Arctic Cat DVX 90 2010 User manual

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 AT THIS POINT directs the technician to certain
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. July 2009
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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DVX 90
90 Utility
TM
SHARE OUR PASSION.
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
8
9
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1-1
1
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 ............................................ 1-3
Genuine Parts ......................................................... 1-3
Preparation For Storage.......................................... 1-4
Preparation After Storage........................................ 1-4
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1-2
Specifications*
* Specifications subject to change without notice.
Torque Specifications
* w/Red Loctite #271
Torque Conversions
(ft-lb/N-m)
CHASSIS
Length (Overall) 146.8 cm (57.8 in.)
Height (Overall) 96.2 cm (37.9 in.)
Width (Overall) 87.6 cm (34.5 in.)
Suspension Travel (Front)
(Rear)
71.00 mm (2.8 in.)
73.66 mm (2.9 in.)
Tire Size (Front)
(Rear)
AT20 x 7-8
AT19 x 8-8
Tire Inflation Pressure 0.21 kg-cm2(3.0 psi)
MISCELLANY
Dry Weight (Approx) 118 kg (260 lb) - DVX
120.2 kg (265 lb) - Utility
Gas Tank Capacity 5.7 L (1.5 U.S. gal.)
Reserve Capacity 1.3 L (0.34 U.S. gal.)
Transmission Lubricant
(Recommended)
SAE 80W-90 Hypoid
Transmission Lubricant Capacity 250 ml (8.4 fl oz)
Engine Oil Capacity 0.8 L (0.84 U.S. qt)
Gasoline (Recommended) 87 Octane Regular Unleaded
Engine Oil (Recommended) Arctic Cat ACX All Weather
(Synthetic)
Brake Type Front Double Drum/Rear Hydraulic
Disc w/Brake Lever Locks
Headlight 12V/35W
Brakelight 12V/5W
Starting System Electric w/Kick Start (Emergency)
EXHAUST COMPONENTS
Part Part Bolted To Torque
ft-lb
Exhaust Pipe Cylinder Head 7
Muffler Frame 32
BRAKE SYSTEM COMPONENTS
Brake Banjo-Fitting Caliper 25
Brakeline Hose Master Cylinder 20
Rear Brake Caliper Rear Axle Housing 22
ELECTRICAL COMPONENTS
Stator* Stator Plate 8
STEERING COMPONENTS
Wheel Front/Rear Hub 30
Front Wheel Hub Spindle Axle 45
Handlebar Cap Lower Clamp 10
Steering Post Outer Bearing Cap Inner Bearing Clamp 20
Steering Post Frame 51
Tie Rod End Steering Post 20
SUSPENSION COMPONENTS
Front Shock Absorber Frame/A-Arm 29
Rear Shock Absorber Frame/Swing Arm 29
Swing Arm Frame 50
Swing Arm Rear Axle Housing 29
A-Arm Frame 29
Knuckle A-Arm 29
Tie 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* Crankshaft 30
Camshaft Holder Cylinder 15
Stationary Drive Sheave* Crankshaft 27.5
Centrifugal Clutch Housing* Driven Pulley/Centrifugal Clutch 40
Oil Pump Crankcase 7
Oil Pump Gear Oil Pump 7
Oil Screen/Filter Cap Crankcase 10
Cam Chain Tensioner Cylinder 7
Transmission Drain Plug Transmission 18
Cylinder Head (Cap Screw) Crankcase 7
Valve Cover Cylinder Head 7
Spline-Lock Drive Sprocket 8
Engine Mount Engine/Frame 32.5
Intake Pipe Cylinder Head 7
DRIVE TRAIN COMPONENTS
Rear Hub Rear Axle Shaft 58
Rear Axle Nut (Inner/Outer)* Rear Axle 86
V-Belt Cover Crankcase 7
Transmission Case Cover Transmission 22
Rear Sprocket Sprocket Retainer 20
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
11.4 26 35.4 51 69.4 76 103.4
22.7 27 36.7 52 70.7 77 104.7
34.1 28 38.1 53 72.1 78 106.1
45.4 29 39.4 54 73.4 79 107.4
56.8 30 40.8 55 74.8 80 108.8
68.2 31 42.2 56 76.2 81 110.2
79.5 32 43.5 57 77.5 82 111.5
810.9 33 44.9 58 78.9 83 112.9
912.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
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1-3
1
Tightening Torque
(General Bolts)
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” (allow-
ing 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 fasteners.
