Arctic CatFOR

2008 ARCTIC
Dvx UtilityCAT
250 Service
ATV Manual
DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
Full download: http://manualplace.com/download/arctic-cat-2008-dvx-utility-250-service-manual/

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2008 Arctic
Cat ATV 250 models. 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. The symbol
! CAUTION identifies 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 infor-
mation worthy of particular attention. The symbol  AT THIS POINT directs the technician to certain and spe-
cific 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.

© 2007 Arctic Cat Inc. September 2007

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®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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TABLE OF CONTENTS

Click on the red text to go.

MORE TO GO ON.
TM

Foreword
DVX 250
1. General Information/Specifications 1
250 Utility
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

08 ATV
8. Steering/Frame 8

9. Controls/Indicators 9

Service Manual
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SECTION 1 - GENERAL INFORMATION

TABLE OF
CONTENTS

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

General Specifications (Utility Model) ..................... 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.......................................... 1-6
Preparation After Storage........................................ 1-6
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General Specifications* General Specifications*

(DVX Model) (Utility Model)

CHASSIS CHASSIS
Dry Weight (approx) 186 kg (410 lb) Dry Weight (approx) 216 kg (477 lb)
Length (overall) 168.3 cm (66.25 in.) Length (overall) 187 cm (73.6 in.)
Height (overall) 114.9 cm (45.25 in.) Height (overall) 111.8 cm (44.0 in.)
Width (overall) 106.0 cm (41.75 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 and Auxiliary Brake
Lock and Auxiliary Brake
Wheelbase 117.9 cm (46.4 in.)
Wheelbase 117.9 cm (46.4 in.)
Tire Size (Front) AT22 x 7-10
Tire Size (Front) AT21 x 7-10 (Rear) AT22 x 10-10
(Rear) AT20 x 11-9
2
Tire Inflation Pressure (Front) 0.28 kg/cm2 (4 psi)
Tire Inflation Pressure2 (Front) 0.28 kg/cm2 (4 psi) 2(Rear)
2 0.25 kg/cm2 (3.5 psi)
(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) 13 L (3.43 U.S. gal.)
Reserve Capacity 4.54 L (1.2 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) 600 ml (20.3 fl/oz)
Transmission (Overhaul) 400 ml (13.5 fl/oz) Lubricant Capacity (Change) 500 ml (16.9 fl/oz)
Lubricant Capacity (Change) 300 ml (10.1 fl/oz)
Gasoline (recommended) 87 Octane Regular
Gasoline (recommended) 87 Octane Regular Unleaded
Unleaded
Engine Oil (recommended) SAE 5W-30
Engine Oil (recommended) SAE 5W-30
Cooling System Capacity 1.6 L (1.7 U.S. qt)
Cooling System Capacity 1.6 L (1.7 U.S. qt)
Rear Drive Capacity 150 ml (5 fl oz)
Brake Fluid DOT 4
Rear Drive Lubricant SAE Approved
Taillight/Brakelight 12V/5W/21W 80W-90 Hypoid
Headlight 12V/35W (2) Brake Fluid DOT 4
Starting System Electric Taillight/Brakelight 12V/5W/21W
Headlight 12V/35W (2)
* Specifications subject to change without notice.
Starting System Electric w/Manual Recoil
(Emergency)
* Specifications subject to change without notice.

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Torque Specifications

DRIVE TRAIN COMPONENTS SUSPENSION COMPONENTS (Rear)

Torque Torque
Part Part Bolted To Part Part Bolted To
ft-lb N-m ft-lb N-m
Engine Mounting Bolt Frame 29 39 Left Pivot Bolt (Utility) Swing Arm 36 in.-lb 5
Engine Mounting Bracket Frame 16 22 Right Pivot Bolt (Utility) Swing Arm 82 112
Cap Screw
Left Pivot Lock Nut (Utility) Left Pivot Bolt 82 112
Rear Axle Housing (Utility) Swing Arm 40 54

