DVX 90 MODEL NUMBER A2008KSB2BUSD (BLACK-RED) MODEL NUMBER A2008KSB2BUSE (BLACK-CAT GREEN) MORE TO GO ON. TM

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1 2008 DVX 90 Illustrated Parts Manual MODEL NUMBER A2008KSB2BUSD (BLACK-RED) MODEL NUMBER A2008KSB2BUSE (BLACK-CAT GREEN) MORE TO GO ON. TM

2 TABLE OF CONTENTS Black-Red (Model No. A2008KSB2BUSD) Black-Cat Green (Model No. A2008KSB2BUSE) BODY PANEL ASSEMBLY... 1 DECALS... 2 FRAME AND RELATED PARTS ASSEMBLY... 3 KICK STARTER ASSEMBLY... 4 HANDLEBAR AND CONTROL ASSEMBLY... 5 THROTTLE CONTROL ASSEMBLY... 6 HYDRAULIC HAND BRAKE ASSEMBLY... 7 STEERING POST ASSEMBLY... 8 FRONT WHEEL AND BRAKE ASSEMBLIES... 9 REAR WHEEL AND BRAKE ASSEMBLIES REAR AXLE ASSEMBLY FRONT SUSPENSION ASSEMBLY REAR SUSPENSION ASSEMBLY ELECTRICAL AND WIRING HARNESS ASSEMBLY BATTERY ASSEMBLY SEAT AND TOOL KIT ASSEMBLY GAS TANK ASSEMBLY HEADLIGHT ASSEMBLY TAILLIGHT ASSEMBLY AIR INTAKE ASSEMBLY EXHAUST ASSEMBLY CARBURETOR ASSEMBLY PISTON ASSEMBLY CYLINDER HEAD ASSEMBLY CRANKCASE COVER ASSEMBLY CRANKCASE ASSEMBLY CLUTCH ASSEMBLIES TRANSMISSION ASSEMBLY STARTER MOTOR AND OIL PUMP ASSEMBLIES STATOR, FLYWHEEL, AND ENGINE SHROUD ASSEMBLIES NOTE: The illustrations used in this Parts Manual are for reference to replacement part numbers only and are not to be used for assembly. For assembly procedures, use an Arctic Cat Service Manual. Underlined part numbers are new for the 2008 model year. For a complete list of related items, refer to the current accessory catalog Arctic Cat Inc. Printed June 2007 Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

3 BODY PANEL ASSEMBLY Panel, Body - Main - Black Bolt w/washer Bolt w/washer Grommet, Rubber Cover, Front Bumper Screw Clip, Mudguard Mudguard, Right - Assembly (inc ) Mudguard, Left - Assembly (inc ) Rubber, Wind Screen Collar, Floor Bolt w/washer Reinforcement, Floor Bolt, Flange Nut Reflector - Front - Amber Reflector - Rear - Red 1

4 DECALS Decal, Graphic - Front Fender - Right Decal, Graphic - Front Fender - Left Decal, Graphic - Front Fender - Right (Black-Cat Green) Decal, Graphic - Front Fender - Left (Black-Cat Green) Decal, Warning - Reverse/Pre-Ride Decal, Warning - Not for Highways Decal, Graphic - Rear Fender - Right Decal, Graphic - Rear Fender - Left Decal, Graphic - Rear Fender - Right (Black-Cat Green) Decal, Graphic - Rear Fender - Left (Black-Cat Green) Decal, Warning - Passenger Decal, Graphic - Side - Right Decal, Graphic - Side - Left Decal, Graphic - Side - Right (Black-Cat Green) Decal, Graphic - Side - Left (Black-Cat Green) Decal, Warning - Tire/Load Decal, Warning - Hill Decal, Warning - General Decal, Graphic - Front 2

5 FRAME AND RELATED PARTS ASSEMBLY Bolt, Flange Nut, Flange Bolt, Flange Nut, Flange Circlip Seal, Oil Seal, Oil Body Frame, Complete Rubber, Taillight Bolt, Hex Grip, Rear - Assembly Bolt, Flange Bearing Hose, Duct Clamp, Hose Bracket, Engine Hanger - Right (inc. one No. 17) Bracket, Engine Hanger - Left (inc. one No. 17) Bushing, Rubber - Engine Hanger Bracket Collar Cable Tie Bumper, Front Bolt, Flange Bracket, Mounting - Front Cover Bracket, Mounting - Rear Fender Nut, Flange Flag Assembly Rubber, Engine - Rear 3

6 KICK STARTER ASSEMBLY Arm, Kick Starter - Assembly Bolt, Flange Adjuster, Drive Train - Assembly (inc. 4-6) Washer Washer Nut E-Clip 4

