Arctic Cat 2012 DVX 90 Service Manual
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Arctic Cat 2012 DVX 90 Service Manual

Arctic Cat 2012 DVX 90 Service Manual

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
FOREWORD
This manual contains service, maintenance, and troubleshooting information for the 2012 Arctic Cat DVX 90/90
Utility ATV. The manual is designed to aid service personnel in service-oriented applications and may be used as a
textbook 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
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.
© 2011 Arctic Cat Inc.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
www.mymowerparts.com
AT THIS POINT directs the technician to certain
Manual
Table of Contents
July 2011

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Summary of Contents for Arctic Cat 2012 DVX 90

  • Page 1 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.
  • Page 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Click on the blue text to go. TABLE OF CONTENTS Service M ervice rv c Manual M n a A A A A A A V V Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the Table of Contents bookmarks on the left side of the screen, or click the blue text below.

  • Page 3: General Information

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Information MAGNETO Timing Sensor (peak voltage) 1.8-3.8 DC volts (blue/ yellow to ground) (resistance) 80-160 ohms (blue/yellow to ground)  NOTE: Some photographs and illustrations used in Regulator/Rectifier 12.1-15.2 DC volts@ 3000...

  • Page 4: Torque Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Specifications Torque Conversions (ft-lb/N-m) EXHAUST COMPONENTS Torque ft-lb ft-lb ft-lb ft-lb Part Part Bolted To ft-lb 35.4 69.4 103.4 Exhaust Pipe Cylinder Head 36.7 70.7 104.7 Muffler Frame 38.1 72.1...

  • Page 5: Gasoline-Oil-Lubricant

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Gasoline-Oil-Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, oxygenates (either etha- nol or MTBE) are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol, 5% methane, or MTBE are acceptable gasolines.

  • Page 6: Preparation After Storage

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Drain the carburetor float chamber. Preparation After 5. Plug the hole in the exhaust system with a clean cloth. Storage 6. Apply light oil to the upper steering post bushing and plungers of the shock absorbers.

  • Page 7: Periodic Maintenance/Tune-Up

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 It is advisable to lubricate certain components periodi- cally to ensure free movement. Apply light oil to the Periodic Maintenance/ components using the following list as reference. Tune-Up A. Throttle Lever Pivot/Cable Ends B.

  • Page 8: Air Filter

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Air Filter 1. Remove the seat; then remove five screws securing the air filter housing cover. CD651 2. Remove the breather tube from the valve cover; then remove the four cap screws and remove the valve cover.

  • Page 9: Testing Engine Compression

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD652 CD658 6. Install the valve cover and tighten the four cap screws to 7 ft-lb using a crisscross pattern; then install the breather tube. 7. Install the fan shroud and tighten the two cap screws securely.

  • Page 10: Spark Plug

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. If compression is now evident, service the piston 1. Remove the cap screw (1) securing the spark arrester rings (see Engine/Transmission section). assembly (2) to the rear of the muffler. Account for a gasket.

  • Page 11: Engine Oil

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the level plug from the lower-right side of the transmission; then remove the fill plug from the upper-right side of the transmission. Be careful not to allow contaminates to enter the opening.
  • Page 12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Headlights  NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE. When replacing the headlight bulb, do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing.

  • Page 13: Brake Systems

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MEASURING/REPLACING BRAKE SHOES/PADS Brake Systems Removing Front Brake Shoes 1. Support the ATV on a support stand. ! WARNING 2. Remove both front wheels and account for the cap After servicing brake-related components, ALWAYS screws.

  • Page 14: Inspecting And Measuring

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Inspecting and Measuring 1. Inspect the pads for gouges, chips, or wear. 2. Inspect the disc for gouges, grooves, cracks, and warpage. 3. Using a calipers, measure the thickness of each brake pad.

  • Page 15: Replacing Drive Belt

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING  NOTE: During the bleeding procedure, watch the reservoir sight glass to make sure there is always a 1. If removed, place the gasket and two alignment pins sufficient amount of brake fluid in the reservoir. Fail- into position on the crankcase.

  • Page 16: Adjusting Shift Linkage

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Adjusting Shift Linkage If the ATV jumps out of gear, is difficult to get in gear, or the neutral and reverse indicator lights do not illuminate, shift linkage adjustment may be necessary.

  • Page 17: Removing Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine/Transmission This section has been organized into sub-sections which show a progression for the complete servicing of the Arc- tic Cat Y-12+ engine/transmission.  NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission.

  • Page 18: Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Remove the air filter housing cover and air filter ele- ment. 6. Remove the intake boot from the carburetor; then remove the cap screws securing the air filter housing to the crankcase and remove the air filter housing and intake boot.

