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Arctic Cat 2016 90 Utility User Manual

Arctic Cat 2016 90 Utility
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SERVICE MANUAL
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Table of Contents

Questions and Answers:

Arctic Cat 2016 90 Utility Specifications

General IconGeneral
BrandArctic Cat
Model2016 90 Utility
CategoryOffroad Vehicle
LanguageEnglish

Summary

General Information and Specifications

Specifications

Details key technical specifications for the ATV chassis and engine systems.

Torque Specifications

Gasoline-Oil-Lubricant

Preparation For Storage

Preparation After Storage

Periodic Maintenance and Tune-Up

Air Filter

Procedure for cleaning and maintaining the air filter element for optimal engine performance.

Valve/Tappet Clearance

Steps to check and adjust valve clearance to ensure proper engine operation.

Testing Engine Compression

Spark Plug

Muffler/Spark Arrester

Transmission Lubricant

Engine Oil

Brake Systems

Checking Front Wheel Brake

Steps to inspect the front wheel brake for proper function and engagement.

Checking Rear Wheel Brake

Steps to inspect the rear wheel brake for proper function and engagement.

Adjusting Front Wheel Brake

Adjusting Parking Brake

Measuring and Replacing Brake Shoes/Pads

Removing Front Brake Shoes

Instructions for removing front brake shoes for inspection or replacement.

Removing Rear Brake Pads

Procedure for removing rear brake pads for inspection or replacement.

Inspecting and Measuring

Guide for inspecting and measuring brake pad thickness and disc condition.

BLEEDING

Replacing Drive Belt

REMOVING

Steps for removing the drive belt cover and related components.

CHECKING

Procedure to inspect the drive belt for wear and measure its condition.

INSTALLING

Steps for installing the drive belt and cover securely.

Adjusting Shift Linkage

Steering/Body/Controls

Body

Instructions for removing body panels and related components for access.

Steering Post/Handlebar/Tie Rods

REMOVING

Steps for removing steering post, handlebar, and tie rod components.

Handlebar Grip

REMOVING

Procedure for removing handlebar grips using air pressure.

INSPECTING

Guide for inspecting handlebar grips for wear or damage.

INSTALLING

Steps for installing handlebar grips with adhesive.

Handlebar Switch

REMOVING

Instructions for disconnecting and removing the handlebar switch assembly.

INSTALLING

Steps for installing the handlebar switch assembly securely.

Hand Brake Lever Assemblies

REMOVING

Steps for removing the right handlebar grip and throttle control housing.

Headlights

BULB VERIFICATION

Visual inspection of the headlight bulb for filament or darkening.

VOLTAGE

Procedure to test headlight bulb voltage with the engine running.

Brakelight/Taillight

Troubleshooting Steering

Problem: Handling too heavy or stiff

Identifies issues causing stiff handling and their potential remedies.

Problem: Steering oscillation

Diagnoses causes of steering wobble and suggests troubleshooting steps.

Problem: Steering pulling to one side

Lists reasons for the ATV pulling to one side and solutions.

Problem: Steering impaired

Addresses general steering impairments and their corrective actions.

Problem: Tire wear rapid or uneven

Troubleshoots causes of rapid or uneven tire wear.

Problem: Steering noise

Identifies sources of steering noise and their remedies.

Engine/Transmission Service

Removing Engine/Transmission

Steps for safely removing the engine and transmission assembly from the ATV frame.

Top-Side Components Service

Removing Top-Side Components

Detailed steps for removing camshaft, cylinder head, and related top-end parts.

Servicing Top-Side Components

VALVE ASSEMBLY

Procedure for inspecting and servicing valve seats, stems, and faces.

Cleaning/Inspecting Cylinder Head Assembly

Inspects combustion area for cracks, burned valves, or carbon build-up.

Measuring Valve Stem to Guide Clearance

Procedure to measure valve stem to guide clearance for wear detection.

PISTON ASSEMBLY

Inspecting Piston

Inspects piston for cracks, seizure marks, scuffing, and signs of blowby.

Removing Piston Rings

Steps for removing piston rings from the piston.

Measuring Piston-Ring End Gap (Installed)

Procedure to measure piston ring end gap when installed in the cylinder.

CYLINDER/CYLINDER HEAD ASSEMBLY

Cleaning/Inspecting Cylinder Head

Procedure for cleaning and inspecting the cylinder head combustion chamber.

Measuring Cylinder Head Distortion

Steps to measure cylinder head distortion using a straightedge and feeler gauge.

Honing Cylinder

Inspecting Cam Chain Guide

Inspecting Camshaft Bearing/Sprocket

Installing Top-Side Components

A. PISTON

Lubricate and install piston on connecting rod with circlips.

B. CYLINDER

Install cylinder gasket, piston holder, and slide cylinder over piston.

C. CYLINDER HEAD/CAMSHAFT

D. CAMSHAFT HOLDER/ROCKER ARMS

Place camshaft holder, flat washers, and nuts on cylinder head.

Left-Side Components

Removing Left-Side Components

Steps for removing V-belt cover, drive clutch, centrifugal clutch, and starter components.

Right-Side Components

Removing Right-Side Components

Steps for removing cooling fan, rotor/flywheel, stator coil, and oil pump.

TRANSMISSION

Removing

Procedure to remove shift arm, transmission case cover, and output shafts.

Disassembling

Steps for disassembling the transmission, including shafts and forks.

Servicing Right-Side Components

TRANSMISSION COMPONENTS

Inspection and servicing of gears, shafts, and other transmission internal parts.

Disassembling Crankcase Halves

Center Crankcase Components

Servicing Crankcase Components

Assembling Crankcase Half

Installing Engine/Transmission

Troubleshooting Engine

Problem: Engine will not start or is hard to start (Compression too low)

Identifies causes of low compression and potential remedies.

