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Arctic Cat DVX 90 2010 User Manual

Arctic Cat DVX 90 2010
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FOREWORD
This manual contains service, maintenance, and troubleshooting information for the 2010 Arctic Cat Y-12+ Youth
ATV. The manual is designed to aid service personnel in service-oriented applications and may be used as a text-
book for service training.
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. A troubleshooting section is also included in this manual.
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 follow the directive because it deals with the possibility of severe personal injury or even death. A
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
information worthy of particular attention. The symbol
AT THIS POINT directs the technician to certain
and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs 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.
© 2009 Arctic Cat Inc. July 2009
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Back to TOC
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

Table of Contents

Questions and Answers:

Arctic Cat DVX 90 2010 Specifications

General IconGeneral
BrandArctic Cat
ModelDVX 90 2010
CategoryOffroad Vehicle
LanguageEnglish

Summary

FOREWORD

SECTION 1 - GENERAL INFORMATION

Specifications

Detailed technical data for chassis, engine, and drivetrain components.

Torque Specifications

Specific torque values for various engine, chassis, and brake components.

Tightening Torque (General Bolts)

General guidelines for tightening bolts based on thread diameter.

Break-In Procedure

Recommended procedure for breaking in a new ATV engine for optimal life.

Gasoline-Oil-Lubricant

Recommended types of gasoline, engine oil, and transmission lubricant.

Preparation For Storage

Steps to properly service and prepare the ATV for storage.

Preparation After Storage

Recommended procedure for taking the ATV out of storage.

SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP

Periodic Maintenance Chart

A chart detailing maintenance intervals and actions for various ATV components.

Lubrication Points

Locations and components requiring periodic lubrication for smooth operation.

Air Filter

Procedure for cleaning and servicing the air filter element.

Valve/Tappet Clearance

How to check and adjust valve/tappet clearance for optimal engine performance.

Testing Engine Compression

Method for testing engine cylinder compression to diagnose performance issues.

Spark Plug

Information on checking and maintaining the spark plug for proper ignition.

Muffler/Spark Arrester

Procedure for cleaning the spark arrester assembly within the muffler.

Transmission Lubricant

Steps for checking and changing the transmission lubricant level.

Engine Oil

Procedure for checking and changing the engine oil level.

Brakelight/Taillight

Procedures for replacing the brakelight and taillight bulbs.

Brake Systems

Checks and adjustments for front and rear brake systems for proper functionality.

Replacing Drive Belt

Step-by-step guide for removing and installing the drive belt.

Adjusting Shift Linkage

How to adjust the shift linkage for proper gear engagement and indicator lights.

SECTION 3 - ENGINE/TRANSMISSION

Specifications

Technical specifications for engine and transmission components.

Removing Engine/Transmission

Step-by-step guide to remove the entire engine and transmission assembly from the frame.

Top-Side Components

Procedures for removing and servicing components located on the top of the engine.

Left-Side Components

Procedures for removing and servicing components located on the left side of the engine.

Removing Right-Side Components

Procedures for removing components located on the right side of the engine.

Transmission Removing

Steps for disassembling the transmission from the engine case.

Disassembling Crankcase Halves

Procedures for disassembling and servicing the center crankcase components.

Servicing Crankcase Components

Inspection and servicing of crankshaft, bearings, and connecting rod.

Assembling Crankcase Half

Steps for assembling the crankcase halves.

Installing Engine/Transmission

Step-by-step guide to install the engine and transmission assembly into the frame.

SECTION 4 - FUEL/LUBRICATION

Carburetor Specifications

Detailed specifications for the carburetor settings and components.

Carburetor Schematic

Diagram identifying the various parts of the carburetor.

Carburetor REMOVING

Step-by-step instructions for removing the carburetor from the ATV.

Carburetor DISASSEMBLING

Procedures for disassembling the carburetor into its individual components.

Carburetor CLEANING AND INSPECTING

How to clean and inspect carburetor components for wear or damage.

Carburetor ASSEMBLING

Steps for reassembling the carburetor after cleaning or repair.

Throttle Cable Free-Play

Procedure for adjusting the free-play in the throttle cable for proper response.

Engine RPM (Idle)

How to adjust the engine idle speed using a tachometer.

