Arctic Cat Alterra 90 Preinstallation Manual

Effective: November 2015

p/n 2261-084

ARCTIC CAT PRE-DELIVERY

INSTRUCTIONS

(Alterra 90)

 NOTE: Read these instructions thoroughly before

starting.

Even though the vehicle has been set up (with some

minor exceptions) and inspected at the factory, EVERY

vehicle must be properly inspected and serviced at the

dealership prior to being released to the customer. Expe-

rience has shown that dealerships that properly prepare

each ATV have fewer warranty problems and more satis-

fied customers.

Removing ATV From Crate

1. Set the crate on a flat surface.

2. Remove the top and sides of the crate; then remove

the flag, flag hardware, front fascia, and wheels from

the crate.

 NOTE: The ATV is crated with the front fascia

removed and the hardware kit, kick start lever, battery

strap, and handlebar cover mount located beneath

the seat.

3. Remove hardware packages and account for the fol-

lowing items:

1. Handlebar Cover Mount (1)

2. Front Fascia (1)

3. Battery (1)

4. Battery Strap (1)

5. Tool Kit (1)

6. 5 mm Cap Screw w/Washer (10)

7. 5 mm Clip Nut (6)

8. 6 mm Cap Screw w/Washer (4)

9. 6 mm Flange Cap Screw (2)

10. 6 mm x 22 mm Flange Cap Screw (1)

11. Self-Tapping Screw (2)

12. Lug Nut (16)

4. Lift or hoist the ATV free of the crate base. Place on

a suitable ATV lift or on a support stand.

Servicing Battery

These ATVs are shipped with a sealed battery. The bat-

tery requires an initial charge after activation as well as

periodic maintenance-charging during periods of non-use

or storage.

Always activate and maintain the battery in accordance

with the following instructions to ensure maximum ser-

vice life and performance from the battery.

 NOTE: Refer to all warnings and cautions provided

with the battery.

Each sealed battery comes with an electrolyte container

and proper amount for each specific battery type. DO

NOT add additional electrolyte to any sealed battery.

Sealed battery electrolyte has a higher concentration of

sulfuric acid.

1. Carefully remove and save the sealing strip from the

battery electrolyte container. This will be used to seal

the battery later.

2. Remove and discard the foil sealing strip covering

the fill holes from the battery.

3. Place electrolyte container with the foil-sealed top of

the cells facing down into the fill ports of the battery.

4. Hold the container level in the fill ports of the bat-

tery. Push down to break the seals. Air bubbles will

appear as the ports fill. Do not tilt the electrolyte

container. Do not remove the container from the bat-

tery until it is empty.

5. From the following chart (or located on the battery),

determine the correct Amp/Hr rating of the battery.

CHECKLIST



Remove ATV from crate

 Service battery

 Install battery

 Install/secure handlebar

 Inflate tires to proper inflation pressure

 Install/secure wheels

 Install front fascia

 Install kick start lever

 Install flag

 Check/adjust throttle lever free-play

 Check engine oil level

 Check transmission lubricant level

 Check front and rear wheel brake systems

 Adjust parking brake

 Check gasoline level

 Te s t r i d e

 Check idle RPM

 Verify all decals and hangtags are properly displayed

 Clean

 Check tool kit contents

 Explain break-in procedure to the customer

 Explain Operator’s Manual and legal obligations to

the customer

 Explain Limited Warranty to the customer

 Complete ATV Rider Training Certificate and Owner

Registration form with customer and submit to Cat

Tracker within 10 days

battery chart

6. For batteries with a rating of 18 Amp/Hr or less, let

the battery stand for 60 minutes (1 Hr) prior to

charging. For batteries with a rating greater than 19

Amp/Hr, let the battery stand for 120 minutes (2 Hr)

prior to charging. This will allow the electrolyte to

permeate into the plates for optimum performance.

