2011 Arctic Cat DVX 300 / 300 Utility ATV Service Manual
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- 2011 arctic cat dvx 300 and 300 utility service manual
Factory Service Manual for Arctic Cat DVX 300 / 300 Utility ATV.
Manual is indexed and searchable for easy access to information. It has hundreds of high quality images and diagrams, a must have manual to perform maintenance and repairs.
Manual Chapters:
- GENERAL INFORMATION/ SPECIFICATIONS
- PERIODIC MAINTENANCE
- ENGINE / TRANSMISSION
- FUEL / LUBRICATION
- ELECTRICAL SYSTEM
- DRIVE SYSTEM
- SUSPENSION
- STEERING / FRAME
- CONTROLS / INDICATORS
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- + Printable: Yes
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Full list of manual chapters:
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