Arctic Cat Wildcat ROV 2013 Service Manual
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Arctic Cat Wildcat ROV 2013 Service Manual

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Yves THERIAULT
January 31, 2025

J’ai le code 0064 je voudrais savoir le diagnostik

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1 comments:
Mr. Anderson
February 10, 2025

Code C0064 for the Arctic Cat Wildcat ROV 2013 indicates "Tilt Sensor Circuit Low/SG/Open."

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Summary of Contents for Arctic Cat Wildcat ROV 2013

  • Page 2 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat 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 fol- low the directive because it deals with the possibility of serious personal injury or even death.

  • Page 4: Table Of Contents

    Drive and Brake Systems..........147 Hydraulic Brake System............14 Front Drive Actuator............... 147 Burnishing Brake Pads ............16 Front Differential ..............148 Replacing V-Belt (“Arctic Cat” Clutch)........16 Drive Axles................160 Replacing V-Belt (“Rapid Response” Clutch)......17 Rear Gear Case..............160 Engine/Transmission ............19 Hub ..................

  • Page 5: General Information

    32 mm (1.25”) - Rapid Piston Ring Groove Width (1st/2nd) 1.202-1.204 mm Response Clutch (oil) 2.501-2.503 mm 35 mm (1.38”) - Arctic Cat Piston Ring Thickness (1st/2nd) 1.170-1.195 mm Clutch Brake Fluid DOT 4 Piston Pin Bore (max) 20.012 mm...

  • Page 6: Torque Specifications

    **w/Red Loctite #271 ****w/“Patch-Lock” Drive Coupler (Front) Drive Flange (Front) *****w/Primer #7649 and Loctite #277 Driveline Coupler Rear Drive Input Flange †Arctic Cat Clutch ††Rapid Response Clutch Front Differential Frame/Differential Bracket Carrier Bearing Bracket Carrier Bearing Support Bracket Frame Input Shaft Assembly...

  • Page 7: Torque Conversions (Ft-Lb/N-M)

    99.3 133.3 CAUTION 32.6 66.6 100.6 134.6 Do not use white gas. Only Arctic Cat approved gaso- line additives should be used. RECOMMENDED ENGINE/ Break-In Procedure TRANSMISSION OIL CAUTION ENGINE On the Wildcat, any oil used in place of the recom- mended oil could cause serious engine damage.

  • Page 8: Genuine Parts

    RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE Preparation For Storage LUBRICANT The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 hypoid. CAUTION This lubricant meets all of the lubrication requirements of the Arctic Cat vehicle front differential and rear drive.
  • Page 9 4. Change the engine/transmission oil and filter. 7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, and 5. Check the coolant level and add properly mixed cool- headlight aim; adjust or replace as necessary. ant as necessary.

  • Page 10: Periodic Maintenance/Tune-Up

    * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 0W-40 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change and strainer inspection interval can be increased to every 1,000 miles or every year.

  • Page 11: Lubrication Points

     NOTE: Foam Filter Cleaner and Foam Filter Oil are available from Arctic Cat. It is advisable to lubricate certain components periodically to ensure free movement. Apply light oil to the compo- 4.

  • Page 12: Valve Adjuster Procedure

    1. Remove the spark plugs and timing inspection plug; then remove the tappet covers (for more detailed information, see Engine/Transmission - Servicing Top-Side Components).  NOTE: Remove the crankshaft end cap and install the special cap screw (left-hand threads) to rotate the engine. 2.

  • Page 13: Spark Plugs

    2. Using compressed air, blow any debris from around the spark plugs. CAUTION ! WARNING Before removing a spark plug, be sure to clean the area around the spark plug. Dirt could enter engine when Always wear safety glasses when using compressed air. removing or installing the spark plug.

  • Page 14: Engine/Transmission Oil - Filter

    WC136 PR078A 4. Using the Oil Filter Wrench and a ratchet handle (or a  NOTE: If the screen or gasket is damaged in any socket or box-end wrench), remove the old oil filter. way, it must be replaced.  NOTE: Clean up any excess oil after removing the filter. 3.

  • Page 15: Front Differential - Rear Drive Lubricant

    CAUTION Do not over-fill the engine with oil. Always make sure that the oil level is not above the upper mark. 12. Inspect the area around the drain plug and oil filter for leaks. Front Differential - Rear Drive Lubricant WC020B To check front differential lubricant, use the following pro- 4.
  • Page 16 CHECKING/ADJUSTING HEADLIGHT The headlights can be adjusted vertically. The geometric center of the HIGH beam light zone is to be used for verti- cal aiming. 1. Position the vehicle on a level floor so the headlights are approximately 6.1 m (20 ft) from an aiming sur- face (wall or similar aiming surface).

  • Page 17: Shift Lever/Shift Cable

    Shift Lever/Shift Cable CHECKING Turn the ignition switch on; then shift the transmission into park. The letter P should illuminate on the LCD gauge and the park icon (P) should illuminate. The vehicle should not be able to move. WC348C Hydraulic Brake System CHECKING/BLEEDING The hydraulic brake system has been filled and bled at the...

  • Page 18: Brake Disc

    3. If thickness of either 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. 4. To replace the brake pads, use the following proce- dure.

  • Page 19: Burnishing Brake Pads

    Burnishing Brake Pads Brake pads must be burnished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure. ! WARNING Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss.