1
Swing Arm Pivot Nut (DVX) Frame 50 68
Rear Axle Housing (DVX) Tube 29 39
Rear Shock Absorber Frame/Swing Arm 29 39
Hub Nut (Front) Front/Spindle 50 68 Mounting Nut (Upper/Lower)
Wheel Lug Nut Hub 32 44 Axle Housing Cap Screw Final Drive Gear 40 54
(Utility) Case
Hub Nut (Rear) Axle 72 98
Axle Housing Cap Screw Swing Arm 29 39
Rear Axle Nut* (Utility) Axle 72 98 (DVX)
Rear Axle Nut* (DVX) Axle 86 117 ENGINE/TRANSMISSION
EXHAUST COMPONENTS Cylinder Head Cylinder 7 10
Exhaust Pipe Engine 25 34 Cylinder Nut Crankcase 7 10
Muffler Mounting Bolt Frame 25 34 Camshaft Holder Cylinder Head 18 24
ELECTRICAL COMPONENTS Bevel Drive Gear (Utility) Driveshaft 72 98
Starter Motor Lead Cable Starter 36 in.-lb 5 Magneto Rotor/Flywheel Crankshaft 47 64
Nut
Bevel Driven Gear (Utility) Output Shaft 72 98
Starter Motor Mounting Bolt Crankcase 9 12
Output Drive Sprocket Plate Drive Shaft 43 59
STEERING COMPONENTS (DVX)
Handlebar Clamp Cap Screw Steering Head 18 24 Crankcase Cap Screw Crankcase 8 11
Steering Post Holder Cap Frame 17 23 Engine Oil Screen/Filter Cap Crankcase 11 15
Screw
Shift Cam Stopper* (Utility) Left Case 20 27
Steering Post Nut Steering Post 50 68
Shift Cam Stopper* (DVX) Transmission 35 48
Upper And Lower Ball Joint Steering Knuckle 22 30 Case
Nut
Camshaft Chain Tensioner Cam Chain 9 12
Tie Rod End Nut Steering Knuckle 15 20 Adjuster Tensioner
Tie Rod Lock Nut Tie Rod 15 20 Camshaft Chain Tensioner Cylinder Head 9 12
Mount
BRAKE COMPONENTS
Camshaft Chain Tension Cam Chain 36 in.-lb 4
Brake Hose Union Bolt Master Cylinder/ 25 34 Spring Holder Plug Tensioner
Caliper
Timing Plug Right Case 16 22
Brake Bleed Screw Caliper 56 in.-lb 5
Driven Pulley Retaining Nut Driven Shaft 43 59
Brake Caliper Mounting Cap Steering Knuckle/ 25 34 (Transmission)
Screw Swing Arm
Drive Plate Nut Fixed Driven Face 43 59
Master Cylinder (Front) Handlebar 13 18
Drive Pulley Nut Crankshaft 72 98
Brake Pad Mounting Pin Brake Caliper 13 18
(Front/Rear) Engine Oil Drain Plug Crankcase 21 29
Brake Caliper Slide Pin Brake Caliper 25 34 Transmission Drain Plug Transmission 21 29
(Front/Rear)
Transmission Case Cover Transmission 20 27
Front Brake Line Nut Brake Line/ 25 34
Junction Block * w/Red Loctite #271
Brake Caliper (Rear) Swing Arm 25 34
Housing
SUSPENSION COMPONENTS (Front)
A-Arm Pivot Nut Frame 32 44
Front Shock Absorber Frame 29 39
Mounting Nut* (Upper/Lower)

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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-
nents to “load” (aiding the mating process) and then
6 8.2 31 42.2 56 76.2 81 110.2 “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
overload the engine too often. Do not pull a trailer or
9 12.2 34 46.2 59 80.2 84 114.2 carry heavy loads during the 10-hour break-in period.
10 13.6 35 47.6 60 81.6 85 115.6
When the engine starts, allow it to warm up properly.
11 15 36 49 61 83 86 117
Idle the engine several minutes until the engine has
12 16.3 37 50.3 62 84.3 87 118.3 reached normal operating temperature. Do not idle the
13 17.7 38 51.7 63 85.7 88 119.7 engine for excessively long periods of time.
14 19 39 53 64 87 89 121 During the break-in period, a maximum of 1/2 throttle
15 20.4 40 54.4 65 88.4 90 122.4 is recommended; however, brief full-throttle accelera-
16 21.8 41 55.8 66 89.8 91 123.8 tions and variations in driving speeds contribute to
good engine break-in.
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5 After the completion of the break-in period, the engine
19 25.8 44 59.8 69 93.8 94 127.8
oil and oil filter should be changed. Other maintenance
after break-in should include checking of all pre-
20 27.2 45 61.2 70 95.2 95 129.2 scribed adjustments and tightening of all fasteners.
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3 Gasoline - Oil -
24 32.6 49 66.6 74 100.6 99 134.6 Lubricant
25 34 50 68 75 102 100 136

