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Arctic Cat DVX 90 2010, Service Manual

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Arctic Cat DVX 90 2010 Service Manual Download Page 95

9-2

Handlebar Switch

REMOVING

 1. Disconnect the handlebar switch assembly wiring

connector.

MD2434

2. Disconnect the brake switch wiring connectors.

MD2438

 3.  Remove the handlebar switch assembly from the

handlebar.

KM544

MD2436

INSTALLING

1. Place the handlebar switch assembly onto the han-

dlebar. Tighten the screw securely.

MD2436

KM544

2. Connect the brake switch wiring connectors.

MD2438

Back to TOC

Back to Section TOC

Next

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

Summary of Contents for DVX 90 2010

Page 1: ...int 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...

Page 2: ...d 1 General Information Specifications 2 Periodic Maintenance Tune Up 3 Engine Transmission 4 Fuel Lubrication Cooling 5 Electrical System 6 Drive System 7 Suspension 8 Steering Frame 9 Controls 1 2 3...

Page 3: ...2 Torque Conversions ft lb N m 1 2 Tightening Torque General Bolts 1 3 Break In Procedure 1 3 Gasoline Oil Lubricant 1 3 Genuine Parts 1 3 Preparation For Storage 1 4 Preparation After Storage 1 4 Bac...

Page 4: ...ie Rod End Knuckle 25 ENGINE COMPONENTS Part Part Bolted To Torque ft lb Oil Drain Plug Crankcase 18 Spark Plug Cylinder Head 9 Cylinder Head Nut Cylinder 15 Crankcase Half Crankcase Half 8 Flywheel C...

Page 5: ...ENDED ENGINE OIL The recommended oil to use is Arctic Cat ACX All Weather Synthetic RECOMMENDED TRANSMISSION LUBRICANT The recommended transmission lubricant to use is SAE 80W 90 hypoid FILLING GAS TA...

Page 6: ...e ATV out of storage and correctly preparing it will assure many miles and hours of trouble free rid ing Arctic Cat recommends the following procedure to prepare the ATV 1 Clean the ATV thoroughly 2 C...

Page 7: ...Compression 2 5 Spark Plug 2 5 Muffler Spark Arrester 2 5 Transmission Lubricant 2 6 Engine Oil 2 6 Nuts Bolts Cap Screws 2 8 Headlights 2 8 Brakelight Taillight 2 8 Brake Systems 2 8 Replacing Drive...

Page 8: ...Throttle Cable I I C L A R Carburetor I D D Engine RPM Idle I I I A Engine Oil R I R Valve Tappet Clearance A A Transmission Lubricant Level R I Fuel Filter I I R Tires Air Pressure Wear I I I R Stee...

Page 9: ...ir filter oil and work the oil into the element 7 Compress the element to remove excess oil 8 Clean any dirt or debris from inside the air cleaner Make sure no dirt enters the carburetor 9 Install the...

Page 10: ...m nut and rotate the tappet adjuster screw until the clearance is within specifications Tighten each jam nut securely after completing the adjustment CD659 YT170 5 Check the valve tappet clearance aft...

Page 11: ...piston rings see Section 3 Spark Plug A light brown insulator indicates that the plug is cor rect A white or dark insulator indicates that the engine may need to be serviced or the carburetor may nee...

Page 12: ...oil level hole Stop pouring if oil is observed at the threads of the oil level hole Install and tighten the oil level plug 5 Start the engine while the ATV is outside on level ground and drive it a sh...

Page 13: ...ft lb CD626 5 Remove the oil level stick and pour the recom mended amount and viscosity oil into the engine then install the oil level stick CD629B 6 Start and warm up the engine 7 Shut the engine off...

Page 14: ...e two screws and remove the lens cover 2 Remove the bulb by pushing it in and turning it counterclockwise 3 Install the new bulb by pushing it in and turning it clockwise 4 Install the lens cover Brak...

Page 15: ...eel hubs 4 Loosen the brake shoe return spring then remove the brake shoes MD2042 Removing Rear Brake Pads 1 Remove the two cap screws securing the brake caliper to the axle housing then lift the cali...

Page 16: ...ystem use the following proce dure 1 Remove the brake fluid reservoir cover and fill the reservoir with DOT 4 brake fluid 2 Install and secure the cover 3 Remove the protective cap from the bleed scre...