  • Page 19: Removing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Top-Side Components A. CAMSHAFT HOLDER/ROCKER ARMS B. CYLINDER HEAD/CAMSHAFT  NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmis- sion.
  • Page 20 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Remove the camshaft from the cylinder head and secure the cam chain to prevent it falling into the crankcase. YT109B YT168A CAUTION Do not rotate the crankshaft without keeping tension on the cam chain or engine damage could occur.

  • Page 21: Removing Valves

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 22 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Valve Stem to Guide Clearance 1. Insert a snap gauge 1/2 way down into each valve guide bore; then remove the gauge and measure it with a micrometer. 2. Using a micrometer, measure the valve stem outside diameter.

  • Page 23: Piston Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT141A CC400D 4. Place a spring retainer over the valve springs; then 2. Remove and discard each ring by working it toward using the valve spring compressor, compress the the top of the piston while rotating it out of the valve springs and install the valve keepers.

  • Page 24: Cylinder/Cylinder Head Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Piston Rings 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap.
  • Page 25 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Place the cylinder head on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion. Inspect the sealing surface for any indication of high spots.

  • Page 26: Measuring Camshaft Lobe Height

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC390D YT127 4. At this point, repeat step 1 and if any measurement exceeds the limit, the cylinder must be replaced. Installing Top-Side Measuring Camshaft Lobe Height Components 1. Using a micrometer, measure each cam lobe height.
  • Page 27 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT161A YT112 3. Lubricate the inside wall of the cylinder; then using a 5. Place a new gasket into position on the cylinder. ring compressor or the fingers, compress the rings Place the alignment pins into position;...
  • Page 28 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT169A YT172A 7. Make sure the crankshaft is positioned at TDC; then 9. Install the two cap screws securing the left side of the install the camshaft with the single large reference...

  • Page 29: Removing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 YT170 1. Remove the V-belt cover noting the location of the different-lengthed cap screw and the location of the alignment pins.
  • Page 30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the V-belt; then remove the movable drive face (A). Account for a bushing (B) and speed lim- iter spacer (C). 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.

  • Page 31: Installing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Left-Side Components A. GEAR POSITION SWITCH B. STARTER ONE-WAY CLUTCH C. ROTOR/FLYWHEEL D. CENTRIFUGAL CLUTCH E. V-BELT/DRIVE CLUTCH/DRIVEN PULLEY YT024B 1. With the transmission in neutral, install a new O-ring 4.

  • Page 32: Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT164 YT160B 7. Place the V-belt over the driven pulley; then over the CAUTION bushing/spacer. Pinch the belt in the middle to draw Failure to fully engage the splines with the kick-start it down into the driven pulley approximately 1 inch.

  • Page 33: Removing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Right-Side Components A. COOLING FAN B. ROTOR/FLYWHEEL C. STATOR COIL D. OIL PUMP 1. Remove the intake pipe/carburetor. Account for an O-ring in the intake pipe. YT145A 2. Remove the cooling fan shroud; then remove the 5.
  • Page 34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT032 YT036A 8. Remove the oil pump assembly being careful not to 3. Carefully remove the transmission case cover while drop the oil pump driveshaft. pressing in on the output driveshaft and shift shaft to leave components in the transmission case.

  • Page 35: Main Shaft

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Remove the shift shaft (E); then remove the shift cam/detent assembly (F). 8. Using a plastic mallet, drive the input driveshaft (D) and bearing from the transmission case. YT041B 5.

  • Page 36: Servicing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT081 YT048A 3. Remove the reverse gear snap ring and splined washer; then remove the reverse gear and thrust washer. YT100A 2. Inspect the shift dog and mating gears for chipping, flaking, discoloration, or signs of excessive wear.

  • Page 37: Oil Pump

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A. MAIN SHAFT 1. Install the non-splined reverse thrust washer (A) on the main shaft; then install the 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.
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Install the shift cam/detent assembly; then install the shift shaft aligning the timing index marks. YT047 3. Install the countershaft with thrust washer into the transmission case. YT069A 6. Engage the shift fork into the shift cam/detent assem- bly;...

  • Page 39: Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Making sure the input driveshaft thrust washer is installed, carefully install the transmission case cover. YT035 Center Crankcase YT039A Components  NOTE: This procedure cannot be done with the engine/transmission in the frame.

  • Page 40: Servicing Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT119 YT134 2. Carefully remove the crankshaft from the left-side 3. Place the crankshaft assembly on a set of V blocks; crankcase half while holding the timing chain clear then using a dial indicator, measure crankshaft of the timing sprocket;...

