Arctic Cat DVX 90/90 UTILITY Service Manual Download

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YT032

8. Remove the oil pump assembly being careful not to

drop the oil pump driveshaft.

YT033

E. TRANSMISSION
Removing

1. Note the orientation of the shift arm for assembly;

then remove the shift arm from the shift shaft.

YT035

2. Loosen the shift detent plug (A) approximately eight

turns; then remove the cap screws securing the trans-

mission case cover. Note the location of two longer

cap screws (B).

YT036A

3. Carefully remove the transmission case cover while

pressing in on the output driveshaft and shift shaft to

leave components in the transmission case. Account

for two alignment pins and gasket.

YT038

YT041A



NOTE: The driveshaft thrust washer may be stuck

to the cover. Make sure to install it 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).

Summary of Contents for DVX 90/90 UTILITY

Page 1: ...DVX 90 90 UTILITY ATV SERVICE MANUAL 2014 ...

Page 2: ...ls 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 serious 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 o...

Page 3: ......

Page 4: ... Left Side Components 36 Installing Left Side Components 38 Right Side Components 39 Removing Right Side Components 40 Servicing Right Side Components 43 Installing Right Side Components 44 Center Crankcase Components 46 Disassembling Crankcase Halves 46 Servicing Crankcase Components 47 Assembling Crankcase Half 48 Installing Engine Transmission 49 Troubleshooting 51 Fuel Lubrication 53 Carbureto...

Page 5: ...ition Coil primary Resistance secondary Less than 1 ohm 2830 3170 ohms Timing Sensor peak voltage resistance 1 8 3 8 DC volts 80 160 ohms Regulator Rectifier 12 1 15 2 DC volts 3000 RPM CDI Ignition Coil peak voltage 190 282 DC volts Stator Coil no load 13 5 16 5 AC volts 3000 RPM Stator Coil Resistance Less than 1 ohm Choke Circuit voltage 3 5 4 5 AC volts ENGINE Piston Ring End top Gap Installed...

Page 6: ...ENTS Front Shock Absorber Frame A Arm 29 Rear Shock Absorber Frame Swing Arm 29 Swing Arm Frame 50 Swing Arm Rear Axle Housing 29 A Arm Frame 29 Knuckle A Arm 29 Tie Rod End Knuckle 25 ENGINE COMPONENTS Oil Drain Plug Crankcase 18 Spark Plug Cylinder Head 9 Cylinder Head Nut Cylinder 15 Crankcase Half Crankcase Half 8 Flywheel Crankshaft 30 Camshaft Holder Cylinder 15 Stationary Drive Sheave Crank...

Page 7: ...eparation For Storage Arctic Cat recommends the following procedure to pre pare the ATV for storage 1 Clean the seat cushion cover and base with a damp cloth and allow to dry 2 Clean the ATV thoroughly by washing dirt oil grass and other foreign matter from the entire ATV Allow the ATV to dry thoroughly DO NOT get water into any part of the engine or air intake 3 Either drain the gas tank or add F...

Page 8: ...V thoroughly 2 Clean the engine 3 Remove the cloth from the exhaust system 4 Check all control wires and cables for signs of wear or fraying Replace if necessary 5 Change the transmission lubricant 6 Charge the battery then install Connect the battery cables making sure to connect the positive cable first 7 Check the entire brake system cables shoes etc and all controls Adjust or replace if necess...

Page 9: ...ntly when operating in adverse conditions Item Initial Service After Break In First Mo Every Day Every Month Every 3 Months Every 6 Months Every Year As Needed Battery I CH I C Fuse I R Air Filter I C R Engine Compression I Spark Plug I C R 18 Mo Chassis C L I Gas Vent Hoses I C R 2 Years Gas Tank Valve I C 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 ...