  • Page 20: Replacing V-Belt ("Rapid Response" Clutch)

     NOTE: The arrows on the V-belt should point in the 2. Remove the right rear shock absorber; then loosen the clamp securing the cooling exhaust duct to the boot. direction of engine rotation. 2. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the driveshaft.
  • Page 21 WC597 WC667 6. Remove the movable sheave and V-belt and any belt threads or debris in the CVT housing or sheaves. WC595 2. Secure the driven clutch with the cap screw (A), washer (B), and alignment shim(s) (C); then tighten to WC594 60 ft-lb.

  • Page 22: Engine/Transmission

    Secondary Drive Gear Holder 0444-253 Spanner Wrench 0444-240  NOTE: Arctic Cat recommends the use of new gas- 0644-016 Surface Plate kets, lock nuts, and seals and lubricating all internal 0644-535 V Blocks components when servicing the engine/transmission.

  • Page 23: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Repair - replace guides 3. Valves mistimed 3. Retime engine 4.
  • Page 24 Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. Drive - driven bevel gears damaged - worn 1. Replace gears 2. Backlash excessive 2. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4.

  • Page 25: Removing Engine/Transmission

    Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. 1. Drive or lift the vehicle onto wheel ramps or other lift that supports vehicle by its wheels; then shift the transmission into park.
  • Page 26 WC153A WC192 9. Remove the two cargo box supports; then remove the heat shield leaving the rear coil attached to the radia- tor assembly. WC193 12. Remove the radiator mounting screws; then discon- nect the coolant hoses from the engine and remove the radiator from the vehicle being careful not to release WC352A the clamps.
  • Page 27 17. Remove the ECT connector (A), front coil primary connector (B), TPS connector (C), MAP/IAT connec- tor (D), and ISC connector (E); then tie the engine har- ness out of the way. WC201A 14. Loosen the inlet boot (A); then remove the crankcase breather hose (B) and the inlet air duct (C).
  • Page 28 20. Remove the E-clip (A); then loosen the jam nut (B) and slide the shift cable out of the mounting bracket and off the shift arm (C). WC170  NOTE: It may be necessary to use a hoist to slightly raise the rear of the vehicle to free the link from the WC362A frame weldment.

  • Page 29: Installing Engine/Transmission

    Installing Engine/ Transmission WC172B  NOTE: Arctic Cat recommends new gaskets and O- rings be installed whenever servicing the vehicle. 1. Install the front exhaust pipe onto the engine with a new grafoil gasket but do not torque; then using a suitable engine hoist and equalizer sling, lower the engine into the vehicle.
  • Page 30 4. Install the engine mounting through-bolts with flat washer, rear first; then front. Tighten new lock nuts to 40 ft-lb. 5. Support the rear of the vehicle; then remove the lateral link pivot bolt, drop the lateral link down, and install the upper through-bolt on the rear drive gear case.
  • Page 31 WC210A WC203A 11. Connect the ECT connector (A), front coil primary 14. Place the inlet air duct into position; then install the connector (B), TPS connector (C), MAP/IAT connec- CVT intake cooling duct and secure with the clamp. tor (D), and ISC connector (E). WC209A WC204A 15.
  • Page 32 20. Install the heat shield and secure with the appropriate fas- teners; then install the cargo box supports and secure with the cap screws and new lock nuts. Tighten to 20 ft-lb. 21. Install the muffler and secure with the spring; then tighten the front and rear exhaust pipe cap screws to 20 ft-lb.

  • Page 33: Servicing "Arctic Cat Clutch" Engine

    Servicing “Arctic Cat Clutch” Engine TABLE OF CONTENTS Top-Side Components ............. 30 Removing Top-Side Components ..........30 Servicing Top-Side Components ..........34 Installing Top-Side Components ..........40 Left-Side Components ............. 46 Removing Left-Side Components..........46 GZ027 Servicing Left-Side Components ..........49 Installing Left-Side Components..........
  • Page 34 3. Remove the cap screws securing the valve cover to the head; account for the four rubber washers on the top side cap screws. Remove the valve cover. Account for and note the orientation of the camshaft plug. Note the location of two alignment pins.
  • Page 35 CC266D GZ151  NOTE: Loop the chain over the cylinder head and secure it to keep it from falling into the crankcase. GZ161 10. If the remaining cylinder head is to be serviced, apply tension to the loose timing chain and rotate the second cylinder to top-dead-center of the compression stroke;...
  • Page 36 12. Remove the two nuts securing the cylinder to the crankcase. AT THIS POINT  To service cylinder, see Servicing Top-Side Compo- nents sub-section. CAUTION When removing the cylinder, be sure to support the pis- ton to prevent damage to the crankcase and piston. 14.

  • Page 37: Servicing Top-Side Components

    Servicing Top-Side Components VALVE ASSEMBLY When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear.  NOTE: Whenever a valve is out of tolerance, it must be replaced.
  • Page 38 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends the components be taken to a qualified machine shop for servicing. CAUTION If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced.
  • Page 39 Cleaning/Inspecting Piston 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45° angle and to a sharp edge. 2. Using the sharpened ring as a tool, clean carbon from the ring-grooves.
  • Page 40 ATV-1070 GZ168 2. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy. GZ169A 2. Install the second compression ring with the marking “E TOP” directed toward the top of the piston. ATV-1069 Measuring Piston Skirt/Cylinder Clearance...
  • Page 41 2. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion. If marks are found, repair the CAUTION surface using a cylinder hone (see Inspecting Cylinder Incorrect installation of the piston rings will result in in this sub-section). engine damage. 3.
  • Page 42 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface using a #320 grit ball hone.  NOTE: To produce the proper 60° cross-hatch pat- tern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute.

