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2011 Arctic Cat ATV 300 Utility DVX 300 Service Manual – PDF DOWNLOAD
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2011 Arctic Cat ATV 300 Utility DVX 300 Service Manual
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Description
2011 Arctic Cat ATV 300 Utility DVX 300 Service Manual
DESCRIPTION:
2011 Arctic Cat ATV 300 Utility DVX 300 Service Manual
FOREWORD:
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arctic Cat ATV 300 Utility/DVX 300. This manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.
- The service technician should become familiar with the operation and construction of each component or system by carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information.
- The symbol ! WARNING identifies personal safety-related information. Be sure to fol- low the directive because it deals with the possibility of severe personal injury or even death. A CAUTION 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 NOTE: identifies supplementary information worthy of particular attention.
- The symbol AT THIS POINT directs the technician to certain and specific 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.
TABLE OF CONTENTS:
2011 Arctic Cat ATV 300 Utility DVX 300 Service Manual
FOREWORD ................................................................................... 1 TABLE OF CONTENTS........................................................................... 2 General Information..................................................................... 3 General Specifications.............................................................. 3 Torque Specifications............................................................... 3 Torque Conversions (ft-lb/N-m)...................................................... 4 Tightening Torque (General Bolts)................................................... 4 Break-In Procedure.................................................................. 5 Gasoline - Oil - Lubricant.......................................................... 5 RECOMMENDED GASOLINE............................................................ 5 RECOMMENDED ENGINE OIL.......................................................... 5 RECOMMENDED REAR DRIVE LUBRICANT (Utility)...................................... 5 RECOMMENDED TRANSMISSION LUBRICANT.............................................. 5 FILLING GAS TANK................................................................ 5 Genuine Parts....................................................................... 6 Preparation For Storage............................................................. 6 Preparation After Storage........................................................... 6 Periodic Maintenance/ Tune-Up........................................................... 8 SPECIAL TOOLS....................................................................... 8 Periodic Maintenance Chart.......................................................... 8 Lubrication Points.................................................................. 9 Air Filter.......................................................................... 9 CLEANING AND INSPECTING FILTER.................................................. 9 CHECKING/DRAINING DRAIN TUBE.................................................... 9 Valve/Tappet Clearance.............................................................. 10 Testing Engine Compression.......................................................... 10 Spark Plug.......................................................................... 10 Muffler/Spark Arrester.............................................................. 11 Engine Oil - Filter................................................................. 11 Rear Drive Lubricant (Utility)...................................................... 12 Transmission Lubricant.............................................................. 12 Drive Chain (DVX)................................................................... 13 INSPECTING...................................................................... 13 CLEANING AND LUBRICATING........................................................ 13 ADJUSTING TENSION............................................................... 13 Driveshaft/Coupling (Utility)....................................................... 14 Nuts/Bolts/Cap Screws............................................................... 14 Headlight/Taillight- Brakelight..................................................... 14 Shift Lever......................................................................... 14 CHECKING ADJUSTMENT............................................................. 15 ADJUSTING SHIFT LEVER........................................................... 15 Hydraulic Brake Systems............................................................. 15 CHECKING/BLEEDING............................................................... 15 INSPECTING HOSES................................................................ 16 CHECKING/REPLACING FRONT PADS................................................... 16 Auxiliary/Rear Hydraulic Brake...................................................... 17 CHECKING........................................................................ 17 BLEEDING........................................................................ 17 MEASURING/REPLACING REAR BRAKE PADS (Utility)................................... 17 Removing........................................................................ 17 Inspecting and Measuring........................................................ 17 Installing...................................................................... 17 MEASURING/REPLACING REAR/ AUXILIARY BRAKE PADS (DVX)............................ 18 Removing........................................................................ 18 Inspecting and Measuring........................................................ 18 Installing...................................................................... 18 Burnishing Brake Pads............................................................... 19 Checking/Replacing V-Belt........................................................... 19 REMOVING........................................................................ 19 INSTALLING...................................................................... 19 Engine/Transmission..................................................................... 21 SPECIAL TOOLS....................................................................... 21 Specifications...................................................................... 21 Removing Engine/ Transmission........................................................... 22 DVX................................................................................. 22 Utility............................................................................. 24 Top-Side Components................................................................. 27 Removing Top-Side Components........................................................ 27 A. Valve Cover B. Cylinder Head................................................. 27 C. Cylinder D. Piston........................................................... 28 Servicing Top-Side Components....................................................... 29 VALVE ASSEMBLY.................................................................. 