7 HANDLEBAR AND CONTROL ASSEMBLY Bolt w/washer Cover, Handlebar Bracket, Handlebar Cover (inc. 4) Grommet Lid, Handlebar Cover Handlebar Switch, Handlebar - Assembly Grip, Handlebar End Cap, Handlebar Bolt Holder, Handlebar - Upper - Right Holder, Handlebar - Upper - Left Holder, Handlebar - Lower Washer Nut, Hex Cable, Brake - Front Cable, Throttle - Kit Clip 5

8 THROTTLE CONTROL ASSEMBLY (Complete Throttle Control Assembly p/n ) Bolt, Flange Cover, Throttle Control Gasket, Throttle Control Cover Screw Cover, Parking Brake Button, Parking Brake Stopper, Parking Brake Bolt, Socket Case, Throttle Control Nut, Hex Screw Nut, Lock Bolt, Wire Adjustment Lever, Throttle Nut Bolt, Handle Cover Pivot Lever, Brake Equalizer, Brake Cable Spacer Bolt, Flange Switch, Brake 6

9 HYDRAULIC HAND BRAKE ASSEMBLY Lever Nut, Flange Switch Assembly Screw w/washer Washer, Crush Bolt, Banjo-Fitting Hose, Brake - Assembly Brake, Master Cylinder - Assembly (inc. 9-14) Clamp, Master Cylinder Cap, Master Cylinder Screw, Flat-Head Plate, Diaphragm Diaphragm Bolt, Lever Bolt, Flange 7

10 STEERING POST ASSEMBLY Sleeve, Steering Post Post, Steering Holder, Steering Post Bolt, Flange Nut Pin, Cotter Nut, Flange Pin, Cotter Tie Rod Assembly - Right (inc. one No ) Ball Joint, Tie Rod - Right Nut, Hex Tie Rod Nut, Hex Ball Joint, Tie Rod - Left Tie Rod Assembly - Left (inc. one No ) 8

11 FRONT WHEEL AND BRAKE ASSEMBLIES Cap, Wheel Shaft Pin, Cotter Nut, Flange Castle Washer Collar, Wheel - Front Nut, Flange Tire - Assembly Wheel - Assembly (inc. 9) Stem, Valve w/cap Hub, Front - Assembly (inc ) Seal, Dust Bearing, Ball - Radial Collar, Front Disc Bearing, Ball - Radial Bolt, Stud Shoe, Front - Assembly (inc. 17) Spring, Brake Shoe Cam, Front Brake Panel - Front - Right Panel - Front - Left Arm, Brake - Right Arm, Brake - Left Bolt, Flange Spring, Return 9

12 *Not a Service Part REAR WHEEL AND BRAKE ASSEMBLIES Cap, Wheel Shaft Pin, Cotter Nut, Flange Castle Washer Tire - Rear Nut, Flange Wheel - Assembly (inc. 8) Stem, Valve w/cap Connector - Assembly (inc. 10) Bolt, Connector Bolt, Flange Caliper, Rear - Assembly (inc ) Bracket Pad, Brake - Assembly Pin, Bolt Piston Seal, Piston 18 * 1 Housing, Caliper - Assembly Plug Valve, Bleed Cap, Bleed Valve Bushing, Pin Bolt Boot B Spring, Brake Pad Seal, Dust Bolt, Disc Disc, Brake - Rear Collar, Hub - Rear O-Ring 10

13 REAR AXLE ASSEMBLY Spacer, Rear Wheel - Right Shaft, Rear Wheel Spacer, Rear Wheel - Left Bolt, Flange Washer, Spring Holder, Sprocket Sprocket, Final Drive Hub, Rear - Assembly (inc. 9-11) Collar, Hub - Right Bearing Seal, Dust Washer Bolt, Flange 11

14 FRONT SUSPENSION ASSEMBLY Shock, Front - Assembly Bolt, Flange Bolt, Hex Nut, Flange Arm, Swing - Set - Front Right (inc. 6-10) Arm, Swing - Set - Front Left (inc. 6-10) Bushing, Swing Arm Bushing, Swing Arm - Top Bushing, Swing Arm - Bottom Fitting, Grease Boot, Grease Fitting Nut, Flange Castle Pin, Cotter Cap, Swing Arm Seal, Swing Arm Shaft, Steering - Right Shaft, Steering - Left Bolt, Flange Nut, Flange 12

15 REAR SUSPENSION ASSEMBLY Shock, Rear - Assembly Bolt, Flange Nut, Flange Fork, Rear - Assembly (inc. 5-11) Boot, Grease Fitting Fitting, Grease Clamp, Brake Hose Bolt Axle, Rear Fork Bushing, Rear Fork Cap, Rear Fork Nut Bolt, Rear Fork Bolt, Flange Guard, Rear Fork Screw, Self-Tapping Slider, Chain Collar, Chain Slider 13