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.
RECOMMENDED 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 TANK
ATV0049B
Since gasoline expands as its temperature rises, the gas
tank must be filled to its rated capacity only. Expan-
sion room must be maintained in the tank particularly
if the tank is filled with cold gasoline and then moved
to a warm area.
Tighten the gas tank cap securely after filling the tank.
Genuine Parts
When replacement of parts is necessary, use only gen-
uine Arctic Cat ATV parts. They are precision-made to
ensure high quality and correct fit. Refer to the appro-
priate Illustrated Parts Manual for the correct part
number, quantity, and description.
Type of Bolt Thread Diameter
A (mm)
Tightening
Torque
(Conventional or 4 Marked Bolt) 5 12-36 in.-lb
6 36-60 in.-lb
8 7-11 ft-lb
10 16-25 ft-lb
(7 Marked Bolt) 5 24-48 in.-lb
6 6-8 ft-lb
8 13-20 ft-lb
10 29-43 ft-lb
CAUTION
Do not use white gas. Only Arctic Cat approved gaso-
line additives should be used.
! 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.
! 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.
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1-4
Preparation For Storage
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 hous-
ing 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 open-
ing for a period of 10 to 20 seconds. Install the air
filter and housing cover.
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.
9. Store the ATV indoors in a level position.
Preparation After
Storage
Taking the 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. 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 bat-
tery 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 neces-
sary.
CAUTION
Prior to storing the ATV, it must be properly serviced
to prevent rusting and component deterioration.
CAUTION
If the interior of the air filter housing is dirty, clean the
area before starting the engine.
CAUTION
This maintenance-free battery should be charged at
the recommended rate every 30 days or permanent
damage will result if the battery completely dis-
charges.
CAUTION
Avoid storing outside in direct sunlight and avoid
using a plastic cover as moisture will collect on the
ATV causing rusting.
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2-1
2
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 ............................................. 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 Belt.............................................. 2-11
Adjusting Shift Linkage.......................................... 2-12
Troubleshooting Brake System.............................. 2-12
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2-2
Periodic Maintenance
Chart
A = Adjust I = Inspect
C = Clean L = Lubricate
CH = Charge R = Replace
D = Drain T = Tighten
*Service/Inspect more frequently when operating in adverse
conditions.
Item
Initial Service
After Break-In
(First Mo)
Every
Day
Every
Month
Every 3
Months
Every 6
Months
Every
Year As Needed
Battery I CH I C
Fuse IR
Air Filter I C* R
Engine Compression I
Spark Plug I/C R (4000 Mi or 18 Mo)
Chassis C*/L* I
Gas/Vent Hoses I C, R (2 Years)
Fuel Valve IC
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
Steering Components I I R
Drive Chain I C*/L* R
Suspension
(Tie Rods, Protective Boots)
II R
Nuts/Bolts/Cap Screws I I/T T
Ignition Timing I
Brakelight I I R
Switches I R
Kick Starter I C
Handlebar/Grips I R
Frame/Welds I l
Electrical Connections I I C
Complete Brake Systems I I C* L, R
Brake Fluid I I R (2 Years)
Shock Absorbers I R
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2-3
2
Lubrication Points
It is advisable to lubricate certain components periodi-
cally to ensure free movement. Apply light oil to the
components using the following list as reference.
A. Throttle Lever Pivot/Cable Ends
B. Brake Lever Pivot/Cable Ends
C. Brake Cable Ends
D. Idle RPM Adjustment Screw (Carburetor)
Air Filter
1. Remove the seat; then remove five screws secur-
ing the air filter housing cover.