  • Page 43: Installing Top-Side Components

    CC145D CF060A 6. If clearance is excessive, measure the journals of the 2. If damaged, the camshaft must be replaced. camshaft. Installing Top-Side Components A. Pistons B. Cylinders 1. Install the piston on the connecting rod making sure the circlip on each side is fully seated in the piston. ...
  • Page 44 GZ159 GZ160A 3. Lubricate the inside wall of the cylinder; then using a 5. Install the coolant hose onto the crankcase union and ring compressor, compress the rings and slide the cyl- tighten the clamp. inder over the piston. Route the cam chain up through C.
  • Page 45 13. With the cam lobes directed down (toward the piston), maneuver the camshaft/sprocket assembly through the chain and towards its seating position; then loop the chain over the sprocket.  NOTE: Note the position of the alignment marks on the end of the camshaft. They must be parallel with the valve cover mating surface.
  • Page 46 AT THIS POINT  Return the engine to TDC on the front cylinder making sure the cam lobes are directed downward to ensure correct starting point for step 19. 19. Keeping tension on the rear cam chain, rotate the engine forward 270° until rear piston is at TDC indi- cated by timing mark R.
  • Page 47 21. Seat the cam sprocket onto the camshaft making sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket; then place the camshaft/sprocket assembly onto the cylinder ensuring the following. GZ195 24. Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed;...
  • Page 48 26. Place the C-rings into position in their grooves in the cylinder heads. CD469 30. Using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner counterclockwise until the CC012D tensioner spring bears tension; then install the cap 27. Install the cylinder head plugs in the cylinder heads with screw into the end of the chain tensioner.

  • Page 49: Left-Side Components

    32. Apply a thin coat of Three Bond Sealant to the mating surfaces of the cylinder heads. GZ208 38. If removed, install the spark plugs. Tighten securely. GZ202 33. Lubricate the camshaft journals and lobes with engine Left-Side Components oil; then place the valve cover into position. ...
  • Page 50 AT THIS POINT  To replace stator coils/crankshaft position sensor, see Electrical System. 2. Remove the starter motor, starter driven gear (A), starter countershaft bushing (B), and starter counter- shaft gear (C); then remove the starter gear shafts (D) noting the longer shaft is nearest the starter. GZ217 5.
  • Page 51 7. Remove the two cap screws securing the water pump 11. Remove the cap screw securing the shift cam plate to to the crankcase. the shift cam shaft and remove the shift cam plate; then remove the shift shaft. GZ230A 8.

  • Page 52: Servicing Left-Side Components

    Servicing Left-Side Components INSPECTING STARTER CLUTCH/ GEAR 1. Place the starter clutch gear onto the rotor/flywheel and attempt to rotate the starter clutch gear clockwise. It should lock up to the rotor/flywheel. Rotate the gear counterclockwise and it should turn freely. If it moves or locks up both ways, the starter clutch must be replaced.

  • Page 53: Installing Left-Side Components

    FI583 H2-017A 2. Thoroughly clean the gear hub; then apply a drop of green Loctite #620 to the bearing outer race and press into the gear hub until even with the lower chamfer radius. H2-027 3. Install the new stator coil assembly and secure with three cap screws using a drop of red Loctite #271 on each.
  • Page 54 2. Install a new O-ring on the oil filler cover and coat it with clean engine oil; then install the oil filler cover into the crankcase and secure with the cap screws. Tighten to 8 ft-lb. FW-017B GZ250 3. Clean the countershaft and trigger splines thoroughly and install the inner snap ring onto the shaft;...
  • Page 55 7. Install the shift shaft into the crankcase making sure the washer is properly located; then align the timing reference marks and completely seat the shift shaft. GZ230A  NOTE: The longer cap screw goes on the top of the water pump.

  • Page 56: Right-Side Components

    GZ225 GZ212B CAUTION Make sure the one-way starter clutch is properly Right-Side Components engaged with the starter ring gear before installing and tightening the rotor/flywheel nut or damage to the clutch assembly could occur.  NOTE: For efficiency, it is preferable to remove and 13.
  • Page 57 GZ074 GZ433A 7. Remove the cap screws securing the clutch cover; then using a rubber mallet, carefully remove the cover. Account for two alignment pins. CD966A 3. Remove the V-belt. 4. Remove the nut securing the fixed driven assembly; then remove the assembly. GZ433B ...

  • Page 58: Servicing Right-Side Components

    11. Remove the water pump drive shaft and gear assem- bly from the engine. CF085 GZ439 Servicing Right-Side Components INSPECTING CENTRIFUGAL CLUTCH SHOES 1. Inspect the clutch shoes for wear, chips, cracks, dam- age, or discoloration. If any shoe is damaged, replace CC596 the centrifugal clutch.

  • Page 59: Installing Right-Side Components

    2. Remove the snap ring securing the bearing in the water pump drive cover; then remove the bearing using an appropriate blind bearing remover. GZ442 3. Install the two snap rings on the driveshaft (flat side away from the gear). GZ441 Installing Right-Side Inspecting...
  • Page 60 5. Place the clutch cover/clutch housing assembly into position on the crankcase; then secure with the cap screws. Tighten in a crisscross pattern to 8 ft-lb. GZ066 8. Slide the fixed drive face onto the clutch shaft. 9. Spread the faces of the driven clutch by threading in a cap screw;...

  • Page 61: Center Crankcase Components

    GZ075 GZ437A CAUTION Make sure the splines extend beyond the drive face and Center Crankcase washer or a false torque reading and spline damage Components may occur.  NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Remov- ing procedures for Top-Side, Left-Side, and Right- Side must precede this procedure.

