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Arctic Cat 250 2008 Service Manual
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Arctic Cat 250 2008 Service Manual

Arctic Cat 250 2008 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 2008 Arctic
Cat ATV 250 models. 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.
© 2007 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-
September 2007

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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 TABLE OF CONTENTS Click on the red text to go. MORE TO GO ON. Foreword DVX 250 DVX 250 250 Utility 250 Utility General Information/Specifications Periodic Maintenance/Tune-Up 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System Drive System Suspension 8. Steering/Frame Controls/Indicators Service Manual...
  • Page 3 SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications (DVX Model) ....... 1-2 General Specifications (Utility Model) ..... 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* General Specifications* (Utility Model) (DVX Model) CHASSIS CHASSIS Dry Weight (approx) 186 kg (410 lb) Dry Weight (approx) 216 kg (477 lb) Length (overall) 168.3 cm (66.25 in.) Length (overall) 187 cm (73.6 in.) Height (overall) 114.9 cm (45.25 in.) Height (overall) 111.8 cm (44.0 in.) Width (overall)
  • Page 5 Torque Specifications SUSPENSION COMPONENTS (Rear) DRIVE TRAIN COMPONENTS Torque Torque Part Part Bolted To Part Part Bolted To ft-lb ft-lb Left Pivot Bolt (Utility) Swing Arm 36 in.-lb Engine Mounting Bolt Frame Right Pivot Bolt (Utility) Swing Arm Engine Mounting Bracket Frame Cap Screw Left Pivot Lock Nut (Utility)
  • Page 6 (Conventional or 4 Marked 12-36 in.-lb Bolt) 36-60 in.-lb ! CAUTION 7-11 ft-lb 16-25 ft-lb Do not use white gas. Only Arctic Cat approved gas- oline additives should be used. (7 Marked Bolt) 24-48 in.-lb 6-8 ft-lb 13-20 ft-lb 29-43 ft-lb...
  • Page 7 The recommended oil to use is Arctic Cat 4-Cycle Engine Oil or an equivalent oil which is rated SE, SF, or SG under API service classification. These oils meet all of the lubrication requirements of the Arctic Cat ATV engine.
  • Page 8 Start the engine and allow wear or fraying. Replace if necessary. it to idle; then using Arctic Cat Engine Storage Preserver, rapidly inject the preserver into the air 4. Change the engine oil and filter.
  • Page 9 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart........2-2 Periodic Maintenance..........2-3 Lubrication Points............ 2-3 Battery..............2-3 Fuses ..............2-4 Air Filter..............2-4 Valve/Tappet Clearance .......... 2-5 Testing Engine Compression ........2-6 Spark Plug............... 2-6 Muffler/Spark Arrester ..........2-7 Gas/Vent Hoses ............
  • Page 10 A = Adjust I = Inspect Periodic Maintenance C = Clean L = Lubricate Chart D = Drain R = Replace Initial Service Every Month Every 3 Every 6 Every Year After Break-In Every Months or Months or Item or Every (First Mo or Every 100 Every 300...
  • Page 11 The following procedure is rec- NOTE: Arctic Cat recommends the use of new ommended for cleaning and maintaining a sealed bat- gaskets, lock nuts, and seals and lubricating all tery.
  • Page 12 ! CAUTION Fuses Never exceed the standard charging rate. ! WARNING The fuses are located in a fuse block under the seat. An overheated battery could explode causing severe injury or death. Always monitor charging times and If there is any type of electrical system failure, always charge rates carefully.
  • Page 13 NOTE: Foam Filter Cleaner and Foam Filter Oil To check and adjust valve/tappet clearance, use the are available from Arctic Cat. following procedure. 5. Dry the filter. NOTE: The seat assembly, side panels, and gas tank must be removed for this procedure.
  • Page 14 7. While holding the adjuster dial at the proper clear- B. Gauge functions properly. ance setting, tighten the jam nut securely with the C. Throttle lever in the full-open position. valve adjuster handle. D. Valve/tappet clearance correct. 8. Place the cylinder head cover with a new O-ring into position;...