KM032A
2. Remove the air filter housing cover; then pull the
filter out of the housing.
3. Fill a wash pan larger than the element with a
non-flammable cleaning solvent; then dip the ele-
ment in the solvent and wash it.
NOTE: Foam Filter Cleaner and Foam Filter Oil
are available from Arctic Cat.
4. Compress the element by pressing it between the
palms of both hands to remove excess solvent. Do
not twist or wring the element or it will develop
cracks.
5. Dry the element.
6. Put the element in a plastic bag; then pour in air
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 air filter. Install air filter housing cover
and secure with the five screws.
Valve/Tappet Clearance
To check and adjust valve/tappet clearance, use the
following procedure.
NOTE: Valve/tappet clearance specifications are
for room temperature (approximately 68° F).
1. Remove the two cap screws and the two self-tap-
ping screws securing the fan shroud; then remove
the fan shroud.
CD651
2. Remove the breather tube from the valve cover;
then remove the four cap screws and remove the
valve cover. Account for the O-ring seal and the
valve cover.
CD654
CAUTION
A torn air filter can cause damage to the ATV engine.
Dirt and dust may get inside the engine if the element
is torn. Carefully examine the element for tears before
and after cleaning it. Replace the element with a new
one if it is torn.
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2-4
CD655
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
aligned with the timing pointer on the crankcase,
and intake and exhaust valve adjuster screws
must not have pressure on them. The two punch
marks on the camshaft gear are aligned with the
valve cover surface, and the hole in the timing
gear points away from the engine.
CD652
CD656A
4. Using a feeler gauge, check each valve tappet
clearance. If the clearance is not within 0.1 mm,
loosen the jam 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 after the jam nut
has been tightened to ensure that the clearance did
not change.
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. Tighten the self-tapping screws
snug taking care not to strip the plastic cover.
8. Install the spark plug and tighten to 9 ft-lb; then
install the spark plug wire.
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2-5
2
Testing Engine
Compression
To test engine compression, use the following proce-
dure.
1. Remove the high tension lead from the spark plug.
2. Using compressed air, blow any debris from
around the spark plug.
3. Remove the spark plug; then attach the high ten-
sion lead to the plug and ground the plug on the
cylinder head well away from the spark plug hole.
4. Attach the Compression Tester Kit (p/n 0444-213).
NOTE: The engine must be warm and the battery
must be fully charged for this test.
5. While holding the throttle lever in the full-open
position, crank the engine over with the electric
starter until the gauge shows a peak reading (five
to 10 compression strokes).
NOTE: Compression should be within a range of
195-230 psi in the full-open throttle position.
6. If compression is abnormally low, inspect the fol-
lowing items.
A. Verify starter cranks engine over.
B. Gauge is functioning properly.
C. Throttle lever in the full-open position.
7. Pour 29.5 ml (1 fl oz) of oil into the spark plug
hole, reattach the gauge, and retest compression.
8. If compression is now evident, service the 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 need to
be adjusted. To maintain a hot, strong spark, keep the
plug free of carbon.
ATV-0051
Adjust the gap to 0.6-0.7 mm (0.024-0.028 in.) for
proper ignition. Use a feeler gauge to check the gap.
ATV-0052A
When installing the spark plug, be sure to tighten it to
specifications. A new spark plug should be tightened
1/2 turn once the washer contacts the cylinder head. A
used spark plug should be tightened 1/8 - 1/4 turn once
the washer contacts the cylinder head.
Muffler/Spark Arrester
To clean the arrester, use the following procedure.
1. Remove the cap screw (1) securing the spark
arrester assembly (2) to the rear of the muffler.
Account for a gasket.
! WARNING
Always wear safety glasses when using compressed
air.
CAUTION
Before removing the spark plug, be sure to clean the
area around the spark plug. Dirt could enter engine
when removing or installing the spark plug.
! WARNING
Before removing the muffler/spark arrester, wait for it
to cool to avoid burns.
