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Arctic Cat 300 Utility User Manual

Arctic Cat 300 Utility
118 pages
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300 UTILITY/DVX 300
[ATV]
SERVICE MANUAL
2014

Table of Contents

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Arctic Cat 300 Utility Specifications

General IconGeneral
BrandArctic Cat
Model300 Utility
CategoryOffroad Vehicle
LanguageEnglish

Summary

General Information

General Specifications

Provides key technical details for the ATV model, covering chassis, fuel system, and electrical specs.

Camshaft and Cylinder Head Specifications

Details specifications related to the camshaft and cylinder head components.

Cylinder, Piston, and Rings Specifications

Lists technical specifications for the cylinder, piston, and rings.

Crankshaft Specifications

Provides technical specifications for the crankshaft and connecting rod.

Torque Specifications

Steering Components Torque

Specifies torque values for steering system fasteners and components.

Brake Components Torque

Torque specifications for brake system components.

Front Suspension Components Torque

Torque values for front suspension fasteners and components.

Engine/Transmission Torque

Torque specifications for engine and transmission fasteners.

Break-In Procedure

Fuel, Oil, and Lubricant Recommendations

Recommended Gasoline

Details the recommended octane and type of gasoline for the ATV.

Recommended Engine Oil

Specifies the recommended engine oil type and viscosity.

Air Filter Service

Cleaning and Inspecting Filter

Procedure for cleaning and inspecting the air filter element.

Checking and Draining Drain Tube

How to check and drain the air filter housing drain tube.

Valve and Tappet Clearance

Testing Engine Compression

Spark Plug Service

Muffler and Spark Arrester Maintenance

Engine Oil and Filter Change

Rear Drive Lubricant (Utility)

Transmission Lubricant

Drive Chain (DVX) Service

Inspecting the Drive Chain

How to inspect the drive chain for wear and damage.

Cleaning and Lubricating the Drive Chain

Procedure for cleaning and lubricating the O-ring type drive chain.

Adjusting Drive Chain Tension

Steps to adjust the drive chain tension for optimal performance.

Headlight and Taillight/Brakelight Bulb Replacement

Replacing Headlight Bulb

Step-by-step guide for replacing the ATV's headlight bulb.

Replacing Taillight-Brakelight Bulb

Instructions for replacing the taillight and brakelight bulbs.

Shift Lever Adjustment

Hydraulic Brake Systems

Checking and Bleeding the System

Procedure for checking and bleeding the hydraulic brake system.

Inspecting Brake Hoses

How to inspect hydraulic brake hoses for damage.

Checking and Replacing Front Brake Pads

Steps to check and replace front brake pads.

Auxiliary/Rear Hydraulic Brake

Checking Auxiliary Brake Function

Procedure to check the function of the auxiliary rear hydraulic brake.

Measuring and Replacing Rear Brake Pads (Utility)

How to measure and replace rear brake pads on the Utility model.

Burnishing Brake Pads

V-Belt Service

Removing V-Belt Components

Steps for removing the V-belt cover and related components.

Installing V-Belt Components

Procedure for installing the V-belt and related components.

Body Service

Removing Body Components (DVX)

Steps to remove the body from the DVX model.

Removing Body Components (Utility)

Steps to remove the body from the Utility model.

Cleaning and Inspecting Body

How to clean and inspect the ATV body components.

Steering Post Cover and Instrument Pod

Removing Steering Post Cover (DVX)

Steps to remove the steering post cover on the DVX model.

Removing Instrument Pod (Utility)

Steps to remove the instrument pod on the Utility model.

Inspecting Indicator Lights (DVX)

How to inspect and service indicator lights on the DVX steering cover.

Installing Steering Post Cover and Instrument Pod

Steps to install the steering post cover and instrument pod.

Steering Post and Tie Rods

Removing Steering Post and Tie Rods

Steps to remove the steering post and tie rods.

Cleaning and Inspecting Steering Components

How to clean and inspect steering post and tie rod components.

Measuring and Adjusting Toe-In/Toe-Out

Front Brake Lever and Master Cylinder Assembly

Removing the Front Brake Assembly

Steps to remove the front brake lever and master cylinder assembly.

