2010 Arctic Cat DVX90 and 90 Utility ATV service manual
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Official service manual for the 2010 Arctic Cat DVX90 and 90 Utility ATV's.
This official service repair manual gives complete step by step information on repair, servicing and preventative maintenance. The official manual is highly detailed with photos and illustrations to help guide you through every repair and troubleshooting procedure. This manual contains all you need to know to keep your ATV working right and is the only service repair manual you will need. It will help you understand, care for, and lower the repair and maintenance cost for your ATV or Quad.
With the abundance of service oriented companies provided in the global economy today, added with the addition of a fast paced, throw away society, repairing an ATV yourself may seem like a waste of time and money. With that said, the cost effectiveness and pride that comes with repairing an ATV at your home can be one of the greatest feelings in the world. This can be easily done with this official repair manual at your disposal, and a minimal amount of time and space.
The first and foremost benefit of having a repair manual for your ATV at arms reach is the fact that most problems associated with a ATV are simple and easy fixes. With all products, the manual will have a section that gives you many options on symptoms of the problem, and a troubleshooting method to go along with the issues at hand. The simple repairs included in this section can not only save you a large amount of money in repair and replacement costs, but also give you the added benefit of immediate results without the time having to be spent either taking it to the repair shop, or going to your local dealer to purchase a new product.
A small sample of some of the topics covered in this manual are: carburettor kits, oil filters, pistons, gaskets, brakes, sprockets, chains, wheel bearings, tires, tyres, lamps, bulbs, guards, gearbox, throttle, handlebar, seat, rack, start, kill, switch, button, tank, fuel, gasoline, petrol, diesel, quad, polaris, Yamaha, rings, wheels, steering, wheels, electrical, suspension, exhaust, body, muffler, drivetrain, con rod, cdi, filter, spark plug, radiator, starter, stator, water pump, recoil, thermostat, intake, head, cams, clutch, cv joint, drive belt, transfer case, chain, sprocket, hub, diff, differential, pegs, cover, guards, skid plate, decals, oil tank, scoop and much more.
As with any product in your home, the average ATV may come across a point in time when a more serious repair is needed. Many people in todays society will go and trade in a perfectly good ATV and purchase an over the top model that is not really used to its fullest capacity. While the cost of ATVs has gone down over the years, the repair kits and parts for the models are a fraction of the cost, and can easily installed with the proper repair manual. This manual will provide step by step instruction on disassembly, repair methods, and illustrations related to the repair. With this knowledge at your disposal, when the next issue comes up, you will have the knowledge and experience to fix the problem with ease.
In the end, you have a simple choice to make. You can be well informed, and pro active in your life by having the skill and drive to repair the items in your home using something as simple as a few inexpensive parts, a little time, and a good repair manual, or you can go about your way spending absurd amounts of money to purchase a product that will come across the same problem at some time or another, providing you with a never ending cycle of spending your hard earned money. At some point, every ATV will have an issue, as a machines quality is measured solely by the users commitment to maintenance. A good way to keep your ATV giving you years of quality service without having years of service bills is to purchase a good repair manual, and learn to do it yourself.
Book marked chapters for easy navigation allowing you to identify exact repair service procedures in the quickest time possible.
Notes, cautions and warnings throughout each chapter pinpoint critical service information.
Numbered instructions guide you through every repair procedure in a step-by-step fashion.
Bold figured numbers help you quickly match illustrations with instructions.
Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure.
Numbered table of contents easy to use so that you can find the information you need fast.
Manual Language: English
File Format: PDF
File Delivery: PDF (Instant Download)
Pages:98
To purchase this repair manual just click on the green instant download button at the upper left hand corner of this page. After purchasing just download it to your computer to save it and print pages from it whenever you need it.
This official service repair manual gives complete step by step information on repair, servicing and preventative maintenance. The official manual is highly detailed with photos and illustrations to help guide you through every repair and troubleshooting procedure. This manual contains all you need to know to keep your ATV working right and is the only service repair manual you will need. It will help you understand, care for, and lower the repair and maintenance cost for your ATV or Quad.
