Arctic Cat DVX 300 (2008-2011) - Service Manual, Repair Manual

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ARCTIC CAT DVX 300 (2008-2011) - SERVICE MANUAL

- English Service Manual / Repair Manual, in PDF format, to Arctic Cat DVX 300.

 

CONTENTS:


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