Page 10: ...k and adjust valve tappet clearance use the fol lowing procedure NOTE Valve tappet clearance specifications are for room temperature approximately 68 F 1 Remove the two cap screws and the two self tapping screws securing the fan shroud then remove the fan shroud CD651 2 Remove the breather tube from the valve cover then remove the four cap screws and remove the valve cover Account for the O ring s...

Page 11: ...ollowing procedure 1 Remove the high tension lead from the spark plug 2 Using compressed air blow any debris from around the spark plug 3 Remove the spark plug then attach the high tension lead to the plug and ground the plug on the cylinder head well away from the spark plug hole 4 Attach the Compression Tester Kit p n 0444 213 NOTE The engine must be warm and the battery must be fully charged fo...

Page 12: ...tened 1 8 1 4 turn once the washer contacts the cylinder head Muffler Spark Arrester To clean the arrester use the following procedure 1 Remove the cap screw 1 securing the spark arrester assembly 2 to the rear of the muffler Account for a gasket KM139A 2 Clean the screen 3 with a brush and parts cleaning solvent Dry with compressed air If the screen has any holes or tears it must be replaced KM14...

Page 13: ...ute Remove the level and recheck the lubricant level The level should be visible at the level hole If lubricant is not visible add recommended lubricant until the level is visible at the level hole 7 Inspect the area around the drain plug for leaks Engine Oil 1 Move the ATV outdoors and start and warm up the engine Shut the engine off then place a drain pan under the engine oil drain plug located ...

Page 14: ...lace a headlight bulb use the following procedure 1 Remove the boot from the back of the headlight housing then remove the three wire connector from the bulb 2 Using care not to bend or deform the spring clip release the two ends of the spring clip from the hous ing then remove the bulb from the headlight housing KM192A 3 Install the new bulb into the headlight housing then secure with the spring ...

Page 15: ...se until both front wheels do not spin freely KM024B 3 Turn both cable adjusters in 1 4 turn increments clockwise until the wheels spin with a very slight amount of drag 4 Lower ATV then push it forward and compress the brake lever 5 If the front wheels lock evenly adjustment is correct 6 If the front wheels do not lock evenly additional adjustment is necessary 7 Once proper adjustment is obtained...

Page 16: ...ng clip into position and install the inner brake pad then install the outer pad onto the holder pins KM214 KM222 2 Place the assembled caliper into position on the disc then secure with the two cap screws Tighten to 22 ft lb NOTE Always compress the hydraulic brake lever several times to check that the brakes are firm If the brakes are not firm bleeding the system will be nec essary BLEEDING To b...

Page 17: ... securing the stationary drive sheave to the crankshaft then remove the stationary drive sheave Account for a washer kick starter ratchet and cooling fan CD621 5 Open the movable sheave on the driven clutch assembly 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 t...

Page 18: ...n shift arm 2 Verify the transmission is in reverse the ignition switch is in the ON position the reverse indicator 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 adjust the linkage to align with the shift arm YT005B 3 Install the cap screw securing the linkage to the lower shift arm Do not tighten at this...

Page 19: ...dically for damage bends cracks deterioration broken compo nents and missing components Steering Post Handlebar Tie Rods REMOVING 1 Remove the seat 2 Remove the control cables from the handlebar then route them through the metal loop on the steering post and out of the way MD2430 MD2431 3 Remove the handlebar MD2139 4 Disconnect the handlebar switch assembly and brake switch connectors then route ...

Page 20: ...nusual bends 4 Inspect all welded areas for cracks or deterioration 5 Inspect the steering post and brackets for cracks bends or wear 6 Inspect the plastic bearing halves and bearing caps for cracks or wear 7 Inspect the handlebar tube for cracks wear or unusual bends INSTALLING 1 Place the steering post into position Tighten the two nuts on the outer bearing cap making sure the two piece plastic ...

Page 21: ...s then tighten the cap screws to 10 ft lb KM060A MD2429 7 Install the control cables onto the handlebar MD2439 8 Make sure the cables brake and throttle are routed down and away so there is no sticking or binding MD2105 MD2441 MD2106 WARNING Make sure there is maximum right left steering capabil ity and the brake and throttle cables are not affected ...

