Arctic CatFOR

2010 ARCTIC
Dvx 300 AndCAT300 ATV
UtilityDISCOUNT
Service Manual
PARTS CALL 606-678-9623 OR 606-561-4983
Full download: http://manualplace.com/download/arctic-cat-2010-dvx-300-and-300-utility-service-manual/

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2010 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 identi-
fies 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.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.

© 2009 Arctic Cat Inc. November 2009

www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Manual
Table
This is the cut pages sample. Download all 133 page(s) at: of Contents
ManualPlace.com
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

TABLE OF CONTENTS
SHARE OUR PAS
S SION.
TM

Click on blue text to go.

Foreword

1. General Information/Specifications
1
2. Periodic Maintenance/Tune-Up
2
3. Engine/Transmission
3
4. Fuel/Lubrication/Cooling
4
5. Electrical System
5
6. Drive System
6
7. Suspension
7
8. Steering/Frame
8
9. Controls/Indicators
DVX 3009
300 Utility

V
www.mymowerparts.com
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

SECTION 1 - GENERAL INFORMATION

TABLE OF
CONTENTS

General Specifications (DVX).................................. 1-2

General Specifications (Utility) ................................ 1-2
Torque Specifications .............................................. 1-3
Torque Conversions (ft-lb/N-m) ............................... 1-4
Tightening Torque (General Bolts) .......................... 1-4
Break-In Procedure ................................................. 1-4
Gasoline - Oil - Lubricant ........................................ 1-4
Genuine Parts ......................................................... 1-5
Preparation For Storage.......................................... 1-5
Preparation After Storage........................................ 1-6
www.mymowerparts.com
Manual 1-1
Table of Contents
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

General Specifications* General Specifications*

(DVX) (Utility)

CHASSIS CHASSIS
Dry Weight (approx) 177.3 kg (391 lb) Dry Weight (approx) 216 kg (477 lb)
Length (overall) 171.9 cm (67.7 in.) Length (overall) 187 cm (73.6 in.)
Height (overall) 113.5 cm (44.7 in.) Height (overall) 111.8 cm (44.0 in.)
Width (overall) 113.5 cm (44.7 in.) Width (overall) 105.1 cm (41.40 in.)
Suspension Travel (Front) 15.5 cm (6.1 in.) Suspension Travel 12.7 cm (5.0 in.)
(Rear) 16.5 cm (6.5 in.)
Brake Type Hydraulic w/Brake Lever
Brake Type Hydraulic w/Brake Lever Lock Lock and Auxiliary Brake
and Auxiliary Brake
Tire Size (Front) AT22 x 7-10
Tire Size (Front) AT21 x 7-10 (Rear) AT22 x 10-10
(Rear) AT20 x 11-9
Tire Inflation Pressure 2(Front) 0.28 kg/cm2 (4 psi)
Tire Inflation Pressure2 (Front) 0.28 kg/cm2 (4 psi) 2
(Rear) 0.25 kg/cm2 (3.5 psi)
2
(Rear) 0.25 kg/cm2 (3.5 psi)
MISCELLANY
MISCELLANY
Gas Tank Capacity (rated) 13 L (3.43 U.S. gal.)
Gas Tank Capacity (rated) 12.5 L (3.3 U.S. gal.)
Reserve Capacity 4.54 L (1.2 U.S. gal.)
Engine Oil Capacity 1.6 L (1.7 U.S. qt)
Engine Oil Capacity 1.6 L (1.7 U.S. qt)
Transmission (Overhaul) 400 ml (13.5 fl/oz)
Lubricant Capacity (Change) 300 ml (10.1 fl/oz) Transmission (Overhaul) 600 ml (20.3 fl/oz)
Lubricant Capacity (Change) 500 ml (16.9 fl/oz)
Gasoline (recommended) 87 Octane Regular Unleaded
Gasoline (recommended) 87 Octane Regular
Engine Oil (recommended) Arctic Cat ACX All Weather Unleaded
(Synthetic)
Engine Oil (recommended) Arctic Cat ACX All Weather
Cooling System Capacity 0.776 L (0.81 U.S. qt) (Synthetic)
Brake Fluid DOT 4 Cooling System Capacity 1.4 L (1.5 U.S. qt)
Taillight/Brakelight 12V/5W/21W Rear Drive Capacity 150 ml (5 fl oz)
Headlight 12V/35W (2) Rear Drive Lubricant SAE Approved
Starting System Electric 80W-90 Hypoid
Brake Fluid DOT 4
* Specifications subject to change without notice. Taillight/Brakelight 12V/5W/21W
Headlight 12V/35W (2)
Starting System Electric w/Manual Recoil
(Emergency)
* Specifications subject to change without notice.

