PARTS MANUAL DVX 300 EU A2015KSF2BEUZ.
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1 PARTS MANUAL DVX 300 EU A2015KSF2BEUZ
2 Contents AIR INTAKE ASSEMBLY [92559] 1 BODY PANEL AND HEADLIGHT ASSEMBLY [300511] 3 CAM CHAIN ASSEMBLY [90409] 5 CARBURETOR ASSEMBLY [300515] 6 CLUTCH ASSEMBLY [94298] 8 COOLING ASSEMBLY [92560] 10 COOLING DUCT ASSEMBLY [90401] 12 CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY [300516] 13 ELECTRICAL AND WIRING HARNESS ASSEMBLY [96092] 15 EXHAUST ASSEMBLY [96091] 17 FRONT FRAME AND RELATED PARTS ASSEMBLY [100739] 18 FRONT SUSPENSION ASSEMBLY [96376] 20 FRONT WHEELS AND BRAKE ASSEMBLY [300513] 21 GAS TANK ASSEMBLY [100742] 23 HANDLEBAR AND CONTROLS ASSEMBLY [300512] 25 HYDRAULIC AND PARKING BRAKE ASSEMBLIES [96378] 26 INSTRUMENT POD ASSEMBLY [100740] 29 LEFT CRANKCASE AND COVER ASSEMBLY [100507] 31 PISTON AND CRANKSHAFT ASSEMBLY [94280] 33 REAR AXLE AND BRAKE ASSEMBLY [96088] 34 REAR FRAME, TAILLIGHT, AND RELATED PARTS ASSEMBLY [96081] 36 REAR SUSPENSION ASSEMBLY [98387] 38 REAR WHEEL ASSEMBLY [300514] 40 REED VALVE ASSEMBLY [100477] 41 RIGHT CRANKCASE AND COVER ASSEMBLY [94278] 43 SEAT, BATTERY, AND TOOL KIT ASSEMBLIES [94293] 45 SHIFT LEVER ASSEMBLY [96380] 46 STARTER MOTOR, MAGNETO, AND OIL PUMP ASSEMBLY [92456] 48 STEERING ASSEMBLY [96082] 50 TRANSMISSION ASSEMBLY [96096] 52 TRANSMISSION CASE ASSEMBLY [96095] 54
3 AIR INTAKE ASSEMBLY [92559] Cover, Air Silencer Seal Filter, Air - Assembly (inc. 4-7).4 1 Screw, Cap Not a Service Part.5 1 Washer, Lock Not a Service Part.6 1 Washer Not a Service Part.7 1 Filter, Air Not a Service Part Clamp, Hose Silencer, Air Clamp, Hose (inc. 11) Screw, Machine Screw, Machine Duct Screw, Cap Clip, Spring Clamp, Hose Hose, Drain Clamp, Hose Joint, Blow-By Tube B - Oil Catch 1
4 Clamp Catch, Oil Clamp, Hose Tube A - Oil Catch BOLT FLANGE 6* Tube C - Oil Catch (inc. two No. 27) Clamp 2
5 BODY PANEL AND HEADLIGHT ASSEMBLY [300511] Body, Main - Green (inc. 2) Decal, Warning - Passenger/Tire Pressure Decal - "AirCat" Decal, Side - DVX Right Decal, Side - DVX Left DECAL,"ARCTIC CAT"-WHT BOLT WASHER 6* Grommet, Rubber CLIP FENDER Bracket, Mounting - Starter/Magneto Switch BOLT WASH 5* Cover, Gas Tank - Black (inc. 12) Decal, Warning - Reverse Guide, Shift Handle SCREW TAPPING 5*16 (CIRCLE HEAD) Nut, Stamped Panel, Trim - Right - Black Panel, Trim - Left - Black Fender, Front - Right - Green Fender, Front - Left - Green 3
6 Decal, Warning - General Decal, Front Fender - Right Decal, Front Fender - Left NUT LOCK Washer Clip, Fender Screw, Machine Screw, Cap MUDGUARD,R FLOOR MUDGUARD,L FLOOR Fender, Rear - Right - Green Fender, Rear - Left - Green Decal, Rear Fender - Right Decal, Rear Fender - Left Headlight - Assembly (inc ) Socket Assembly BULB HEAD LIGHT Lens, Headlight 4
7 CAM CHAIN ASSEMBLY [90409] Guide, Chain Chain, Cam Tensioner, Chain Gasket Tensioner Assembly BOLT FLANGE SHF 6* O-RING 1.5* Screw, Adjuster Pivot, Tensioner 5
