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Arctic Cat DVX 90/90 UTILITY User Manual

Arctic Cat DVX 90/90 UTILITY
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DVX 90/90 UTILITY
[ATV]
SERVICE MANUAL
2014

Table of Contents

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Arctic Cat DVX 90/90 UTILITY Specifications

General IconGeneral
BrandArctic Cat
ModelDVX 90/90 UTILITY
CategoryOffroad Vehicle
LanguageEnglish

Summary

Torque Specifications

Break-In Procedure

Gasoline-Oil-Lubricant

Periodic Maintenance/Tune-Up

Periodic Maintenance Chart

A comprehensive chart detailing maintenance items, intervals, and actions required.

Air Filter

Valve/Tappet Clearance

Testing Engine Compression

Spark Plug

Transmission Lubricant

Engine Oil

Brake Systems

Measuring/Replacing Brake Shoes/Pads

Instructions for removing and replacing front and rear brake shoes and pads.

Installing Front Brake Shoes

Installing Rear Brake Pads

BLEEDING (Brakes)

Replacing Drive Belt

Troubleshooting Brake System

Steering/Frame/Controls

Steering Post Installation

Hand Brake Lever Assemblies (REMOVING)

Hand Brake Lever Assemblies (INSTALLING)

Installing Front Brake Levers

Installing Brake Cables/Hoses

Troubleshooting (Steering)

Engine/Transmission

Removing Engine/Transmission

Detailed steps for removing the engine and transmission from the ATV frame.

Top-Side Components

Removing Top-Side Components

Removing Valves

Servicing Top-Side Components

Installing Valves

PISTON ASSEMBLY

Installing Piston Rings

CYLINDER/CYLINDER HEAD ASSEMBLY

Honing Cylinder

Cleaning/Inspecting Cylinder

Installing Top-Side Components

C. CYLINDER HEAD/CAMSHAFT

D. CAMSHAFT HOLDER/ROCKER ARMS

Removing Left-Side Components

Left-Side Components Removal

Procedures for removing V-belt cover, clutch, starter, and gear position switch.

Installing Left-Side Components

Left-Side Components Installation

Steps for installing gear switch, starter clutch, rotor, centrifugal clutch, and V-belt assembly.

Right-Side Components

Removing Right-Side Components

Right-Side Components Removal

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

E. TRANSMISSION

Removing Transmission

Steps for removing the transmission from the engine case.

Disassembling Transmission

Detailed instructions for disassembling the transmission.

F. MAIN SHAFT

Servicing Right-Side Components

Transmission Components Service

Inspection and servicing of various transmission gears and shafts.

OIL PUMP

Installing Right-Side Components

Center Crankcase Components

Disassembling Crankcase Halves

Detailed steps for separating the crankcase halves.

Servicing Crankcase Components

Assembling Crankcase Half

Installing Engine/Transmission

Troubleshooting

Engine Starting and Idling Issues

Troubleshooting for engine not starting, hard starting, and poor idling.

No Spark Issues

Diagnosing and resolving issues related to lack of spark.

Fuel Delivery Issues

Troubleshooting for no fuel reaching the carburetor.

Engine Performance Troubleshooting

Fuel/Lubrication

Carburetor (DISASSEMBLING)

Carburetor (CLEANING AND INSPECTING)

Carburetor (ASSEMBLING)

Carburetor (INSTALLING)

Engine RPM (Idle)

Gas Tank

Oil Pump Assembly

Oil Screen/Filter

Troubleshooting (Fuel/Lubrication)

Electrical System

Battery

Information on battery location, cleaning, and maintenance.

Testing Electrical Components

Ignition Coil

Magneto Assembly (REMOVING)

Ignition System Components and Testing

Troubleshooting (Electrical System)

Spark Issues Troubleshooting

Troubleshooting for spark absent or weak issues.

Magneto and Charging Issues

Diagnosing magneto charging problems and charging system instability.

Drive System

Drive Chain/Sprockets (Installing/Removing)

Rear Hub/Drive Axle

Removing Axle Housing

Removing Bearings and Seals (Axle Housing)

Installing Bearings and Seals (Axle Housing)

Installing Axle Housing

Installing Drive Axle/Rear Hub

Front Hub

Installing Hub Bearings and Seals (Front)

Installing Hub (Front)

Troubleshooting (Drive System)

Suspension

Installing Front Shock Absorbers

Installing Rear Shock Absorber

A-Arm

Installing A-Arm

Swing Arm

Installing Swing Arm

Wheels and Tires (Maintenance)

Troubleshooting (Suspension)

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