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2-6
KM139A
2. Clean the screen (3) with a brush and parts-clean-
ing solvent. Dry with compressed air. If the screen
has any holes or tears, it must be replaced.
KM140B
3. Install the spark arrester in the muffler and secure
with the cap screw. Tighten securely.
KM139
Transmission Lubricant
1. Park the ATV on level ground.
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.
YT188A
3. Remove the drain plug from the bottom of the
transmission and drain the lubricant into a drain
pan.
KM038A
4. Install the drain plug and tighten to 18 ft-lb. Pour
the recommended lubricant in the fill hole while
observing the 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 short distance.
6. Turn the engine off and wait approximately one
minute. Remove the level and recheck the lubri-
cant level. The level should be visible at the level
hole. If lubricant is not visible, add recommended
lubricant until the level is visible at the level hole.
7. Inspect the area around the drain plug for leaks.
Engine Oil
1. Move the ATV outdoors and start and warm up the
engine. Shut the engine off; then place a drain pan
under the engine oil drain plug located on the
left-side rear of the engine under the kick starter.
! WARNING
Before installing the spark arrester, wait for the muffler
to cool to avoid burns.
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2-7
2
CD634A
2. Remove the oil drain plug and drain the engine oil
into the pan; then install the oil drain plug and
tighten to 18 ft-lb.
3. Move the drain pan to the right-front of the engine
and remove the oil screen/filter cap. Account for a
screen, spring, and O-ring.
KM040A
CD628
4. Clean the oil screen in parts-cleaning solvent using
a brush; then install the screen, spring, and cap
making sure the O-ring is seated properly in the
cap. Tighten to 10 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 and allow to stand for 2-3 min-
utes.
8. Remove the oil level stick and wipe with a clean
cloth.
9. Install the oil level completely into the engine.
10. Remove the oil level stick; the engine oil level
should be at the appropriate level.
KM022A
11. Inspect the area around the drain plug and oil
screen/filter cap for leaks.
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2-8
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure rivets
holding components together are tight. Replace all
loose rivets. Care must be taken that all calibrated nuts,
bolts, and cap screws are tightened to specifications.
Headlights
NOTE: The bulb portion of the headlight is frag-
ile. 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. Skin oil residue
on the bulb will shorten the life of the bulb.
To replace a headlight bulb, use the following proce-
dure.
1. Remove the boot from the back of the headlight
housing; then remove the three-wire connector
from the bulb.
2. Using care not to bend or deform the spring clip,
release the two ends of the spring clip from the
housing; then remove the bulb from the headlight
housing.
KM192A
3. Install the new bulb into the headlight housing;
then secure with the spring clip.
4. Connect the three-wire connector to the bulb; then
install the boot.
Brakelight/Taillight
Rotate the ignition switch to the ON position and com-
press both brake levers. The brakelight should illumi-
nate.
To replace the brakelight bulb, use the following pro-
cedure.
1. Remove the 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.
Brake Systems
Although the brake systems have been adjusted at the
factory, the brakes should be checked for proper opera-
tion. The brakes must be maintained to be fully func-
tional.
CHECKING FRONT WHEEL BRAKE
1. With the engine off, compress the right-hand
(front) brake lever and attempt to move the ATV.
2. If the front wheels are locked, it is adjusted prop-
erly.
3. If the front wheels are not locked or if only one
wheel locks, adjustment is necessary.
CHECKING REAR WHEEL BRAKE
1. With the engine off, compress the left-hand (rear)
brake lever and set the brake lever lock; then
attempt to move the ATV.
2. If the rear wheels are locked, it is serviceable.
3. If the rear wheels are not locked, bleed the brake
system or replace the pads as necessary.
ADJUSTING FRONT WHEEL BRAKE
1. Raise the ATV enough to allow the front wheels to
spin freely.
! WARNING
Do not attempt to remove the bulb when it is hot.
Severe burns may result.
CAUTION
Tighten the lens cover screws only until they are snug.