www.mymowerparts.com
1-2 Manual Section Next
Table of Contents Table of Contents
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

Torque Specifications ENGINE/TRANSMISSION

Torque
Part Part Bolted To
ft-lb N-m
Cylinder Head Cylinder 7 10
DRIVE TRAIN COMPONENTS Cylinder Nut Crankcase 7 10
Torque Camshaft Holder Cylinder Head 18 24
Part Part Bolted To
ft-lb N-m Bevel Drive Gear (Utility) Driveshaft 72 98
Engine Mounting Through-Bolt Frame 29 39 Magneto Rotor/Flywheel Crankshaft 47 64
Engine Mounting Bracket Cap Screw Frame 16 22 Bevel Driven Gear (Utility) Driven Shaft 72 98
Rear Axle Housing (Utility) Swing Arm 40 54 Output Drive Sprocket Lock Plate Driveshaft 43 59
Rear Axle Housing (DVX) Tube 29 39 (DVX)

Gear Case Swing Arm Crankcase Cap Screw Crankcase 8 11

50 68

1
Engine Oil Screen/Filter Cap Crankcase 11 15
Hub Nut (Front) Front/Spindle 50 68
Shift Cam Stopper Plug* (Utility) Left Case 20 27
Wheel Lug Nut Hub 32 44
Hub Nut (Rear) Axle 72 98 Shift Cam Stopper Plug* (DVX) Transmission Case 35 48
Rear Axle Nut* (Utility) Axle 72 98 Camshaft Chain Tensioner Adjuster Cam Chain 9 12
Tensioner
Rear Axle Nut* (DVX) Axle 86 117 Camshaft Chain Tensioner Mount Cylinder Head 9 12
EXHAUST COMPONENTS Camshaft Chain Tension Spring Holder Cam Chain 36 4
Exhaust Pipe Engine 25 34 Plug Tensioner in.-lb
Muffler Mounting Bolt Frame 25 34 Starter Ratchet Crankshaft 68 93
ELECTRICAL COMPONENTS Centrifugal Clutch Housing Driveshaft 40 54
Starter Motor Lead Cable Starter 36 5 Timing Plug Right Case 16 22
Nut in.-lb Driven Pulley Retaining Nut Driven Shaft 43 59
Starter Motor Mounting Bolt Crankcase 9 12 (Transmission)
STEERING COMPONENTS Drive Plate Nut* Fixed Driven Face 43 59
Handlebar Clamp Cap Screw Steering Head 18 24 Drive Pulley Nut Crankshaft 72 98
Steering Post Support Block Frame 17 23 Engine Oil Drain Plug Crankcase 21 29
Steering Post Nut Steering Post 50 68 Transmission Drain Plug Transmission 21 29
Upper And Lower Ball Joint Nut Steering Knuckle 22 30 Transmission Case Cover Transmission 20 27
Tie Rod End Nut Steering Knuckle 15 20 * w/Red Loctite #271
Tie Rod Lock Nut Tie Rod 15 20
BRAKE COMPONENTS
Brake Hose Union Bolt Master Cylinder/ 25 34
Caliper
Brake Bleed Screw Caliper 56 5
in.-lb
Brake Caliper Mounting Cap Screw Steering Knuckle/ 25 34
Swing Arm
Master Cylinder (Front) Handlebar 13 18
Brake Pad Mounting Pin (Front/Rear) Brake Caliper 13 18
Brake Caliper Slide Pin (Front/Rear) Brake Caliper 25 34
Front Brake Line Nut Brake Line/Junction 25 34
Block
Brake Caliper (Rear) Swing Arm Housing 25 34
SUSPENSION COMPONENTS (Front)
A-Arm Pivot Nut Frame 32 44
Front Shock Absorber Mounting Nut* Frame 29 39
(Upper/Lower)
SUSPENSION COMPONENTS (Rear)
Left Pivot Bolt (Utility) Swing Arm 36 5
in.-lb
Right Pivot Bolt (Utility) Swing Arm 82 112
Left Pivot Lock Nut (Utility) Left Pivot Bolt 82 112
Swing Arm Pivot Nut (DVX) Frame 50 68
Rear Shock Absorber Mounting Nut Frame/Swing Arm 29 39
(Upper/Lower)
Axle Housing Cap Screw (Utility) Final Drive Gear 40 54
Case
Axle Housing Cap Screw (DVX) Swing Arm 29 39

www.mymowerparts.com
Back Manual Section 1-3
Next
Table of Contents Table of Contents
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

