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Arctic Cat DVX 90 2010, Руководство по обслуживанию

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DVX 90

90 Utility

T M

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ATV 

ATV 

Service Manual

Service Manual

TABLE OF CONTENTS

Forward

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

4

5

6

7

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

www.mymowerparts.com

Содержание DVX 90 2010

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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