Page 17: ...with a suitable pry bar or wedge then remove the drive belt CD624 INSTALLING 1 If removed place the gasket and two alignment pins into position on the crankcase 2 Spread the faces of the driven clutc...

Page 18: ...ion switch is in the ON position the reverse indi cator light is illuminated and the shift lever is fully in the reverse position then loosen the upper and lower jam nuts on the shift linkage and adju...

Page 19: ...TRANSMISSION Table of Contents Engine Transmission 3 2 Specifications 3 2 Y 12 Table of Contents 3 3 Troubleshooting 3 31 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 498...

Page 20: ...m Connecting Rod Small End Inside Diameter Max 13 06 mm Connecting Rod Small End Deflection Max 0 40 mm Connecting Rod Crankshaft Clearance Side to Side Max 0 05 mm Crankshaft Runout Max 0 10 mm Camsh...

Page 21: ...Removing Engine Transmission 1 Turn the gas tank valve to the OFF position then remove the seat and disconnect the negative bat tery cable securing it away from the battery CD643 KM853A 2 Drain the tr...

Page 22: ...ark plug cap YT010A 9 Remove the gasline hose from the carburetor 10 Remove the nuts from the one rear and two front through bolts Do not remove the bolts at this time 11 Remove the cooling duct from...

Page 23: ...ransmission 1 Remove the intake pipe carburetor assembly Account for an O ring between the intake pipe and cylinder head 2 Remove the fan shroud then remove the cylin der cylinder head shroud Note the...

Page 24: ...eft side of the cylinder head then remove the cylinder head Account for two alignment pins and remove and discard the cylinder head gasket YT109B YT110A 10 Lift the cylinder off the crankcase taking c...

Page 25: ...ned valves or carbon build up NOTE If valves are discolored they must be replaced Arctic Cat recommends taking heads to a qualified machine shop for valve replacement or valve seat grinding REMOVING V...

Page 26: ...de edge of the valve face then zero the indicator ATV1082A 3 Rotate the valve in the V blocks 4 Maximum runout must not exceed specifications Measuring Valve Stem to Guide Clearance 1 Insert a snap ga...

Page 27: ...Inspecting Piston 1 Using a non metallic carbon removal tool remove any carbon buildup from the top of the piston 2 Inspect the piston for cracks in the piston pin boss top and skirt areas 3 Inspect t...

Page 28: ...r into the piston pin bore Take two measurements to ensure accuracy The diameter must not exceed specifications If the diameter exceeds specifications the piston must be replaced ATV 1069 Measuring Pi...

Page 29: ...Distortion 1 Remove any carbon buildup in the combustion chamber 2 Lay a straightedge across the cylinder head then using a feeler gauge check the distortion between the head and the straightedge 3 Ma...

Page 30: ...oduce the proper 60 cross hatch pattern use a low RPM drill 600 RPM at the rate of 30 strokes per minute If honing oil is not avail able use a lightweight petroleum based oil Thor oughly clean cylinde...

Page 31: ...r then using a ring compressor or the fingers compress the rings and slide the cylinder over the piston Route the cam chain up through the cylinder cam chain housing then remove the piston holder and...

Page 32: ...tall the camshaft with the single large ref erence hole A directed up and the two small tim ing holes B parallel to the top of the cylinder head YT095A YT173A 8 Place the camshaft holder into position...

Page 33: ...ft lb YT170 YT090A 13 Install the intake pipe carburetor assembly onto the cylinder head using a new O ring Tighten the flange nuts to 7 ft lb Left Side Components NOTE For efficiency it is preferabl...

Page 34: ...Account for a bushing B and speed limiter spacer C YT021A 4 Remove the centrifugal clutch housing then remove the centrifugal clutch shoe driven pulley assembly YT022 5 Remove the starter reduction g...

Page 35: ...CH C ROTOR FLYWHEEL D CENTRIFUGAL CLUTCH E V BELT DRIVE CLUTCH DRIVEN PULLEY 1 With the transmission in neutral install a new O ring on the gear shift position switch then ori ent the pin as shown and...

Page 36: ...nd speed limiter spacer YT164 7 Place the V belt over the driven pulley then over the bushing spacer Pinch the belt in the middle to draw it down into the driven pulley approximately 1 inch YT157 YT16...

Page 37: ...EL C STATOR COIL D OIL PUMP 1 Remove the intake pipe carburetor Account for an O ring in the intake pipe 2 Remove the cooling fan shroud then remove the cooling shroud from the cylinder and cylinder h...

