Front and Rear Suspension Assembly Schematics ............7-2 Front Shock Absorbers..........7-2 Rear Shock Absorber ..........7-3 Swing Arm............... 7-4 Front A-Arms ............7-7 Wheels and Tires ..........7-10 Troubleshooting ............. 7-11 Back to TOC...

  • Page 107: Suspension

    DVX 300 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 108: Rear Shock Absorber

    INSTALLING 1. Install each shock absorber to the frame and A-arm with cap screws and nuts. Tighten all nuts to 29 ft-lb. ! CAUTION Do not tighten the nut beyond the recommended spec- ification or the shock eyelet or mount WILL be dam- aged.

  • Page 109: Swing Arm

    INSTALLING 4. Remove the cushion arm lock nut and cap screw; then remove the lock nut and cap screw securing 1. Raise the swing-arm and place the shock absorber the cushion arm link to the swing arm. Remove the in position; then install the upper and lower cap cushion arm/link assembly.
  • Page 110 2. To inspect the swing arm and swing arm axle, place the swing arm axle and bushings in the swing arm; then using the flange bolt, rock the bushings and axle from side to side and up and down. If excessive play is noted, the bushings, axle, or swing arm must be replaced.
  • Page 111 4. Install the bushings in the cushion arm and cush- ion link; then connect the cushion link to the cush- ion arm with the flange cap screw and lock nut. Tighten securely. KM564B 6. Inspect the drive chain and sprockets for excessive wear, chain stiffness, or rust/corrosion.

  • Page 112: Front A-Arms

    KM557A KM464 9. Install the shock absorber and secure with the 14. Remove the ATV from the support stand. existing hardware. Tighten to 29 ft-lb. 10. Install the axle housing, axle, and brake assembly Front A-Arms (see Section 6). 11. Install the drive chain and sprockets (see Section 6);...
  • Page 113 KM266A KM570 5. Remove the hub assembly; then on the 250 Utility, 8. Remove the shock absorber mounting cap screws; remove the disc cover. then remove the shock absorber assembly. 9. Using a ball joint remover, remove the ball joints from the knuckle;...
  • Page 114 5. Install the arms to the frame with the pivot cap NOTE: All bearings, bushings, and seals that are screws; then tighten the nuts to 32 ft-lb. removed must be replaced with new ones. INSTALLING 1. Install the bearings in the upper arm pivot to a depth of 13.6 mm (0.535 in.) with a bearing installer and suitable spacer.

  • Page 115: Wheels And Tires

    (the “rotation arrow” must indicate forward direction of rotation). 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 (see Section 1).

  • Page 116: Troubleshooting

    Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring(s) weak 1. Replace spring(s) 2. Shock absorber damaged 2. Replace shock absorber Problem: Suspension too stiff Condition Remedy 1. A-arm-related bushings worn or binding 1. Replace bushing Problem: Suspension noisy Condition Remedy 1.
  • Page 117 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Steering Post/Tie Rods ........... 8-2 Measuring/Adjusting Toe-In/Toe-Out ....... 8-4 Body ................ 8-4 Steering Post Cover/Instrument Pod ....... 8-7 Troubleshooting ............8-9 Back to TOC...

  • Page 118: Steering/Frame

    2. Remove the steering post cover (DVX 300) or the instrument pod (250 Utility) (see Steering Post Steering/Frame Cover/Instrument Pod in this section); then remove the cap screws securing the handlebar to the steer- ing post. Account for two handlebar holders. The following steering components should be inspected periodically to ensure safe and proper opera- tion.
  • Page 119 KM589 KM593 6. Remove the steering post from the ATV. 2. Apply a thin coat of grease to the upper steering post bushing; then secure the steering post with the CLEANING AND INSPECTING support blocks and existing hardware. Tighten to 17 ft-lb.

  • Page 120: Measuring/Adjusting Toe-In/Toe-Out

    6. Install the instrument pod (250 Utility) or steering post cover (DVX 300). 7. Install the center panel and front rack (250 Utility). Measuring/Adjusting Toe-In/Toe-Out 1. With the ATV on a level surface, center the han- dlebar for straight ahead using a suitable means of measuring centering;...
  • Page 121 NOTE: Always remove the negative battery cable first; then the positive cable. KM785A SP107 2. Remove the CDI, start-in-gear relay, and fuse block and lay aside without disconnecting the wires; then remove the shift knob. 3. Remove the six cap screws securing the body to the top of the frame;...
  • Page 122 KM793A KM799B 2. Disconnect the negative battery cable first; then 7. Disconnect the left and right headlight connectors; the positive cable. then disconnect the taillight. 3. Remove the battery hold-down strap; then remove 8. Remove the gas tank cover; then remove the shift the battery.

  • Page 123: Steering Post Cover/Instrument Pod

    5. Install the fuse block, start-in-gear relay, and the CDI; then install the body mounting cap screw into the bottom of the battery box. 6. Install the battery and battery hold-down strap; then connect the positive battery cable and the negative battery cable.
  • Page 124 3. Inspect the indicator lamp holder for loose sock- 2. Place the steering post cover onto the mounting ets, broken wires, or loose connections. Replace as bracket; then secure with the reinstallable rivets. required. INSTALLING (250 Utility) INSPECTING (250 Utility) 1.

  • Page 125: Troubleshooting

    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. Tie rod ends seizing 4. Replace tie rod ends 5.
  • Page 126 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Front Brake Lever/Master Cylinder Assembly ..9-2 Auxiliary Brake Pedal/Master Cylinder Assembly..9-3 Throttle Control ............9-4 Back to TOC...
  • Page 127 INSPECTING Front Brake Lever/ NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is Master Cylinder necessary. Assembly 1. Inspect the pivot bolt securing the brake lever for wear. NOTE: The master cylinder is a non-serviceable 2.

  • Page 128: Auxiliary Brake

    KM800B KM801A 4. Using new crush washers, secure the brake hose to 3. Remove the cotter pin from the clevis pin and the master cylinder with the brake hose union bolt. remove the clevis pin; then remove the two cap Tighten to 25 ft-lb.

  • Page 129: Throttle Control

    2. Remove the three machine screws securing the cover to the throttle control; then remove the cover and disengage the throttle cable from the throttle arm. 3. Turn the cable adjuster out of the throttle control housing; then remove the two machine screws securing the throttle control to the handlebar and remove the throttle control.

This manual is also suitable for:

Dvx 300 2009

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