Torque Conversions Break-In Procedure

(ft-lb/N-m)
A new ATV and an overhauled ATV engine require a
“break-in” period. The first 10 hours (or 200 miles) are
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
most critical to the life of this ATV. Proper operation
1 1.4 26 35.4 51 69.4 76 103.4 during this break-in period will help assure maximum
2 2.7 27 36.7 52 70.7 77 104.7 life and performance from the ATV.
3 4.1 28 38.1 53 72.1 78 106.1
During the first 10 hours (or 200 miles) of operation,
4 5.4 29 39.4 54 73.4 79 107.4 always use less than 1/2 throttle. Varying the engine
5 6.8 30 40.8 55 74.8 80 108.8 RPM during the break-in period allows the compo-
6 8.2 31 42.2 56 76.2 81 110.2 nents to “load” (aiding the mating process) and then
“unload” (allowing components to cool). Although it
7 9.5 32 43.5 57 77.5 82 111.5
is essential to place some stress on the engine compo-
8 10.9 33 44.9 58 78.9 83 112.9 nents during break-in, care should be taken not to
9 12.2 34 46.2 59 80.2 84 114.2 overload the engine too often. Do not pull a trailer or
10 13.6 35 47.6 60 81.6 85 115.6 carry heavy loads during the 10-hour break-in period.
11 15 36 49 61 83 86 117 When the engine starts, allow it to warm up properly.
12 16.3 37 50.3 62 84.3 87 118.3 Idle the engine several minutes until the engine has
13 17.7 38 51.7 63 85.7 88 119.7 reached normal operating temperature. Do not idle the
engine for excessively long periods of time.
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4 During the break-in period, a maximum of 1/2 throttle
16 21.8 41 55.8 66 89.8 91 123.8 is recommended; however, brief full-throttle accelera-
17 23.1 42 57.1 67 91.1 92 125.1
tions and variations in driving speeds contribute to
good engine break-in.
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8 After the completion of the break-in period, the engine
20 27.2 45 61.2 70 95.2 95 129.2
oil and oil filter should be changed. Other maintenance
after break-in should include checking of all pre-
21 28.6 46 62.6 71 96.6 96 130.6
scribed adjustments and tightening of all fasteners.
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6 Gasoline - Oil -
25 34 50 68 75 102 100 136
Lubricant

Tightening Torque RECOMMENDED GASOLINE

(General Bolts) The recommended gasoline to use is 87 minimum
octane regular unleaded. In many areas, oxygenates
(either ethanol or MTBE) are added to the gasoline.
Thread
Tightening
Oxygenated gasolines containing up to 10% ethanol,
Type of Bolt Diameter A
Torque 5% methane, or 5% MTBE are acceptable gasolines.
(mm)
(Conventional or 4 Marked Bolt) 5 12-36 in.-lb When using ethanol blended gasoline, it is not neces-
6 36-60 in.-lb sary to add a gasoline antifreeze since ethanol will pre-
vent the accumulation of moisture in the fuel system.
8 7-11 ft-lb
10 16-25 ft-lb
CAUTION
(7 Marked Bolt) 5 24-48 in.-lb
Do not use white gas. Only Arctic Cat approved gaso-
6 6-8 ft-lb line additives should be used.
8 13-20 ft-lb
10 29-43 ft-lb