Inspecting the Front Brake Assembly

How to inspect the front brake lever and master cylinder.

Installing the Front Brake Assembly

Steps to install the front brake lever and master cylinder assembly.

Auxiliary Brake Pedal and Master Cylinder Assembly

Removing the Auxiliary Brake Assembly

Steps to remove the auxiliary brake pedal master cylinder.

Throttle Control Service

Removing the Throttle Control

Steps to remove the throttle control assembly.

Installing the Throttle Control

Steps to install the throttle control assembly.

Troubleshooting: Handling and Steering

Handling Too Heavy or Stiff

Identifies causes and remedies for heavy or stiff ATV handling.

Steering Oscillation

Identifies causes and remedies for steering oscillation.

Steering Pulling to One Side

Identifies causes and remedies for steering pulling issues.

Steering Impaired

Identifies causes and remedies for impaired steering.

Engine and Transmission Service

Special Tools for Engine/Transmission

Lists special tools required for engine/transmission service.

Engine and Transmission Removal

Removing Engine/Transmission (DVX)

Procedure for removing the engine/transmission from the DVX model.

Removing Engine/Transmission (Utility)

Procedure for removing the engine/transmission from the Utility model.

Top-Side Engine Components Service

Removing Top-Side Components

Steps for removing top-side engine components like valve cover and cylinder head.

Servicing Valve Assembly

Inspecting and servicing valve components, camshaft, and cylinder head.

Servicing Piston Assembly

Procedures for servicing the piston, rings, and pin.

Servicing Cylinder Assembly

Procedures for cleaning, inspecting, and assembling the cylinder.

Left-Side Engine Components Service

Removing Left-Side Components

Steps to remove left-side engine components like recoil starter and V-belt cover.

Servicing Drive Pulley and Clutch Assembly

Procedures for servicing drive pulley, driven pulley, and V-belt cover.

Recoil Starter Service (Utility)

Procedures for removing, disassembling, cleaning, and assembling the recoil starter.

Right-Side Engine Components Service

Removing Transmission Components (DVX)

Steps to remove the transmission from the DVX model.

Removing Transmission Components (Utility)

Steps to remove the transmission from the Utility model.

Servicing Transmission Components (DVX)

Steps for removing DVX transmission components like gears, shafts, and forks.

Servicing Transmission Components (Utility)

Steps for removing Utility transmission components like gears and shafts.

Other Engine Components Service

Servicing Water Pump, Coils, Stator, Flywheel, and Oil Pump

Procedures for servicing water pump, coils, stator, rotor, flywheel, and oil pump.

Transmission Gear Service

Transmission (DVX) Inspection

Inspecting DVX transmission components like shift forks and gears.

Transmission (Utility) Inspection

Inspecting Utility transmission components like shift forks and gears.

Secondary Gears Service

Checking and correcting backlash and tooth contact on secondary gears.

Center Crankcase Components Service

Separating Crankcase Halves

Steps to separate the crankcase halves.

Crankshaft Assembly Service

Procedures for servicing crankshaft assembly, including rod measurements.

Crankshaft Measurements

Measuring connecting rod and crankshaft dimensions for wear.

Assembling Crankcase Halves

Steps for assembling the crankcase halves.

Engine and Transmission Installation

Installing Engine/Transmission (DVX)

Steps to install the engine/transmission into the DVX frame.

Installing Engine/Transmission (Utility)

Steps to install the engine/transmission into the Utility frame.

Troubleshooting: Engine Starting and Running

Engine Will Not Start or Hard to Start (Compression Low)

Identifies causes and remedies for low engine compression.

Engine Will Not Start or Hard to Start (No Spark)

Identifies causes and remedies for no spark issues.

Engine Will Not Start or Hard to Start (No Fuel)

Identifies causes and remedies for fuel delivery problems.

Engine Stalling Easily

Identifies causes and remedies for engine stalling.

Fuel, Lubrication, and Cooling System

Carburetor Service

Procedures for removing and disassembling the carburetor.

Carburetor Disassembly

Steps for disassembling the carburetor components.

Carburetor Cleaning and Inspection

How to clean and inspect carburetor parts.