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

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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.
cause serious engine damage. Do not use oils which Never add fuel to the ATV gas tank near any open
contain graphite or molybdenum additives. These flames or with the engine running. DO NOT SMOKE
oils can adversely affect clutch operation. Also, not while filling the gas tank.
recommended are racing, vegetable, non-detergent,
and castor-based oils.

The recommended oil to use is Arctic Cat 4-Cycle

Engine Oil or an equivalent oil which is rated SE, SF,
or SG under API service classification. These oils
meet all of the lubrication requirements of the Arctic
Cat ATV engine. The recommended engine oil viscos- 1
ity is SAE 5W-30. Ambient temperature should deter-
mine the correct weight of oil. See the following
viscosity chart for details.

Viscosity Chart

ATV0049B
Since gasoline expands as its temperature rises, the gas
tank must be filled to its rated capacity only. Expan-
sion room must be maintained in the tank particularly
if the tank is filled with cold gasoline and then moved
to a warm area.

! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the
OILCHARTC engine to cool before filling the gas tank.

RECOMMENDED REAR DRIVE Tighten the gas tank cap securely after filling the tank.
LUBRICANT (Utility)
! WARNING
The recommended lubricant is Arctic Cat Gear Lube
or an equivalent gear lube which is SAE approved Do not over-fill the gas tank.
80W-90 hypoid. This lubricant meets all of the lubrica-
tion requirements of the Arctic Cat ATV rear drives.
Genuine Parts
! CAUTION
Any lubricant used in place of the recommended
lubricant could cause serious rear drive damage. When replacement of parts is necessary, use only gen-
uine Arctic Cat ATV parts. They are precision-made to
RECOMMENDED TRANSMISSION ensure high quality and correct fit. Refer to the appro-
LUBRICANT priate Illustrated Parts Manual for the correct part
number, quantity, and description.
The recommended lubricant is Arctic Cat Gear Lube
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-
tials and rear drives.

! CAUTION
Any lubricant used in place of the recommended
lubricant could cause serious front differential/rear
drive damage.

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10. Store the ATV indoors in a level position.
Preparation ! CAUTION
For Storage Avoid storing outside in direct sunlight and avoid
using a plastic cover as moisture will collect on the
ATV causing rusting.
! CAUTION
Prior to storing the ATV, it must be properly serviced
to prevent rusting and component deterioration. Preparation After
Arctic Cat recommends the following procedure to
Storage
prepare the ATV for storage.
1. Clean the seat cushion (cover and base) with a Taking the ATV out of storage and correctly preparing
damp cloth and allow it to dry. it will assure many miles and hours of trouble-free
riding. Arctic Cat recommends the following proce-
2. Clean the ATV thoroughly by washing dirt, oil, dure to prepare the ATV.
grass, and other foreign matter from the entire
ATV. Allow the ATV to dry thoroughly. DO NOT 1. Clean the ATV thoroughly.
get water into any part of the engine or air intake.
2. Clean the engine. Remove the cloth from the
3. Either drain the gas tank or add Fuel Stabilizer to exhaust system.
the gas in the gas tank. Remove the air filter hous-
ing cover and air filter. Start the engine and allow 3. Check all control wires and cables for signs of
it to idle; then using Arctic Cat Engine Storage wear or fraying. Replace if necessary.
Preserver, rapidly inject the preserver into the air
filter opening for a period of 10 to 20 seconds; 4. Change the engine oil and filter.
then stop the engine. Install the air filter and hous- 5. Check the coolant level and add properly mixed
ing cover. coolant as necessary.

