Arctic Cat ATV Cat Y-12+ Youth, DVX 90, 90 Utility 2010 COMPLETE OFFICIAL FACTORY Service / Repair / Full Workshop 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 photographs 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 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

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 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

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

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-cm 2 (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 1 1.4 26 35.4 51 69.4 76 103.4 2 2.7 27 36.7 52 70.7 77 104.7 3 4.1 28 38.1 53 72.1 78 106.1 4 5.4 29 39.4 54 73.4 79 107.4 5 6.8 30 40.8 55 74.8 80 108.8 6 8.2 31 42.2 56 76.2 81 110.2 7 9.5 32 43.5 57 77.5 82 111.5 8 10.9 33 44.9 58 78.9 83 112.9 9 12.2 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 Back to TOC Back to Section TOC Next FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

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 genuine 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 gasoline 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. Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

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

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

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 I R 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 I C 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) I I 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 Back to TOC Back to Section TOC Next FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

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 securing 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 element 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-tapping 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. Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

2-4 CD655 3. Remove the spark plug wire and the spark plug; then rotate the engine clockwise to the TDC position 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. Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

Arctic Cat ATV Cat Y-12+ Youth, DVX 90, 90 Utility 2010 COMPLETE OFFICIAL FACTORY Service / Repair / Full Workshop Manual

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