16 ELECTRICAL AND WIRING HARNESS ASSEMBLY *Not a Service Part Regulator, Voltage Nut, Flange Harness, Main (inc. 4) Fuse Cable Tie Sub-Cord Resistor Relay, Starter CDI Assembly Coil Assembly - Ignition (inc. 11) Cap, Noise Suppressor - Assembly Bolt, Flange Switch, Ignition - Assembly (inc ) 14 * 1 Switch, Ignition Key, Ignition - Set - Right-Side Cut Key, Ignition - Set - Left-Side Cut Cover, Key - Arctic Cat 14

17 BATTERY ASSEMBLY Battery Band, Battery 15

18 SEAT AND TOOL KIT ASSEMBLY Tool - Kit Seat - Assembly (inc. 3-5) Latch, Seat - Assembly Rubber, Seat Cushion Nut, Flange Band, Tool Kit 16

19 GAS TANK ASSEMBLY Cap, Gas Tank Seal, Gas Tank Cap Gas Tank - Assembly (inc. 4) Rubber, Gas Tank Collar Bolt, Flange Hose, Gas - Assembly (inc. two No. 8) Clip Strainer, Fuel - Assembly Hose, Gas - Assembly (inc. 11) Clip Screen, Fuel Strainer Hose, Gas - Assembly (inc. two No. 8 and 14) Clamp, Tube Bracket, Shut-Off Valve Nut, Flange Screw Valve, Shut-Off w/screws 17

20 HEADLIGHT ASSEMBLY Headlight - Assembly (inc. 2-4) Lens, Headlight Bulb, Headlight Socket Assembly Screw, Self-Tapping 18

21 TAILLIGHT ASSEMBLY Taillight - Assembly (inc. 2-5) Base, Taillight Bulb, Taillight Lens, Taillight Screw Collar, Front Fender Nut, Flange 19

22 AIR INTAKE ASSEMBLY *Not a Service Part Bracket, Mounting Bolt, Flange Bolt, Flange Cover, Air Cleaner (inc. 5) 5 * 1 Fitting Element, Air Cleaner Screw, Self-Tapping Seal, Air Cleaner Case, Air Cleaner Clip Tube, Drain Catch, Air Cleaner Element Clip Tube Clip, Breather Tube Tube Clip Clamp Clamp Assembly - Air Cleaner Tube Bolt, Flange 20

23 EXHAUST ASSEMBLY Bolt, Flange Bracket, Mounting - Muffler Nut, Cap - 8 mm Gasket, Exhaust Pipe Muffler - Assembly (inc. 6) Bushing, Rubber Bolt, Flange Bolt, Flange 21

24 *Not a Service Part **Optional CARBURETOR ASSEMBLY (Complete Carburetor Assembly p/n ) 1 * 1 Body, Carburetor O-Ring Set Plate Screw w/washer Automatic Bypass/Starter Assembly Holder, Cap Set, Top (inc. 8) Gasket, Top Spring, Compression Valve, Throttle - Assembly (inc ) Plate, Needle Clip Clip, Needle Needle Jet Tube, Rubber - Assembly (inc. 15) Clip, Tube Screw, Adjustment - Assembly (inc. 17) Spring, Compression Screw, Stop - Assembly (inc ) Spring, Compression Screw, Stop Holder, Needle Jet - Assembly (inc. 22) Jet, Main Jet, Main - 75** Jet, Main - 78** Jet, Slow Valve, Float - Assembly (inc ) Valve, Float - Set Clip Float Assembly Pin, Float Arm Body, Float Chamber - Assembly (inc ) 30 * 1 Gasket Screw, Drain O-Ring Clip, Tube Tube, Drain Screw w/washer 22

25 PISTON ASSEMBLY Bolt, Flange Screw O-Ring Adjuster, Cam Chain Gasket, Cam Chain Adjuster Cylinder A Gasket, Cylinder A Pin, Dowel Tensioner, Cam Chain Pivot, Cam Chain Tensioner O-Ring Cam Chain Guide, Cam Chain Ring, Piston - Set Piston Pin, Piston Clip, Piston Pin Crankshaft Key 23