  • Page 15 ATV0052B KM140B When installing the spark plug, make sure to tighten it 3. Install the spark arrester and secure with the cap securely. A new spark plug should be tightened 1/2 screw. Tighten securely. turn once the washer contacts the cylinder head. A used spark plug should be tightened 1/8-1/4 turn once the washer contacts the cylinder head.
  • Page 16 Engine Oil - Filter Replace the engine oil and clean the screen/filter at the scheduled intervals. The engine should always be warm when the oil is changed so the oil will drain eas- ily and completely. 1. Park the ATV on level ground. 2.
  • Page 17 2. If low, add SAE approved 80W-90 hypoid gear lube as necessary. ! CAUTION To change the lubricant, use the following procedure. Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which 1.
  • Page 18 CLEANING AND LUBRICATING The drive chain should be cleaned and lubricated fre- quently to prolong chain and sprocket life. Use the fol- lowing procedure to clean and lubricate the chain. NOTE: This ATV is equipped with an O-ring type roller chain. Each link incorporates small O-rings to seal out water and dirt.
  • Page 19 3. With a person seated on the ATV, check chain ten- B. Handlebar not bent or cracked and has equal sion at the mid-point of the chain. and complete full-left and full-right capability. C. Steering post bearing assembly/bearing housing NOTE: Chain “slack” should be within a range not broken, worn, or binding.
  • Page 20 Ignition Timing The ignition timing cannot be adjusted; however, veri- fying ignition timing can aid in troubleshooting other components. To verify ignition timing, use the follow- ing procedure. 1. Attach the Timing Light to the spark plug high tension lead; then remove the timing inspection plug from the left-side crankcase cover.
  • Page 21 2. Loosen the jam nuts on both ends of the shift rod and turn the shift rod until the neutral light illumi- Shift Lever nates. Tighten the jam nuts securely. CHECKING ADJUSTMENT KM313 NOTE: On the DVX model, the neutral position in the transmission is indexed by passing a Phil- lips screwdriver through the transmission shift KM363A...
  • Page 22 C. Remove the protective cap, install one end of a clear hose onto one FRONT bleed screw, and Hydraulic Brake direct the other end into a container; then while Systems holding slight pressure on the brake lever, open the bleed screw and watch for air bubbles. Close the bleed screw before releasing the brake lever.
  • Page 23 3. If thickness of either brake pad is less than 1.0 mm (0.039 in.), the brake pad must be replaced. NOTE: The brake pads should be replaced as a set. 4. To replace the brake pads, use the following proce- dure.
  • Page 24 MEASURING/REPLACING REAR 2. Spread the brake pads and place the brake caliper over the disc; then secure with the mounting cap BRAKE PADS (Utility Model) screws (B). Tighten the cap screws to 25 ft-lb; then tighten the alignment pins (A) to 13 ft-lb. Removing 1.
  • Page 25 KM242 KM245 2. Install the brake pad retaining pin and secure with the clip pin; then install the dust cover. KM244 2. Remove the brake spring plate; then remove the brake pads. KM244 3. Burnish the brake pads (see Burnishing Brake Inspecting and Measuring Pads in this section).
  • Page 26 3. Remove the cap screws securing the V-belt cover noting the location of the different-lengthed cap Coolant screws for installing purposes; then using a rubber mallet, gently tap on the cover tabs to loosen the cover. Remove the cover. Account for two align- ment pins and one gasket.
  • Page 27 2. Install the centrifugal clutch housing onto the 4. Secure the movable drive face to the crankshaft driven shaft; then install the splined bushing and with the drive pulley nut and tighten to 68 ft-lb. secure with the driven pulley retaining nut. 5.
  • Page 28 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 Table of Contents ............ 3-4 Troubleshooting ............. 3-48 Back to TOC...
  • Page 29 (0.0012-0.0024 in.) Valve Guide/Stem Deflection (max) 0.35 mm (0.014 in.) NOTE: Arctic Cat recommends the use of new (wobble deflection) gaskets, lock nuts, and seals and lubricating all Valve Guide Inside Diameter 5.500-5.512 mm internal components when servicing the engine/ (0.2165-0.2170 in.)