Page 38: ...baffle then remove the nut from the oil pump shaft and remove the driven gear and drive chain YT032 8 Remove the oil pump assembly being careful not to drop the oil pump driveshaft YT033 E TRANSMISSIO...

Page 39: ...t on the driveshaft and keep together for assembly Disassembling NOTE For steps 4 8 refer to illustration YT041B 4 Remove the output driveshaft A then remove the shift fork shaft G YT041B 5 Remove the...

Page 40: ...washer then remove the forward gear Account for the forward gear bushing and washer YT063 YT085 2 Remove the forward reverse shift dog YT081 3 Remove the reverse gear snap ring and splined washer then...

Page 41: ...discol oration or looseness in the transmission case or cover YT065 7 Inspect the detent spring and ball Replace any worn or broken component 8 Examine the transmission case and cover for cracks disco...

Page 42: ...and cover then coat the inner surfaces of the seals with multi purpose grease 2 Making sure the bearing is properly aligned in the transmission case drive the input driveshaft and bearing into place w...

Page 43: ...l a new gasket on the transmission case YT041A 9 Making sure the input driveshaft thrust washer is installed carefully install the transmission case cover YT039A YT078 10 Secure the cover with the cap...

Page 44: ...e only those components The technician should use discretion and sound judgment Disassembling Crankcase Halves 1 Remove one remaining cap screw from the right side crankcase half then tap the right si...

Page 45: ...sure crank shaft runout Runout must not exceed specifica tions YT133 4 Using an appropriate caliper measure crankshaft web to web distance Measurement must not exceed specifications YT136 5 Examine cr...

Page 46: ...ure with two cap screws and tighten to 7 ft lb YT151A 4 Install the oil pump drive chain and driven gear and secure the gear to the pump shaft with the nut tightened to 7 ft lb then install the oil pu...

Page 47: ...front engine mounting brackets on the frame and tighten the cap screws securely then install the two front through bolts Do not tighten at this time YT012 3 Install the rear engine mounting through bo...

Page 48: ...the frame with a nylon tie 10 Install the left side footwell mounting plate to the frame then install the left and right footwells and secure to the mountings and fenders Tighten all hardware securely...

Page 49: ...edle 3 Clean replace hose 4 Clean replace inlet screen valve screen Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magneto defective 3 CDI unit defective 4 Carburetor jets obstruc...

Page 50: ...3 Drain excess oil from crankcase recheck oil level 4 Use recommended type and quantity air filter element oil 5 Use recommended carburetor jets Problem Engine lacks power Condition Remedy 1 Piston r...

Page 51: ...Schematic 4 2 Carburetor 4 2 Throttle Cable Free Play 4 7 Engine RPM Idle 4 7 Gas Tank 4 7 Fuel Valve 4 9 Gas Vent Hoses 4 9 Oil Pump Assembly 4 9 Oil Screen Filter 4 9 Troubleshooting 4 10 Back to T...

Page 52: ...0 25 in KEY 1 Carburetor Body 2 O Ring 3 Set Plate 4 Screw w Washer 5 Choke Assembly 6 Jet Needle 7 Carburetor Cap 8 Gasket 9 Throttle Valve Spring 10 Throttle Valve 11 Needle Clip Plate 12 Needle Cl...

Page 53: ...the assembly Account for the washers and the O ring 2 Remove the Phillips head screws securing the float chamber then remove the chamber Account for the seal and the washers CD600 3 Remove the float p...

Page 54: ...s and any other imperfections in the casting 6 Inspect float for damage 7 Inspect gasket seal and O rings for distortion tears or noticeable damage 8 Inspect tips of the jet needle pilot screw and the...

Page 55: ...alve assembly into the carburetor then install the float pin CD763 NOTE Check float arm height by inverting the carburetor freeing the float arm then measure with a ruler the height when the float arm...

Page 56: ...e clip needle clip plate and gasket 2 Thread the carburetor cap onto the carburetor then tighten securely CD594 3 Connect the choke assembly connector CD591 4 Install the carburetor onto the intake ma...

Page 57: ...le adjustment screw in or out until the engine idles at 1700 RPM YT015B Gas Tank REMOVING 1 Turn the fuel valve to the OFF position 2 Remove the gas hose from the carburetor by removing the spring cla...

Page 58: ...ure it out of the way MD2393 10 Remove the gas hoses from the fuel valve noting where each one is attached MD1865 NOTE Mark the gas hoses for assembling pur poses MD1848 CLEANING AND INSPECTING NOTE W...