With the abundance of service oriented companies provided in the global economy today, added with the addition of a fast paced, throw away society, repairing an ATV yourself may seem like a waste of time and money. With that said, the cost effectiveness and pride that comes with repairing an ATV at your home can be one of the greatest feelings in the world. This can be easily done with this official repair manual at your disposal, and a minimal amount of time and space.
The first and foremost benefit of having a repair manual for your ATV at arms reach is the fact that most problems associated with a ATV are simple and easy fixes. With all products, the manual will have a section that gives you many options on symptoms of the problem, and a troubleshooting method to go along with the issues at hand. The simple repairs included in this section can not only save you a large amount of money in repair and replacement costs, but also give you the added benefit of immediate results without the time having to be spent either taking it to the repair shop, or going to your local dealer to purchase a new product.
A small sample of some of the topics covered in this manual are: carburettor kits, oil filters, pistons, gaskets, brakes, sprockets, chains, wheel bearings, tires, tyres, lamps, bulbs, guards, gearbox, throttle, handlebar, seat, rack, start, kill, switch, button, tank, fuel, gasoline, petrol, diesel, quad, polaris, Yamaha, rings, wheels, steering, wheels, electrical, suspension, exhaust, body, muffler, drivetrain, con rod, cdi, filter, spark plug, radiator, starter, stator, water pump, recoil, thermostat, intake, head, cams, clutch, cv joint, drive belt, transfer case, chain, sprocket, hub, diff, differential, pegs, cover, guards, skid plate, decals, oil tank, scoop and much more.
As with any product in your home, the average ATV may come across a point in time when a more serious repair is needed. Many people in todays society will go and trade in a perfectly good ATV and purchase an over the top model that is not really used to its fullest capacity. While the cost of ATVs has gone down over the years, the repair kits and parts for the models are a fraction of the cost, and can easily installed with the proper repair manual. This manual will provide step by step instruction on disassembly, repair methods, and illustrations related to the repair. With this knowledge at your disposal, when the next issue comes up, you will have the knowledge and experience to fix the problem with ease.
In the end, you have a simple choice to make. You can be well informed, and pro active in your life by having the skill and drive to repair the items in your home using something as simple as a few inexpensive parts, a little time, and a good repair manual, or you can go about your way spending absurd amounts of money to purchase a product that will come across the same problem at some time or another, providing you with a never ending cycle of spending your hard earned money. At some point, every ATV will have an issue, as a machines quality is measured solely by the users commitment to maintenance. A good way to keep your ATV giving you years of quality service without having years of service bills is to purchase a good repair manual, and learn to do it yourself.
Book marked chapters for easy navigation allowing you to identify exact repair service procedures in the quickest time possible.
Notes, cautions and warnings throughout each chapter pinpoint critical service information.
Numbered instructions guide you through every repair procedure in a step-by-step fashion.
Bold figured numbers help you quickly match illustrations with instructions.
Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure.
Numbered table of contents easy to use so that you can find the information you need fast.
Manual Language: English
File Format: PDF
File Delivery: PDF (Instant Download)
Pages:98
To purchase this repair manual just click on the green instant download button at the upper left hand corner of this page. After purchasing just download it to your computer to save it and print pages from it whenever you need it.