  • Page 30 CYLINDER, PISTON, AND RINGS CLUTCH Piston Skirt/Cylinder Clearance (max) 0.12 mm (0.0047 in.) Clutch Release Screw 1/8 turn back Cylinder Bore (max) 66.09 mm (2.602 in.) Drive Plate (fiber) Thickness (min) 2.4 mm (0.094 in.) Piston Diameter 65.880 mm 18 mm (0.71 in.) from Skirt End (2.5936 in.) Drive Plate (fiber) Tab (min) 11 mm (0.43 in.)
  • Page 31 2. Remove the negative cable from the battery; then remove the positive cable. Remove the battery Table of Contents hold-down strap; then remove the battery. ! WARNING Removing Engine/Transmission......3-4 Battery acid is harmful if it contacts eyes, skin, or Top-Side Components...........
  • Page 32 KM324A KM106A 12. Remove the starter positive wire; then remove the 14. Loosen the clamps; then remove the front and rear engine ground wire. V-belt cooling boots from the V-belt housing. KM319A KM359A 13. Drain the coolant, engine oil, and transmission gear lubricant;...
  • Page 33 KM314 KM332 16. Remove the output drive sprocket cover; then 20. Raise the engine lift to take the slack out of the remove the output drive sprocket. sling; then remove the upper rear and lower rear engine through-bolts. KM344A 17. Disconnect the shift linkage from the transmission KM333A shift arm.
  • Page 34 KM330 KM314A KM331 KM314B Utility Model 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 rack and front fenders (see Section 8). KM133A 6.
  • Page 35 KM347A KM360A KM324A KM323 12. Remove the starter positive wire; then remove the engine ground wire from the crankcase. KM314 14. Loosen the output drive boot clamp; then slide the boot off the output housing. KM319A 13. Remove the front and rear V-belt cooling boots from the V-belt housing;...
  • Page 36 16. Remove the front engine through-bolt; then remove the two engine mounting brackets from the frame. KM325A 19. Swing the rear of the engine/transmission to the left; then slide the engine out of the left-side of the frame. KM414A 17. Attach a suitable lifting sling and engine lift to the front engine mounting boss;...
  • Page 37 KM706A NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing engine/transmission. 1. Remove the cap screws securing the cylinder head cover.
  • Page 38 KM718A KM451 6. Remove the cam chain guide; then disconnect the 8. Using Piston Pin Puller, remove the piston pin. coolant hose and remove the cylinder. Support the Account for the opposite-side circlip. Remove the piston with rubber bands or other suitable sup- piston.
  • Page 39 Removing Valves Servicing Top-Side NOTE: Keep all valves and valve components as Components a set. Note the original location of each valve set for use during installation. Return each valve set to its original location during installation. NOTE: Whenever a part is worn excessively, 1.
  • Page 40 Measuring Cylinder Head 2. Acceptable width range must be within specifica- tions. Distortion Measuring Valve Guide 1. Remove any carbon buildup in the combustion (Inside Diameter) chamber. 2. Lay a straightedge across the cylinder head; then 1. Insert a snap gauge 1/2 way down into each valve using a feeler gauge, check the distortion factor guide bore;...
  • Page 41 ATV1013A ATV-1011A 2. The lobe heights must not be less than minimum 4. Place a spring retainer over the valve springs; then specifications. using the valve spring compressor, compress the valve springs and install the valve cotters. Inspecting Camshaft Bearing Journal 1.
  • Page 42 Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove. KM452 Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore CC400D 1. Measure the piston pin outside diameter at each 2. Remove each ring by working it toward the dome end and in the center.
  • Page 43 Measuring Piston Skirt/ Cylinder Clearance 1. Measure the cylinder front to back in six places. 726-306A ! CAUTION Incorrect installation of the piston rings will result in engine damage. CC397D 2. Measure the corresponding piston diameter at a CYLINDER ASSEMBLY point 15 mm (0.6 in.) above the piston skirt at a right angle to the piston-pin bore.