8 CARBURETOR ASSEMBLY [300515] Complete Carburetor Assembly SCREW, TOP COVER Cover, Top Spring Seat, Spring JET NEEDLE COMP Piston, Vacuum Valve, Float Clip, Float Valve Float Set Pin, Float Arm Chamber, Float - Assembly SCREW NEEDLE JET HOLDER, NEEDLE- JET 6
9 Jet, Main JET,SLOW # Jet, Starter SCREW, DRAIN RUBBER PIPE Clamp, Hose O-Ring Washer Spring Screw, Pilot Screw, Stop Washer Spring Valve, Starter Spring O-Ring Cap Cap, Sealing Hose, Vent SCREW(TOP COVER) Cover 7
10 CLUTCH ASSEMBLY [94298] Pulley, Driven - Assembly (inc. 2-21) Clutch, Centrifugal - Assembly (inc. 3-8) Ring, Retaining Plate, Clutch Spring Weight, Clutch Roller Plate, Clutch SPECIAL NUT 28MM Face, Driven - Fixed (inc ) Bearing Ring, Retaining Bearing Seal Pin, Guide Guide, Roller Face, Driven - Movable O-Ring Sleeve, Spring Spring 8
11 Sleeve, Spring Clutch, Outer Sleeve Nut Plate, Ramp Slide Roller Face, Drive - Movable (inc ) Ring, Retaining Sleeve Belt, Drive Sleeve Face, Drive - Fixed Washer Nut 9
12 COOLING ASSEMBLY [92560] Fascia, Radiator BOLT WASH 5*12 **9000 C Screen, Radiator SCREW WASHER 4MM Fan, Cooling Motor, Fan Shroud, Fan BOLT WASHER 6* Clamp, Wire Bracket, Radiator - Upper Grommet BOLT WASHER 6* Screw, Cap Radiator Assembly Switch, Temperature Bracket, Radiator - Lower Hose, Overflow (inc. 18) Clamp, Hose Cap, Filler Neck Neck, Filler 10
13 BOLT FLANGE 6* CLIP WATER HOSE Hose, Coolant - Filler Neck/Radiator Clamp, Hose Hose, Coolant - Radiator/Water Pump Hose, Cooling - Engine/Radiator Shield, Reservoir Tank Cap, Reservoir Tank, Reservoir Hose, Drain (inc. 31) Clamp, Hose Hose, Reservoir Tank (inc. 33 and one No. 31) Clamp, Hose BOLT FLANGE SH 6* Housing, Thermostat O-Ring Unit, Thermostat Thermostat Cap, Thermostat Screw, Machine 11
14 COOLING DUCT ASSEMBLY [90401] Duct, Inlet SCREW TAPPING 5*16 (CIRCLE HEAD) Clamp w/screw (inc. 4) Screw, Machine Duct, Cooling Clamp w/screw Clamp w/screw Duct, Cooling 12
15 CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY [300516] Complete Engine Assembly Screw, Cap Cover, Cylinder Head Gasket Plate, Stop NUT TAPPET ADJUSTING SCREW TAPPET ADJUSTING Arm, Rocker Nut, Lock WASHER 8MM HOLDER COMP CAM SHAFT Shaft, Rocker Arm - Intake Shaft, Rocker Arm - Exhaust Camshaft SPARK PLUG-NGK DPR7EA-9 DPR7EA Pin, Dowel Cotter, Valve RETAINER VALVE SPRING Spring, Valve - Outer Spring, Valve - Inner 13
16 Seat, Valve Spring SEAL VALVE STEM Valve, Exhaust Valve, Intake Nut Flange, Intake (inc. 26) O-Ring Bolt, Stud Head, Cylinder (inc. 29) BOLT SEALING 12MM Screw, Cap Washer Bolt, Stud Gasket, Cylinder Head Cylinder GASKET CYLINDER Clamp, Routing Insert, Intake Flange Clamp, Intake Flange 14