Carburetor Assembly and Installation

Steps for assembling and installing the carburetor components.

Throttle Cable and Idle Adjustment

Adjusting Throttle Cable Free-Play

Procedure to adjust throttle cable free-play.

Adjusting Engine RPM (Idle)

Procedure to properly adjust the idle RPM.

Gas Tank Service

Removing the Gas Tank

Steps to remove the gas tank.

Cleaning and Inspecting Gas Tank

How to clean and inspect gas tank components.

Installing the Gas Tank

Steps to install the gas tank.

Gas Tank Valve Service

Removing and Inspecting Valve

Steps to remove and inspect the gas tank valve.

Installing Gas Tank Valve

Steps to install the gas tank valve.

Oil Pump Service

Removing and Disassembling Oil Pump

Steps to remove and disassemble the oil pump.

Cleaning and Inspecting Oil Pump

How to clean and inspect oil pump components.

Assembling and Installing Oil Pump

Steps to assemble and install the oil pump.

Liquid Cooling System

Radiator Service

Steps to remove, clean, inspect, and install the radiator.

Hoses and Thermostat Service

Removing Hoses and Thermostat

Steps to remove the thermostat housing and thermostat.

Inspecting Thermostat

How to inspect the thermostat for proper operation.

Installing Thermostat

Steps to install the thermostat and housing.

Fan Service

Removing the Fan

Steps to remove the fan assembly.

Installing the Fan

Steps to install the fan assembly.

Water Pump Service

Removing and Disassembling Water Pump

Steps to remove and disassemble the water pump.

Troubleshooting: Fuel System

Starting Impaired

Identifies causes and remedies for starting problems.

Idling or Low Speed Impaired

Identifies causes and remedies for poor idling or low speed performance.

Medium or High Speed Impaired

Identifies causes and remedies for performance issues at medium/high speeds.

Overflow and Fuel Level Fluctuations

Identifies causes and remedies for fuel overflow and level fluctuations.

Electrical System Overview

Special Tools for Electrical Service

Lists special tools required for electrical system service.

RPM Limiter Information

Information about the ATV's RPM limiter and CDI unit.

Testing Electrical Components

General guidance for testing electrical components.

Switches Inspection

Battery Maintenance

Battery Charging Guidelines

Guidelines for charging the battery using constant-current chargers.

Brakelight Switch Service

Auxiliary Switch Voltage and Resistance Tests

How to test the voltage and resistance of the auxiliary brakelight switch.

Handlebar Switch Resistance Tests

How to test the resistance of the handlebar brakelight switch.

Fan Motor Electrical Tests

Fan Motor Voltage Test

How to test voltage at the fan motor connector.

Fan Motor Resistance Test

How to test resistance at the fan motor connector.

Fuse Block Inspection

Ignition Coil Electrical Tests

Peak Voltage Test (Primary/CDI Side)

How to perform peak voltage tests on the ignition coil primary side.

Ignition Coil Resistance Tests

How to test the resistance of the ignition coil primary and secondary windings.

Spark Plug Cap Resistance Test

How to test the resistance of the spark plug cap.

Indicator Lights and LCD Gauge Service

Indicator Lights (DVX) Inspection

Steps to access and inspect indicator lights on the DVX model.

LCD Gauge Assembly Removal and Testing

Steps to remove and test the LCD gauge assembly.

Ignition Switch Electrical Tests

Ignition Switch Voltage Test

How to test the voltage at the ignition switch connector.

Ignition Switch Resistance Test

How to test the resistance of the ignition switch.

Handlebar Control Switches Resistance Tests

Hi-Beam Switch Resistance Test

How to test the resistance of the handlebar Hi-beam switch.

Lo-Beam Switch Resistance Test

How to test the resistance of the handlebar Lo-beam switch.

Starter Button Resistance Test

How to test the resistance of the starter button switch.

Emergency Stop Switch Resistance Test

How to test the resistance of the emergency stop switch.

Reverse Override Switch Resistance Test

Magneto Coils Electrical Tests

Charging Coil Output Voltage Test

How to test the output voltage of the charging coil.

Stator Coil No-Load Voltage Test

How to test the stator coil voltage with no load.