Page 22: ...r cuts or cracks 2 Inspect the grip for deterioration INSTALLING NOTE Before installing a handlebar grip use con tact 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 Adhesive to the inside of the grip 2 Slide the grip onto the handlebar until it is fully seated 3 Wipe off any excess adhesive ...

Page 23: ... 3 Connect the handlebar switch assembly wiring con nector MD2434 Hand Brake Lever Assemblies REMOVING 1 Remove the right handlebar grip 2 Remove the cover from the throttle control housing exposing the throttle cable then remove the cable MD2440 WARNING After removing and installing brake related components ALWAYS check and adjust brakes as necessary before operating the ATV ...

Page 24: ...D2450 5 Place a suitable container beneath the left hand brake master cylinder 6 Remove the brakeline hose bolt then drain brake fluid into the container Account for two copper washers KM208B 7 Remove the cap screws securing the hand brake lever assembly to the handlebar and remove the hand brake master cylinder assembly KM208A MD2442 INSTALLING 1 Slide the right brake lever assembly onto the hand...

Page 25: ...nder the master cylinder and compress the lever slowly Brake fluid should flow from the loose connection 8 Tighten the brakeline hose bolt to 20 ft lb from step 5 then check the rear brake operation The brake lever should be firm and the rear brake should stop the wheels NOTE If the brake is not firm the system must be bled see Brake Systems BLEEDING in Periodic Maintenance Tune Up section NOTE Be...

Page 26: ...od ends 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts Problem 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 pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Replace shock absorber Problem Steering impaired Condition Rem...

Page 27: ... then remove the seat and disconnect the negative battery cable securing it away from the battery CD643 KM853A 2 Drain the transmission lubricant NOTE The drain plug is located on the bottom of the transmission KM038A 3 Drain the engine oil NOTE The drain plug is located at the left rear of the engine KM041A 4 Remove the left and right footwells and the left side footwell mounting plate then remov...

Page 28: ...cooling duct from the front of the V belt housing then disconnect the gear shift position switch connectors 12 Remove the cap screws securing the front engine mounting brackets to the frame then remove the through bolts and brackets 13 Slide the engine transmission forward sufficiently to clear the rear mounting brackets then swing the rear of the assembly out the left side and remove the engine t...

Page 29: ...he fan shroud then remove the cylinder cylinder head shroud Note the location of the carbu retor float bowl drain hose clip YT016A YT017A 3 Remove the cylinder head cover Account for the gasket 4 Rotate the engine to top dead center TDC on the compression stroke then remove the cam chain ten sioner assembly YT095 YT098A 5 Remove the cylinder head nuts on top of the cam shaft holder Account for fou...

Page 30: ...and two alignment pins 11 Remove the cam chain tensioner pivot bolt then remove the chain tensioner YT114A 12 Using a needle nose pliers remove the circlip secur ing the piston pin in the piston then remove the pis ton pin and piston Take care not to drop the circlip into the crankcase CAUTION Do not rotate the crankshaft without keeping tension on the cam chain or engine damage could occur AT THI...

Page 31: ... valve replacement or valve seat grinding REMOVING VALVES NOTE Keep all valves and valve components as a set Note the original location of each valve set for use during installation Return each valve set to its original location during installation 1 Using a valve spring compressor compress the valve springs and remove the valve cotters Account for an upper spring retainer CC391D 2 Remove the valv...

Page 32: ...learance exceeds specifica tions the cylinder head assembly must be replaced Servicing Valves Valve Guides Valve Seats If valves valve guides or valve seats require servicing or replacement Arctic Cat recommends the components be taken to a qualified machine shop for servicing Measuring Rocker Arm to Shaft Clearance 1 Using a dial calipers measure the inside diameter of the rocker arm 2 Using a mi...

