Arctic Cat DVX 90 2010 Service Manual
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Arctic Cat DVX 90 2010 Service Manual

Arctic Cat DVX 90 2010 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 2010 Arctic Cat Y-12+ Youth
ATV. The manual is designed to aid service personnel in service-oriented applications and may be used as a text-
book 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.
© 2009 Arctic Cat Inc.
www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
AT THIS POINT directs the technician to certain
Back to TOC
July 2009

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Summary of Contents for Arctic Cat DVX 90 2010

  • 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 TABLE OF CONTENTS SHARE OUR PASSION. Click on the blue text to go. Forward General Information/Specifications Periodic Maintenance/Tune-Up 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System 6. Drive System Suspension 8. Steering/Frame Controls...
  • Page 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS Specifications ............1-2 Torque Specifications ..........1-2 Torque Conversions (ft-lb/N-m) ....... 1-2 Tightening Torque (General Bolts) ......1-3 Break-In Procedure ..........1-3 Gasoline-Oil-Lubricant ..........

  • Page 4: Torque Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ENGINE COMPONENTS Specifications* Torque Part Part Bolted To ft-lb Oil Drain Plug Crankcase CHASSIS Spark Plug Cylinder Head Length (Overall) 146.8 cm (57.8 in.) Cylinder Head (Nut) Cylinder Crankcase Half*...

  • Page 5: Break-In Procedure

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAUTION Tightening Torque Do not use white gas. Only Arctic Cat approved gaso- (General Bolts) line additives should be used. RECOMMENDED ENGINE OIL The recommended oil to use is Arctic Cat ACX All Weather (Synthetic).

  • Page 6: Preparation For Storage

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Store the ATV indoors in a level position. Preparation For Storage CAUTION Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the CAUTION ATV causing rusting.

  • Page 7: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart........2-2 Lubrication Points............ 2-3 Air Filter..............2-3 Valve/Tappet Clearance ......... 2-3 Testing Engine Compression ........2-5 Spark Plug............... 2-5 Muffler/Spark Arrester ..........

  • Page 8: Periodic Maintenance Chart

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A = Adjust I = Inspect C = Clean L = Lubricate Periodic Maintenance CH = Charge R = Replace Chart D = Drain T = Tighten Initial Service Every...

  • Page 9: Lubrication Points

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Compress the element to remove excess oil. Lubrication Points CAUTION A torn air filter can cause damage to the ATV engine. Dirt and dust may get inside the engine if the element It is advisable to lubricate certain components periodi- is torn.
  • Page 10 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD655 CD659 3. Remove the spark plug wire and the spark plug; then rotate the engine clockwise to the TDC posi- tion on the compression stroke. NOTE: The “T” mark on the rotor/flywheel is...

  • Page 11: Testing Engine Compression

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAUTION Testing Engine Before removing the spark plug, be sure to clean the Compression area around the spark plug. Dirt could enter engine when removing or installing the spark plug.

  • Page 12: Transmission Lubricant

    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 13 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD634A CD626 2. Remove the oil drain plug and drain the engine oil 5. Remove the oil level stick and pour the recom- into the pan; then install the oil drain plug and mended amount and viscosity oil into the engine;...

  • Page 14: Nuts/Bolts/Cap Screws

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Nuts/Bolts/Cap Screws Brakelight/Taillight Tighten all nuts, bolts, and cap screws. Make sure rivets Rotate the ignition switch to the ON position and com- holding components together are tight. Replace all press both brake levers.
  • Page 15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Rear Brake Pads 2. Loosen both jam nuts on the right-hand (front) brake lever. Turn both cable adjusters counter- 1. Remove the two cap screws securing the brake clockwise until both front wheels do not spin caliper to the axle housing;...
  • Page 16 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 necessary (see BLEEDING in this sub-sec- tion).

  • Page 17: Replacing Drive Belt

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Spread the faces of the driven clutch with a suit- able pry bar or wedge; then when the faces are Replacing Drive Belt separated, insert the drive belt. REMOVING 1.

  • Page 18: 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 illu- minate, shift linkage adjustment may be necessary.
  • Page 19 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 3 - ENGINE/TRANSMISSION Table of Contents Engine/Transmission ..........3-2 Specifications ............3-2 Y-12+ (Table of Contents)........3-3 Troubleshooting ............. 3-31 www.mymowerparts.com Back to TOC...