! CAUTION 6. Charge the battery; then install. Connect the bat-

tery cables.
If the interior of the air filter housing is dirty, clean
the area before starting the engine.
! CAUTION
4. Drain the carburetor float chamber. The ignition switch must be in the OFF position prior
to installing the battery or damage may occur to the
5. Plug the exhaust hole in the exhaust system with a ignition system.
clean cloth.
6. Apply light oil to the upper steering post bushing ! CAUTION
and plungers of the shock absorbers. Connect the positive battery cable first; then the
negative.
7. Tighten all nuts, bolts, cap screws, and screws.
Make sure rivets holding components together are 7. Check the entire brake systems (fluid level, pads,
tight. Replace all loose rivets. Care must be taken etc.), all controls, headlights, taillight, brakelight,
that all calibrated nuts, cap screws, and bolts are and headlight aim; adjust or replace as necessary.
tightened to specifications.
8. Tighten all nuts, bolts, cap screws, and screws
8. Fill the cooling system to the FULL line in the making sure all calibrated nuts, cap screws, and
cooling system reservoir with properly mixed bolts are tightened to specifications.
coolant.
9. Check tire pressure. Inflate to recommended pres-
9. Disconnect the battery cables; then remove the sure as necessary.
battery, clean the battery posts and cables, and
store in a clean, dry area. 10. Make sure the steering moves freely and does not
bind.
! CAUTION
11. Check the spark plug. Clean or replace as neces-
This maintenance-free battery should be charged at sary.
the recommended rate every 30 days or permanent
damage may occur if the battery completely dis-
charges.

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SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP

TABLE OF
CONTENTS

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

Periodic Maintenance.............................................. 2-3
Lubrication Points.................................................... 2-3
Battery..................................................................... 2-3
Fuses ...................................................................... 2-4
Air Filter................................................................... 2-4
Valve/Tappet Clearance .......................................... 2-5
Testing Engine Compression .................................. 2-6
Spark Plug............................................................... 2-6
Muffler/Spark Arrester ............................................. 2-7
Gas/Vent Hoses ...................................................... 2-7
Adjusting Throttle Cable .......................................... 2-7
Adjusting Engine RPM (Idle) ................................... 2-8
Engine Oil - Filter .................................................... 2-8
Rear Drive Lubricant (Utility Model) ........................ 2-9
Transmission Lubricant ........................................... 2-9
Drive Chain (DVX Model) ...................................... 2-10
Tires ...................................................................... 2-11
Steering Components ........................................... 2-11
Driveshaft/Coupling (Utility Model) ........................ 2-11
Suspension/Shock Absorbers/Bushings ............... 2-11
Nuts/Bolts/Cap Screws.......................................... 2-11
Ignition Timing ....................................................... 2-12
Headlight/Taillight-Brakelight ................................. 2-12
Switches................................................................ 2-12
Shift Lever ............................................................. 2-13
Frame/Welds/Racks .............................................. 2-13
Electrical Connections........................................... 2-13
Hydraulic Brake Systems ...................................... 2-14
Auxiliary/Rear Hydraulic Brake.............................. 2-15
Burnishing Brake Pads.......................................... 2-17
Coolant.................................................................. 2-18
www.mymowerparts.com Checking/Replacing V-Belt.................................... 2-18

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Arctic CatFOR
2008 ARCTIC
Dvx UtilityCAT
250 Service
ATV Manual
DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
Full download: http://manualplace.com/download/arctic-cat-2008-dvx-utility-250-service-manual/
A = Adjust I = Inspect
Periodic Maintenance C = Clean L = Lubricate
Chart D = Drain R = Replace

Initial Service Every Month Every 3 Every 6

Every Year
After Break-In Every or Months or Months or As
Item or Every
(First Mo or Day Every 100 Every 300 Every 500 Needed
1500 Miles
100 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 Model) I I C-L
Rear Drive Lubricant I I R A
(Utility Model)
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, I I l* R
tie 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 Model) 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.

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