Page 33: ...groove CC400D 2 Remove and discard each ring by working it toward the top of the piston while rotating it out of the groove NOTE New rings must be installed as a complete set only Cleaning Inspecting Piston Ring Grooves 1 Take an old piston ring and snap it into two pieces then grind the end of the old ring to a 45 angle and to a sharp edge 2 Using the sharpened ring as a tool clean carbon from th...

Page 34: ...er the expander making sure the expander ends do not overlap Stagger the end gaps of the upper and lower thin oil rings according to the illustration NOTE Note the direction of the exhaust side of the piston 5 for correct ring end gap orientation ATV 1085B 2 Install the compression rings 1 and 2 so the letter T on the top surface of each ring faces the dome of the piston Rotate the rings until the...

Page 35: ... figure eight motion until a uniform bright metallic finish is attained CC997 Inspecting Cam Chain Guide 1 Inspect cam chain guide for cuts tears breaks or chips 2 If the chain guide is damaged it must be replaced Honing Cylinder 1 Using a slide gauge and a dial indicator or a snap gauge measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90 fro...

Page 36: ... sprocket for excessive wear YT127 Installing Top Side Components A PISTON B CYLINDER 1 Lubricate the piston pin connecting rod and piston pin bore with motor oil then install the piston on the connecting rod making sure there is a circlip on each side and the open end of the circlip is directed upwards or downwards NOTE The piston should be installed so the word IN points upward YT161 YT159 2 Pla...

Page 37: ...lace the front cam chain guide into the cylinder YT112 5 Place a new gasket into position on the cylinder Place the alignment pins into position then place the head assembly into position on the cylinder making sure the cam chain is routed through the chain cavity YT167A YT168 6 Install two alignment pins into the top of the cylinder head as illustrated CAUTION The cylinder should slide on easily ...

Page 38: ...cross pattern to 15 ft lb YT172A 9 Install the two cap screws securing the left side of the cylinder head and cylinder to the crankcase and tighten to 7 ft lb YT098B 10 Install the cam chain tensioner assembly into the cyl inder using a new gasket then secure with two cap screws and tighten to 7 ft lb YT098C 11 Using a small flat screwdriver release the cam chain tension spring by rotating clockwi...

Page 39: ...d from the frame for this procedure Removing Left Side Components A V BELT COVER B V BELT DRIVE CLUTCH DRIVEN PULLEY C CENTRIFUGAL CLUTCH D GEAR POSITION SWITCH E STARTER ONE WAY CLUTCH 1 Remove the V belt cover noting the location of the different lengthed cap screw and the location of the alignment pins Account for a gasket YT099A YT160A 2 Remove the flange nut A securing the fixed drive face to...

Page 40: ...ntershaft housing 6 Remove the starter one way nut using Starter One Way Clutch Nut Wrench p n 0444 191 then install Starter One Way Clutch Puller p n 0444 188 to the one way housing YT104 7 Install the push bolt into the puller then using two wrenches as illustrated tighten the push bolt until the one way clutch is free of the crankshaft YT104 NOTE It may be necessary to strike the head of the bo...

Page 41: ...own clip securely YT165A 3 Install the starter one way clutch gear assembly on the crankshaft then with a thrust washer on each side of the starter countershaft gear install the starter countershaft gear countershaft into the crankcase YT024B 4 Install the starter countershaft housing then install the starter one way clutch cover Tighten the cap screws securely YT023A 5 Install the driven pulley c...

Page 42: ...n to 7 ft lb Make sure the different lengthed cap screw is located as illustrated YT099A Right Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to be removed from the frame for this pro...

Page 43: ...ing the rotor flywheel YT029 4 Remove the rotor flywheel using the rotor flywheel puller Account for a key YT145A 5 Remove the stator coil trigger coil assembly YT155A 6 Remove the five internal and three external cap screws securing the inner magneto housing to the crankcase then remove the housing Account for two alignment pins and a gasket NOTE Some engine oil will spill when the cap screws are...