Problem: Engine will not start or is hard to start (No spark)

Diagnoses ignition system faults preventing starting.

Problem: Engine stalls easily

Identifies causes for the engine stalling and their solutions.

Fuel/Lubrication

Carburetor

Instructions for removing the carburetor from the intake manifold.

Carburetor Disassembly

DISASSEMBLING

Steps for disassembling the carburetor for cleaning and inspection.

Carburetor Cleaning and Inspection

CLEANING AND INSPECTING

Procedures for cleaning and inspecting carburetor components for proper function.

Throttle Cable Free-Play

Engine RPM (Idle)

Gas Tank

REMOVING

Steps for removing the gas tank from the ATV frame.

Gas Tank Valve

REMOVING/INSPECTING

Procedure to remove and inspect the gas tank valve.

INSTALLING

Steps for installing the gas tank valve onto the frame.

Troubleshooting Fuel System

Problem: Starting impaired

Diagnoses issues preventing engine starting and suggests remedies.

Problem: Idling or low speed impaired

Troubleshoots problems with engine idling or low-speed operation.

Problem: Medium or high speed impaired

Addresses performance issues at medium and high speeds.

Problem: Overflow and fuel level fluctuations

Diagnoses causes of fuel overflow and fluctuations.

Electrical System Overview

Battery

Guide for proper charging and maintenance of the ATV battery.

Ignition Switch

Ignition Coil Service

PRIMARY WINDING RESISTANCE

Tests the primary winding resistance of the ignition coil.

SECONDARY WINDING RESISTANCE

Tests the secondary winding resistance of the ignition coil.

Handlebar Control Switches

RESISTANCE (Starter Button)

Tests the resistance of the starter button switch.

RESISTANCE (Emergency Stop)

Tests the resistance of the emergency stop switch.

Brakelight Switches

VOLTAGE (Wiring Harness Connector)

Tests the voltage at the brakelight switch wiring harness.

RESISTANCE (Brakelight Switch Connector)

Tests the resistance of the brakelight switch connector.

Headlights

BULB VERIFICATION

Visual inspection of the headlight bulb for filament or darkening.

VOLTAGE

Procedure to test headlight bulb voltage with the engine running.

Stator Coil Service

VOLTAGE (No Load)

Tests stator coil voltage output without load.

RESISTANCE

Tests stator coil resistance.

Regulator/Rectifier Service

VOLTAGE

Tests the voltage output of the regulator/rectifier.

Timing Sensor Service

RESISTANCE

Tests the resistance of the timing sensor.

Starter Motor Service

REMOVING

Steps for removing the starter motor from the engine.

INSTALLING

Steps for installing the starter motor onto the engine.

Choke Circuit Service

VOLTAGE

Tests the voltage supplied to the choke circuit.

Fuse

Troubleshooting Electrical

Problem: Spark absent or weak

Diagnoses causes of absent or weak spark and provides remedies.

Problem: Spark plug fouled with carbon

Identifies reasons for carbon fouling and suggests solutions.

Problem: Spark plug electrodes overheat or burn

Troubleshoots causes of spark plug overheating or burning.

Problem: Magneto does not charge

Diagnoses issues with the magneto not charging the battery.

Problem: Magneto charges, but charging rate is below the specification

Troubleshoots low battery charging rates from the magneto.

Problem: Magneto overcharges

Identifies causes of magneto overcharging the battery.

Problem: Charging unstable

Diagnoses causes of unstable battery charging.

Drive System Overview

Drive Chain/Sprockets

Checks and adjusts drive chain slack and inspects sprockets.

Front Drive Sprocket Service

Rear Sprocket Service

Rear Hub and Drive Axle

REMOVING REAR HUB/DRIVE AXLE

Steps for removing the rear hub and drive axle assembly.

Axle Housing Service

REMOVING AXLE HOUSING

Steps for removing the axle housing from the swing arm.

Bearings and Seals Service

REMOVING BEARINGS AND SEALS

Instructions for removing axle housing bearings and seals.

Front Hub Service

REMOVING HUB

Steps for removing the front hub assembly from the spindle.

CLEANING AND INSPECTING

Procedures for cleaning and inspecting hub components.

REMOVING HUB BEARINGS AND SEALS

Instructions for removing hub bearings and seals.

Installing Hub Bearings and Seals

Installing Hub

Brake Systems Information

Suspension Overview

Shock Absorbers

General inspection points for shock absorbers.

REMOVING FRONT SHOCK ABSORBERS

Steps for removing the front shock absorbers from the frame.

REMOVING REAR SHOCK ABSORBER

Steps for removing the rear shock absorber from the frame.

Installing Front Shock Absorbers

Installing Rear Shock Absorber

A-Arm Service

REMOVING

Steps for removing the A-arm components from the ATV frame.

A-Arm Installation

INSTALLING

Procedures for lubricating and installing the A-arm.

Swing Arm Service

REMOVING

Steps for removing the swing arm assembly from the ATV.

Wheels and Tires

TIRE SIZE

Information on approved tire sizes and types for the ATV.

TIRE INFLATION PRESSURE

Specifies recommended tire inflation pressure.

REMOVING

Steps for removing the ATV wheels.

Wheel and Tire Cleaning and Inspection

Wheel and Tire Installation

Wheel and Tire Checking and Inflating

Troubleshooting Suspension

Problem: Suspension too soft

Identifies causes of soft suspension and suggests remedies.

Problem: Suspension too stiff

Troubleshoots causes of stiff suspension and offers solutions.

Problem: Suspension noisy

Diagnoses sources of suspension noise and their remedies.

Problem: Rear wheel oscillation

Identifies causes of rear wheel wobble and their solutions.

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