Page 59: ...ee posi tions be sure the indicator is pointed directly at the position desired REMOVING INSPECTING 1 Remove the cap screw securing the valve to the frame then pull the valve out far enough to gain ac...

Page 60: ...speed impaired Condition Remedy 1 Main jet obstructed 2 Needle jet obstructed 3 Throttle valve not operating properly 4 Filter obstructed 5 Float level incorrect 1 Clean main jet 2 Clean needle jet 3...

Page 61: ...CDI Ignition Coil 5 3 Stator Coil 5 4 Choke Circuit 5 4 Brakelight Switch 5 4 Fuse 5 5 Ignition Coil 5 5 Ignition Switch 5 5 Handlebar Control Switches 5 6 Magneto Assembly 5 6 Starter Motor 5 6 Regul...

Page 62: ...OTE At this point if the meter reads as speci fied the battery may be returned to service see step 8 5 If the meter reads less than specified voltage charge the battery using the following guidelines...

Page 63: ...ture approximately 68 F Timing Sensor Disconnect the three wire connector next to the steer ing post PEAK VOLTAGE NOTE All of the peak voltage tests should be made using the Fluke Model 77 Multimeter...

Page 64: ...e red tester lead to the yellow wire then connect the black tester lead to the green black wire 3 Crank the engine over using the electric starter The meter must read 3 5 4 5 AC volts Brakelight Switc...

Page 65: ...e red tester lead to one end of the cap then connect the black tester lead to the other end of the cap 2 The meter must read 4725 5775 ohms NOTE If the meter does not read as specified replace the spa...

Page 66: ...1 ohm NOTE If the meter reads more than 1 ohm of resistance troubleshoot or replace the switch component the connector or the switch wiring harness Magneto Assembly REMOVING 1 Disconnect the battery...

Page 67: ...loose bulb base VOLTAGE NOTE Perform this test on the main harness side of the connectors The engine must be running for this test 1 Set the meter to the AC Voltage position 2 Connect the black tester...

Page 68: ...ctive 3 Starter motor brushes not seating 4 Starter relay defective 5 Emergency stop ignition switch off 6 Wiring connections loose disconnected 1 Charge replace battery 2 Replace switch 3 Repair repl...

Page 69: ...TEM TABLE OF CONTENTS Drive Chain Sprockets 6 2 Rear Hub Drive Axle 6 5 Front Hub 6 7 Brake Systems 6 9 Troubleshooting 6 9 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4...

Page 70: ...ack is present at mid span of the chain KM218A 3 Tighten the four cap screws REMOVING DRIVE CHAIN 1 Remove the drive chain master link clip MD2357 2 Remove the link plate and link noting the position...

Page 71: ...on a support stand to elevate the rear wheels 2 Remove the cotter pins from the axle shaft and dis card then apply the rear brake and remove the cas tle nuts from the axle Account for the flat washer...

Page 72: ...mpress the left hand brake and engage the brake lever lock to prevent the rear axle from turning TR235 T Torque wrench reading to be calculated Ts Specified torque value 86 ft lb Ls Tool offset length...

Page 73: ...spacer REMOVING AXLE HOUSING 1 Secure the ATV on a support stand to elevate the rear wheels 2 Remove two cap screws securing the brake caliper to the axle housing then lift the caliper off the disc K...

Page 74: ...arpage that might interfere with bearing bore or alignment INSTALLING BEARINGS AND SEALS 1 Using a plastic mallet and bearing driver or appro priate size socket carefully install the first bearing int...

Page 75: ...the sprocket retainer Tighten the three cap screws to 20 ft lb YT197A 4 Install the axle nuts securing the brake hub to the axle see Drive Train Sprockets Installing Rear Sprockets in this section 5 I...

Page 76: ...nspect the hub splines for signs of wear 6 Inspect the hub for cracks 7 Verify that the bearings turn freely REMOVING HUB BEARINGS AND SEALS 1 Carefully pry out inner and outer seals MD2385 2 Drive ou...

Page 77: ...ransmitted from engine to wheels Condition Remedy 1 Drive chain worn broken 2 Countershaft sprocket worn broken 3 Rear sprocket worn broken 4 Chain slipped off sprockets 5 Master link worn broken miss...