  • Page 20: Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine/Transmission Specifications* This section has been organized into sub-sections Piston Ring End Gap (Installed) (top) 0.15-0.30 mm which show a progression for the complete servicing (2nd) 0.30-0.45 mm (oil) 0.20-0.70 mm of the Arctic Cat Y-12+ engine/transmission.

  • Page 21: Table Of Contents)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Y-12+ (Table of Contents) Removing Engine/Transmission......3-3 Top-Side Components..........3-5 Removing Top-Side Components ......3-5 Servicing Top-Side Components......3-7 Installing Top-Side Components ......3-13 Left-Side Components .......... 3-15 Removing Left-Side Components ......3-16 KM853A Installing Left-Side Components ......

  • Page 22: Www.mymowerparts.com

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT002A YT008A YT009 YT005A 5. Remove the air filter housing cover and air filter 8. Disconnect the electric choke connector (C), stator element. coil connector (B), and starter harness connector (A);...

  • Page 23: Rocker Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT014 YT016A Top-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.
  • Page 24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Remove the cylinder head nuts on top of the cam 8. Remove the cam chain guide. shaft holder. Account for four flat washers.  AT THIS POINT To inspect cam chain guide, see Servicing Top-Side Components sub-section.

  • Page 25: Servicing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  AT THIS POINT  AT THIS POINT To service center crankcase components only, pro- To service cylinder, see Servicing Top-Side Compo- ceed to Removing Left-Side Components. nents sub-section. CAUTION...
  • Page 26 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-1004 CC928 2. Acceptable width must be at or above specifica- tions. Measuring Valve Face Radial Runout 1. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks.
  • Page 27 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAUTION If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced. Do not attempt to grind the valves or severe engine damage may occur.
  • Page 28 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Cleaning/Inspecting Piston Ring 3. Insert an inside dial indicator into the piston-pin bore. Take two measurements to ensure accuracy. Grooves The diameter must not exceed specifications. If 1. Take an old piston ring and snap it into two pieces;...
  • Page 29 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Place the cylinder head on the surface plate cov- ered 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 30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC997 CC390D 4. At this point, repeat step 1 and if any measurement Inspecting Cam Chain Guide exceeds the limit, the cylinder must be replaced. 1. Inspect cam chain guide for cuts, tears, breaks, or Measuring Camshaft Lobe Height chips.

  • Page 31: Installing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place the two alignment pins into position. Place a new cylinder gasket into position; then place a pis- ton holder (or suitable substitute) beneath the pis- ton skirt and square the piston in respect to the crankcase.
  • Page 32 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT112 YT169A 5. Place a new gasket into position on the cylinder. 7. Make sure the crankshaft is positioned at TDC; Place the alignment pins into position; then place then install the camshaft with the single large ref-...

  • Page 33: Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT172A YT170 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. YT090A 13. Install the intake pipe/carburetor assembly onto the cylinder head using a new O-ring.

  • Page 34: Driven Pulley

    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 Removing Left-Side speed limiter spacer (C). Components A. V-BELT COVER B. V-BELT/DRIVE CLUTCH/ DRIVEN PULLEY C.

  • Page 35: Installing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Left-Side Components A. GEAR SHIFT POSITION SWITCH B. STARTER ONE-WAY CLUTCH C. ROTOR/FLYWHEEL D. CENTRIFUGAL CLUTCH E. V-BELT/DRIVE CLUTCH/ DRIVEN PULLEY YT104 1. With the transmission in neutral, install a new 7.
  • Page 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT024B YT164 4. Install the starter countershaft housing; then install 7. Place the V-belt over the driven pulley; then over the starter one-way clutch cover. Tighten the cap the bushing/spacer. Pinch the belt in the middle to screws securely.

  • Page 37: 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. YT160B 2. Remove the cooling fan shroud; then remove the...
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the rotor/flywheel using the rotor/fly- wheel puller. Account for a key. YT032 8. Remove the oil pump assembly being careful not to drop the oil pump driveshaft. YT145A 5.
  • Page 39 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT036A YT041B 3. Carefully remove the transmission case cover 5. Remove the main shaft (B) and shift fork together. while pressing in on the output driveshaft and shift Account for the shift fork, a spacer, and a thrust shaft to leave components in the transmission washer.

