Arctic Cat 2012 Dvx 300 300 Utility Service Manual-21031A320052.pdf -Bookmark created by https://wimanual.com FOREWORD TABLE OF CONTENTS General Information General Specifications Torque Specifications Torque Conversions (ft-lb 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 SPECIAL TOOLS Periodic Maintenance Chart Lubrication Points Air Filter CLEANING AND INSPECTING FILTER CHECKING Valve Testing Engine Compression Spark Plug Muffler Engine Oil - Filter Rear Drive Lubricant (Utility) Transmission Lubricant Drive Chain (DVX) INSPECTING CLEANING AND LUBRICATING ADJUSTING TENSION Driveshaft Nuts Headlight Shift Lever CHECKING ADJUSTMENT ADJUSTING SHIFT LEVER Hydraulic Brake Systems CHECKING INSPECTING HOSES CHECKING Auxiliary CHECKING BLEEDING MEASURING Removing Inspecting and Measuring Installing MEASURING Removing Inspecting and Measuring Installing Burnishing Brake Pads Checking REMOVING INSTALLING Engine SPECIAL TOOLS Removing Engine 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 Removing Valves Measuring Valve Stem Inspecting Valve Face CYLINDER HEAD ASSEMBLY Cleaning Measuring Cylinder Head Distortion Measuring Camshaft Lobe Height Inspecting Camshaft Bearing Journal Measuring Rocker Arm Installing Valves PISTON ASSEMBLY Cleaning Removing Piston Rings Cleaning Measuring Piston-Ring End Gap (Installed) Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore Measuring Piston Skirt Installing Piston Rings CYLINDER ASSEMBLY Cleaning 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 Servicing Left-Side Components RECOIL STARTER (Utility) Removing Cleaning and Inspecting Assembling V-BELT COVER DRIVE PULLEY DRIVEN PULLEY Disassembling Inspecting Assembling Installing Left-Side Components A. Drive Pulley B. Driven Pulley Right-Side Components Removing Right-Side Components A. Transmission (DVX) A. Transmission (Utility) B. Water Pump C. Trigger Coil D. Stator Coil E. Rotor 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 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 DVX Utility Troubleshooting Fuel 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 INSTALLING Gas Oil Flow Chart Oil Pump REMOVING CLEANING AND INSPECTING ASSEMBLING Liquid Cooling System Radiator REMOVING CLEANING AND INSPECTING INSTALLING Hoses REMOVING INSPECTING INSTALLING Fan REMOVING INSTALLING Water Pump REMOVING CLEANING AND INSPECTING ASSEMBLING 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 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 Starter Relay VOLTAGE CDI Unit Regulator 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 Troubleshooting Steering Steering Post REMOVING CLEANING AND INSPECTING INSTALLING Measuring Body REMOVING (DVX) REMOVING (Utility) CLEANING AND INSPECTING INSTALLING (DVX) INSTALLING (Utility) Steering Post Cover REMOVING (DVX) REMOVING (Utility) INSPECTING INSPECTING (Utility) INSTALLING (DVX) INSTALLING (Utility) Front Brake Lever REMOVING INSPECTING INSTALLING Auxiliary Brake Pedal REMOVING INSTALLING Throttle Control REMOVING INSTALLING Troubleshooting . 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