  • Page 44 Honing Cylinder Installing Top-Side 1. Using a slide gauge and a dial indicator or a snap Components gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first measurements for a total measurements.
  • Page 45 1. Install the piston on the connecting rod making 6. Place the head gasket into position on the cylinder. sure there is a circlip on each side and the open Place the alignment pins into position; then place end of the circlip is directed upwards or down- the head assembly into position on the cylinder wards.
  • Page 46 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 47 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 48 2. Rotate the reel clockwise until the notch of the reel is near the rope guide in the case. Guide the rope into the notch and slowly allow the reel to unwind until all spiral spring tension is released. ! CAUTION During the disassembling procedure, make sure all spring tension is released before continuing.
  • Page 49 KM402 KM401 2. Insert the rope through the hole in the reel and tie a 6. Install the ratchets making sure the ends are prop- knot in the end; then wrap the rope clockwise erly oriented on the reel. around the reel leaving approximately 50 cm (20 in.) of rope free of the reel.
  • Page 50 KM410 KM254 9. With the 50 cm (20 in.) of rope exposed, hook the 2. Inspect the V-belt cover for cracks, distortion, and rope in the notch of the reel. loose alignment pins. 10. Rotate the reel four turns clockwise; then release NOTE: If the V-belt cover is cracked or distorted the rope from the notch and allow the rope to or if the bearing is loose in the cover, the cover...
  • Page 51 KM389 KM375 4. Remove the spring and spring seat; then remove DRIVEN PULLEY/CENTRIFUGAL the hub collar. CLUTCH ASSEMBLY Disassembling ! WARNING This procedure involves relaxing a compressed spring assembly. DO NOT attempt disassembling without the proper tools. 1. Place the driven pulley on a suitable spring com- pressor;...
  • Page 52 Inspecting 1. Inspect the pulley faces for wear, galling, or grooving. KM382A 4. Inspect the pins and bushings for wear, flat spots, looseness, or cracking. KM394A 2. Inspect the O-rings on the movable face for nicks, tears, or swelling. KM379 5.
  • Page 53 3. Install the pins and spacers into the fixed face hub; then pack the cam slots in the movable face with multi-purpose grease. KM378 7. Measure the thickness of the centrifugal clutch shoe lining. The minimum service limit for the lin- ing is 0.5 mm (0.020 in.).
  • Page 54 KM373 KM369 7. Using a suitable holding fixture, tighten the drive 4. Place the fixed drive face into position on the plate nut to 43 ft-lb. crankshaft and engage the splines making sure the splines extend beyond the pulley face hub. Installing Left-Side Components A.
  • Page 55 Right-Side Components AT THIS POINT To service center crankcase components only, pro- ceed to Removing Right-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 KM365 components.
  • Page 56 KM344A KM677A 3. Remove the cap screws securing the transmission case cover to the transmission; then remove the cover. Account for the dowel pins and gasket. KM619A 6. Remove the shift fork guide shaft; then hold the shift fork away from the shift cam and remove the shift cam.
  • Page 57 KM622A KM646A 8. Remove the countershaft; then remove the primary 3. Remove the three cap screws securing the second- drive axle. ary drive bevel gear cover; then remove the cover. Account for a gasket. KM627B KM648A A. Transmission (Utility Model) 4.
  • Page 58 KM650 KM677A NOTE: If the engine has been removed and the left-side components are removed, install the cen- trifugal clutch housing on the driveshaft. If the left-side components have not been removed, see Removing Left-Side Components in this section. Remove only the V-belt cover. 6.
  • Page 59 KM681 KM689A 11. To disassemble the countershaft, use the following B. Remove a thrust washer and the low/reverse procedure. clutch dog. A. Remove the thrust washer and high gear clutch dog. KM690A C. Remove the low driven gear snap ring and washer;...