Gas Tank REMOVING

Step-by-step instructions for removing the ATV's gas tank.

Fuel Valve

Information on the fuel valve positions and its operation.

Gas/Vent Hoses

Guidelines for replacing and inspecting fuel and vent hoses.

SECTION 5 - ELECTRICAL SYSTEM

Specifications

Electrical system specifications including ignition, magneto, and charging system values.

Electrical Connections

Importance of checking electrical connections for proper function and troubleshooting.

Switches

Checking operation of ignition, emergency stop, and brakelight switches.

Battery

Procedures for cleaning, charging, and maintaining the ATV battery.

Testing Electrical Components

Guidelines for testing electrical components using a multimeter.

Timing Sensor

Procedures for testing the peak voltage and resistance of the timing sensor.

CDI/Ignition Coil

Testing procedures for the CDI unit and ignition coil.

Stator Coil

Testing voltage and resistance of the stator coil.

Choke Circuit

Testing the voltage output of the choke circuit.

Brakelight Switch

Testing voltage and resistance of the brakelight switch.

Fuse

Location and testing procedure for the main electrical fuse.

Ignition Coil

Testing primary and secondary winding resistance of the ignition coil.

Ignition Switch

Testing voltage and resistance of the ignition switch.

Handlebar Control Switches

Resistance testing for starter button and emergency stop switches.

Magneto Assembly

Procedures for removing, inspecting, and installing the magneto assembly.

Starter Motor

Information on removing and replacing the starter motor.

Regulator/Rectifier

Testing the voltage output of the regulator/rectifier.

Ignition Timing

Procedure for verifying ignition timing using a timing light and tachometer.

Headlights

Visual inspection and voltage testing of the headlight bulbs.

SECTION 6 - DRIVE SYSTEM

Drive Chain/Sprockets

Procedures for checking, adjusting, removing, and installing the drive chain and sprockets.

Removing Front Drive Sprocket

Steps to remove the front drive sprocket.

Installing Front Drive Sprocket

Steps to install the front drive sprocket.

Removing Rear Sprocket

Steps to remove the rear sprocket.

Installing Rear Sprocket

Steps to install the rear sprocket.

Rear Hub/Drive Axle

Procedures for removing, servicing, and installing the rear hub and drive axle.

Removing Bearings and Seals

How to remove bearings and seals from the axle housing.

Removing Axle Housing

Steps to remove the rear axle housing from the swing arm.

Installing Bearings and Seals

Procedures for installing bearings and seals into the axle housing.

Installing Axle Housing

Steps to install the axle housing onto the swing arm.

Installing Drive Axle/Rear Hub

Steps to install the drive axle and rear hub assembly.

Front Hub

Procedures for removing, cleaning, inspecting, and installing the front hub.

Troubleshooting (Drive System)

Common problems and remedies for the drive system components.

SECTION 7 - SUSPENSION

Shock Absorbers

Procedures for removing, installing, cleaning, and inspecting front and rear shock absorbers.

Removing Front Shock Absorbers

Steps to remove the front shock absorbers from the ATV.

Removing Rear Shock Absorber

Steps to remove the rear shock absorber from the ATV.

Installing Front Shock Absorbers

Steps to install the front shock absorbers onto the ATV.

Installing Rear Shock Absorber

Steps to install the rear shock absorber onto the ATV.

A-Arm

Procedures for removing, cleaning, inspecting, and installing the front A-arms.

Swing Arm

Procedures for removing, cleaning, inspecting, and installing the rear swing arm.

Wheels and Tires

Information on tire size, inflation, cleaning, inspection, and installation of wheels and tires.

Troubleshooting (Suspension)

Common problems and remedies related to suspension components.

SECTION 8 - STEERING/FRAME

Steering Post/Handlebar/Tie Rods

Procedures for removing, cleaning, inspecting, and installing steering post, handlebar, and tie rods.

Handlebar Grip

Procedures for removing, inspecting, and installing handlebar grips.

Troubleshooting (Steering/Frame)

Common problems and remedies related to steering and frame components.

SECTION 9 - CONTROLS

Handlebar Switch

Procedures for removing and installing handlebar switch assemblies.

Hand Brake Lever Assemblies

Procedures for removing and installing hand brake lever assemblies and master cylinders.

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