  • Page 62: Disassembling Crankcase Half

     NOTE: Do not disassemble these assemblies unless service is required. If disassembled, second- ary gear sets will have to be reset for backlash and gear contact (see Servicing Center Crankcase Com- ponents sub-section). 4. Remove one cap screw from the right-side crankcase and eight cap screws from the left-side crankcase;...
  • Page 63  NOTE: To aid in installing, it is recommended the assemblies are kept together and IN ORDER. 1. Support the right-side crankcase assembly on suitable support blocks; then carefully remove the crankshaft assembly (A) from the crankcase. GZ463B 5. Remove the shift fork shaft (E); then remove the gear shift shaft assembly (F).

  • Page 64: Servicing Center Crankcase Components

    7. Remove the driveshaft (G); then remove the counter- shaft assembly (with shift forks) (H). Account for two flat washers on the countershaft. MT011A 2. Using a suitable press, install the driven gear (C) on the shaft until the gear firmly seats on the shoulder of the shaft.
  • Page 65 Checking Backlash 1. Install the drive bevel gear assembly and driven bevel gear/output shaft assembly into the crankcase bottom cover. 2. Mount the dial indicator so the tip is contacting a tooth on the secondary drive bevel gear. FW-003A 4. Install a new seal (F), output flange (G), washer, and nut (coated with red Loctite #271) and tighten to 74 ft-lb.
  • Page 66 2. If backlash measurement is more than specified, remove an existing shim, measure it, and install a thicker shim.  NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. Backlash Measurement Shim Correction Under 0.127 mm (0.005 in.) Decrease Shim Thickness At 0.127-0.381 mm (0.005-0.015 in.)
  • Page 67 Assembling 1. Install a new oil seal into the oil pump cover; then coat the lips of the seal with grease and install the pump driveshaft from the seal side. GZ360 4. Place a new O-ring seal on the outside of the oil pump cover.
  • Page 68 Measuring Connecting Rod (Small End Deflection) 1. Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate. Position the indicator contact point against the center of the connecting rod small end journal. 2.
  • Page 69 GZ296 GZ320 GZ312 GZ319 3. Remove the reverse driven gear dog. GZ318A 6. Remove the low driven gear. Account for a bearing, GZ313A bushing, and thrust washer. 4. Remove the snap ring securing the reverse driven gear and washer; then remove the washer and gear. GZ316 Assembling GZ314...
  • Page 70 GZ317A GZ286A GZ318 GZ287 2. Install the low driven gear locking washer; then install 4. Install the outer reverse driven washer; then secure the the inner reverse driven gear washer. reverse driven gear assembly with a snap ring. GZ319B GZ288A GZ320B GZ314 3.

  • Page 71: Assembling Crankcase Half

    GZ313A GZ305 2. Install a flat washer, drive pin, and drive gear onto the oil pump shaft; then secure with a snap ring (flat-side away from the gear). GZ312 6. From the opposite end of the countershaft, install the high/low driven gear dog (A), thrust washer (B), bush- ing (C), bearing (D), high/low driven gear (E), and GZ347 spacer washer (F).
  • Page 72 GZ299A FW-025 5. Using rubber bands to support the connecting rods, 7. Apply a generous amount of molybdenum grease to carefully install the crankshaft assembly into the the sholder of the shaft just past the splines. crankcase. FW-027 8. Place a new seal on the input shaft by carefully sliding GZ474 it over the shoulder of the input shaft and pressing it ...

  • Page 73: Joining Crankcase Halves

    DE677A GZ339 AT THIS POINT  Proper transmission shifting should be verified by turn- ing the gear shift shaft to select High, Low, Neutral, and Reverse while rotating the input shaft and observing the countershaft rotation. The right-side crankcase is now ready for installation to the left-side crankcase.
  • Page 74  NOTE: When applying silicone, make sure to keep clear 6. Install the locating ring in the crankcase assembly; then install the secondary driven shaft assembly and of all oil galleys and ports. Do not over-apply silicone. secondary drive assembly making sure the locating ring and bearing engage correctly.
  • Page 75 GZ447 GZ451 10. Install the oil screen; then apply a thin bead of silicone 9. Carefully place the lower crankcase cover onto the joined sealant to the oil strainer cap and secure with the cap crankcase halves; then secure with the cap screws. screws.

  • Page 76: Servicing "Rapid Response Clutch" Engine

    Servicing “Rapid Response Clutch” Engine TABLE OF CONTENTS Top-Side Components ............. 73 Removing Top-Side Components ..........73 Servicing Top-Side Components ..........77 Installing Top-Side Components ..........83 Left-Side Components ............. 90 Removing Left-Side Components..........90 GZ027 Servicing Left-Side Components ..........92 Installing Left-Side Components..........
  • Page 77 3. Remove the cap screws securing the valve cover to the head; account for the four rubber washers on the top side cap screws. Remove the valve cover. Account for and note the orientation of the camshaft plug. Note the location of two alignment pins.
  • Page 78 CC266D GZ151  NOTE: Loop the chain over the cylinder head and secure it to keep it from falling into the crankcase. GZ161 10. If the remaining cylinder head is to be serviced, apply tension to the loose timing chain and rotate the second cylinder to top-dead-center of the compression stroke;...
  • Page 79 12. Remove the two nuts securing the cylinder to the crankcase. AT THIS POINT  To service cylinder, see Servicing Top-Side Compo- nents sub-section. CAUTION When removing the cylinder, be sure to support the pis- ton to prevent damage to the crankcase and piston. 14.