! WARNING
After servicing components that are brake-related,
ALWAYS check and adjust brakes as necessary before
operating the ATV.
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2-9
2
2. Loosen both jam nuts on the right-hand (front)
brake lever. Turn both cable adjusters counter-
clockwise until both front wheels do not spin
freely.
KM024B
3. Turn both cable adjusters in 1/4 turn increments
(clockwise) until the wheels spin with a very slight
amount of drag.
4. Lower ATV; then push it forward and compress
the brake lever.
5. If the front wheels lock evenly, adjustment is cor-
rect.
6. If the front wheels do not lock evenly, additional
adjustment is necessary.
7. Once proper adjustment is obtained, tighten the
jam nuts.
MEASURING/REPLACING BRAKE
SHOES/PADS
Removing Front Brake Shoes
1. Support the ATV on a support stand.
2. Remove both front wheels and account for the cap
screws.
3. Remove the cotter pins, castle nuts, and washers;
then remove the brake drums/wheel 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 caliper off
the disc.
KM234A
2. Depress the holder pins and disengage and remove
the outer pad; then remove the inner pad. Account
for the spring clip.
KM221A
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.
4. If the thickness of any brake pad is less than 1.0
mm (0.039 in.), the brake pads must be replaced.
NOTE: The brake pads should be replaced as a
set.
Installing Front Brake Shoes
1. Place the brake shoes onto the backing plate over
the stationary pivot pin and rotating cam.
2. Install the brake return spring.
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2-10
MD2044
3. Install the wheel hub, washer, and castle nut.
Tighten the castle nut to 45 ft-lb; then install a new
cotter pin.
4. Install the wheel. Tighten to 30 ft-lb.
5. Repeat this procedure for the other side; then
adjust the brake (see Adjusting Front Wheel Brake
in this sub-section).
6. Remove the ATV from the support stand.
Installing Rear Brake Pads
1. Place the inner pad spring clip into position and
install the inner brake pad; then install the outer
pad onto the holder pins.
KM214
KM222
2. Place the assembled caliper into position on the
disc; then secure with the two cap screws. Tighten
to 22 ft-lb.
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).
BLEEDING
To bleed the brake system, 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 screw
and connect one end of a clear hose to the bleed
screw and direct the other end into a suitable con-
tainer.
KM207A
AF637D
4. Slowly compress the brake lever several times;
then while holding slight pressure on the brake
lever, open the bleed screw and watch for air bub-
bles in the hose. Close the bleed screw before
releasing the brake lever. Repeat this procedure
until no air bubbles are present.
NOTE: During the bleeding procedure, watch the
reservoir sight glass to make sure there is always
a sufficient amount of brake fluid in the reservoir.
Failure to maintain sufficient amount of fluid in the
reservoir will result in air being in the system.
5. Repeat step 4 until the brake lever is firm.
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2-11
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Replacing Drive Belt
REMOVING
1. Remove the eight Phillips-head cap screws and
four cap screws securing the footrest cover to the
footrest and front and rear fenders; then remove
footrest cover.
2. Remove the cooling duct.
3. Remove the eight cap screws securing the drive
clutch cover; then remove the cover. Account for a
gasket and two alignment pins.
NOTE: The gasket does not need to be removed
unless it is being replaced or unless additional
servicing is being done requiring its removal.
4. Remove the nut securing the stationary drive
sheave to the crankshaft; then remove the station-
ary drive sheave. Account for a washer, kick
starter ratchet, and cooling fan.
CD621
5. Open the movable sheave on the driven clutch
assembly 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 clutch with a suit-
able pry bar or wedge; then when the faces are
separated, insert the drive belt.
CD624
NOTE: If the drive belt has an arrow stamped on
the outer face, it should point forward (direction of
rotation).
3. Pinch the drive belt together near its center and
slide the stationary drive sheave over the crank-
shaft. Install the washer, kick starter ratchet, and
cooling fan. Secure the stationary drive sheave
with a nut (threads coated with red Loctite #271).