  • Page 40: Servicing Right-Side Components

    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. YT081 3.

  • Page 41: Oil Pump

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT048A YT065 7. Inspect the detent spring and ball. Replace any worn or broken component. 8. Examine the transmission case and cover for cracks, discoloration, or chipped bearing bosses. YT100A 2.
  • Page 42 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. TRANSMISSION Assembling 1. Install new oil seals in the transmission case 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 with a plastic mallet.
  • Page 43 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Place the alignment pins in the correct locations; then install a new gasket on the transmission case. YT083 5. Install the shift cam/detent assembly; then install the shift shaft aligning the timing index marks.

  • Page 44: Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT036B YT118A 11. Install the shift arm on the shift shaft and secure with the cap screw. Tighten securely. YT119 2. Carefully remove the crankshaft from the left-side crankcase half while holding the timing chain clear YT035 of the timing sprocket;...

  • Page 45: Servicing Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  AT THIS POINT The center components are now disassembled for inspection. Servicing Crankcase Components 1. Inspect the crankshaft, crankshaft bearings, and connecting rod for excessive wear, damage, or dis- YT136 coloration.

  • Page 46: Assembling Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling Crankcase Half 1. Place the timing chain into the crankcase; then install the crankshaft assembly into the crankcase half. 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;...

  • Page 47: Installing Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT031A YT014 6. Install the stator/trigger coil assembly and secure 2. Install the two front engine mounting brackets on with four cap screws. Tighten securely. the frame and tighten the cap screws securely; then install the two front through-bolts.
  • Page 48 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT008A YT010A 8. Connect the gasline hose (A) to the carburetor; then connect the crankcase breather hose (B) to the air filter housing. YT005A 6. Connect the shift linkage; then install the air filter housing and air filter.
  • Page 49 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Piston rings worn excessively 1. Replace rings 2. Cylinder bore worn 2. Replace - rebore cylinder 3.
  • Page 50 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine idles poorly Condition Remedy 1. Magneto defective 1. Replace magneto 2. CDI unit defective 2. Replace CDI unit 3. Spark plug fouled - gap too wide 3. Adjust gap - replace plug 4.
  • Page 51 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 4 - FUEL/LUBRICATION TABLE OF CONTENTS Carburetor Specifications ........4-2 Carburetor Schematic ..........4-2 Carburetor ............... 4-2 Throttle Cable Free-Play ......... 4-7 Engine RPM (Idle)........... 4-7 Gas Tank ..............4-7 Fuel Valve ...............

  • Page 52: Carburetor Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Carburetor Carburetor Specifications ! WARNING ITEM Whenever any maintenance or inspection is per- formed on the fuel system during which there may be Type Keihin PTE fuel leakage, there should be no welding, smoking, Main Jet open flames, etc., in the area.
  • Page 53 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD592 CD600 5. Unscrew the carburetor cap; then lift the cap 3. Remove the float pin; then lift the float with nee- removing the throttle valve, spring, and jet needle.
  • Page 54 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 necessary. ! WARNING When drying components with compressed air, always wear safety glasses.
  • Page 55 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Install the main jet by threading it into the jet NOTE: Check float arm height by inverting the holder; then install the jet holder into the carbure- carburetor freeing the float arm; then measure tor.
  • Page 56 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD598 CD592 9. Insert the throttle cable into the top of the cap assembly and through the spring. 10. Compress the spring to expose the end of the throt- tle cable; then hook the end of the cable into the throttle valve.

  • Page 57: Throttle Cable Free-Play

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Throttle Cable Free-Play To adjust the throttle cable free-play, use the following procedure. 1. Pull back rubber boot to access cable adjustment nut. YT015B ! WARNING Adjust the idle to the correct RPM. Make sure the engine is at normal operating temperature before adjusting the idle RPM.
  • Page 58 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Mark the gas hoses for assembling pur- poses. MD2139 6. Carefully lay the handlebar assembly forward on the front fender panel. MD1848 NOTE: To access the gas tank, it is necessary to...

  • Page 59: Fuel Valve

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 In the OFF position, the valve will not allow gasoline to flow to the carburetor. In the ON position (the nor- mal operating position), gasoline will flow from the tank to the carburetor. In this position, 1.3 L (0.34 U.S.

