Arctic Cat 2012 DVX 90 Service Manual page 2

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General Information........................................................... 2
Specifications ............................................................... 2
Torque Specifications.................................................... 3
Torque Conversions (ft-lb/N-m)..................................... 3
Break-In Procedure ...................................................... 3
Gasoline-Oil-Lubricant .................................................. 4
Genuine Parts............................................................... 4
Preparation For Storage ............................................... 4
Preparation After Storage ............................................. 5
Periodic Maintenance/Tune-Up......................................... 6
Periodic Maintenance Chart ......................................... 6
Air Filter ........................................................................ 7
Valve/Tappet Clearance ................................................ 7
Testing Engine Compression ........................................ 8
Spark Plug .................................................................... 9
Muffler/Spark Arrester .................................................. 9
Transmission Lubricant ................................................. 9
Engine Oil ................................................................... 10
Headlights................................................................... 11
Brakelight/Taillight....................................................... 11
Brake Systems............................................................ 12
Replacing Drive Belt ................................................... 14
Adjusting Shift Linkage ............................................... 15
Troubleshooting Brake System ................................... 15
Engine/Transmission....................................................... 16
Removing Engine/Transmission ................................. 16
Top-Side Components ................................................ 17
Removing Top-Side Components ............................... 18
Servicing Top-Side Components ................................ 20
Installing Top-Side Components ................................. 25
Left-Side Components ................................................ 28
Removing Left-Side Components............................... 28
Installing Left-Side Components................................. 30
Right-Side Components ............................................. 31
Removing Right-Side Components ............................ 32
Servicing Right-Side Components.............................. 35
Installing Right-Side Components .............................. 36
Center Crankcase Components ................................. 38
Disassembling Crankcase Halves .............................. 38
Servicing Crankcase Components ............................. 39
Assembling Crankcase Half........................................ 40
Installing Engine/Transmission ................................... 41
DVX 90 DVX DVX 90 0 0 D D V V X X DV V VX VX X 9 X 9 X X Troubleshooting .......................................................... 43 9 90 90 0 0 0
Fuel/Lubrication ............................................................... 45
Carburetor Schematic................................................. 45
90 90 Utility 9 9 0 0 0 0 U U 90 U 90 Utility 0 Utility ti ity i l i y y
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TABLE OF CONTENTS
S S S S S S Service M ervice e rv c r v i c e M M M n a M Manual
A A A A A A V V
Carburetor ...................................................................45
Throttle Cable Free-Play .............................................49
Engine RPM (Idle) .......................................................49
Gas Tank .....................................................................50
Gas Tank Valve ...........................................................51
Gas/Vent Hoses ..........................................................52
Oil Pump Assembly .....................................................52
Oil Screen/Filter ..........................................................52
Troubleshooting ...........................................................52
Electrical System..............................................................53
Battery.........................................................................53
Testing Electrical Components ....................................54
Timing Sensor .............................................................54
CDI/Ignition Coil ..........................................................54
Stator Coil ...................................................................54
Choke Circuit...............................................................55
Brakelight Switch.........................................................55
Fuse ............................................................................55
Ignition Coil .................................................................55
Ignition Switch .............................................................56
Handlebar Control Switches........................................56
Magneto Assembly......................................................56
Starter Motor ...............................................................57
Regulator/Rectifier ......................................................57
Ignition Timing .............................................................57
Headlights ...................................................................57
Troubleshooting ...........................................................57
Drive System.....................................................................59
Drive Chain/Sprockets.................................................59
Rear Hub/Drive Axle....................................................61
Front Hub ....................................................................64
Brake Systems ............................................................65
Troubleshooting ...........................................................66
Suspension .......................................................................67
Shock Absorbers .........................................................67
A-Arm ..........................................................................68
Swing Arm...................................................................70
Wheels and Tires ........................................................72
Troubleshooting ...........................................................74
Steering/Frame/Controls..................................................75
Steering Post/Handlebar/Tie Rods..............................75
Handlebar Grip............................................................78
Handlebar Switch ........................................................78
Hand Brake Lever Assemblies ....................................79
Troubleshooting ...........................................................82
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