Tighten the nut to 27.5 ft-lb.
CD623
CD619
4. Rotate the drive belt and sheaves until the drive
belt is flush with the top of the driven clutch.
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2-12
CD620
5. Place the V-belt cover and one rear brake cable tab
into position; then secure with the eight cap
screws.
CD617
6. Tighten the cover cap screws to 7 ft-lb.
7. Install the cooling duct.
8. Place the footrest cover into position and secure it
to the footrest with the Phillips-head cap screws.
Tighten securely.
9. Secure the footrest cover to the front and rear fend-
ers with the Phillips-head cap screws and four cap
screws. Tighten securely.
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.
1. Shift the transmission into reverse; then remove
the cap screw securing the linkage to the transmis-
sion shift arm.
2. Verify that the transmission is in reverse, the igni-
tion 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 adjust
the linkage to align with the shift arm.
YT005B
3. Install the cap screw securing the linkage to the
lower shift arm. Do not tighten at this time.
4. Shift the transmission into neutral and verify that
the neutral indicator illuminates; then tighten the
jam-nuts and the linkage cap screw securely.
Troubleshooting Brake
System
Problem: Braking poor
Condition Remedy
1. Brake shoe(s) - pad(s) worn
2. Lever free-play excessive
3. Brake drum(s) worn
1. Replace brake shoe(s) - pad(s)
2. Adjust free-play
3. Replace brake drum(s)
Problem: Brakes drag
Condition Remedy
1. Lever free-play less than minimum
2. Brake shoe return spring(s) loose - sprung
1. Adjust free-play
2. Connect - replace return spring(s)
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3-1
3
SECTION 3 - ENGINE/TRANSMISSION
Table of Contents
Engine/Transmission ............................................... 3-2
Specifications .......................................................... 3-2
Y-12+ (Table of Contents)........................................ 3-3
Troubleshooting ..................................................... 3-31
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3-2
Engine/Transmission
This section has been organized into sub-sections
which show a progression for the complete servicing
of the Arctic Cat Y-12+ engine/transmission.
NOTE: Arctic Cat recommends the use of new
gaskets, lock nuts, and seals and lubricating all
internal components when servicing the engine/
transmission.
NOTE: Some photographs and illustrations used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.
NOTE: Critical torque specifications are located
in Section 1.
Specifications*
*Specifications subject to change without notice.
Piston Ring End Gap (Installed) (top)
(2nd)
(oil)
0.15-0.30 mm
0.30-0.45 mm
0.20-0.70 mm
Piston Pin Outside Diameter (Min) 12.96 mm
Piston Pin Bore (Max) 13.03 mm
Piston Skirt/Cylinder Clearance (Max) 0.10 mm
Cylinder Head Distortion (Max) 0.05 mm
Cylinder Bore Trueness 50.00-50.05 mm
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
Camshaft Lobe Height (Intake) (Min) 26.33 mm
Camshaft Lobe Height (Exhaust) (Min) 25.65 mm
Rocker Arm to Shaft Clearance (Max) 0.10 mm
Intake Valve Stem to Guide Clearance (Max) 0.06 mm
Exhaust Valve Stem to Guide Clearance (Max) 0.08 mm
Valve Stem Runout 0.02 mm
Valve Face/Seat Width 0.63 mm
Valve Face Radial Runout 0.025 mm
Crankshaft Web-to-Web Distance 45.15-45.20 mm
Oil Pump Outer Rotor to Body Clearance (Max) 0.25 mm
Oil Pump Outer to Inner Rotor Clearance (Max) 0.20 mm
Oil Pump Rotor End Clearance (Max) 0.12 mm
V-Belt Width (Min) 16.5 mm
Centrifugal Clutch Housing (Max) 107.5 mm
Centrifugal Clutch Lining Thickness (Min) 1.0 mm
Driven Pulley Spring Free Length (Min) 154.6 mm
Roller Guide Diameter (Min) 15.4 mm
Movable Drive Face Collar (Max) 24.06 mm
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