17 ELECTRICAL AND WIRING HARNESS ASSEMBLY [96092] Harness, Main (inc. 2-4) Fuse - 10 Amp Fuse - 15 Amp Fuse - 30 Amp Box, Fuse Diode, Neutral AR BAND OIL HANDLE NUT FLANGE 6MM Relay, Starter Regulator, Voltage Coil, Ignition (inc. 10) Cap, Noise Suppression BOLT FLANGE 6*16MM Relay, Start-in-Gear CDI Unit (inc. 14) Cushion, CDI Unit AR Tie, Cable SUB CORD Cable, Battery Control, Fan Motor 15
18 Control, Hazard 16
19 EXHAUST ASSEMBLY [96091] Pipe, Exhaust - Assembly (inc. 2-12).2 1 Pipe, Exhaust Part Number not Available BOLT FLANGE SH 6* Washer, Lock Washer Washer, Fiber Shield, Exhaust Washer BOLT FLANGE 6* Bushing Washer, Fiber Insert Nut Screw, Cap Nut Gasket, Exhaust 17
20 FRONT FRAME AND RELATED PARTS ASSEMBLY [100739] Frame, Main - Front End Cap, Frame Ring, Retaining Bearing Seal, Oil Seal, Dust PIPE COMP FR BUMPER BOLT FLANGE 8* NUT FLANGE 6MM Turn Signal - Right - Assembly (inc ) Turn Signal - Left - Assembly (inc ) Lens - Right Lens - Left Bulb Nut, Lock Relay, Turn Signal Insert Bracket, Turn Signal Relay Bracket, Support - Fender - Front - Right 18
21 Bracket, Support - Fender - Front - Left BOLT FLANGE 6* Screw, Cap Horn, Electric - 12V Screw, Machine Lock, Steering Bracket, Mounting - Engine BOLT FLANGE 10* NUT U 10MM SCREW,CAP-HFH M10X1.25X Screw, Cap Insert Grommet Bracket, Mounting - Radiator Bracket, Mounting - Fender Support - Right Bracket, Mounting - Fender Support - Left Bracket, Support - Gas Tank Nut, Stamped 19
22 FRONT SUSPENSION ASSEMBLY [96376] ARM ASSY R UP SWING-PLT (inc. 2-4) ARM ASSY LEFT UP SWING-PLT (inc. 2-4) Seal COLLAR SWING ARM Bearing NUT U 10MM BOLT FLANGE 10* SCREW,CAP-HFH M10X1.25X Knuckle - Assembly - Right Knuckle - Assembly - Left Shock/Spring Assembly White BOLT FLANGE 10* ARM ASSY R LOW SWING-PLT (inc. 2-4) ARM ASSY L LOW SWING (inc. 2-4) Washer Nut, Castle Pin, Cotter 20
23 FRONT WHEELS AND BRAKE ASSEMBLY [300513] Tire - Front Pin, Cotter Nut, Lock Wheel, Front Stem, Valve Nut, Lug Hub, Wheel - Assembly - Front (inc. 8-16).8 2 Hub, Wheel - Front Not a Service Part Seal, Oil Collar, Wheel - Inside Bearing Collar, Wheel - Center Bearing Collar, Wheel - Outside Seal, Oil Stud Disc, Brake - Front - Right Disc, Brake - Front - Left Screw, Shoulder Caliper Assembly - Front - Right (inc ) 21
24 .20 1 Housing, Caliper - Assembly - Right Not a Service Part Caliper Assembly - Front - Left (inc ).20 1 Housing, Caliper - Assembly - Left Not a Service Part Plug Pin Valve, Bleed Cap, Bleed Valve Bracket, Right Bracket, Left Pad, Brake - Set Spring Boot Bushing SEAL PISTON (FOOT BRAKE) DUST SEAL (FOOT BRAKE) PISTON (FOOT BRAKE) Screw, Cap 22
25 GAS TANK ASSEMBLY [100742] Shut-Off, Fuel SCREW Cover, Fuel Shut-Off Screw, Machine BOLT WASHER 5* Bracket, Mounting - Fuel Shut-Off Bracket, Support Hose Assembly (inc. 9) Clamp, Hose Filter, Fuel Hose Assembly (inc. 9) Cap, Gas Tank (inc. 13) Hose, Vent Strainer, Fuel Tank, Gas Screw, Cap Cover, Access Seal BOLT FLANGE 6* Insert 23
26 Grommet NUT FLANGE 6MM Grommet Hose Assembly (inc. 25 and two No. 9) Clamp, Hose 24