  • Page 80: Servicing Top-Side Components

    Servicing Top-Side Components VALVE ASSEMBLY When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear.  NOTE: Whenever a valve is out of tolerance, it must be replaced.
  • Page 81 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends the components be taken to a qualified machine shop for servicing. CAUTION If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced.
  • Page 82 CC144D CC400D 2. Insert each valve into its original location. Cleaning/Inspecting Piston 3. Install the valve springs with the painted end of the 1. Take an old piston ring and snap it into two pieces; spring facing away from the cylinder head. then grind the end of the old ring to a 45°...
  • Page 83 Measuring Piston Pin (Outside Installing Piston Rings Diameter) and Piston-Pin Bore 1. Install the expander spring making sure the ends are aligned on the wire; then install the oil ring with the 1. Measure the piston pin outside diameter at each end ring gap 90°...
  • Page 84 GZ187A CC141D CAUTION Cleaning/Inspecting Cylinder Incorrect installation of the piston rings will result in 1. Wash the cylinder in parts-cleaning solvent. engine damage. 2. Inspect the cylinder for pitting, scoring, scuffing, CYLINDER/CYLINDER HEAD warpage, and corrosion. If marks are found, repair the surface using a cylinder hone (see Inspecting Cylinder ASSEMBLY in this sub-section).
  • Page 85 CC127D CC283D 2. Wash the cylinder in parts-cleaning solvent. 2. Rotate the camshaft and note runout; maximum toler- ance must not exceed specifications. 3. Inspect the cylinder for pitting, scoring, scuffing, and Measuring Camshaft Lobe Height corrosion. If marks are found, repair the surface using a #320 grit ball hone.

  • Page 86: Installing Top-Side Components

    3. Place the valve cover on the cylinder head and secure with the valve cover cap screws. Tighten securely.  NOTE: Do not rotate the camshaft when measuring clearance. 4. Remove the cap screws securing the valve cover to the cylinder;...
  • Page 87 GZ142 GZ161A 4. Loosely install the two nuts securing the cylinder to 7. Place a new head gasket into position on the cylinder. the crankcase. Place the alignment pins into position; then place the head assembly into position on the cylinder while ...
  • Page 88 12. With the alignment pin installed in the camshaft,  NOTE: On the Wildcat, the marks must slightly favor loosely place the cam sprocket (with the recessed side the intake side of the cylinder. facing the cam shaft lobes) onto the camshaft. At this point, do not “seat”...
  • Page 89 AT THIS POINT  Return the engine to TDC on the front cylinder making sure the cam lobes are directed downward to ensure correct starting point for step 19. 19. Keeping tension on the rear cam chain, rotate the engine forward 270° until rear piston is at TDC indi- cated by timing mark R.
  • Page 90 FW014 ATV-1027 CAUTION Care must be taken that the tab-washer is installed cor- rectly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result. 23. Install the first cap screw (threads coated with red Loctite #271) securing the sprocket and tab-washer to the camshaft.
  • Page 91 CD465 GZ162A 25. Rotate the crankshaft until the first cap screw (from 28. Remove the cap screw from the end of the chain ten- step 23) can be addressed; then tighten to 11 ft-lb. sioner; then using a flat-blade screwdriver, rotate the Bend the tab to secure the cap screw.
  • Page 92 GZ201 GZ206  NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. 34. Install the top side cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug. CD471 31.

  • Page 93: Left-Side Components

    Left-Side Components  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT  To service any one specific component, only limited dis- GZ224A assembly of components may be necessary.
  • Page 94 7. Remove the two cap screws securing the water pump to the crankcase. GZ217 5. With the flywheel key removed, remove the starter ring-gear and spacer washer. GZ230A 8. Remove the water pump. Account for an O-ring.  NOTE: The water pump is a non-serviceable compo- nent and must be replaced as a complete assembly.

  • Page 95: Servicing Left-Side Components

    2. Inspect the starter clutch gear for chipped or missing teeth or discoloration/scoring of the clutch surface. Inspect the bearing for loose, worn, or discolored roll- ers. If bearing is damaged, it must be replaced. H2-022A 12. Remove the snap ring securing the speed sensor trigger to the shaft and remove the trigger using a suitable “two- jawed”...
  • Page 96 FI576A FI580 INSPECTING STATOR COIL/ MAGNETO COVER ASSEMBLY 1. Inspect the stator coil for burned or discolored wiring, broken or missing hold-down clips, or loose cap screws. 2. Inspect the bearings in the magneto housing for dis- coloration, roughness when rotated, and secure fit in bearing bores.

  • Page 97: Installing Left-Side Components

    3. Install the new stator coil assembly and secure with three cap screws using a drop of red Loctite #271 on each. Tighten according to the chart. Cover Bolt Type ft-lb Original Hex-Head Hex-Head 4. Place the stator wire harness hold-down into position; then install the crankshaft position sensor and secure with two cap screws.
  • Page 98 8. Apply grease to the lips of the shift shaft seal in the shifter housing; then using a new gasket, install the shifter housing and secure with the cap screws. Tighten in a crisscross pattern to 8 ft-lb. H2-019 6. Install the shift cam plate onto the shift cam shaft and secure with the cap screw.