Page 44: ...sion case cover Note the location of two longer cap screws B YT036A 3 Carefully remove the transmission case cover while pressing in on the output driveshaft and shift shaft to leave components in the transmission case Account for two alignment pins and gasket YT038 YT041A NOTE The driveshaft thrust washer may be stuck to the cover Make sure to install it on the driveshaft and keep together for as...

Page 45: ...embly F 8 Using a plastic mallet drive the input driveshaft D and bearing from the transmission case YT037 F MAIN SHAFT NOTE If not absolutely necessary to replace com ponents do not disassemble the main shaft To disassemble the main shaft components use the fol lowing procedure 1 Remove the forward gear spacer and thrust washer then remove the forward gear Account for the for ward gear bushing an...

Page 46: ...ipping flaking discoloration or signs of excessive wear YT100B 3 Inspect all splined shafts for excessive spline wear twisting or discoloration 4 Inspect the shift fork and shift dog mating surfaces for galling discoloration or excessive wear 5 Inspect the shift shaft and shift cam detent assembly for wear chipping or broken spring 6 Rotate all bearings to check for roughness discolor ation or loo...

Page 47: ... reverse gear B and splined thrust washer C Secure with the snap ring D pressing firmly toward the reverse gear to seat in the groove YT080 2 Install the forward reverse shift dog E forward gear thrust washer F and forward gear bushing G then install the forward gear with the flat side toward the shift dog YT084A 3 Install the forward gear thrust washer H and the spacer I B TRANSMISSION Assembling...

Page 48: ...nd thrust washer do not fall off the shaft YT072 YT083 5 Install the shift cam detent assembly then install the shift shaft aligning the timing index marks YT069A 6 Engage the shift fork into the shift cam detent assem bly then secure with the shift fork shaft YT075 7 Install the output driveshaft then install the thrust washer on the input driveshaft YT077 8 Place the alignment pins in the correc...

Page 49: ...n the frame Complete Remov ing procedures for Top Side Left Side and Right Side must precede this procedure NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment Disassembling Crankcase Halves 1 Remove one remaining cap screw from the right side cra...

Page 50: ... the side to side clearance between the connecting rod and crank shaft Clearance must not be greater than specified YT134 3 Place the crankshaft assembly on a set of V blocks then using a dial indicator measure crankshaft run out Runout must not exceed specifications YT133 4 Using an appropriate caliper measure crankshaft web to web distance Measurement must not exceed specifications YT136 5 Exami...

Page 51: ...install the crankshaft assembly into the crankcase half YT120 2 Install two alignment pins and a gasket then install the right side crankcase half Secure with a cap screw threads coated with red Loctite 271 and tighten to 8 ft lb YT119A YT118A 3 Install the oil pump into the crankcase with the arrow and dot directed upward then secure with two cap screws and tighten to 7 ft lb YT151A ...

Page 52: ...our cap screws Tighten securely YT155A 7 Install the rotor flywheel making sure the crankshaft and flywheel bore are clean and free of any oil then with the key in place secure with the flywheel nut coated with red Loctite 271 Tighten to 30 ft lb YT143 8 Install the cooling fan and secure with four cap screws then install the fan shroud Installing Engine Transmission 1 From the left side place the...

Page 53: ...secure with the clamp then install the exhaust pipe muffler assembly using a new grafoil seal in the cylinder head Tighten the exhaust pipe to cylinder head nuts to 7 ft lb and the muffler mounting cap screws to 32 ft lb YT008A YT005A 6 Connect the shift linkage then install the air filter housing and air filter Tighten all hardware securely YT007A YT003A 7 Connect the starter harness connector A ...