  • Page 60: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Starting impaired Condition Remedy 1. Carburetor leaking air 1. Tighten - adjust carburetor - replace gasket 2. Choke not operating properly 2. Check choke assembly Problem: Idling or low speed impaired...

  • Page 61: Electrical System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Specifications ............5-2 Electrical Connections..........5-2 Switches..............5-2 Battery..............5-2 Testing Electrical Components........ 5-3 Timing Sensor ............5-3 CDI/Ignition Coil ............5-3 Stator Coil ...............

  • Page 62: Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 After being in service, batteries require regular clean- ing and recharging in order to deliver peak perfor- Specifications mance and maximum service life. The following procedure is recommended for cleaning and maintain- ing a sealed battery.

  • Page 63: Testing Electrical Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! WARNING Testing Electrical An overheated battery could explode causing severe injury or death. Always monitor charging times and Components charge rates carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.

  • Page 64: Stator Coil

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PEAK VOLTAGE 3. Crank the engine over using the electric starter. The meter must read 3.5-4.5 AC volts. NOTE: All of the peak voltage tests should be made using the Fluke Model 77 Multimeter (p/n...

  • Page 65: Fuse

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECONDARY WINDING RESISTANCE Fuse 1. Connect the red tester lead to the high tension lead (plug cap removed); then connect the black tester lead to a suitable ground. The main (7 amp) fuse is located on the frame near the battery under the seat.

  • Page 66: Handlebar Control Switches

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. With the switch in the OFF position, connect the red tester lead to the red wire and the black tester Magneto Assembly lead to each of the remaining wires. The meter must read an open circuit on both wires.

  • Page 67: Regulator/Rectifier

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Install the timing inspection plug. Regulator/Rectifier If ignition timing cannot be verified, the rotor may be damaged, the key may be sheared, the trigger coil bracket may be bent or damaged, or the CDI unit may be faulty.
  • Page 68 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Magneto does not charge Condition Remedy 1. Repair - replace - tighten lead wires 1. Lead wires - connections shorted loose open 2. Replace magneto coils 2. Magneto coils shorted - grounded - open 3.

  • Page 69: Drive System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 6 - DRIVE SYSTEM 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 www.mymowerparts.com Back to TOC...

  • Page 70: Drive Chain/Sprockets

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Drive Chain/Sprockets CHECKING DRIVE CHAIN AND SPROCKETS The following drive system components should be inspected periodically to ensure proper operation. A. Chain (excessive stretch or slack). B. Sprockets (excessive wear/hooking, missing or MD2357 broken teeth).
  • Page 71 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the cotter pins from the axle shaft and dis- card; then apply the rear brake and remove the cas- tle nuts from the axle. Account for the flat washer.
  • Page 72 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 YT198 TR235 L x Ts NOTE: It is not necessary to remove the chain L + Ls guard to remove the rear sprocket. T: Torque wrench reading to be calculated...

  • Page 73: Rear Hub/Drive Axle

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING BEARINGS AND SEALS Rear Hub/Drive Axle 1. Secure the ATV on a support stand to elevate the rear wheels. ! WARNING REMOVING REAR HUB/DRIVE AXLE Make sure the ATV is solidly supported on the support 1.
  • Page 74 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING BEARINGS AND NOTE: Do not remove more components than nec- SEALS essary to perform the intended service. The axle housing will separate from the swing arm with all 1. Using a plastic mallet and bearing driver or appro- components attached if necessary.

  • Page 75: Front Hub

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KM207 YT197A 3. Install the drive chain (see Installing Drive Chain 4. Install the axle nuts securing the brake hub to the sub-section). axle (see Drive Train/Sprockets - Installing Rear Sprockets in this section).
  • Page 76 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2421 MD2385 2. Remove the cotter pin from the castle nut. 2. Drive out the inner and outer bearings. Account for a spacer. NOTE: During installing, a new cotter pin should be installed.

  • Page 77: Brake Systems

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2380 MD2354 4. Repeat procedure for the other hub. 3. Install wheel. Tighten the four cap screws to 30 ft-lb. INSTALLING HUB 4. Repeat procedure for other hub assembly. 1. Lightly lubricate the seals with bearing grease;...
  • Page 78 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 7 - SUSPENSION 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 www.mymowerparts.com Back to TOC...