  • Page 99: Right-Side Components

    GZ251 GZ226 15. Using Seal Protector Tool, install the outer magneto 12. Place the key into the keyway in the crankshaft; then cover using a new gasket and secure with the cap wipe all oil from the crankshaft surface and rotor/fly- screws.
  • Page 100 2. Remove the cap screw securing the driven clutch; then remove the outer sheave of the driven clutch. Account for a flat washer and alignment shim(s). GZ246B 7. Using a suitable press, remove the clutch housing from the clutch cover. Discard the fixed drive face spacer and O-ring.

  • Page 101: Servicing Right-Side Components

    9. Using a suitable press, remove the bearing from the clutch cover. WC658 2. Remove the cover, spring, and nylon shift stop. GZ507 10. Carefully remove the existing clutch housing seal using caution not to damage the sealing surface of the cover. WC657 GZ513 Servicing Right-Side...
  • Page 102 4. Secure the drive clutch to the holder using the clutch bolt and washer. WC647A  NOTE: The spider is a non-serviceable component. If damaged or worn parts are found, the clutch FC084 assembly must be replaced. 5. Remove the lock nuts from the cam arm pivot pins; then remove the pins and account for six thrust wash- ers and three cam arms.
  • Page 103 8. Inspect all threaded areas for any cracked or stripped  NOTE: Allow the Loctite to cure at room tempera- threads. ture for 24 hours. 9. Inspect the roller bushings for damage or fraying.  NOTE: Grasp the moveable sheave and lift it 10.
  • Page 104 4. Remove the E-clips securing the cam rollers to the spider; then remove the thrust washer and roller. WC639 2. Install the clutch into an appropriate driven clutch compressor tool. Finger-tighten the wing nut to WC628 tighten.  NOTE: The relief in the roller is directed towards the spider.
  • Page 105 5. Place the insert and spider onto the bearing assembly. WC673A 2. Slide the roller pin into place; then using suitable punch, insert the pin spring until flush. WC670 6. Insert the bearing assembly with spider insert into the spider making sure to line up the (x) marks. WC682 3.
  • Page 106 WC686 GZ440A 2. Inspect the bearing (B) for smooth rotation and no dis- WATER PUMP DRIVE ASSEMBLY coloration or scoring. Disassembling 3. Inspect the gear (C) for chipped or missing teeth, excessive hub wear, or excessive wear in the drive pin 1.

  • Page 107: Installing Right-Side Components

    4. Press the clutch housing assembly into the clutch cover until it is seated against the bearing. Installing Right-Side Components 1. Place a new clutch housing seal (spring side facing Clutch Housing Seal Tool) into the clutch cover and secure with a rubber mallet or press. GZ512 5.

  • Page 108: Center Crankcase Components

    WC741A GZ244A 7. Place the fixed driven sheave onto the driveshaft; then 9. Place the transmission in neutral and rotate the driven install the V-belt making sure the directional arrow is clutch and drive belt by hand in a clockwise direction for three complete revolutions.

  • Page 109: Separating Crankcase Halves

     NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. Separating Crankcase Halves 1. Remove the oil strainer cap; then remove the oil strainer.

  • Page 110: Disassembling Crankcase Half

    GZ272B GZ299A 3. Remove the snap ring securing the water pump idler shaft (C) in the crankcase; then remove the shaft and Disassembling Crankcase bearings. Half  NOTE: For steps 1-8, refer to illustration GZ474A. GZ463A 4. Remove the snap ring securing the oil pump driven gear (D) to the oil pump driveshaft;...

  • Page 111: Servicing Center Crankcase Components

    8. Remove the reverse idler gear (I), shaft bushing, and two washers. DE677A GZ279  NOTE: Do not disassemble the countershaft assem- bly unless necessary. If necessary, see Servicing Center Crankcase Components sub-section. Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS GZ276 6.
  • Page 112  NOTE: Do not use a new lock nut at this time as this procedure may have to be repeated. 5. Place the assembled shaft into the left crankshaft case; then lightly coat the gear teeth with machinist’s lay- out dye. Rotate the shafts through several rotations in both directions.
  • Page 113 GZ398 GZ393B 4. Acceptable backlash range is 0.127-0.381 mm (0.005- OIL PUMP ASSEMBLY 0.015 in.). Disassembling and Inspecting Correcting Backlash 1. Remove the oil pump cover; then remove the gerotor  NOTE: If backlash measurement is within the set, shaft, and pin (see Disassembling Crankcase Half acceptable range, no correction is necessary.
  • Page 114 2. Noting the reference dots on the gerotor set, separate the inner rotor from the outer rotor and with the refer- ence dot directed toward the oil pump cover, place the rotor on the shaft; then install the drive pin and push the shaft into the rotor.
  • Page 115 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crank- shaft. GZ362 CRANKSHAFT ASSEMBLY H2-006  NOTE: The crankshaft and connecting rod is a non- 3. Zero the indicator and rotate the crankshaft slowly. serviceable assembly.
  • Page 116 CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces. If a major component is installed facing the wrong direction, transmission damage may occur and/ or the transmission will malfunction. In either case, complete disassembly and assembly will be required.
  • Page 117 2. Install the low driven gear locking washer; then install the inner reverse driven gear washer. GZ318A 6. Remove the low driven gear. Account for a bearing, bushing, and thrust washer. GZ319B GZ316 GZ320B 3. Install the reverse driven bushing and bearing; then Assembling install the reverse driven gear.

