Arctic Cat DVX 300 Wartungshandbuch Seite 32
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29
Engine/Transmission
This section has been organized into sub-sections which
show a progression for the complete servicing of the Arc-
tic Cat ATV engine/transmission.
To service the center crankcase halves, the engine/trans-
mission must be removed from the frame.
To service top-side, left-side, and right-side components,
the engine/transmission does not have to be removed
from the frame.
NOTE: Arctic Cat recommends the use of new gas-
kets, lock nuts, and seals and lubricating all internal
components when servicing the engine/transmission.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appro-
priate tool description.
NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
Description p/n
Crankcase Separator/Crankshaft Remover 0444-152
Piston Pin Puller 0644-328
Spanner Wrench 0444-192
Flywheel Holder 0444-193
Magneto Rotor Remover 0444-187
Tappet Adjuster 0444-189
Surface Plate 0644-016
Driven Pulley Compressor 0444-195
V Blocks 0644-535
- SERVICE MANUAL 1
- FOREWORD 2
- TABLE OF CONTENTS 4
- General Information 5
- General Specifications 5
- Torque Specifications 6
- Torque Conversions 7
- (ft-lb/N-m) 7
- Break-In Procedure 7
- Gasoline - Oil - Lubricant 7
- Genuine Parts 8
- Preparation For Storage 8
- Preparation After 9
- SPECIAL TOOLS 10
- Lubrication Points 11
- Air Filter 11
- Valve/Tappet Clearance 11
- Testing Engine 12
- Compression 12
- Spark Plug 12
- Muffler/Spark Arrester 13
- Engine Oil - Filter 13
- Rear Drive Lubricant 14
- (Utility) 14
- Transmission Lubricant 14
- Drive Chain (DVX) 15
- ! WARNING 16
- Hydraulic Brake Systems 17
- INSPECTING HOSES 18
- CHECKING/REPLACING FRONT 18
- Auxiliary/Rear Hydraulic 19
- MEASURING/REPLACING REAR/ 20
- AUXILIARY BRAKE PADS (DVX) 20
- Removing 20
- Inspecting and Measuring 20
- Installing 20
- Burnishing Brake Pads 21
- Checking/Replacing 21
- Steering/Frame/Controls 23
- REMOVING (Utility) 24
- INSTALLING (DVX) 24
- Steering Post Cover/ 25
- Instrument Pod 25
- Steering Post/Tie Rods 26
- Measuring/Adjusting 28
- Toe-In/Toe-Out 28
- Front Brake Lever/Master 28
- Cylinder Assembly 28
- Auxiliary Brake Pedal/ 29
- Master Cylinder 29
- Assembly 29
- Throttle Control 30
- Engine/Transmission 32
- Removing Engine/ 33
- Transmission 33
- Top-Side Components 38
- Removing Top-Side 38
- Components 38
- AT THIS POINT 39
- Servicing Top-Side 40
- ATV1013A 41
- ATV-1011A 42
- ATV-1070 43
- ATV-1069 43
- ATV-1085B 43
- 726-306A 43
- Installing Top-Side 44
- C. Cylinder Head 45
- D. Valve Cover 45
- Left-Side Components 46
- Removing Left-Side 46
- Servicing Left-Side 47
- Cleaning and Inspecting 48
- Assembling/Installing 48
- V-BELT COVER 49
- DRIVE PULLEY 50
- DRIVEN PULLEY/CENTRIFUGAL 50
- CLUTCH ASSEMBLY 50
- Disassembling 50
- Inspecting 51
- Assembling 52
- Installing Left-Side 53
- Right-Side Components 54
- Removing Right-Side 55
- A. Transmission (Utility) 56
- Servicing Right-Side 60
- TRANSMISSION (Utility) 62
- SECONDARY GEARS 63
- Correcting Backlash 63
- Installing Right-Side 67
- Assembling Crankcase 69
- Joining Crankcase Halves 70
- Installing Engine/ 70
- Problem: Engine lacks power 75
- Condition Remedy 75
- Problem: Engine overheats 75
- Fuel/Lubrication/Cooling 76
- Carburetor 76
- Throttle Cable Free-Play 80
- Engine RPM (Idle) 80
- Gas Tank 80
- Gas Tank Valve 81
- Gas/Vent Hoses 81
- Oil Flow Chart 81
- Oil Pump 82
- Liquid Cooling System 82
- Radiator 82
- Hoses/Thermostat 83
- Water Pump 83
- Brakelight Switch 86
- (Auxiliary) 86
- (Handlebar Control) 86
- Coolant Temperature and 87
- Cooling Fan Switches 87
- Fan Motor 87
- Fuse Block 87
- Ignition Coil 88
- Indicator Lights (DVX) 89
- LCD Gauge Assembly 89
- Ignition Switch 90
- Handlebar Control 90
- Switches 90
- Magneto Coils 91
- Starter Motor 91
- Starter Relay 91
- CDI Unit 92
- Regulator/Rectifier 92
- Start-in-Gear Relay 92
- Headlights 93
- Taillight - Brakelight 93
- Ignition Timing 93
- Rear Drive Assembly 96
- Rear Drive Axle (DVX) 96
- Removing Bearings 98
- Installing Bearings 98
- Rear Drive Axle (Utility) 99
- CLEANING AND INSPECTING 101
- DISASSEMBLING 101
- ASSEMBLING 103
- Checking Tooth Contact 104
- AND BEARINGS 105
- Correcting Tooth Contact 105
- Checking Backlash 105
- REPLACING SWING ARM SEALS 105
- INSTALLING 106
- Troubleshooting 108
- Drive System 108
- Brake System 108
- Suspension 109
- Front and Rear 109
- Suspension Assembly 109
- Schematics 109
- Front Shock Absorbers 109
- Rear Shock Absorber 110
- Swing Arm 111
- ASSEMBLING AND INSTALLING 112
- Front A-Arms 114
- Wheels and Tires 116
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