7. Fully insert the sealing strip over the fill holes by

hand. DO NOT use a hammer.

8. Charge battery completely before installation (see

Charging New Battery).

Charging New Battery

 NOTE: Refer to all warnings and cautions provided

with the battery or battery charger.

 NOTE: Batteries filled with electrolyte are only at

80% of their capacity.

 NOTE: All battery chargers are not the same. Arctic

Cat recommends the use of the CTEK Multi US 3300

battery charger.

Batteries can be charged two ways - Standard Charge and

Fast Charge. Standard charging is the only recommended

way to charge a battery. It gives the battery optimal per-

formance and battery life.

1. Be sure the charger is unplugged from the 110-volt

electrical outlet.

2. Connect the red terminal lead from the charger to the

positive terminal of the battery; then connect the

black terminal lead of the charger to the negative ter-

minal of the battery.

3. Plug the charger into a 110-volt electrical outlet.

4. By pushing the Mode button on the left of the char-

ger, select the Initial Charge Icon. The Normal

Charge Indicator should illuminate on the upper left

portion of the charger.

 NOTE: The Maintenance Charge Indicator will illu-

minate when the battery has accepted its bulk

charge, but the charger should remain attached for a

minimum of five full hours for optimal battery perfor-

mance and battery life. If the battery becomes hot to

the touch, stop charging. Resume after it has cooled.

5. Once the battery has reached full charge, unplug the

charger from the 110-volt electrical outlet and dis-

connect the charging leads.

6. Allow the battery to sit for 2 hours before testing.

Arctic Cat recommends the use of the Yuasa BTY01

Battery Tester. See Testing In-Service Battery for

proper test procedure when using a Yuasa BTY01

Battery Tester.

7. When installing the battery into a vehicle, coat the

battery terminals with a light coat of grease to mini-

mize battery terminal corrosion and then cover with

the terminal boot if provided.

Testing In-Service Battery

Loss of battery charge may be caused by ambient tem-

perature, ignition OFF current draw, corroded terminals,

self-discharge, frequent start/stops, and other factors.

1. Arctic Cat recommends the use of the Yuasa BTY01

Battery Tester to check Battery State (Charge) and

Battery Condition (Health).

 NOTE: Battery Condition (Health) is explained as

the battery’s ability to take a charge and maintain cur-

rent flow for a specific amount of time while under

load.

 NOTE: Batteries should be removed from the vehi-

cle for proper cleaning, testing, and charging. DO

NOT charge the battery prior to the initial test (tester

will prompt for charging).

2. Clean the battery and terminals with a baking soda

and water solution.

3. Connect the red tester lead to the positive terminal of

the battery; then connect the black tester lead to the

negative terminal of the battery. The LCD will show

battery voltage. Press the ENTER button.

4. The tester will display the type of Battery - “VRLA/

MF/AGM/SLA” (SEALED type), by using the up/

down arrow key, it will display “Standard SLI”

(REMOVABLE FILLER CAPS type). Choose the

correct battery type and press the ENTER button.

5. Determine the Amp/Hr rating from the battery label

on the face of the battery or referring to the chart.

Select the proper Amp/Hr rating of the battery to be

tested by using the up/down arrow keys. Press

ENTER.

6. If battery tests low, the tester may display “has bat-

tery been charged.” Select correct answer (yes/no)

using the up/down arrow keys (unless the battery has

just finished a complete charging cycle on a battery

charger the answer is NO). Press ENTER.

7. The tester will now indicate the battery condition,

whether the battery needs to be charged, and the

O.C.V. (open circuit voltage). Use the up/down

arrows to display battery Health and Charge state.

8. If the battery tester indicates the battery needs to be

charged, remove the tester leads from the battery and

charge the battery (see Charging In-Service Battery).

Charging In-Service Battery

 NOTE: Refer to all warnings and cautions provided

with the battery or battery charger.

 NOTE: The sealing strip should NOT be removed

and NO fluid should be added.