  • Page 60 KM653 KM772A B. Remove the nut securing the driven bevel gear; 16. Remove the three cap screws securing the stator then remove the gear. Account for a washer. coil to the crankcase cover; then remove the stator coil and trigger coil. ! CAUTION Use extreme care to avoid damaging or shorting the wiring.
  • Page 61 KM766A KM766A 21. Remove the two cap screws securing the oil baffle NOTE: The starter one-way clutch bearing is to the crankcase and remove the baffle; then direction oriented and will only function if installed remove the snap ring securing the oil pump driven properly.
  • Page 62 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 Model) Inspecting KM626 5. Inspect all gear teeth for chipping, discoloration, 1. Measure the shift fork guide shaft runout. If runout pitting, or excessive wear.
  • Page 63 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 64 8. Inspect transmission housing and cover for cracks, scoring or galling of bearing bores, or case discol- oration. 9. Inspect the drive and driven bevel gears for chip- ping, flaking, or excessive wear in the splines. Replace as required. KM623 2.
  • Page 65 2. Replace any required bearings and seals in the sec- ondary driven bevel gear shaft case. Apply oil to all seal lips. KM426A 6. Install the high drive gear thrust washer on the countershaft; then install the high drive gear and secure with a snap ring.
  • Page 66 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 67 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 68 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 69 KM721 CC290D 2. Remove the balance shaft from the left crankcase 2. Maximum diameter must not exceed specifica- half. tions. 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 70 CRANK BALANCER SHAFT 2. Acceptable width range must be within specifica- tions. Inspecting Measuring Crankshaft (Runout) Inspect the gear teeth and bearing surfaces for chips, 1. Place the crankshaft on a set of V blocks. discoloration, or excessive wear. 2. Mount a dial indicator and base on the surface plate.
  • Page 71 NOTE: Rotate the crankshaft back and forth to DVX Model ensure no binding or sticking occurs while tighten- ing the cap screws. NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. 1. Attach a suitable engine lift to the front engine mounting boss;...
  • Page 72 11. Connect the front and rear cooling boots to the V-belt housing and secure with the clamps. Tighten securely. NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the 12. Connect the starter wire to the starter stud and ATV.
  • Page 73 KM414 KM307A 5. Install the front engine through-bolt; then tighten 10. Connect the engine ground wire to the engine; the frame brackets to 29 ft-lb. then connect the starter positive cable to the starter using the existing hardware. Tighten securely. KM414A 6.
  • Page 74 12. Install the coil (see Section 5). 18. Install the battery; then connect the positive and negative battery cables. 13. Install the carburetor (see Section 4). 19. Pour in the recommended amount and grade of 14. Install the muffler assembly (see Section 8). engine coolant, engine oil, and transmission lubri- cant.
  • Page 75 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 76 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 77 Problem: Engine idles poorly Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve seating poor 2. Replace - service seats - valves 3. Valve guides defective 3. Replace guides 4. Rocker arms - arm shaft worn 4.
  • Page 78 Problem: Engine overheats Condition Remedy 1. Carbon deposit (piston crown) excessive 1. Clean piston 2. Oil low 2. Add oil 3. Octane low - gasoline poor 3. Drain - replace gasoline 4. Oil pump defective 4. Replace pump 5. Oil circuit obstructed 5.
  • Page 79 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Carburetor Specifications ........4-2 Carburetor Schematic ..........4-2 Carburetor ............... 4-2 Throttle Cable Free-Play ......... 4-6 Engine RPM (Idle)........... 4-6 Gas Tank ..............4-6 Gas Tank Valve ............4-7 Gas/Vent Hoses ............. 4-7 Oil Flow Chart ............
  • Page 80 Carburetor Carburetor Specifications ! WARNING Type Keihin CVK32 Whenever any maintenance or inspection is per- Main Jet formed on the fuel system during which there may Starter Jet be fuel leakage, there should be no welding, smok- Slow Jet ing, open flames, etc., in the area. Pilot Screw Setting (turns) 2 1/4 REMOVING...