  • Page 41: Assembling Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT122A YT120 6. Replace all oil seals with new seals and coat wear 2. Install two alignment pins and a gasket; then install surfaces with clean, fresh grease. the right-side crankcase half. Secure with a cap screw (threads coated with red Loctite #271) and tighten to 8 ft-lb.

  • Page 42: Installing Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the oil pump drive chain and driven gear and secure the gear to the pump shaft with the nut tight- ened to 7 ft-lb; then install the oil pump baffle and secure with the cap screws.
  • Page 43 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT012 YT005A 3. Install the rear engine mounting through-bolt and 6. Connect the shift linkage; then install the air filter nut; then tighten the front and rear nuts to 32.5 ft-lb.

  • Page 44: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Connect the gasline hose (A) to the carburetor; then 11. Pour the recommended quantity of engine oil into the connect the crankcase breather hose (B) to the air fil- crankcase;...
  • Page 45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine noisy (Noise seems to come from clutch) Condition Remedy 1. Clutch shoe(s) worn 1. Replace clutch shoe(s) 2. Driven clutch hub warped - worn 2. Replace clutch Problem: Engine noisy (Noise seems to come from crankshaft)

  • Page 46: Carburetor Schematic

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuel/Lubrication This section has been organized for servicing the fuel system. The technician should use discretion and sound judgment when removing/disassembling and assembling/ installing components. ! 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.
  • Page 47 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD594 CD603 6. Disconnect the choke assembly connector; then 4. Remove the pilot screw assembly. Account for a remove the carburetor. spring and O-ring. CD591 CD608 5. Remove the idle adjustment screw assembly.

  • Page 48: Cleaning And Inspecting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Inspect tips of the jet needle, pilot screw, and the needle valve for wear, damage, or distortion. 9. Inspect the slow jet and main jet for obstructions or damage.
  • Page 49 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  NOTE: Turn the pilot screw clockwise until it is lightly seated; then turn it counterclockwise the rec- ommended number of turns as an initial setting. 4. Install the idle adjustment screw with the spring.

  • Page 50: Throttle Cable Free-Play

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Install the gas hose onto the carburetor. CD591 4. Install the carburetor onto the intake manifold; then CD588 tighten the cap screws securely. Throttle Cable Free-Play To adjust the throttle cable free-play, use the following procedure.

  • Page 51: Gas Tank

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Turn the idle adjustment screw in or out until the  NOTE: To access the gas tank, it is necessary to engine idles at 1700 RPM. move the front fender panel, which requires removing the handlebar from its clamp.

  • Page 52: Gas Tank Valve

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. 1. Clean all gas tank components with parts-cleaning solvent.

  • Page 53: Gas/Vent Hoses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place the valve into position on the frame and secure with the cap screw. Tighten securely. Oil Pump Assembly Gas/Vent Hoses For complete servicing of the oil pump, see Right-Side Components in Engine/Transmission section.

  • Page 54: Electrical System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Clean the battery terminals with a solution of baking soda and water. Electrical System  NOTE: The sealing strip should NOT be removed and NO fluid should be added.

  • Page 55: Testing Electrical Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  NOTE: The sealing strip should NOT be removed 1. Set the meter selector to the DC Voltage position. and NO fluid should be added. 2. Connect the red tester lead to the blue/yellow wire;...

  • Page 56: Choke Circuit

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Choke Circuit Fuse Disconnect the white two-pin connector adjacent to the The main (7 amp) fuse is located on the frame near the steering post. battery under the seat. CHOKE VOLTAGE ...

  • Page 57: Ignition Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  NOTE: If the meter does not read as specified, replace the ignition coil. Handlebar Control SPARK PLUG CAP RESISTANCE Switches 1. Connect the red tester lead to one end of the cap;...

  • Page 58: Starter Motor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSPECTING 3. With the engine running at a constant 3000 RPM, the meter must read 12.1-15.2 DC volts. 1. Check stator for signs of overheating, broken wires, or other damage.
  • Page 59 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Spark plug fouled with carbon Condition Remedy 1. Idle RPM too high 1. Adjust carburetor 2. Gasoline incorrect 2. Change to correct gasoline 3. Air filter element dirty 3. Clean element 4.

  • Page 60: Drive System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Drive System  NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. Drive Chain/Sprockets MD2357 CHECKING DRIVE CHAIN AND 2.

  • Page 61: Removing Front Drive Sprocket

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1854 YT175A 3. Remove the left and right rear wheels. REMOVING FRONT DRIVE 4. Remove the two axle nuts securing the brake hub to SPROCKET the axle; then remove three cap screws securing the 1.