29 Cleaning/Inspecting Camshaft Holder......................................... 29 Removing Valves............................................................. 29 Measuring Valve Stem/Valve Guide Clearance.................................. 30 Inspecting Valve Face....................................................... 30 CYLINDER HEAD ASSEMBLY.......................................................... 30 Cleaning/Inspecting Cylinder Head........................................... 30 Measuring Cylinder Head Distortion.......................................... 30 Measuring Camshaft Lobe Height.............................................. 30 Inspecting Camshaft Bearing Journal......................................... 30 Measuring Rocker Arm/ Shaft Clearance....................................... 30 Installing Valves........................................................... 30 PISTON ASSEMBLY................................................................. 31 Cleaning/Inspecting Piston.................................................. 31 Removing Piston Rings....................................................... 31 Cleaning/Inspecting Piston Rings............................................ 31 Measuring Piston-Ring End Gap (Installed)................................... 31 Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore................. 32 Measuring Piston Skirt/ Cylinder Clearance.................................. 32 Installing Piston Rings..................................................... 32 CYLINDER ASSEMBLY............................................................... 32 Cleaning/Inspecting Cylinder................................................ 32 Inspecting Cam Chain Guide.................................................. 33 Honing Cylinder............................................................. 33 Installing Top-Side Components...................................................... 33 A. Piston B. Cylinder........................................................... 33 C. Cylinder Head D. Valve Cover................................................. 34 Left-Side Components................................................................ 35 Removing Left-Side Components....................................................... 35 A. Recoil Starter (Utility)..................................................... 35 B. V-Belt Cover C. Drive Pulley D. Driven Pulley/Centrifugal Clutch Assembly.... 35 Servicing Left-Side Components...................................................... 36 RECOIL STARTER (Utility)........................................................ 36 Removing/Disassembling...................................................... 36 Cleaning and Inspecting..................................................... 37 Assembling/Installing....................................................... 37 V-BELT COVER.................................................................... 38 DRIVE PULLEY.................................................................... 39 DRIVEN PULLEY/CENTRIFUGAL CLUTCH ASSEMBLY....................................... 39 Disassembling............................................................... 39 Inspecting.................................................................. 40 Assembling.................................................................. 41 Installing Left-Side Components..................................................... 42 A. Drive Pulley B. Driven Pulley/Centrifugal Clutch Assembly C. V-Belt Cover.... 42 Right-Side Components............................................................... 43 Removing Right-Side Components...................................................... 43 A. Transmission (DVX)........................................................... 43 A. Transmission (Utility)....................................................... 45 B. Water Pump C. Trigger Coil D. Stator Coil E. Rotor/Flywheel.................. 48 F. Oil Pump..................................................................... 48 Servicing Right-Side Components..................................................... 49 TRANSMISSION (DVX).............................................................. 49 Inspecting...................................................................... 49 Assembling...................................................................... 50 TRANSMISSION (Utility).......................................................... 51 Inspecting...................................................................... 51 Assembling...................................................................... 52 Installing Right-Side Components.................................................... 55 A. Oil Pump..................................................................... 55 B. Rotor/Flywheel C. Trigger Coil D. Stator Coil................................ 55 E. Water Pump F. Transmission................................................... 55 Center Crankcase Components......................................................... 55 Separating Crankcase Halves......................................................... 55 Disassembling Crankcase Half........................................................ 56 Servicing Center Crankcase Components............................................... 56 CRANKSHAFT ASSEMBLY............................................................. 56 Measuring Connecting Rod (Small End Inside Diameter)........................ 56 Measuring Connecting Rod (Small End Deflection)............................. 56 Measuring Connecting Rod (Big End Side-to-Side)............................. 56 Measuring Crankshaft (Runout)............................................... 56 Measuring Crankshaft (Web-to- Web).......................................... 57 CRANK BALANCER SHAFT............................................................ 57 Inspecting.................................................................. 57 Assembling Crankcase Half................................................... 57 Joining Crankcase Halves.................................................... 57 Installing Engine/ Transmission..................................................... 58 DVX............................................................................. 58 Utility......................................................................... 59 Troubleshooting..................................................................... 61 Fuel/Lubrication/Cooling................................................................ 64 Carburetor Specifications........................................................... 64 Carburetor.......................................................................... 64 REMOVING........................................................................ 64 DISASSEMBLING................................................................... 65 CLEANING AND INSPECTING......................................................... 66 ASSEMBLING...................................................................... 66 INSTALLING...................................................................... 67 Throttle Cable Free-Play............................................................ 68 Engine RPM (Idle)................................................................... 68 Gas Tank............................................................................ 69 REMOVING........................................................................ 