27 HANDLEBAR AND CONTROLS ASSEMBLY [300512] Screw, Cap End Cap, Handlebar GRIP,HANDLE-4040 SPEC Handlebar Case, Throttle - Assembly CABLE COMP THROT AR Tie, Cable Clamp, Handlebar - Upper Clamp, Handlebar - Lower Washer Nut Mirror Assembly - Right Mirror Assembly - Left Cable, Choke Switch, Control - Assembly 25
28 HYDRAULIC AND PARKING BRAKE ASSEMBLIES [96378] Brake Assembly - Right (inc. 2-5) Screw, Machine Cover, Reservoir Diaphragm Clamp, Handlebar Screw, Cap BOLT HANDLE LEVER **(0) C Lever, Brake - Right - Assembly (inc. 9-11) Pin, Brake Lever Spring Lock, Brake Lever Ring, Retaining Switch, Brake NUT FLANGE 6MM OIL BOLT 10*22 **6110-M1 C WASHER OIL BOLT **(1) C Hose, Brake - Right Brake Assembly/Brake Assist OIL BOLT 10* Brake Assist Hose, Brake - Brake Assist/Front Brake Hose 26
29 Hose, Brake w/junction Block BOLT FLANGE 8* BOLT FLANGE 6* Clamp, Brake Hose Hose, Brake - Brake Assist/Rear Brake Assembly BOLT FLANGE 6* AR Tie, Cable - 8 in MASTER CYLINDER ASSY RR(ACE) (inc and one No. 37) Reservoir, Brake (inc ) Screw, Machine Cover, Reservoir Clamp, Hose Hose, Brake Nut, Jam Actuator, Push Rod Connector Screw, Machine Pin, Clevis Washer Pin, Cotter Spring, Set Switch, Brake Spring, Stop Pin, Cotter Lever, Brake Washer Hose, Brake - Brake Assist/Rear Caliper Clamp, Brake Hose Hose, Brake - Brake Assist/Left Brake Assembly CYLINDER SET RR MASTER (inc ) Screw, Machine Cover, Reservoir Diaphragm SW ASSY RR STOP Screw, Shoulder Lever, Brake - Left Lever, Park Brake Bumper Lever, Gear Shift 27
30 Bracket, Retaining Screw, Machine Pin, Pivot Cable, Brake Screw, Cap Caliper, Brake (inc. 66) BRAKE PAD ASSY 28
31 INSTRUMENT POD ASSEMBLY [100740] Gauge, Speedometer (inc. 2) Bulb Washer NUT FLANGE 6MM CABLE COMP SPDMT Instrument Pod Black Clip, Retaining Switch, Ignition - Assembly (inc. 9-10) Cover, Key Key, Ignition - Set - Right-Side Cut Key, Ignition - Set - Left-Side Cut Running Light Assembly (inc ) Harness Bulb Lens Screw, Self-Tapping PILOT LAMP COMP (inc. 17) Bulb SCREW TAPPING 5*16 (CIRCLE HEAD) Screw, Cap 29
32 Bracket, Instrument Pod Grommet Insert 30
33 LEFT CRANKCASE AND COVER ASSEMBLY [100507] Crankcase Bearing BRG NEEDLE 20*26* BRG BALL RADIAL Bearing Bolt, Stud Screw, Cap Retainer, Bearing Screw, Cap Clamp, Wire Bearing, Ball Spring, Seat Washer Screw, Seat Retainer, Wire Seal, Oil Seal, Oil Screw, Cap Switch, Gear Position (inc. 20) O RING 15.5X2.5 31
34 Screw, Cap Retainer, Bearing BEARING BALL RADIAL Gasket, Cover Pin, Dowel Cover, Crankcase Screw, Cap Pin, Dowel Screw, Cap Gasket, Cover Cover BOLT FLANGE SH 6* Screw, Cap Cover, Protective Screw, Machine 32
35 PISTON AND CRANKSHAFT ASSEMBLY [94280] RING SET PISTON Piston Pin, Piston Circlip Crankshaft Assembly Spring Oil Through Washer, Thrust Nut Balancer, Crankshaft (inc. 11) Pin, Dowel 33