  • Page 81 PR154B KC0019A 5. Remove the throttle cable from the actuator arm. 2. Remove the vacuum piston assembly from the car- buretor body. Account for a spring, spring seat, and the jet needle. PR162C 6. Loosen the outer jam nut securing the throttle cable to the carburetor body;...
  • Page 82 4. Remove the float pin. KC0030A 7. Remove the needle jet holder; then remove the KC0024A needle jet, slow jet, and the starter jet. 5. Lift the float assembly from the carburetor. Account for the float valve. 8. Remove the pilot screw. Account for a spring, washer, and an O-ring.
  • Page 83 5. Inspect the carburetor body for cracks, nicks, 2. Install the slow jet. Tighten securely. stripped threads, and any imperfections in the cast- 3. Install the main jet into the needle jet holder and ing. tighten securely; then install the needle jet, starter 6.
  • Page 84 6. Place the jet needle, spring seat, and spring into the vacuum piston; then place the assembly down into the carburetor. 7. Place the top cover into position; then secure with the Phillips-head screws. Tighten securely. PR154B 5. Connect the choke assembly to the carburetor. 6.
  • Page 85 KM327A KM043A 6. Remove the vent hose; then remove the gas tank. In the OFF position, the valve will not allow gasoline to flow to the carburetor. In the ON position (the nor- CLEANING AND INSPECTING mal operating position), gasoline will flow from the tank to the carburetor.
  • Page 86 ASSEMBLING/INSTALLING Oil Flow Chart 1. Place the rotors into the pump housing making sure the alignment pin is in the groove of the rotor. 2. Place the cover onto the pump housing. 3. Secure the pump with the Phillips-head screw coated with red Loctite #271.
  • Page 87 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Flush the radiator with water to remove any con- taminants. 2. Inspect the radiator for leaks and damage. 3. Inspect all hoses for cracks and deterioration. 4.
  • Page 88 INSTALLING B. Grip the screw with a pair of vise-grip pliers and pull the seal out. Account for the pump drive seal. 1. Place the thermostat and O-ring into the thermo- stat housing; then secure the thermostat housing CLEANING AND INSPECTING cover to the thermostat housing with the two cap screws.
  • Page 89 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 90 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical System............. 5-2 Specifications ............5-2 Battery..............5-2 RPM Limiter ............5-2 Testing Electrical Components........ 5-2 Brakelight Switch (Auxiliary)........5-2 Brakelight Switch (Handlebar Control) ....5-3 Coolant Temperature and Cooling Fan Switches ..5-3 Fan Motor ..............
  • Page 91 This section has been organized into sub-sections For battery related information, see Section 2. which show procedures for the complete servicing of the Arctic Cat ATV electrical system. RPM Limiter NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions.
  • Page 92 RESISTANCE (Switch) NOTE: If the meter shows battery voltage, the main wiring harness is good; proceed to test the ! CAUTION switch/component, the connector, and the switch wiring harness for resistance. Always disconnect the battery when performing RESISTANCE (Switch Connector) resistance tests to avoid damaging the multimeter.
  • Page 93 4. Allow the oil to cool. On the cooling fan switch NOTE: To determine if the fan motor is good, when the temperature is within a range of 80-85° connect the blue wire from the fan connector to a C (176-185° F), the meter should read an open cir- 12 volt DC power supply;...
  • Page 94 2. Connect the red tester lead to the black/white wire; then connect the black tester lead to ground. Fuses 3. The meter must show 12V ± 20%. NOTE: If the voltage is not as specified in the ! CAUTION above test, inspect the main wiring harness, main fuse, ignition fuse, ignition switch, or engine stop Always disconnect the battery when performing switch.
  • Page 95 Indicator Lights DVX Model) To access the indicator lights, use the following proce- dure. 1. Remove the two cap screws and one reinstallable rivet securing the instrument pod; then turn the instrument pod over to access the indicator lights. 2. Remove the light to be tested by pulling the bulb KM123D socket from the light pod;...
  • Page 96 13. Depress and hold the Mode/Set buttons (1) and (2) 3. Connect the red tester lead to the red wire; then simultaneously. The hour segment of the clock connect the black tester lead to the black wire. should flash indicating the clock (13) is in the set 4.