69 CLEANING AND INSPECTING......................................................... 69 INSTALLING...................................................................... 69 Gas Tank Valve...................................................................... 69 REMOVING/INSPECTING............................................................. 69 INSTALLING...................................................................... 69 Gas/Vent Hoses...................................................................... 69 Oil Flow Chart...................................................................... 70 Oil Pump............................................................................ 70 REMOVING/DISASSEMBLING.......................................................... 70 CLEANING AND INSPECTING......................................................... 70 ASSEMBLING/INSTALLING........................................................... 70 Liquid Cooling System............................................................... 70 Radiator............................................................................ 70 REMOVING........................................................................ 70 CLEANING AND INSPECTING......................................................... 71 INSTALLING...................................................................... 71 Hoses/Thermostat.................................................................... 71 REMOVING........................................................................ 71 INSPECTING...................................................................... 71 INSTALLING...................................................................... 71 Fan................................................................................. 72 REMOVING........................................................................ 72 INSTALLING...................................................................... 72 Water Pump.......................................................................... 72 REMOVING/DISASSEMBLING.......................................................... 72 CLEANING AND INSPECTING......................................................... 72 ASSEMBLING/INSTALLING........................................................... 72 Troubleshooting..................................................................... 73 Electrical System....................................................................... 74 SPECIAL TOOLS....................................................................... 74 Specifications...................................................................... 74 RPM Limiter......................................................................... 74 Testing Electrical Components....................................................... 74 Electrical Connections.............................................................. 74 Switches............................................................................ 74 Battery............................................................................. 74 Brakelight Switch (Auxiliary)....................................................... 75 VOLTAGE (Wiring Harness Side)................................................... 75 RESISTANCE (Switch Connector)................................................... 75 Brakelight Switch (Handlebar Control)............................................... 76 VOLTAGE (Wiring Harness Connector).............................................. 76 RESISTANCE (Switch)............................................................. 76 Coolant Temperature and Cooling Fan Switches........................................ 76 Fan Motor........................................................................... 76 VOLTAGE (Main Harness Connector to Fan Motor)................................... 76 RESISTANCE (Fan Motor Connector)................................................ 76 Fuse Block.......................................................................... 77 Fuses............................................................................... 77 Ignition Coil....................................................................... 77 PEAK VOLTAGE (Primary/CDI Side)................................................. 77 RESISTANCE...................................................................... 77 Primary Winding............................................................. 78 Secondary Winding........................................................... 78 Spark Plug Cap.............................................................. 78 Indicator Lights (DVX).............................................................. 78 LCD Gauge Assembly.................................................................. 78 REMOVING........................................................................ 78 TESTING......................................................................... 78 INSTALLING...................................................................... 79 Ignition Switch..................................................................... 79 VOLTAGE......................................................................... 79 RESISTANCE...................................................................... 79 Handlebar Control Switches.......................................................... 79 RESISTANCE (HI Beam)............................................................ 79 RESISTANCE (LO Beam)............................................................ 79 RESISTANCE (Starter Button)..................................................... 79 RESISTANCE (Emergency Stop)..................................................... 79 RESISTANCE (Reverse Override)................................................... 80 Magneto Coils....................................................................... 80 VOLTAGE (Charging Coil - Output)................................................ 80 VOLTAGE (Stator Coil - No Load)................................................. 80 RESISTANCE (Charging Coil)...................................................... 80 RESISTANCE (Trigger Coil)....................................................... 80 PEAK VOLTAGE.................................................................... 80 Stator Coil (Trigger)........................................................... 80 Starter Motor....................................................................... 80 REMOVING/INSTALLING............................................................. 80 Starter Relay....................................................................... 81 VOLTAGE......................................................................... 81 CDI Unit............................................................................ 81 Regulator/Rectifier................................................................. 81 TESTING......................................................................... 81 Start-in-Gear Relay................................................................. 81 TESTING......................................................................... 81 Headlights.......................................................................... 82 BULB VERIFICATION (LO and HI Beam).............................................. 82 VOLTAGE......................................................................... 82 Taillight - Brakelight.............................................................. 