Charging Coil Resistance Test

How to test the resistance of the charging coil.

Trigger Coil Resistance Test

How to test the resistance of the trigger coil.

Stator Coil (Trigger) Voltage Test

How to test the trigger coil voltage.

Starter Motor Service

Starter Motor Removal and Installation

Steps to remove and install the starter motor.

Starter Relay Voltage Test

Troubleshooting: Electrical System

Spark Absent or Weak

Identifies causes and remedies for absent or weak spark.

Spark Plug Fouled with Carbon

Identifies causes and remedies for carbon-fouled spark plugs.

Spark Plug Electrodes Overheat or Burn

Identifies causes and remedies for spark plug electrode overheating.

Magneto Does Not Charge

Identifies causes and remedies for magneto charging issues.

Magneto Charging Rate Below Specification

Identifies causes and remedies for low charging rate.

Magneto Overcharges

Identifies causes and remedies for magneto overcharging.

Charging Unstable

Identifies causes and remedies for unstable charging output.

Starter Button Not Effective

Identifies causes and remedies for starter button issues.

Battery Sulfation

Identifies causes and remedies for battery sulfation.

Troubleshooting: Battery

Battery Discharges Too Rapidly

Identifies causes and remedies for rapid battery discharge.

Battery Polarity Reversed

Identifies causes and remedies for reversed battery polarity.

Drive System Overview

Special Tools for Drive System

Lists special tools required for drive system service.

Rear Drive Assembly Schematics

Diagrams of the rear drive assembly for DVX and Utility models.

Rear Drive Axle (DVX) Service

Removing the Rear Drive Axle (DVX)

Steps to remove the rear drive axle from the DVX model.

Cleaning and Inspecting Drive Axle Components

How to clean and inspect drive axle components.

Rear Drive Axle (Utility) Service

Removing the Rear Drive Axle (Utility)

Steps to remove the rear drive axle from the Utility model.

Cleaning and Inspecting Drive Axle Components

How to clean and inspect drive axle components.

Disassembling the Rear Drive Gear Case

Steps to disassemble the rear drive gear case.

Assembling the Rear Drive Gear Case

Steps to assemble the rear drive gear case.

Swing Arm Service

Replacing Swing Arm Seals and Bearings

Steps to replace swing arm pivot bearings and dust seals.

Installing Swing Arm Components

Steps to install new bearings and seals into the swing arm.

Suspension System Components

Front Shock Absorbers Service

Steps to remove, clean, inspect, and install the front shock absorbers.

Rear Shock Absorber Service

Removing the Rear Shock Absorber

Steps to remove the rear shock absorber.

Cleaning and Inspecting Rear Shock Absorber

How to clean and inspect the rear shock absorber.

Installing the Rear Shock Absorber

Steps to install the rear shock absorber.

Adjusting Rear Spring Preload

How to adjust the rear shock absorber spring preload.

Swing Arm Service

Removing and Disassembling Swing Arm

Steps to remove and disassemble the swing arm assembly.

Cleaning and Inspecting Swing Arm

How to clean and inspect swing arm components.

Assembling and Installing Swing Arm

Steps to assemble and install the swing arm assembly.

Front A-Arms Service

Removing Front A-Arms

Steps to remove the front A-arms.

Cleaning and Inspecting Front A-Arms

How to clean and inspect front A-arm components.

Installing Front A-Arms

Steps to install the front A-arms.

Wheels and Tires Service

Tire Size Information

Information on the correct tire size and type for the ATV.

Tire Inflation Pressure Importance

Importance of maintaining correct tire inflation pressure.

Removing Wheels

Steps to remove the wheels from the ATV.

Cleaning and Inspecting Wheels and Tires

How to clean and inspect wheels and tires.

Installing Wheels

Steps to install the wheels onto the hubs.

Checking and Inflating Tire Pressure

How to check and adjust tire air pressure.

Troubleshooting: Suspension

Suspension Too Soft

Identifies causes and remedies for soft suspension.

Suspension Too Stiff

Identifies causes and remedies for stiff suspension.

Suspension Noisy

Identifies causes and remedies for noisy suspension.

Rear Wheel Oscillation

Identifies causes and remedies for rear wheel oscillation.

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