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Specifications* CHASSIS Length (Overall) Height (Overall) Width (Overall) Suspension Travel Tire Size Tire Inflation Pressure Dry Weight (Approx) Gas Tank Capacity Reserve Capacity Transmission Lubricant (Recommended) Transmission Lubricant Capacity Engine Oil Capacity Gasoline (Recommended) Engine Oil (Recommended) Brake Type Headlight Brakelight Starting System 146.8 cm (57.8 in.) 96.2 cm (37.9 in.) 87.6 cm (34.5 in.) (Front) 71.00 mm (2.8 in.) (Rear) 73.66 mm (2.9 in.) (Front) AT20 x 7-8 (Rear) AT19 x 8-8 0.21 kg-cm (3.0 psi) 2 ENGINE COMPONENTS Part Oil Drain Plug Spark Plug Cylinder Head (Nut) Crankcase Half* Flywheel* Camshaft Holder Stationary Drive Sheave* Oil Pump Oil Pump Gear Oil Screen/Filter Cap Cam Chain Tensioner Transmission Drain Plug Cylinder Head (Cap Screw) Valve Cover Spline-Lock Engine Mount Intake Pipe Rear Hub V-Belt Cover Transmission Case Cover Rear Sprocket Part Bolted To Crankcase Cylinder Head Cylinder Crankcase Half Crankshaft Cylinder Crankshaft Crankcase Oil Pump Crankcase Cylinder Transmission Crankcase Cylinder Head Drive Sprocket Engine/Frame Cylinder Head Torque ft-lb 18 9 15 8 30 15 27.5 7 7 10 7 18 7 7 8 32.5 7 58 86 7 22 20 Centrifugal Clutch Housing* Driven Pulley/Centrifugal Clutch 40 MISCELLANY 118 kg (260 lb) - DVX 120.2 kg (265 lb) - Utility 5.7 L (1.5 U.S. gal.) 1.3 L (0.34 U.S. gal.) SAE 80W-90 Hypoid 250 ml (8.4 fl oz) 0.8 L (0.84 U.S. qt) 87 Octane Regular Unleaded Arctic Cat ACX All Weather (Synthetic) Front Double Drum/Rear Hydraulic Disc w/Brake Lever Locks 12V/35W 12V/5W Electric w/Kick Start (Emergency) DRIVE TRAIN COMPONENTS Rear Axle Shaft Crankcase Transmission Sprocket Retainer Rear Axle Nut (Inner/Outer)* Rear Axle * w/Red Loctite #271 * Specifications subject to change without notice. Torque Specifications EXHAUST COMPONENTS Part Exhaust Pipe Muffler Brake Banjo-Fitting Brakeline Hose Rear Brake Caliper Stator* Wheel Front Wheel Hub Handlebar Cap Steering Post Tie Rod End Front Shock Absorber Rear Shock Absorber Swing Arm Swing Arm A-Arm Knuckle Tie Rod End Torque Conversions (ft-lb/N-m) ft-lb N-m 1.4 2.7 4.1 5.4 6.8 8.2 9.5 10.9 12.2 13.6 15 16.3 17.7 19 20.4 21.8 23.1 24.5 25.8 27.2 28.6 29.9 31.3 32.6 34 ft-lb 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 N-m 35.4 36.7 38.1 39.4 40.8 42.2 43.5 44.9 46.2 47.6 49 50.3 51.7 53 54.4 55.8 57.1 58.5 59.8 61.2 62.6 63.9 65.3 66.6 68 ft-lb 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 N-m 69.4 70.7 72.1 73.4 74.8 76.2 77.5 78.9 80.2 81.6 83 84.3 85.7 87 88.4 89.8 91.1 92.5 93.8 95.2 96.6 97.9 99.3 100.6 102 ft-lb 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 N-m 103.4 104.7 106.1 107.4 108.8 110.2 111.5 112.9 114.2 115.6 117 118.3 119.7 121 122.4 123.8 125.1 126.5 127.8 129.2 130.6 131.9 133.3 134.6 136 Part Bolted To Cylinder Head Frame Torque ft-lb 7 32 25 20 22 8 30 45 10 20 51 20 29 29 50 29 29 29 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 BRAKE SYSTEM COMPONENTS Caliper Master Cylinder Rear Axle Housing Stator Plate ELECTRICAL COMPONENTS STEERING COMPONENTS Front/Rear Hub Spindle Axle Lower Clamp Frame Steering Post Steering Post Outer Bearing Cap Inner Bearing Clamp SUSPENSION COMPONENTS Frame/A-Arm Frame/Swing Arm Frame Rear Axle Housing Frame A-Arm Knuckle 1-2 Back to TOC Back to Section TOC Next Tightening Torque (General Bolts) CAUTION Do not use white gas. Only Arctic Cat approved gasoline additives should be used. RECOMMENDED ENGINE OIL Type of Bolt (Conventional or 4 Marked Bolt) Thread Diameter Tightening A (mm) Torque 5 6 8 10 12-36 in.-lb 36-60 in.-lb 7-11 ft-lb 16-25 ft-lb 24-48 in.