36 REAR AXLE AND BRAKE ASSEMBLY [96088] Chain, Drive Sprocket, Drive NUT U 10MM Flange, Sprocket O-Ring Bolt, Carriage Axle, Rear Hub, Rear - Assembly (inc. 9-11) Seal Bearing Spacer Ring, Retaining Screw, Cap Screw, Cap BRACKET,CALIPER - ASSY (inc. 16) O-Ring Ring, Retaining Insert Screw, Shoulder Hub, Brake Disc (inc. one No. 5) 34
37 Disc, Brake Spacer Pin, Dowel Washer, Lock Caliper Assembly - Rear (inc ) Cover, Dust Pin, Lock Pin Screw, Cap Cap, Bleed Valve Valve, Bleed Plug Spring, Brake Pad Bracket Pad, Brake - Set PISTON, CALIPER SEAL PISTON (FOOT BRAKE) Seal, Dust Screw, Cap 35
38 REAR FRAME, TAILLIGHT, AND RELATED PARTS ASSEMBLY [96081] Frame, Main - Rear Grommet Support, Gas Tank Screw, Cap Screw, Cap NUT FLANGE 10MM BOLT FLANGE 8* Footpeg Bracket, Mounting - Fender - Right STAY L RR FENDER Nut Bracket, Support - Fender - Rear - Right Bracket, Support - Fender - Rear - Left Nut, Stamped NUT FLANGE 6MM Bracket, Mounting - Fender - Rear - Right Bracket, Mounting - Fender - Rear - Left Taillight - Assembly (inc ) Screw, Self-Tapping 36
39 Lens, Taillight BULB TAIL & STOP 12V21W/5W Housing, Taillight Insert Mount, License Plate Reflector, Rear Red Nut, Lock Turn Signal - Right - Assembly (inc ) Turn Signal - Left - Assembly (inc ) Bulb Lens - Right Lens - Left 37
40 REAR SUSPENSION ASSEMBLY [98387] Fork, Rear - Assembly (inc. 2-5) Cap Bushing Axle, Rear Fork Fitting, Grease Screw, Cap Guide, Chain Guide, Chain Screw, Self-Tapping Bushing Nut Screw, Cap Screw, Cap NUT U 10MM Link, Arm - Assembly SCREW,CAP-HFH M10X1.25X Screw, Cap Shock/Spring Assembly White Screw, Cap Link, Shock - Assembly (inc ) 38
41 Seal Seal Collar Bearing Sleeve Axle BOLT WASHER 6* PROTECTOR ASSY RR FORK (inc ) Guard, Chain Guard, Brake Disc Washer Rivet 39
42 REAR WHEEL ASSEMBLY [300514] Pin, Cotter Nut Hub, Wheel (inc. 4) Stud Tire Wheel - Assembly Stem, Valve Nut, Lug 40
43 REED VALVE ASSEMBLY [100477] Screw, Cap Screw, Cap Cover, Reed Valve Valve, Reed Gasket Pipe, Air Nut, Cap Gasket Bolt, Stud Duct, Air Clamp Clamp Vacuum, Air - Assembly Mount, Air Vacuum Duct, Air 41
44 Hose Assembly Clamp, Hose 42
45 RIGHT CRANKCASE AND COVER ASSEMBLY [94278] Cover, Crankcase (inc. 2-7) Plate, Sight Gauge.3 1 Washer Part Number not Available Screw, Cap Seal, Mechanical Seal, Oil Bearing Pin, Dowel Gasket Gauge, Oil Level (inc. 11) O-RING 18* Cap, Spark Plug O-Ring Screw, Cap Screw, Cap BOLT FLANGE 6*16MM Cap, Crankcase Cover (inc ) O-RING 30.8MM O-Ring 43
46 BOLT FLANGE SH 6* Screw, Cap Screw, Cap Washer Cover, Water Pump Gasket, Water Pump Pin, Dowel Impeller, Water Pump Washer Hose, Coolant - Water Pump/Cylinder CLIP WATER HOSE Shaft, Water Pump Bearing Ring, Retaining Bolt, Stud Crankcase - Right (inc. 36) Plug SCREEN OIL FILTER SPG OIL FILTER SCREEN Cap, Inspection Bearing Gasket, Crankcase BOLT FLANGE SH 6* BOLT DRAIN PLUG SPECIAL 44
