2007 Arctic Cat 250 DVX & Utility ATV Service Manual

Factory service manual for the 2007 Arctic Cat ATV 250 DVX and Utility models, published August 2006, covering maintenance, fault diagnosis, engine repair and chassis service.

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One printable English PDF with 146 pages, including two preliminary pages containing the foreword and main table of contents.

Engine, CVT and Chassis Service Coverage

These selected service topics outline the repair coverage rather than reproduce the full contents. Other subjects include storage preparation and muffler/spark-arrester cleaning.

• Engine and tune-up: Engine removal and installation, top-end inspection, crankcase separation, valve/tappet adjustment, and engine-compression testing.

• CVT and transmission: Step-by-step V-belt replacement, centrifugal-clutch disassembly, pulley inspection, and separate DVX and Utility transmission procedures.

• Fuel system: Keihin carburetor removal, disassembly, cleaning and inspection, with float-height checks and fuel-tank/valve service.

• Cooling and lubrication: Radiator and fan removal, thermostat testing, water-pump seal service, and oil-pump inspection.

• Electrical diagnosis: Ignition, charging and starting-system tests, start-in-gear relay checks, and model-specific indicator and gauge testing.

• Chassis and brakes: Rear axle, front A-arm, swing arm and steering-post service, hydraulic brake bleeding, and brake-pad replacement.

Written for service personnel, this manual includes procedures requiring precision measuring tools, specialized test equipment and appropriate workshop experience.

In-Frame Service and Internal Engine Repair

Top-side, left-side and right-side service can be performed with the engine/transmission in the frame; center-crankcase work requires removal. These distinctions help you plan access before teardown.

Valve, camshaft, piston, ring and cylinder inspections provide the measurements needed to assess wear before reassembly. Separate torque entries distinguish the cylinder-head-to-cylinder fasteners from the camshaft-holder fasteners.

The starter one-way clutch bearing is directional and will not function correctly if reversed. The drive-pulley installation notes explain how an under-tightened pulley can cause severe drive sheave or crankshaft damage.

DVX and Utility Drivetrain Differences

Separate transmission sections cover shift forks, shafts and clutch dogs; the Utility procedures also address secondary bevel gears. Utility recoil-starter disassembly and reassembly are covered as well.

Rear Drive Assembly Schematics distinguish the two layouts. The Utility axle procedures include swing-arm bearing and seal replacement, while a noisy or binding final-drive gearcase is replaced as an assembly. Separate DVX and Utility torque tables provide model-specific fastener specifications.

Carburetor, Oil Flow and Cooling Service

The Carburetor Schematic identifies the PTG-22’s jets, float valve and diaphragm alongside the cleaning and inspection procedures. The Viscosity Chart and Oil Flow Chart accompany lubricant selection and oil-pump inspection; a defective oil pump is replaced.

Cooling-system service includes thermostat operation checks and water-pump mechanical-seal replacement, with instructions for refilling the system and checking for trapped air.

Electrical Tests and Instrument Checks

Electrical tests provide wire colors, connector locations, resistance checks and peak-voltage conditions for tracing faults before replacing components. The manual specifies the Fluke Model 73 Multimeter (P/N 0644-191) with Peak Voltage Reading Adapter (P/N 0644-307) for peak-voltage testing.

DVX indicator lights and the Utility LCD gauge have separate checks. The starter motor and LCD gauge are tested and replaced rather than internally rebuilt. Full vehicle wiring diagrams are not included.

Suspension, Steering and Hydraulic Brakes

Front and Rear Suspension Assembly Schematics support A-arm, shock and swing-arm work. The procedures add bearing and bushing replacement, rear spring-preload adjustment, and toe-in/toe-out measurement.

Brake coverage includes pad replacement and burnishing, hydraulic bleeding, and lever/pedal assembly inspection. Both master cylinders are non-serviceable assemblies, so those procedures cover replacement rather than internal overhaul.

Safety note: Always follow standard shop safety practices and verify vehicle stability on your lift before beginning any teardown, as improper handling of heavy ATV components can lead to serious injury.

Selected Jetting, Valve and Cooling Data

For both variants, the carburetor tables specify a 95 main jet and 35 slow jet for the Keihin PTG-22.

Top-end data lists intake and exhaust valve face diameters of 33 mm and 28 mm, respectively. Valve/tappet adjustment ranges for a cold engine are 0.03–0.08 mm intake and 0.08–0.13 mm exhaust.

Cooling-system capacity is listed as 1.6 L (1.7 U.S. qt), alongside the related coolant inspection and refill instructions.