82 BULB VERIFICATION............................................................... 82 VOLTAGE (Taillight)............................................................. 82 VOLTAGE (Brakelight)............................................................ 82 Ignition Timing..................................................................... 82 Troubleshooting..................................................................... 83 Drive System............................................................................ 85 SPECIAL TOOLS....................................................................... 85 Rear Drive Assembly Schematics...................................................... 85 Rear Drive Axle (DVX)............................................................... 85 REMOVING........................................................................ 85 CLEANING AND INSPECTING......................................................... 86 Removing Bearings........................................................... 87 Installing Bearings......................................................... 87 INSTALLING...................................................................... 87 Rear Drive Axle (Utility)........................................................... 88 REMOVING........................................................................ 88 CLEANING AND INSPECTING......................................................... 90 DISASSEMBLING................................................................... 90 CLEANING AND INSPECTING......................................................... 92 ASSEMBLING...................................................................... 92 Checking Tooth Contact...................................................... 93 Correcting Tooth Contact.................................................... 94 Checking Backlash........................................................... 94 REPLACING SWING ARM SEALS AND BEARINGS.......................................... 94 INSTALLING...................................................................... 95 Troubleshooting Drive System........................................................ 97 Troubleshooting Brake System........................................................ 97 Suspension.............................................................................. 98 Front and Rear Suspension Assembly Schematics....................................... 98 Front Shock Absorbers............................................................... 98 REMOVING........................................................................ 98 CLEANING AND INSPECTING......................................................... 98 INSTALLING...................................................................... 98 Rear Shock Absorber................................................................. 99 REMOVING........................................................................ 99 CLEANING AND INSPECTING......................................................... 99 INSTALLING...................................................................... 99 ADJUSTING SPRING PRELOAD........................................................ 99 Swing Arm...........................................................................100 REMOVING AND DISASSEMBLING......................................................100 CLEANING AND INSPECTING.........................................................101 ASSEMBLING AND INSTALLING.......................................................102 Front A-Arms........................................................................103 REMOVING........................................................................103 CLEANING AND INSPECTING.........................................................104 INSTALLING......................................................................104 Wheels and Tires....................................................................105 TIRE SIZE.......................................................................105 TIRE INFLATION PRESSURE.........................................................105 REMOVING........................................................................105 CLEANING AND INSPECTING.........................................................105 INSTALLING......................................................................106 CHECKING/INFLATING..............................................................106 Troubleshooting.....................................................................106 Steering/Frame..........................................................................107 Steering Post/Tie Rods..............................................................107 REMOVING........................................................................107 CLEANING AND INSPECTING.........................................................108 INSTALLING......................................................................108 Measuring/Adjusting Toe-In/Toe-Out..................................................109 Body................................................................................109 REMOVING (DVX)..................................................................109 REMOVING (Utility)..............................................................110 CLEANING AND INSPECTING.........................................................111 INSTALLING (DVX)................................................................111 INSTALLING (Utility)............................................................111 Steering Post Cover/ Instrument Pod.................................................112 REMOVING (DVX)..................................................................112 REMOVING (Utility)..............................................................112 INSPECTING/SERVICING (DVX)......................................................112 INSPECTING (Utility)............................................................112 INSTALLING (DVX)................................................................112 INSTALLING (Utility)............................................................112 Troubleshooting.....................................................................113 Controls/Indicators.....................................................................114 Front Brake Lever/Master Cylinder Assembly..........................................114 REMOVING........................................................................114 INSPECTING......................................................................114 INSTALLING......................................................................114 Auxiliary Brake Pedal/ Master Cylinder Assembly.....................................115 REMOVING........................................................................115 INSTALLING......................................................................115 Throttle Control....................................................................116 REMOVING........................................................................116 INSTALLING......................................................................116 BACK COVER .................................................................................117
2011 ARCTIC CAT ATV 300 UTILITY DVX 300 SERVICE MANUAL – PDF DOWNLOAD:
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