Table Of Contents - Arctic Cat 300 Utility Service Manual

General Information........................................................... 2
General Specifications.................................................. 2
Torque Specifications.................................................... 3
Torque Conversions (ft-lb/N-m)..................................... 4
Break-In Procedure....................................................... 4
Gasoline - Oil - Lubricant .............................................. 4
Genuine Parts............................................................... 5
Preparation For Storage ............................................... 5
Preparation After Storage ............................................. 6
Periodic Maintenance/Tune-Up......................................... 7
Periodic Maintenance Chart ......................................... 7
Lubrication Points ......................................................... 8
Air Filter ........................................................................ 8
Valve/Tappet Clearance ................................................ 8
Testing Engine Compression ........................................ 9
Spark Plug .................................................................... 9
Muffler/Spark Arrester ................................................ 10
Engine Oil - Filter ........................................................ 10
Rear Drive Lubricant (Utility)....................................... 11
Transmission Lubricant ............................................... 11
Drive Chain (DVX) ...................................................... 12
Driveshaft/Coupling (Utility) ........................................ 13
Nuts/Bolts/Cap Screws ............................................... 13
Headlight/Taillight- Brakelight ..................................... 13
Shift Lever................................................................... 13
Hydraulic Brake Systems............................................ 14
Auxiliary/Rear Hydraulic Brake ................................... 16
Burnishing Brake Pads ............................................... 18
Checking/Replacing V-Belt ......................................... 18
Steering/Frame/Controls ................................................. 20
Body............................................................................ 20
Steering Post Cover/Instrument Pod........................... 22
Steering Post/Tie Rods ............................................... 23
Measuring/Adjusting Toe-In/Toe-Out........................... 25
Front Brake Lever/Master Cylinder Assembly............. 25
Auxiliary Brake Pedal/Master Cylinder Assembly ....... 26
Throttle Control ........................................................... 27
Troubleshooting .......................................................... 28
Engine/Transmission....................................................... 29
Removing Engine/ Transmission................................. 30
Top-Side Components ................................................ 35
Removing Top-Side Components ............................... 35
Servicing Top-Side Components ................................ 37
Installing Top-Side Components ................................. 41
Left-Side Components ................................................ 43
Removing Left-Side Components............................... 43
Servicing Left-Side Components ................................ 44
Installing Left-Side Components................................. 50
Right-Side Components.............................................. 51
Removing Right-Side Components ............................ 52
Servicing Right-Side Components.............................. 57
Installing Right-Side Components .............................. 64
Center Crankcase Components ................................. 65
Separating Crankcase Halves .................................... 65
Disassembling Crankcase Half ................................... 65
Servicing Center Crankcase Components ................. 65
Assembling Crankcase Half........................................ 66
Joining Crankcase Halves .......................................... 67

TABLE OF CONTENTS

Installing Engine/Transmission ................................... 67
Troubleshooting .......................................................... 70
Fuel/Lubrication/Cooling ................................................ 73
Carburetor .................................................................. 73
Throttle Cable Free-Play............................................. 77
Engine RPM (Idle) ...................................................... 77
Gas Tank .................................................................... 77
Gas Tank Valve ........................................................... 78
Gas/Vent Hoses.......................................................... 78
Oil Flow Chart............................................................. 78
Oil Pump..................................................................... 79
Liquid Cooling System................................................ 79
Radiator ...................................................................... 79
Hoses/Thermostat ...................................................... 80
Fan ............................................................................. 80
Water Pump................................................................ 80
Troubleshooting .......................................................... 81
Electrical System ............................................................. 82
RPM Limiter................................................................ 82
Testing Electrical Components ................................... 82
Electrical Connections................................................ 82
Switches ..................................................................... 82
Battery ........................................................................ 82
Brakelight Switch (Auxiliary) ....................................... 83
Brakelight Switch (Handlebar Control) ....................... 83
Coolant Temperature and Cooling Fan Switches........ 84
Fan Motor ................................................................... 84
Fuse Block.................................................................. 84
Fuses.......................................................................... 85
Ignition Coil................................................................. 85
Indicator Lights (DVX)................................................. 86
LCD Gauge Assembly ................................................ 86
Ignition Switch ............................................................ 87
Handlebar Control Switches ....................................... 87
Magneto Coils ............................................................ 88
Starter Motor .............................................................. 88
Starter Relay .............................................................. 88
CDI Unit ...................................................................... 89
Regulator/Rectifier...................................................... 89
Start-in-Gear Relay .................................................... 89
Headlights .................................................................. 90
Taillight - Brakelight .................................................... 90
Ignition Timing ............................................................ 90
Troubleshooting .......................................................... 91
Drive System .................................................................... 93
Rear Drive Assembly Schematics .............................. 93
Rear Drive Axle (DVX)................................................ 93
Rear Drive Axle (Utility) .............................................. 96
Troubleshooting Drive System.................................. 105
Troubleshooting Brake System ................................. 105
Suspension .................................................................... 106
Front and Rear Suspension Assembly Schematics.. 106
Front Shock Absorbers ............................................. 106
Rear Shock Absorber ............................................... 107
Swing Arm ................................................................ 108
Front A-Arms ............................................................ 111
Wheels and Tires...................................................... 113
Troubleshooting ........................................................ 114
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