26 CYLINDER HEAD ASSEMBLY AC20BC (Complete Engine Assembly p/n )* Cover, Head - Assembly Gasket, Head Cover Bolt, Flange Plug, Spark Nut, Tappet Adjusting Screw, Tappet Adjusting Valve, Rocker Arm Shaft, Rocker Arm - Intake Holder, Camshaft Washer, Sealing Nut, Flange Pin, Dowel Shaft, Rocker Arm - Exhaust Camshaft Cotter, Valve Retainer, Valve Spring Spring, Valve - Inner Spring, Valve - Outer Seat, Valve Spring - Outer Seal, Valve Stem Head, Cylinder Bolt, Flange Bolt, Stud Bolt, Stud Pipe, Intake - Assembly (inc. 26) O-Ring Nut, Flange Bolt, Flange Insulator, Carburetor - Assembly (inc. 30) O-Ring Gasket, Cylinder Head Valve, Exhaust Valve, Intake Bolt, Flange Bolt, Flange * The Complete Engine Assembly Includes a Starter Motor Assembly and Carburetor. 24

27 CRANKCASE COVER ASSEMBLY Gauge, Oil Level - Assembly (inc. 2) O-Ring Bolt, Flange Bolt, Flange Cover, Crankcase (inc. 6) Seal, Oil Pin, Dowel Gasket, Crankcase Screen, Oil Filter Spring, Oil Filter Screen O-Ring Cap, Oil Filter 25

28 CRANKCASE ASSEMBLY Bolt, Stud Bolt, Stud Spindle, Kick Starter Spring, Return - Kick Starter Collar, Boss - Kick Starter Bushing, Spindle - Kick Starter Washer, Spindle - Kick Starter Circlip Gear, Driven - Kick Starter Washer, Thrust Spring, Driven - Kick Starter Pin, Dowel Gasket, Crankcase Cover - Left Cover, Crankcase - Left Bolt, Flange Bolt, Flange Washer Bolt, Flange Bolt, Flange Bolt, Flange Bolt, Flange Bolt, Drain Plug - Assembly Seal, Oil Crankcase, Set - Left (inc. 25, one No. 26, and 27) Bushing, Rubber - Rear Cushion Bushing, Rubber - Engine Hanger Bushing Bearing, Ball Bearing, Needle Bearing, Ball Seal, Oil Gasket, Crankcase - Right Crankcase, Set - Right (inc. one No. 26) Bolt Plate, Cover 26

29 CLUTCH ASSEMBLIES Pulley, Driven - Assembly (inc. 2-22) Seal, Oil Guide, Pin Guide, Roller Face, Driven - Movable O-Ring O-Ring Collar, Spring Spring, Driven Face Collar, Seal Face, Driven - Fixed - Assembly (inc ) Bearing, Ball Circlip Bearing, Needle Clutch, Centrifugal - Assembly (inc ) E-Ring Washer, Thrust Spring, Clutch Weight, Clutch Rubber, Clutch Damper Plate, Drive Clutch Nut Clutch, Outer Nut, Flange Plate, Ramp Slide Guide, Roller Face, Drive - Movable Boss, Drive Face Collar, Drive Face Belt, Drive Face, Drive Ratchet, Kick Starter Nut, Flange Plate, Dust Bolt, Flange 27

30 TRANSMISSION ASSEMBLY Case, Transmission - Set (inc. 2-6) Bolt, Engine Brake O-Ring Nut, Flange Bearing, Ball Bearing, Ball Pin, Dowel Gasket, Transmission Case A Seal, Oil Chain, Drive Cover, Chain Bolt, Flange Sprocket, Drive Plate Bolt Gear, Final Circlip Shaft, Final Driveshaft Washer Countershaft - Assembly Washer Nut, Flange Bracket, Engine Hanger - Assembly (inc. 25) Bushing, Rubber Bolt, Flange 28

31 STARTER MOTOR AND OIL PUMP ASSEMBLIES Pump, Oil - Assembly (inc. 2-3) Screw, Pan-Head Pin, Dowel Bolt, Flange Sprocket Nut, Flange Chain, Oil Pump Bolt, Flange Separator, Oil Washer Shaft, Starter Reduction Gear, Starter Reduction Motor, Starter - Assembly O-Ring Boss, Starter Clutch Roller Roller, Starter Spring, Roller - Outer Clutch Roller Bolt Clutch, Outer Gear, Starter Bearing, Ball Circlip Nut Holder, Starter 29

32 STATOR, FLYWHEEL, AND ENGINE SHROUD ASSEMBLIES Shroud B - Assembly (inc. one No. 2 and 3-4) Nut, Clip Clip, Vacuum Tube Grommet, Shroud Seal, Shroud Bolt, Flange Bolt, Flange Shroud A - Assembly (inc. one No. 2) Clamp, Carburetor Drain Tube Cover, Fan - Assembly Screw, Self-Tapping Fan, Cooling Nut, Flange Flywheel (A) - D Flywheel (B) - D Flywheel (C) - D Bolt, Flange Bolt Stator - Assembly (O) - D Stator - Assembly (A) - D Stator - Assembly (B) - D414 30

33 Printed in U.S.A. p/n

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