  • Page 118: Assembling Crankcase Half

    GZ288A GZ283B 7. Install the drive gear washer and the shift forks. The countershaft is now ready for installation. Assembling Crankcase Half 1. Install the oil pump gerotor assembly and oil pump cover in the crankcase and secure with two cap screws.
  • Page 119 GZ463A GZ332 4. Install the countershaft gear onto the countershaft and secure with a snap ring (flat-side away from the gear). GZ333 7. Install the gear shift shaft into the crankcase making sure the flat washer is in place on the right case end GZ299A and the spacer on the gear shift stop end.

  • Page 120: Joining Crankcase Halves

    GZ280B GZ340 2. Coat both sides with engine oil; then install the spacer washer on the crankshaft with the radius directed toward the crankshaft. GZ336 9. Engage the shift forks into the gear shift shaft and push the shift fork shaft into the crankcase. GZ341 3.
  • Page 121 GZ448A GZ342 7. Make sure the locating pins on the front and rear bear- 5. Tighten the 6 mm cap screws to 8 ft-lb and the 8 mm ings are correctly seated in the crankcase. cap screws to 20 ft-lb using the pattern shown and turning the shafts frequently to ensure there is no 8.
  • Page 122 H2-012B H2-012A 10. Install the oil screen; then apply a thin bead of silicone sealant to the oil strainer cap and secure with the cap screws. Tighten to 8 ft-lb. AT THIS POINT  After completing center crankcase components, proceed to Installing Right-Side Components, to Installing Left-Side Components, and to Installing Top-Side Components.

  • Page 123: Fuel/Lubrication/Cooling

    3. Remove the rear body panel; then remove the cargo box. Fuel/Lubrication/Cooling 4. Remove the two screws securing the heat shield to the radiator/cooling fan assembly. SPECIAL TOOLS A number of special tools must be available to the techni- cian when performing service procedures in this section. Refer to the current Special Tools Catalog for the appropri- ate tool description.

  • Page 124: Gas Tank

    WC215A WC206B 4. Remove the holding strap and move the radiator back INSTALLING THROTTLE BODY into position and secure with the mounting screws. Tighten securely. 1. Connect the throttle cable to the throttle arm; then install the throttle cable housing to the throttle body 5.

  • Page 125: Gas/Vent Hoses

    TESTING OIL PUMP PRESSURE 6. Remove the cargo box supports and the heat shield; then wrap a shop cloth around the gas line connector  NOTE: The engine must be warmed up to operating to catch any fuel spray and disconnect from the fuel temperature (cooling fan cycling) for this test.

  • Page 126: Oil Cooler

    5. Clamp the coolant hoses off; then loosen the coolant hose clamps. When filling the cooling system, use premixed Arctic Cat Antifreeze. While the cooling system is being filled, air pockets may develop; therefore, open the bleed screw on the upper coolant pipe or the water pump housing to allow air to bleed from the cooling system.

  • Page 127: Thermostat

     NOTE: Note the routing of hoses and location of any ties used to secure hoses to frame. 6. Remove the four fasteners securing the radiator to the frame weldments. WC354A 6. Start the engine and allow it to warm up while check- ing for leaks;...

  • Page 128: Fans

    C. The thermostat should start to open at 71.0-86.0° C  NOTE: Always use a large container and have suffi- (160-187° F). cient floor drying material available when draining the coolant in case of coolant spillage. D. If the thermostat does not open, it must be replaced.

  • Page 129: Fuel Pump/Fuel Level Sensor

    6. If fuse is OK, check the FUEL relay by swapping with another relay. If the pump runs, replace the FUEL Fuel Pump/Fuel Level relay. Sensor 7. If the pump still is inoperative, replace as follows. REMOVING  NOTE: Preliminary checks may be performed on 1.
  • Page 130 ATV2116 WC226 2. Secure the pump assembly with the mounting screws  NOTE: If readings are erratic, clean the resistor and tighten securely in a crisscross pattern. wiper and resistor with clean alcohol and retest. If still not correct, replace the fuel level sensor. 4.

  • Page 131: Troubleshooting

    Troubleshooting Problem: Starting impaired Condition Remedy 1. Gas contaminated 1. Drain gas tank and fill with clean gas Problem: Idling or low speed impaired Condition Remedy 1. TPS out of adjustment 1. Adjust TPS Problem: Medium or high speed impaired Condition Remedy 1.

  • Page 132: Electrical System

    RPM operation, short trips, and high amperage accessory usage are also reasons for battery discharge. Maintenance Charging  NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging. Maintenance charging is required on all batteries not used for more than two weeks or as required by battery drain.

  • Page 133: Rpm Limiter

    Accessory Receptacle/ Charging Connector  NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging.  NOTE: This test procedure is for either the recepta- 1.

  • Page 134: Engine Coolant Temperature (Ect) Sensor

    4. On the ECT sensor when the temperature reaches 100° C (212° F), the meter should read approximately 155 ohms. 5. If the readings are not as indicated, the sensor must be replaced. 6. Install the sensor and tighten securely. 7.

  • Page 135: Ignition Coil

    The 4-pin relays are identical plug-in type located on the power 3. Turn the ignition switch to the ON position. The meter distribution module. Relay function can be checked by switch- must show battery voltage. ing relay positions. The 4-pin relays are interchangeable. RESISTANCE ...

  • Page 136: Speed Sensor

    2. Select DC Voltage on the tester and turn the ignition 1. Disconnect the three-wire connector from the speed sensor switch to the ON position. harness or from the speed sensor; then remove the Allen- head cap screw securing the sensor to the sensor housing. 3.

  • Page 137: Ignition Switch

    If a system malfunction occurs, a diagnostic trouble code  NOTE: Prior to troubleshooting below, make sure the (DTC) will be displayed on the LCD gauge. Initially, the Ignition Key Switch has not been left on with the engine gauge will go blank for 30 seconds and the code will flash; not started.