47 SEAT, BATTERY, AND TOOL KIT ASSEMBLIES [94293] Seat Assembly (inc. 2-3) Latch, Seat Nut BUMPER,SEAT Bumper, Seat - Front Kit, Tool Retainer, Tool Kit Wrench, Spanner Optional Hold-Down, Battery BATTERY YTX12-BS 45
48 SHIFT LEVER ASSEMBLY [96380] Knob, Gear Shift Screw, Cap Rod, Gear Shift Pin, Shift Lever WASHER PLAIN 8MM Spring Bracket, Gear Shift NUT HEX 6MM Screw, Cap Pin, Cotter Cover, Gear Shift Nut Lever, Gear Shift Nut, Cap Tie Rod - Assembly (inc ) Ball Joint, Tie Rod - Left WASHER SPRING 8MM Nut Tie Rod Nut 46
49 Ball Joint, Tie Rod - Right Link, Gear Shift Screw, Cap BOLT FLANGE 8*28 47
50 STARTER MOTOR, MAGNETO, AND OIL PUMP ASSEMBLY [92456] Stator Screw, Machine Screw, Cap Screw, Cap Rotor/Flywheel Clutch, One-Way Shaft, Starter Reduction Gear, Starter Reduction GEAR COMP STARTING CLUTCH Motor, Starter (inc ) O-Ring Nut w/washer BOLT FLANGE SHF 6* Cable, Battery/Starter (inc ) Boot, Terminal Boot, Terminal Cable, Battery/Ground Separator, Oil Screw, Cap Ring, Retaining 48
51 Chain, Oil Pump Sprocket, Oil Pump Screw, Cap Pump, Oil (inc ) Screw, Cap Pin, Alignment 49
52 STEERING ASSEMBLY [96082] STEM COMP,STEERING (ACE) STEERING BUSHING Block, Mounting - Steering Post Screw, Cap Clamp, Mounting Block Nut, Castle Washer Spacer Nut Pin, Cotter Tie Rod - Assembly (inc ) Ball Joint, Tie Rod - Left Nut, Hex - Right-Hand Thread Tube, Tie Rod Nut - Right-Hand Thread 50
53 Ball Joint, Tie Rod - Right Pin, Cotter 51
54 TRANSMISSION ASSEMBLY [96096] BOLT FLANGE SH 6* Cover, Chain Guide, Chain SCREW TAPPING 5*16 (CIRCLE HEAD) Screw, Cap Plate, Retaining Sprocket, Drive CIR CLIP EX 25MM Shaft, Output Shaft, Driven Drum, Gear Shift - Assembly (inc. two No. 12 and 13-14) E-Ring Washer, Thrust Spring SPINDLE COMP DRUM SHIFT Shaft, Shift Fork Fork, Shift Ring, Retaining Shaft, Main WASHER THRUST 25MM 52
55 Gear, Reverse Bearing Washer Ring, Retaining Gear Select, Sliding Washer, Thrust Gear, Forward Bushing Spacer Washer, Thrust Shaft, Counterbalance 53
56 TRANSMISSION CASE ASSEMBLY [96095] Case, Transmission BOLT DRAIN PLUG SPECIAL Screw, Self-Tapping BOLT FLANGE 8* Seal, Oil Screw, Cap Washer Pin, Dowel Gasket BRG BALL RADIAL Bearing Bearing Seal, Oil Bearing Tube, Breather (inc. 16) Clamp, Hose BOLT TACHOMETER Gear, Speedometer Drive THRUST WASHER 8MM OIL SEAL 12*18*3 54
57
58 The illustrations used in this Parts Manual are for reference to replacement part numbers only and are not to be used for assembly. For assembly procedures, use an Arctic Cat Service Manual. For a complete list of related items, refer to the current accessory catalog. Once printed, Arctic Cat does not guarantee the accuracy of the information contained in this manual. Our parts lists and illustrations are constantly revised to reflect part number changes, discrepancies, and enhancements. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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