 NOTE: Batteries should be removed from the vehi-

cle for proper cleaning, testing, and charging.

1. Clean the battery and terminals with a baking soda

and water solution.

2. Place the charger and battery in a well-ventilated

area.

3. Be sure the charger is unplugged from the 110-volt

electrical outlet.

4. Connect the red terminal lead from the charger to the

positive terminal of the battery; then connect the

black terminal lead of the charger to the negative ter-

minal of the battery.

5. Plug the charger into a 110-volt electrical outlet.

6. By pushing the Mode Button on the left side of the

charger, select the Normal Charge Icon. The Normal

Charge Indicator should illuminate on the upper left

portion of the charger.

7. The battery will charge to 95% of its capacity at

which time the Maintenance Charge Indicator will

illuminate.

 NOTE: For optimal charge and performance, leave

the charger connected to the battery for a minimum

of 1 hour after the Maintenance Charge Icon illumi-

nates. If the battery becomes hot to the touch, stop

charging. Resume after it has cooled.

8. Once the battery has reached full charge, unplug the

charger from the 110-volt electrical outlet. Let the

battery stand for 2 hours before testing battery volt-

age and health with the Yuasa BTY01 Battery Tester.

 NOTE: Arctic Cat recommends the use of the

Yuasa BTY01 Battery Tester to check battery Health

and Charge state.

 NOTE: Battery Condition (Health) is explained as

the battery’s ability to take a charge and maintain cur-

rent flow for a specific amount of time while under

load.

9. See Testing In-Service Batteries to check the battery

Health and Charge state.

Installing Battery

1. Install the serviced battery into the battery box con-

necting the + (red) lead to the + (positive) battery ter-

minal and the - (black) lead to the - (negative) battery

terminal.

 NOTE: Always connect the + (positive) lead first;

then the - (negative) lead.

2. Install the battery; then secure with the battery strap.

3. Install the seat making sure it is securely latched.

Installing/Securing Handlebar

1. Loosen the handlebar clamp screws; then adjust the

handlebar in the holders so it is centered and the

punch mark aligns with the lower handlebar holder

surface. Tighten the handlebar clamp screws to 7 ft-lb.

KM060A

2. Route the ignition switch wires behind the handlebar

cover mount.

3. Install the handlebar cover mount on the handlebar

clamps; then secure with the two 6 mm flange cap

screws and tighten securely.

KM974

4. Place the handlebar cover into position on the han-

dlebar cover mount and secure with the two 5 mm

cap screws with washers.

KM966

5. Make sure the cables (brake and throttle) are routed

down and away so there is no sticking or binding.

Tire Inflation Pressure

Use a low-pressure gauge to measure the air pressure in the

tires. Check the air pressure in all tires before use of the

ATV. Recommended tire pressure is 27.6 kPa (4.0 psi).

 NOTE: The ATV is equipped with low-pressure

tubeless tires of the size and type listed. Do not

under any circumstances substitute tires of a differ-

ent type or size.

! WARNING

Make sure there is maximum right/left steering capa-

bility and the brake and throttle cables are not

affected.

! WARNING

Operating an ATV with improper or uneven tire infla-

tion pressure is hazardous. Always maintain proper

tire inflation pressure.

Front Rear

AT20 X 7-8 AT19 X 8-8

Installing/Securing Wheels

Mount the front wheels to the front hubs noting the rota-

tion arrows on the tires. Finger-tighten the wheel nuts.

Mount the rear wheels on the rear axle with wheel nuts

noting the rotation arrows on the tires; then tighten all

wheel nuts in a crisscross pattern to 30 ft-lb.

Installing Front Fascia

1. Install the six clip nuts to the front fascia with the

threads positioned on the front side.

KM975

2. Remove the two cap screws securing each headlight

to the front fender.