Page 54: ...ngs 2 Replace rebore cylinder 3 Tighten plug 4 See Electrical System section 5 Replace valves adjust tappets Problem Engine will not start or is hard to start No spark Condition Remedy 1 Spark plug fouled 2 Spark plug wet 3 Magneto defective 4 CDI unit defective 5 Ignition coil defective 6 High tension lead open shorted 1 Clean replace plug 2 Clean dry plug 3 Replace magneto 4 Replace CDI unit 5 R...

Page 55: ...e obstruction Problem Exhaust smoke dirty or heavy Condition Remedy 1 Piston rings cylinder worn 2 Cylinder wall scored scuffed 3 Crankcase over full of oil 4 Air filter too much air filter element oil 5 Carburetor jets incorrect size too big 1 Replace service rings cylinder 2 Replace service cylinder 3 Drain excess oil from crankcase recheck oil level 4 Use recommended type and quantity air filte...

Page 56: ...or cap then lift the cap remov ing the throttle valve spring and jet needle Account for a gasket a needle clip plate and a needle clip WARNING Whenever any maintenance or inspection is made on a fuel system when there may be fuel leakage there should be no welding smoking open flames etc in the area KEY 1 Carburetor Body 2 O Ring 3 Set Plate 4 Screw w Washer 5 Choke Assembly 6 Jet Needle 7 Carbure...

Page 57: ...move the Phillips head screws securing the float chamber then remove the chamber Account for the seal and the washers CD600 3 Remove the float pin then lift the float with needle valve from the carburetor body CD603 4 Remove the pilot screw assembly Account for a spring and O ring CD608 5 Remove the idle adjustment screw assembly Account for a spring CD610 6 Remove the jet holder then remove the m...

Page 58: ... jet and main jet for obstructions or damage NOTE If the slow jet is obstructed the mixture will be extremely lean at idle and part throttle operation 10 Inspect the choke assembly for wear or damage ASSEMBLING 1 Install the slow jet CD606 2 Install the main jet by threading it into the jet holder then install the jet holder into the carburetor Tighten both components securely CD604 3 Install the ...

Page 59: ...th the Phillips head screws and washers CD600 8 Install the choke assembly Tighten the two Phillips head screws with washers securely CD598 9 Insert the throttle cable into the top of the cap assem bly and through the spring 10 Compress the spring to expose the end of the throttle cable then hook the end of the cable into the throttle valve Release tension on the spring to hold the throt tle cable...

Page 60: ... access cable adjustment nut KM071A 2 Loosen jam nut to allow cable adjustment nut to be adjusted 3 Turn cable adjustment nut clockwise to increase free play in the cable Turn the adjustment nut counter clockwise to decrease free play in the cable 4 There should be approximately 6 mm 0 25 in free play in the cable 5 Tighten the jam nut to secure the adjustment then slide the rubber boot back into ...

Page 61: ...les and wires do not need to be discon nected The front fender panel and handlebar assem bly can be tilted forward far enough to gain access to the gas tank 7 Remove the four Phillips head cap screws and six nuts securing the front fender panel Account for eight washers 8 Remove the gas tank cap then tilt the front fender panel and handlebar forward 9 Remove the two cap screws securing the gas tan...

Page 62: ... to 10 ft lb MD2138 Gas Tank Valve This ATV has a valve mounted on the side of the frame separate from the gas tank There are three positions ON RES and OFF KM043A In the OFF position the valve will not allow gasoline to flow to the carburetor In the ON position the normal operating position gasoline will flow from the tank to the carburetor In this position 1 3 L 0 34 U S gal of gasoline will rem...

Page 63: ... Choke not operating properly 1 Tighten adjust carburetor replace gasket 2 Check choke assembly Problem Idling or low speed impaired Condition Remedy 1 Slow jet obstructed loose 2 Needle jet obstructed 3 Pilot screw setting incorrect 4 Float level incorrect 1 Clean tighten jet 2 Clean jet 3 Adjust pilot screw 4 Adjust float arm height Problem Medium or high speed impaired Condition Remedy 1 Main j...

