arctic%20cat%20dvx%20300%20and%20300%20utility%20-%20workshop,%20repair,%20service%20manual.gif

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

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

CONTENTS:

2011 SERVICE MANUAL

FOREWORD 
TABLE OF CONTENTS

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

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

ENGINE/TRANSMISSION 
- SPECIAL TOOLS 
- Specifications

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

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

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

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

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

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

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

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

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

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

BACK COVER

2012 SERVICE MANUAL

FOREWORD 
TABLE OF CONTENTS

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

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

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

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

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

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

Arctic Cat Dvx 300 and 300 Utility Service Manual

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cami?n - truck

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arctic cat dvx 300 & 300 utility

WORKSHOP, REPAIR, SERVICE MANUAL