KM976A

3. Position the front fascia into the front fender.

4. Snap the outer sections of the front fascia to the

fender; then secure the front fascia with the four 5

mm cap screws with washers and four 6 mm cap

screws with washers.

KM977A

5. Install the front headlights using the two existing 5

mm cap screws with washers, two new 5 mm cap

screws with washers, and two self-tapping screws.

KM978A

Installing Kick Start Lever

1. Align and install the kick start lever.

KM979

2. Secure using the 6 mm x 22 mm flange cap screw.

Installing Flag

Using the cap screw, washers, and flag spring supplied

with the flag, secure the flag mount to the rear bumper;

then install the flag.

KM980

Checking/Adjusting Throttle Lever

Free-Play

The throttle has been adjusted at the factory, and no

adjustment should be necessary. If adjustment is neces-

sary, use the following procedure:

1. Pull back rubber boot to access cable adjustment nut.

KM981A

2. Loosen jam nut to allow cable adjuster to be

adjusted.

3. Turn cable adjuster clockwise to decrease free-play

in the cable. Turn the adjuster counterclockwise to

increase free-play in the cable.

4. There should be approximately 6 mm (1/4 in.) free-

play in the cable.

5. Tighten the jam nut to secure the adjustment; then

slide the rubber boot back into position.

Checking Engine Oil Level

 NOTE: When checking oil level, the ATV must be

positioned on a level surface.

1. Check the tightness of the drain plug; the correct

torque value is 22 ft-lb.

KM041A

 NOTE: Inspect the area around the drain plug for

leaks.

2. Check the engine oil level using the oil level stick.

Oil level should be between upper and lower marks

on the stick. If not, add recommended oil until the

level is correct on the stick. Do not over-fill.

 NOTE: The oil level stick must be threaded in for

checking purposes.

KM021A

Recommended Engine Oil

The recommended oil to use is Arctic Cat ACX All

Weather synthetic engine oil, which has been specifically

formulated for use in this Arctic Cat engine. Although

Arctic Cat ACX All Weather synthetic engine oil is the

only oil recommended for use in these engines, use of

any API certified SM 0W-40 oil is acceptable.

OILCHARTJ

Checking Transmission Lubricant

Level

 NOTE: When checking lubricant level, the ATV

must be positioned on a level surface.

1. Check the tightness of the transmission drain plug;

the correct torque value is 22 ft-lb.

CAUTION

Any oil used in place of the recommended oil could

cause serious engine damage. Do not use oils which

contain graphite or molybdenum additives. These

oils can adversely affect clutch operation. Also, not

recommended are racing, vegetable, non-detergent,

and castor-based oils.

KM970A

 NOTE: Inspect the area around the drain plug for

leaks.

2. On the transmission, check the lubricant level using

the level plug. If the lubricant is not visible at the

level hole, add recommended lubricant until the level

is visible at the bottom of level hole. Do not over-fill.

Recommended Transmission

Lubricant

The recommended transmission lubricant to use is SAE

80W-90 hypoid.

Checking Front Wheel Brake

System

The front wheel brake system will need to be adjusted

before delivery. To adjust the system, use the following

procedure:

1. Raise ATV enough to allow the wheels to spin freely.

2. On the brake lever/cable assembly (A), loosen both

jam nuts (B). Turn both cable adjusters (C) counter-

clockwise until both front wheels do not spin freely.

KC555A

3. Turn both cable adjusters in 1/4 turn increments

(clockwise) until wheels spin with a very slight

amount of drag.

4. Lower AT V, pu sh AT V f o rward, and compress brake

lever.

5. If front wheels lock, adjustment is correct.

6. If front wheels do not lock, additional adjustment is

necessary.

Checking Hydraulic Brake System

The hydraulic brake system has been filled and bled at the

factory.

Rear Brake Lever

1. With the hydraulic brake reservoir in a level position,

check the fluid level. It must be visible in the sight

glass.