Page 64: ...ean the battery terminals with a solution of baking soda and water NOTE The sealing strip should NOT be removed and NO fluid should be added 3 Be sure the charger and battery are in a well venti lated area Be sure the charger is unplugged from the 110 volt electrical outlet 4 Connect the red terminal lead from the charger to the positive terminal of the battery then connect the black terminal lead...

Page 65: ... post PEAK VOLTAGE NOTE All of the peak voltage tests should be made using the Fluke Model 77 Multimeter p n 0644 559 with Peak Voltage Reading Adapter p n 0644 307 If any other type of tester is used readings may vary due to internal circuitry NOTE The battery must be at full charge for this test 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the blue yellow ...

Page 66: ...switch component the connector or the switch wiring harness Fuse The main 7 amp fuse is located on the frame near the battery under the seat NOTE To remove the fuse compress the locking tabs on either side of the fuse case and lift out If there is any type of electrical system failure always check the fuse first 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to one spa...

Page 67: ...troubleshoot or replace the switch compo nent the connector or the switch wiring harness Handlebar Control Switches The connector is in front of the steering post The con nector is accessible beneath the front fender NOTE These tests should be made on the switch side of the connector RESISTANCE Starter Button 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the yellow...

Page 68: ...ure 1 Attach the Timing Light p n 0644 296 to the spark plug high tension lead then remove the timing inspection plug from the right side crankcase cover 2 Using the Tachometer p n 0644 275 start the engine and run at 4000 RPM ignition timing should be 28 BTDC F mark 3 Install the timing inspection plug If ignition timing cannot be verified the rotor may be damaged the key may be sheared the trigg...

Page 69: ...ion Problem Charging unstable Condition Remedy 1 Lead wire intermittently shorting 2 Magneto internally shorted 3 Regulator rectifier defective 1 Replace lead wire 2 Replace magneto 3 Replace regulator rectifier Problem Starter button not effective Condition Remedy 1 Battery charge low 2 Switch contacts defective 3 Starter motor brushes not seating 4 Starter relay defective 5 Emergency stop igniti...

Page 70: ... the rear axle housing to the rear swing arm KM831A 2 Tighten the adjuster nut B on the adjusting bolt until approximately 30 mm 1 18 in of slack is pres ent 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 of the O rings then remove the chain KM238A INSTALLING DR...

Page 71: ...KET 1 Secure the ATV 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 castle nuts from the axle Account for the flat washer YT175A 3 Remove the left and right rear wheels 4 Remove the two axle nuts securing the brake hub to the axle then remove three cap screws securing the rear sprocket to the sprocket...

Page 72: ...e calculated Ts Specified torque value 86 ft lb Ls Tool offset length center to center L Length of torque wrench handle pivot to headcenter ATV2189 4 Install the outer axle nut and tighten to 86 ft lb 5 Adjust the chain 6 Install the rear wheels hubs and secure with two flat washers and castle nuts Tighten to 58 ft lb then install new cotter pins NOTE If cotter pin hole and notch in castle nut do ...

Page 73: ...NOTE Do not remove more components than nec essary to perform 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 hous ing to the swing arm then remove the axle housing KM217B KM212A AT THIS POINT If the technician s objective is to service replace the drive axle the axle housing does not ...

Page 74: ...axle hous ing then using a plastic mallet install the second bearing NOTE It may be helpful to insert the axle through the previously installed bearing and into the axle housing to align the center axle housing spacer with the bearing bore Axle installation may be difficult if the spacer is offset from the bearing bore 3 Apply a light coat of axle bearing grease to the inside mating surface of the...

Page 75: ...cotter pin should be installed 3 Remove the castle nut securing the hub Account for a washer MD2133 4 Remove the hub assembly Account for outer hub spacer 5 Repeat procedure for other hub CLEANING AND INSPECTING 1 Clean all hub components 2 Inspect all threads for stripping or damage 3 Inspect the brake shoes for excessive wear or gouges 4 Inspect the sealing area of the hub for pits 5 Inspect the...