  • Page 79: Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Suspension NOTE: Critical torque specifications are located in Section 1. The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods bent, pitted, or damaged.
  • Page 80 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2315 MD2132 4. Compress the shock absorber spring and remove 2. Repeat the procedure for the other front shock the spring retainer. Remove the spring and spring absorber. preload adjuster.

  • Page 81: A-Arm

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Remove the rubber spindle pin boot; then remove the cotter pin and flanged castle nut from the spin- CAUTION dle pin. Lower the steering knuckle assembly from Do not tighten the cap screws beyond the 29 ft-lb the A-arm.
  • Page 82 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2119 MD2424 3. Lubricate the steering knuckle assembly with CLEANING AND INSPECTING grease; then install it into the A-arm and secure with the flanged castle nut. Tighten the nut to 29 NOTE: Whenever a part is worn excessively,...

  • Page 83: Swing Arm

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the four cap screws (A) securing the axle housing to the swing arm; then remove the axle housing. MD2381 6. Place the hub assembly onto the spindle; then install the washer and castle nut.
  • Page 84 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 into the swing arm. 2. If removed, install the rubber swing arm guard.

  • Page 85: Wheels And Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TIRE INFLATION PRESSURE Front and rear tire inflation pressure should be 0.21 kg-cm (3.0 psi). ! WARNING Always maintain proper tire inflation pressure. REMOVING 1. Secure the ATV on a support stand to elevate the wheels.

  • Page 86: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally. NOTE: Be sure all tires are the specified size and have identical tread pattern.
  • Page 87 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Steering Post/Handlebar/Tie Rods......8-2 Handlebar Grip............8-5 Troubleshooting ............8-7 www.mymowerparts.com Back to TOC...

  • Page 88: Steering/Frame

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering/Frame NOTE: Critical torque specifications are located in Section 1. The following steering components should be inspected periodically to ensure safe and proper opera- tion. A. Handlebar grips worn, broken, or loose.
  • Page 89 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Remove the gas tank cap and lift off the panel. MD2142 CLEANING AND INSPECTING MD2405 7. Remove the cotter pins; then remove the two inner NOTE: Whenever a part is worn excessively, tie rod ends from the steering post.
  • Page 90 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Install the steering post nut and tighten to 51 ft-lb. Install a new cotter pin. MD2405 6. Install handlebar with marks aligned with the han- dlebar mounting clamps. Install the caps; then MD2418 tighten the cap screws to 10 ft-lb.

  • Page 91: Handlebar Grip

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Make sure the cables (brake and throttle) are routed down and away so there is no sticking or binding. ! WARNING Make sure that there is maximum right/left steering capability and that the brake and throttle cables are not affected.
  • Page 92 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Inspect the grip for wear, cuts, or cracks. 2. Inspect the grip for deterioration. INSTALLING NOTE: Before installing a handlebar grip, use contact spray or alcohol to clean the inside of the grip and the handlebar of glue residue, oil, or any other contaminant.

  • Page 93: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. Adjust pressure 4.
  • Page 94 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 9 - CONTROLS TABLE OF CONTENTS Handlebar Switch ............ 9-2 Hand Brake Lever Assemblies ........ 9-3 www.mymowerparts.com Back to TOC...

  • Page 95: Handlebar Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Handlebar Switch REMOVING 1. Disconnect the handlebar switch assembly wiring connector. MD2436 INSTALLING 1. Place the handlebar switch assembly onto the han- dlebar. Tighten the screw securely. MD2434 2. Disconnect the brake switch wiring connectors.
  • Page 96 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Connect the handlebar switch assembly wiring 3. Remove the front brake cables from their adjusters connector. by screwing the adjusters inward to loosen the cables; then pulling them free.
  • Page 97 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KM208A KM548A 3. Install the brake cable to the lever assembly. MD2442 INSTALLING 1. Slide the right brake lever assembly onto the han- MD2453 dlebar; do not tighten the Allen-head screw com- 4.
  • Page 98 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Before installing a handlebar grip, use contact spray or alcohol to clean the inside of the grip and the handlebar of adhesive residue, oil, or any other contaminant. 9. Apply a liberal amount of Handlebar Grip Adhe- sive to the inside of the grip;...

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