  • Page 97 RESISTANCE (Starter Button) 3. With the engine running at a constant 5000 RPM (with the headlights on), the meter must show 14-15.5 DC volts. 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the black/white wire; ! CAUTION then connect the black tester lead to the yellow/red wire.
  • Page 98 PEAK VOLTAGE NOTE: All of the peak voltage tests should be made using the Fluke Model 73 Multimeter with Peak Voltage Reading Adapter. If any other type of tester is used, readings may vary due to internal circuitry. NOTE: The battery must be at full charge for these tests.
  • Page 99 3. Disconnect the four-wire connector from the start-in-gear relay; then using a voltmeter, connect Regulator/Rectifier the red tester lead to the green/yellow wire (1) and the black tester lead to the green wire (3). The regulator/rectifier is located on the right side of the frame.
  • Page 100 BULB VERIFICATION VOLTAGE (Taillight) (LO and HI Beam) NOTE: Perform this test on the main harness side Visually inspect the bulb for broken filaments, black- of the connector. Also, the ignition switch should ening, or loose bulb base. be in the LIGHTS position. VOLTAGE 1.
  • Page 101 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 102 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. Starter relay defective 4. Replace relay 5.
  • Page 103 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Rear Drive Assembly Schematics ......6-2 Rear Drive Axle (DVX Model)........6-2 Rear Drive Axle (Utility Model) ........ 6-6 Troubleshooting Drive System....... 6-11 Troubleshooting Brake System......6-11 Back to TOC...
  • Page 104 Drive System Rear Drive Axle (DVX Model) NOTE: Some photographs and illustrations used REMOVING in this section are used for clarity purposes only and are not designed to depict actual conditions. 1. Secure the ATV on a support stand to elevate the rear wheels.
  • Page 105 KM472 KM483 7. Loosen the drive chain (see Section 2); then slip 10. Remove the two cap screws from the rear of the the chain off the sprocket and remove the axle swing arm assembly; then remove the rear axle assembly from the right side.
  • Page 106 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 107 KM482 KM471 3. Slide the axle into the axle housing from the right side; then apply multipurpose grease to all splined L x Ts areas of the axle. L + Ls 4. Install the sprocket and sprocket hub on the axle T: Torque wrench reading to be calculated and secure with the snap ring;...
  • Page 108 10. Install the rear wheels and tighten to 32 ft-lb. Rear Drive Axle (Utility Model) REMOVING 1. Secure the ATV on a support stand to elevate the rear wheels. KM504 ! WARNING 7. Remove the clamp securing the brakeline hose to the swing arm;...
  • Page 109 KM533B KM513 10. Remove the swing arm assembly. Account for the 13. Support the swing arm from the right side; then driveshaft spring. using a rubber mallet, drive the axle shaft from the swing arm tube. Account for two O-rings. KM508 11.
  • Page 110 4. Check that all bearings turn freely and smoothly ! CAUTION and are not worn, discolored, or missing dust seals. Support the gear case by hand or damage to the gear case could occur as it will fall free once it clears 5.
  • Page 111 KM522 KM528A 3. Remove the three cap screws, the dust plate, and 3. Apply grease to the universal joint splines and one O-ring from the left axle housing on the swing driveshaft splines; then install the driveshaft arm; then from the right side, drive out the axle spring into the driveshaft.
  • Page 112 KM531 KM505A 6. Align the swing arm assembly in the frame and 10. Tighten the final drive gear case drain plug engage the universal joint onto the splines of the securely; then remove the fill plug and level plug. secondary driven bevel gear shaft. KM131A 11.
  • Page 113 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. Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1.
  • Page 114 SECTION 7 - SUSPENSION TABLE OF CONTENTS 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 115 Front and Rear Front Shock Absorbers Suspension Assembly Schematics NOTE: Critical torque specifications are located in Section 1. 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 sup- port stand to avoid injury.