Page 76: ... a plastic mallet install the inner and outer seals into the hub MD2380 4 Repeat procedure for the other hub INSTALLING HUB 1 Lightly lubricate the seals with bearing grease then install the hub assembly 2 Install the outer spacer washer and castle nut Tighten the castle nut to 45 ft lb then install a new cotter pin MD2388 MD2354 3 Install wheel Tighten the four cap screws to 30 ft lb 4 Repeat pro...

Page 77: ...off sprockets 5 Master link worn broken missing 1 Replace chain 2 Replace countershaft sprocket 3 Replace rear sprocket 4 Replace adjust drive chain 5 Replace master link Problem Clutch slipping Condition Remedy 1 Clutch shoes worn damaged 1 Replace clutch shoes Problem Clutch dragging Condition Remedy 1 Clutch return springs weak 2 Clutch worn damaged 1 Replace return springs 2 Replace clutch ...

Page 78: ...ers REMOVING REAR SHOCK ABSORBER 1 Secure the ATV on a support stand to elevate the wheels and to release the load on the suspension 2 Remove the cap screw securing the rear shock absorber to the frame MD2314 3 Remove the cap screw securing the rear shock absorber to the swing arm then remove the rear shock absorber MD2315 4 Compress the shock absorber spring and remove the spring retainer Remove ...

Page 79: ...sorber into position on the frame and swing arm and install the two cap screws Tighten the cap screws to 29 ft lb MD2314 MD2315 3 Remove the ATV from the support stand A Arm REMOVING 1 Secure the ATV on a support stand to elevate the front wheel then remove the wheel 2 Remove the cotter pin castle nut and washer then remove the hub assembly MD2133 CAUTION Do not tighten the nuts beyond the 29 ft l...

Page 80: ... the A arm MD2132 8 Remove the cap screws and self locking nuts secur ing the A arm to the frame MD2121 9 Remove the A arm MD2119 CLEANING AND INSPECTING 1 Clean all A arm components in parts cleaning solvent 2 Clean the tie rod mounting hole of all residual Loc tite grease oil or dirt for installing purposes 3 Inspect the A arm for bends cracks and worn bushings 4 Inspect the tie rod mounting hol...

Page 81: ...Tighten the castle nut to 45 ft lb then install a new cotter pin Install the wheel and tighten the cap screws to 30 ft lb 7 Remove the ATV from the support stand Swing Arm REMOVING 1 Secure the ATV on a support stand to elevate the rear wheels then remove the wheels 2 Remove two cap screws securing the brake caliper to the axle housing KM207 3 Remove drive chain hubs spacers and axle as nec essary...

Page 82: ...G 1 Clean all swing arm components in parts cleaning solvent 2 Inspect all swing arm welds for cracks or unusual bends 3 Inspect all tubing for cracks or unusual bends 4 Inspect the pressed in bushings for damage 5 Inspect the rubber swing arm guard for damage 6 Inspect the seals for damage INSTALLING 1 Lubricate the pressed in swing arm bushings with a light coat of grease then install the spacer...

Page 83: ...te tires of a different type or size TIRE INFLATION PRESSURE Front and rear tire inflation pressure should be 0 21 kg cm2 3 0 psi REMOVING 1 Secure the ATV on a support stand to elevate the wheels 2 Remove the four cap screws securing each wheel then remove the wheels NOTE Keep left side and right side wheels sepa rated for installing them on their proper sides CAUTION Do not tighten the cap screw...

Page 84: ...es on the opposite side If pulling is noted during braking only check and adjust the brakes as necessary and recheck operation see the Periodic Maintenance Tune Up section 4 Increase the air pressure in the tires with the smallest circumference measurement until all tires are equal in circumference 5 Repeat steps 3 4 as necessary to ensure proper handling Troubleshooting WARNING Do not operate the...

Page 85: ...82 NOTES ...

Page 86: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2259 817 ...

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