  • Page 62: Installing Rear Sprocket

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 L x Ts L + Ls T: Torque wrench reading to be calculated Ts: Specified torque value (86 ft-lb) Ls: Tool offset length (center to center) L: Length of torque wrench (handle pivot to headcenter) YT198 ...

  • Page 63: Removing Axle Housing

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING AXLE HOUSING 1. Secure the ATV on a support stand to elevate the rear wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.

  • Page 64: Installing Bearings And Seals

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING  NOTE: Always clean and inspect the drive axle com- ponents to determine if any service or replacement is necessary. Replace all components showing signs of wear or damage.

  • Page 65: Removing Hub Bearings And Seals

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Slide the axle through the brake disc. MD2133 4. Remove the hub assembly. Account for outer hub KM234 spacer. 3. Secure the rear sprocket to the sprocket retainer. 5. Repeat procedure for other hub.

  • Page 66: Installing Hub

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 67 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Power not transmitted from engine to wheels Condition Remedy 1. Drive chain worn - broken 1. Replace chain 2. Countershaft sprocket worn - broken 2. Replace countershaft sprocket 3.

  • Page 68: Removing Rear Shock Absorber

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the front shock absorbers. Suspension REMOVING REAR SHOCK ABSORBER 1. Secure the ATV on a support stand to elevate the The following suspension system components should be wheels and to release the load on the suspension.

  • Page 69: Installing Front Shock Absorbers

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Inspect all springs, spring retainers, shock rods, dampers, bushings, shock bodies, and eyelets for cracks, leaks, and bends. INSTALLING FRONT SHOCK ABSORBERS 1. Place a shock absorber into position on the frame and A-arm and install the two cap screws and self-lock- ing nuts.
  • Page 70 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Slide brake backing plate assembly off the spindle shaft and secure it out of the way. 4. Remove the cotter pin from the outer tie rod end; then while holding the flat on the tie rod end, remove the castle nut.

  • Page 71: Swing Arm

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2425 MD2426 2. Secure the shock absorber to the A-arm with the cap 5. Apply a light coat of grease to spindle shaft; then screw and self-locking nut. Tighten the nut to 29 ft- install the brake backing plate assembly onto the shaft.
  • Page 72 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KM207 MD2014 3. Remove drive chain, hubs, spacers, and axle as nec- 6. Remove the cap screw securing the shock absorber essary (see Rear Hub/Drive Axle in Drive System to the swing arm.

  • Page 73: Wheels And Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING CAUTION  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- Do not tighten the cap screw beyond the 29 ft-lb specifi- cation or the shock eyelet or mount WILL be damaged.

  • Page 74: Tire Inflation Pressure

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING ! WARNING 1. Install each wheel on its hub. Do not mix tire tread patterns. Use the same pattern type  NOTE: Make sure each wheel is installed on its on front and rear.
  • Page 75 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring(s) weak 1. Replace spring(s) 2. Shock absorber damaged 2. Replace shock absorber Problem: Suspension too stiff Condition Remedy 1. A-arm bushings worn 1.

  • Page 76: Steering Post/Handlebar/Tie Rods

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the handlebar. Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips worn, broken, or loose. B. Handlebar bent, cracked, and an equal and com- plete full-left and full-right turn capability.
  • Page 77 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Inspect the tie rods for cracks or unusual bends. 4. Inspect all welded areas for cracks or deterioration. 5. Inspect the steering post and brackets for cracks, bends, or wear.
  • Page 78 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Route the control cables and wiring through the 7. Install the control cables onto the handlebar. metal loop on the steering post. MD2439 8. Make sure the cables (brake and throttle) are routed MD2135 down and away so there is no sticking or binding.

  • Page 79: Handlebar Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Connect the handlebar switch assembly and brake 1. Inspect the grip for wear, cuts, or cracks. switch connectors. 2. Inspect the grip for deterioration. INSTALLING  NOTE: Before installing a handlebar grip, use con-...

  • Page 80: Hand Brake Lever Assemblies

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KM544 MD2438 3. Connect the handlebar switch assembly wiring con- nector. MD2436 INSTALLING MD2434 1. Place the handlebar switch assembly onto the han- dlebar. Tighten the screw securely. Hand Brake Lever...
  • Page 81 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2439 KM208B 3. Remove the front brake cables from their adjusters 7. Remove the cap screws securing the hand brake by screwing the adjusters inward to loosen the lever assembly to the handlebar and remove the hand cables;...
  • Page 82 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Position the left brake lever assembly onto the han- dlebar and secure with the clamp and two cap screws. Tighten securely. MD2452 2. Install the throttle cable into the throttle control housing;...
  • Page 83 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2461 Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure incorrect 3.

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2012 90 utility

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