KM026A

2. Compress the brake lever several times to check for a

firm lever. If the lever is not firm, the brake system

must be bled.

3. To bleed the brake system, use the following procedure:

A. Remove the cover and fill the reservoir with DOT

4 brake fluid.

B. Install and secure the cover; then slowly com-

press the brake lever several times.

C. Install one end of a clear hose onto the bleed

screw and direct the other end into a container;

then while holding slight pressure on the brake

lever, open the bleed screw and watch for air bub-

bles. Close the bleed screw before releasing the

brake lever. Repeat this procedure until no air

bubbles are present.

KM982

 NOTE: During the bleeding procedure, watch the

reservoir very closely to make sure there is always a

sufficient amount of brake fluid. If the fluid level gets

low in the reservoir, refill the reservoir before the

bleeding procedure is continued.

D. Repeat step C until the brake lever is firm.

4. Carefully check the entire hydraulic brake system

that all hose connections are tight, the bleed screw is

tight, and no leakage is present.

5. Make sure to burnish the brake pads during the test ride.

Adjusting Parking Brake

 NOTE: The parking brake lever must be in the off

position when adjusting the parking brake cable.

1. Loosen the jam nut (A); then finger tighten the

adjuster bolt (B) until resistance is felt.

KC553A

2. Loosen the adjuster bolt (B) 1/8-1/4 turn.

3. While holding the adjuster bolt (B); tighten the jam

nut (A) securely.

 NOTE: There should be no resistance on the brake

disc from the brake pads after adjusting.

Recommended Gasoline

The recommended gasoline to use is 87 minimum octane

regular unleaded. In many areas, oxygenates are added to

the gasoline. Oxygenated gasolines containing up to 10%

ethanol or 5% methane are acceptable gasolines.

When using ethanol blended gasoline, it is not necessary

to add gasoline antifreeze since ethanol will prevent the

accumulation of moisture in the system.

Test Riding the ATV

1. Check all mechanical functions.

2. Confirm all cables and wiring harnesses are con-

nected and routed correctly.

3. Confirm the brakelight is working properly.

4. After test ride, check the brake system and engine

idle RPM.

5. Closely inspect the owner’s packet to ensure it is

complete.

6. Sign and affix the O.K. FOR DELIVERY tag.

7. Visually inspect the entire ATV for any loose fasten-

ers. Tighten as required to the appropriate specifica-

tions.

8. Confirm final “check-off” of items on the Pre-Deliv-

ery Checklist.

Check/Adjust Idle RPM

1. Start engine and warm it up to operating temperature.

Use a tachometer to adjust idle RPM.

2. Turn the idle adjustment screw (located at the left

side of the carburetor) clockwise or counterclock-

wise until the engine idles at 1700 RPM.

KM004A

Transporting ATV

 NOTE: When transporting the vehicle, make sure

the parking brake is engaged.

Inform the owner/operator that the vehicle must be trans-

ported in its normal operating position (on all four

wheels) and secured with hold-down straps in the proper

areas. Shown is the minimum number of hold-down

straps to be used.

ATV-0067

Break-In Procedure

To ensure maximum durability and optimal performance

and to avoid engine damage, do not operate the ATV at

more than half-throttle for the first 3 hours. During break-

in period, operate the ATV at various RPM and do not

drive the ATV above half-throttle for extended periods.

! WARNING

Using the Operator’s Manual as a guide, instruct the

customer on the proper use, care, burnishing proce-

dure (when brake pads are new), and maintenance

of the hydraulic brake system.

CAUTION

Do not use white gas. Only Arctic Cat approved gas-

oline and/or additives should be used.

! WARNING

Adjust the idle to the correct RPM. Make sure the

engine is fully warm before adjusting the idle RPM.

CAUTION

If using additional hold-down straps in other areas,

use caution not to damage the vehicle.

®TM

Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 1115

Arctic Cat Alterra 90 Preinstallation Manual

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