-lb 6-8 ft-lb 13-20 ft-lb 29-43 ft-lb 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 TANK (7 Marked Bolt) 5 6 8 10 ! WARNING Always fill the gas tank in a well-ventilated area. Never add gasoline to the ATV gas tank near any open flames or with the engine running or hot. DO NOT SMOKE while filling the gas tank. 1 Break-In Procedure A new ATV and an overhauled ATV engine require a "break-in" period. The first month is most critical to the life of this ATV. Proper operation during this break-in period will help assure maximum life and performance from the ATV. During the first three hours of operation, always use less than 1/2 throttle. Varying the engine RPM during the break-in period allows the components to "load" (aiding the mating process) and then "unload" (allowing components to cool). Although it is essential to place some stress on the engine components during break-in, care should be taken not to overload the engine too often. When the engine starts, allow it to warm up properly. Idle the engine several minutes until the engine has reached normal operating temperature. Do not idle the engine for excessively long periods of time. After the completion of the break-in period, the engine lubricant should be changed. Other maintenance after break-in should include checking of all prescribed adjustments and tightening of all fastener s. ATV0049B Since gasoline expands as its temperature rises, the gas tank must be filled to its rated capacity only. Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area. ! WARNING Do not over-fill or overflow gasoline when filling the gas tank. A fire hazard could materialize. Always allow the engine to cool before filling the gas tank. Tighten the gas tank cap securely after filling the tank. Gasoline-Oil-Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol, 5% methane, or MTBE are acceptable gasolines. Genuine Parts When replacement of parts is necessary, use only genuine Arctic Cat ATV parts. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illustrated Parts Manual for the correct part number, quantity, and description. Back Back to TOC Back to Section TOC 1-3 Next 9. Store the ATV indoors in a level position. Preparation For Storage CAUTION Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration. CAUTION Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the ATV causing rusting. Arctic Cat recommends the following procedure to prepare the ATV for storage. 1. Clean the seat cushion (cover and base) with a damp cloth and allow to dry. 2. Clean the ATV thoroughly by washing dirt, oil, grass, and other foreign matter from the entire ATV. Allow the ATV to dry thoroughly. DO NOT get water into any part of the engine or air intake. 3. Either drain the gas tank or add Fuel Stabilizer to the gas in the gas tank. Remove the air filter housing cover and air filter. Start the engine and allow it to idle; then using Arctic Cat Engine Preserver, rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds. Install the air filter and housing cover. Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. Arctic Cat recommends the following procedure to prepare the ATV. 1. Clean the ATV thoroughly. 2. Clean the engine. 3. Remove the cloth from the exhaust system. 4. Check all control wires and cables for signs of wear or fraying. Replace if necessary. 5. Change the transmission lubricant. 6. Charge the battery; then install. Connect the battery cables making sure to connect the positive cable first. 7. Check the entire brake system (cables, shoes, etc.), and all controls. Adjust or replace if necessary. 8. Check the tire pressure. Inflate to recommended pressure as necessary. 9. Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap screws, and bolts are tightened to specifications. 10. Make sure the steering moves freely and does not bind. 11. Check the spark plug. Clean or replace as necessary. CAUTION If the interior of the air filter housing is dirty, clean the area before starting the engine. 4. Drain the carburetor float chamber. 5. Plug the hole in the exhaust system with a clean cloth. 6. Apply light oil to the upper steering post bushing and plungers of the shock absorbers. 7. Tighten all nuts, bolts, cap screws, and screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, cap screws, and bolts are tightened to specifications. 8. Disconnect the battery cables (negative cable first); then remove the battery, clean the battery posts and cables, and store in a clean, dry area. CAUTION This maintenance-free battery should be charged at the recommended rate every 30 days or permanent damage will result if the battery completely discharges. Back1-4 Back to TOC Back to Section TOC |
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