www.mymowerparts.com
1-4
Back Manual Section Next
Table of Contents Table of Contents
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
RECOMMENDED ENGINE OIL FILLING GAS TANK
CAUTION ! WARNING
Any oil used in place of the recommended oil could Always fill the gas tank in a well-ventilated area. Never
cause serious engine damage. Do not use oils which add fuel to the ATV gas tank near any open flames or
contain graphite or molybdenum additives. These oils with the engine running. DO NOT SMOKE while filling
can adversely affect clutch operation. Also, not recom- the gas tank.
mended are racing, vegetable, non-detergent, and cas-
tor-based oils. Since gasoline expands as its temperature rises, the gas
tank must be filled to its rated capacity only. Expan-
The recommended oil to use is Arctic Cat ACX All sion room must be maintained in the tank particularly
Weather synthetic engine oil, which has been specifi- if the tank is filled with cold gasoline and then moved
cally formulated for use in this Arctic Cat engine. to a warm area.
Although Arctic Cat ACX All Weather synthetic
engine oil is the only oil recommended for use in this
engine, use of any API certified SM 5W-50 oil is
acceptable.
1

ATV0049B

! WARNING
Do not overflow gasoline when filling the gas tank. A
OILCHARTI fire hazard could materialize. Always allow the engine
to cool before filling the gas tank.
RECOMMENDED REAR DRIVE
LUBRICANT (Utility) ! WARNING
Do not over-fill the gas tank.
The recommended lubricant is Arctic Cat Gear Lube
or an equivalent gear lube which is SAE approved Tighten the gas tank cap securely after filling the tank.
80W-90 hypoid. This lubricant meets all of the lubrica-
tion requirements of the Arctic Cat ATV rear drive.

CAUTION
Genuine Parts
Any lubricant used in place of the recommended lubri-
cant could cause serious rear drive damage.
When replacement of parts is necessary, use only gen-
RECOMMENDED TRANSMISSION uine Arctic Cat ATV parts. They are precision-made to
ensure high quality and correct fit. Refer to the appro-
LUBRICANT priate Illustrated Parts Manual for the correct part
The recommended lubricant is Arctic Cat Gear Lube number, quantity, and description.
or an equivalent gear lube which is SAE approved
80W-90 hypoid. This lubricant meets all the lubrica-
tion requirements of the Arctic Cat ATV front differen-
tial and rear drive. Preparation
For Storage
CAUTION
Any lubricant used in place of the recommended
lubricant could cause serious front differential/rear CAUTION
drive damage.
Prior to storing the ATV, it must be properly serviced
to prevent rusting and component deterioration.

Arctic Cat recommends the following procedure to

prepare the ATV for storage.
1. Clean the seat cushion (cover and base) with a
www.mymowerparts.com damp cloth and allow it to dry.

Back Manual Section 1-5

Next
Table of Contents Table of Contents
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
2. Clean the ATV thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire
ATV. Allow the ATV to dry thoroughly. DO NOT Preparation After
get water into any part of the engine or air intake. Storage
3. Either drain the gas tank or add Fuel Stabilizer to
the gas in the gas tank. Remove the air filter hous-
ing cover and air filter. Start the engine and allow it Taking the ATV out of storage and correctly preparing
to idle; then using Arctic Cat Engine Storage Pre- it will assure many miles and hours of trouble-free rid-
server, slowly inject the preserver into the air filter ing. Arctic Cat recommends the following procedure
opening for a period of 10 to 20 seconds; then stop to prepare the ATV.
the engine. Install the air filter and housing cover.
1. Clean the ATV thoroughly.
CAUTION 2. Clean the engine. Remove the cloth from the
Rapid induction of oil or any liquid into a four-cycle exhaust system.
engine can cause “hydraulic-lock” resulting in severe
engine damage. 3. Check all control wires and cables for signs of
wear or fraying. Replace if necessary.
CAUTION
If the interior of the air filter housing is dirty, clean the 4. Change the engine oil and filter.
area before starting the engine.
5. Check the coolant level and add properly mixed
4. Drain the carburetor float chamber. coolant as necessary.

5. Plug the exhaust hole in the exhaust system with a 6. Charge the battery; then install. Connect the bat-
clean cloth. tery cables.