  • Page 116 2. Remove the ATV from the support stand. Rear Shock Absorber NOTE: Critical torque specifications are located in Section 1. REMOVING 1. Secure the ATV on a support stand to elevate the wheels and to release load on the suspension. KM554 CLEANING AND INSPECTING ! WARNING...
  • Page 117 KM551B KM568A 2. Tighten the lock nut securely. 5. Remove the axle housing (see Section 6). 6. Remove the brake hose guide clamp. Swing Arm NOTE: Critical torque specifications are located in Section 1. REMOVING AND DISASSEMBLING For the Utility model, see Rear Drive Axle in Section 6.
  • Page 118 KM499A KM564A 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. KM500 10. Remove the lock nut and cap screw securing the cushion link to the cushion arm.
  • Page 119 6. Inspect the drive chain and sprockets for excessive wear, chain stiffness, or rust/corrosion. KM568 5. Install the swing arm axle and bushings; then install the dust seals and lubricate the lips with ATV2185 grease. ASSEMBLING AND INSTALLING 6. Place the swing arm into position in the frame; then install the swing arm pivot cap screw and 1.
  • Page 120 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 121 KM266A KM570 5. Remove the hub assembly; then on the Utility 8. Remove the shock absorber mounting cap screws; model, remove the disc cover. then remove the shock absorber assembly. 9. Using a ball joint remover, remove the ball joints from the knuckle;...
  • Page 122 NOTE: All bearings, bushings, and seals that are 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. SP390 5.
  • Page 123 1. Clean the wheels and hubs with parts-cleaning sol- vent. ! WARNING 2. Clean the tires with soap and water. Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV 3. Inspect each wheel for cracks, dents, or bends. operation.
  • Page 124 NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally. NOTE: Make sure all tires are the specified size and have identical tread pattern. 3. Check the front wheel toe-in and toe-out and adjust as necessary (see Section 8).
  • Page 125 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS 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 ............8-8 Back to TOC...
  • Page 126 Steering Post/ Tie Rods NOTE: Critical torque specifications are located in Section 1. KM590 5. Remove the cotter pin and slotted nut from the lower end of the steering post; then remove the upper steering shaft support block. Account for a cable guide, two steering support blocks, and the upper steering post bushing.
  • Page 127 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Wash the tie rod ends in parts-cleaning solvent. Dry with compressed air. Inspect the pivot area for wear. Apply a low-temperature grease to the ends. ! WARNING Always wear safety glasses when using compressed air.
  • Page 128 5. Install the handlebar and tighten the cap screws to 18 ft-lb making sure to tighten the front cap screws first. ATV2205 4. Adjust toe-in to 15 mm (0.60 in.); then measure distances (C) and (D). Distances (C) and (D) should be equal.
  • Page 129 KM782A KM352A 6. Turn the handlebar to the left; then raise the body turning it to the right and lift clear of the handle- bar. REMOVING (Utility Model) 1. Remove the seat; then remove the battery box cover. KM790A 4. Remove four flange nuts and cap screws securing the rear fender support;...
  • Page 130 5. Remove the cap screws and flange nuts securing 1. Clean all body components with soap and water. the mud guards to the front and rear fenders; then 2. Inspect the body and fenders for cracks. remove the cap screws securing the mud guards to the front rests and remove the mud guards.
  • Page 131 REMOVING (Utility Model) 4. Install the mud guards and secure to the fenders and foot rest supports with the existing hardware. Make sure all locating tabs are appropriately 1. Remove the reinstallable rivet on the front of the engaged with the fenders and side panels. instrument pod and the two cap screws on the rear;...
  • Page 132 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 133 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 134 3. Remove the brake lever, brakelight switch, and brake lever lock. Front Brake Lever/ INSPECTING Master Cylinder Assembly NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. NOTE: Critical torque specifications are located 1.
  • Page 135 2. Compress the reservoir clamp and remove the res- ervoir hose; then remove the union bolt. Account for and discard two crush washers. KM800B 4. Using new crush washers, secure the brakeline hose to the master cylinder with the brakeline hose union bolt.
  • Page 136 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 250 2008250 utility 2008