Page 78: ...ION TABLE OF CONTENTS Suspension 7 2 Shock Absorbers 7 2 A Arm 7 4 Swing Arm 7 6 Wheels and Tires 7 8 Troubleshooting 7 9 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 498...

Page 79: ...absorber to the frame MD2131 3 Remove the cap screw and self locking nut secur ing each front shock to the A arms MD2132 4 Remove the front shock absorbers REMOVING REAR SHOCK ABSORBER 1 Secure the A...

Page 80: ...e frame and A arm and install the two cap screws and self locking nuts Tighten the nuts to 29 ft lb MD2131 MD2132 2 Repeat the procedure for the other front shock absorber 3 Remove the ATV from the su...

Page 81: ...Remove the rubber spindle pin boot then remove the cotter pin and flanged castle nut from the spin dle pin Lower the steering knuckle assembly from the A arm MD2113 7 Remove the cap screw and self loc...

Page 82: ...the cap screw and self locking nut Tighten the nut to 29 ft lb MD2424 3 Lubricate the steering knuckle assembly with grease then install it into the A arm and secure with the flanged castle nut Tighte...

Page 83: ...rform the intended service The axle housing will separate from the swing arm with all components attached if necessary 4 Remove the four cap screws A securing the axle housing to the swing arm then re...

Page 84: ...se then install the spacer into the swing arm 2 If removed install the rubber swing arm guard 3 Lubricate the two seals with a light coat of grease then install them on the ends of the swing arm 4 Pos...

Page 85: ...1 Clean the wheels and hubs with parts cleaning sol vent 2 Clean the tires with soap and water 3 Inspect each wheel for cracks dents or bends 4 Inspect each tire for cuts wear missing lugs and leaks I...

Page 86: ...erence 5 Repeat steps 3 4 as necessary to ensure proper handling Troubleshooting WARNING Do not operate the ATV if tire damage exists Problem Suspension too soft Condition Remedy 1 Spring s weak 2 Sho...

Page 87: ...NG FRAME TABLE OF CONTENTS Steering Frame 8 2 Steering Post Handlebar Tie Rods 8 2 Handlebar Grip 8 5 Troubleshooting 8 7 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 498...

Page 88: ...welds should be checked periodically for damage bends cracks deterioration broken com ponents and missing components Steering Post Handlebar Tie Rods REMOVING 1 Remove the seat MD2415 2 Remove the co...

Page 89: ...Dry with compressed air Inspect the pivot area for wear Apply a low temperature grease to the ends 2 Inspect the tie rods for damaged threads or wear 3 Inspect the tie rods for cracks or unusual bends...

Page 90: ...rough the metal loop on the steering post MD2135 5 Install the body panel and gas tank cap MD2405 6 Install handlebar with marks aligned with the han dlebar mounting clamps Install the caps then tight...

Page 91: ...nd rear racks Handlebar Grip REMOVING 1 Using a compressed air nozzle and low pressure peel up the inner corner of the grip 2 Apply air pressure while twisting the grip back and forth until it slides...

Page 92: ...dlebar grip use contact spray or alcohol to clean the inside of the grip and the handlebar of glue residue oil or any other contaminant 1 Apply a liberal amount of Handlebar Grip Adhe sive to the insi...

Page 93: ...oblem Steering pulling to one side Condition Remedy 1 Tires inflated unequally 2 Front wheel alignment incorrect 3 Wheel hub bearings worn broken 4 Frame distorted 5 Shock absorber defective 1 Adjust...

Page 94: ...9 1 9 SECTION 9 CONTROLS TABLE OF CONTENTS Handlebar Switch 9 2 Hand Brake Lever Assemblies 9 3 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com...

Page 95: ...emove the handlebar switch assembly from the handlebar KM544 MD2436 INSTALLING 1 Place the handlebar switch assembly onto the han dlebar Tighten the screw securely MD2436 KM544 2 Connect the brake swi...

Page 96: ...t brake lever assembly and slide the assembly off the handlebar MD2450 5 Place a suitable container beneath the left hand brake master cylinder 6 Remove the brakeline hose bolt then drain brake fluid...

Page 97: ...ews MD2454 KM548A 3 Install the brake cable to the lever assembly MD2453 4 Position the left brake lever assembly onto the handlebar and secure with the clamp and two cap screws Tighten securely KM208...

Page 98: ...the brake is not firm the system must be bled see Brake Systems BLEEDING in Sec tion 2 NOTE Before installing a handlebar grip use contact spray or alcohol to clean the inside of the grip and the han...

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