6. Apply light oil to the upper steering post bushing CAUTION

and plungers of the shock absorbers. The ignition switch must be in the OFF position prior
7. Tighten all nuts, bolts, cap screws, and screws. to installing the battery or damage may occur to the
Make sure rivets holding components together are ignition system.
tight. Replace all loose rivets. Care must be taken CAUTION
that all calibrated nuts, cap screws, and bolts are
tightened to specifications. Connect the positive battery cable first; then the nega-
tive.
8. Fill the cooling system to the FULL line in the cool-
ing system reservoir with properly mixed coolant. 7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight,
9. Disconnect the battery cables; then remove the and headlight aim; adjust or replace as necessary.
battery, clean the battery posts and cables, and
store in a clean, dry area. 8. Tighten all nuts, bolts, cap screws, and screws
making sure all calibrated nuts, cap screws, and
bolts are tightened to specifications.
CAUTION
This maintenance-free battery should be charged at 9. Check tire pressure. Inflate to recommended pres-
the recommended rate every 30 days or permanent sure as necessary.
damage may occur if the battery completely dis-
charges. 10. Make sure the steering moves freely and does not
bind.
10. Store the ATV indoors in a level position.
11. Check the spark plug. Clean or replace as neces-
CAUTION sary.
Avoid storing outside in direct sunlight and avoid
using a plastic cover as moisture will collect on the
ATV causing rusting.

www.mymowerparts.com
1-6
Back Manual Section
Table of Contents Table of Contents
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP

TABLE OF
CONTENTS

Periodic Maintenance Chart.................................... 2-2

Periodic Maintenance.............................................. 2-3
Lubrication Points.................................................... 2-3
Air Filter................................................................... 2-3
Valve/Tappet Clearance .......................................... 2-4
Testing Engine Compression .................................. 2-4
Spark Plug............................................................... 2-5
Muffler/Spark Arrester ............................................. 2-5
Engine Oil - Filter .................................................... 2-6
Rear Drive Lubricant (Utility) ................................... 2-6
Transmission Lubricant ........................................... 2-7
Drive Chain (DVX) ................................................... 2-7
Driveshaft/Coupling (Utility)..................................... 2-8
Nuts/Bolts/Cap Screws............................................ 2-8
Headlight/Taillight-Brakelight ................................... 2-9
Shift Lever ............................................................... 2-9
Hydraulic Brake Systems ...................................... 2-10
Auxiliary/Rear Hydraulic Brake.............................. 2-12
Burnishing Brake Pads.......................................... 2-14
www.mymowerparts.com Checking/Replacing V-Belt.................................... 2-14
Manual 2-1
Table of Contents
Arctic CatFOR
2010 ARCTIC
Dvx 300 AndCAT300 ATV
UtilityDISCOUNT
Service Manual
PARTS CALL 606-678-9623 OR 606-561-4983
Full download: http://manualplace.com/download/arctic-cat-2010-dvx-300-and-300-utility-service-manual/
A = Adjust I = Inspect
Periodic Maintenance C = Clean L = Lubricate
Chart D = Drain R = Replace
T = Tighten
Initial Service Every Month Every 3 Every 6
Every Year or
After Break-In Every or Months or Months or As
Item Every 1500
(First Mo or 100 Day Every 100 Every 300 Every 500 Miles Needed
Mi) Miles Miles Miles
Battery I I C
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Spark Plug I I R (4000 Mi or
18 Mo)
Muffler/Spark Arrester C R
Gas/Vent Hoses I I R (2 Yrs)
Gas Tank Valve I C
Throttle Cable I I C-L A-R
Carb Float Chamber D*
Engine RPM (Idle) I I A
Engine Oil Level I A
Engine Oil - Screen C C* C
Drive Chain (DVX) I I C-L
Rear Drive Lubricant I I R A
(Utility)
Transmission Lubricant I I R A
Tires/Air Pressure I I A-R
Steering Components I I I R
V-Belt I I R
Suspension (Ball joint boots, tie I I l* R
rods, differential and rear drive
bellows)
Nuts/Cap Screws/Screws I I T
Ignition Timing I
Headlight/Taillight- I I R
Brakelight
Switches I I R
Shift Lever I A-L
Choke Cable I C-L R
Recoil Starter (Utility) I C-R
Handlebar Grips I R
Handlebars I I R
Gauges/Indicators I I R
Frame/Welds/Racks I I l
Electrical Connections l C
Complete Brake System I I C L-R
(Hydraulic and Auxiliary)
Brake Pads I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Coolant/Cooling System I I R (2 Yrs)

* Service/Inspect more frequently when operating in adverse conditions.

www.mymowerparts.com
2-2 Manual Section Next
Table
This is the cut pages sample. Download all of
133Contents Table of Contents
page(s) at: ManualPlace.com