  • Page 138: Headlight Switch

    VOLTAGE Headlight Switch  NOTE: Voltage tests must be made with the switch and the actuator connected. The meter can be con- nected at the actuator connector using a break-out harness or MaxiClips. VOLTAGE 1. Connect the black tester lead to the black wire; then 1.

  • Page 139: Stator Coil/Crankshaft Position (Ckp) Sensor

    Stator Coil/Crankshaft Position (CKP) Sensor  NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this section). VOLTAGE (AC Generator - Regulated Output) 1. Set the meter selector to the DC Voltage position. PR293 2.

  • Page 140: Starter Motor

    2. Test between the three black wires for a total of three  NOTE: The ignition switch must be in the ON posi- tests. tion, and the shift lever in the NEUTRAL position. 3. The meter reading must be within specification. 1.

  • Page 141: Engine Control Module (Ecm)

    3. Depress the starter button while observing the multi- The regulator/rectifier is located under the hood above the meter. The multimeter should drop to 0 volts and the differential. Verify all other charging system components stater should engage. before the regulator/rectifier is replaced. TESTING ...

  • Page 142: Ignition Timing

    SUPPLY VOLTAGE  NOTE: If battery voltage is not shown and the head- lights are illuminated, inspect the three-wire connec- 1. Disconnect the three-wire connector from the sensor; tor in the left-rear canopy tube at the juncture of the then select DC Voltage on the multimeter and connect canopy tube and lower frame.

  • Page 143: Throttle Position Sensor (Tps)

     NOTE: When replacing the sensor after testing make sure the arrow is directed up. PR538A  NOTE: If the meter does not read as specified, check for poor connections at the ECM or open/bro- WC159A ken wires in the wiring harness. Throttle Position Sensor CAUTION (TPS)

  • Page 144: Efi Diagnostic System

    3. Using a multimeter, connect the black tester lead to the white socket (VAR) on the analyzer and the red tester lead to the red socket (+SV); then select the DC Voltage position. PR546A 8. Select the DC Voltage position on the meter and turn the ignition switch to the ON position.
  • Page 145 Coolant (COOL) Diagnostic Mode 3. Cycle the display by depressing either the Set or Mode button to step to the desired function. EFI032 Display: Engine coolant temperature as measured by the ECT sensor. EFI025A NOTE: The gauge can be utilized dynamically DTC: P0116, P0117, P0118, P0119 (engine running/vehicle moving) or statically Usage: Monitor coolant temperature to verify the following.
  • Page 146 Tachometer (tACH) Diagnostic TPS (tPS) Diagnostic Mode Mode EFI028 Display: % of TPS (0% closed, 95-100% WOT). EFI030 Display: Engine RPM DTC: P0121, P0122, P0123 DTC: P0336, P0337, P0339 Usage: Verify TPS signal and adjust throttle cable. Usage: Verify engine speed signal from the following. MAP (bArO) Diagnostic Mode 1.
  • Page 147 Inlet Air Temperature (AIr) Display: System DC voltage. Diagnostic Mode DTC: P0562, P0563, P2531, P2532 Usage: Verify system voltage under following condi- tions. 1. Battery voltage with engine and accessories off (>12.2 VDC for fully charged). 2. Battery voltage with engine running (charging = 13.8 VDC or greater).
  • Page 148 Gauge DTC Wrench Icon Status ECM PIN Description Tilt Sensor Circuit High C0063 Tilt Sensor Circuit Low/SG/Open C0064 C1400 17 (Gauge) Fuel Sender Open C1401 17 (Gauge) Fuel Sender High/SP C1402 17 (Gauge) Fuel Sender Low/SG P0107 MAP Sensor Circuit Low/SG/Open P0108 MAP Sensor Circuit High/SP P0112...

  • Page 149: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug(s) defective 2. Replace plug(s) 3. CKP sensor defective 3. Replace CKP sensor 4. ECM defective 4. Replace ECM Problem: Spark plug fouled with carbon Condition Remedy 1.

  • Page 150: Drive And Brake Systems

    Drive and Brake Systems GENERAL INFORMATION All gear cases are tagged beneath a cover bolt. This tag is marked with a production date code, sequence code, and a ratio code. The die-cast aluminum housings have been assembled with thread-rolling screws (trilobular). When assembling with these screws, start the screws carefully into the hous- ing;...

  • Page 151: Front Differential

    Front Differential REMOVING 1. Remove the forward belly panel; then drain the lubri- cant from the differential. 2. Using an appropriate jack or lift, raise the vehicle so the wheels are off the floor and support with jack- stands under the lower A-arms. GC002A 3.
  • Page 152 7. Push in on the axle shaft while pulling outward on the axle coupler and remove the axle assembly from the differential. WC269 5. Holding the upper A-arm/ball joint down into the knuckle, remove and discard the retaining cap screw. PR729C 8.
  • Page 153 WC267A GC004A 10. Remove the front drive actuator from the differential; 2. Using a rubber mallet, remove the housing. Account then remove the front boot clamp from the front drive for a gasket. Remove the fork, collar, and spring. Note coupler and slide the boot off.
  • Page 154 Assembling Input Shaft 4. Using a seal removal tool, remove the input shaft seal. Account for a spacer. 1. Place the pinion housing in a press and install the input shaft bearing. Secure the bearing with the exist- ing snap ring making sure the sharp edge of the snap ring faces to the outside.
  • Page 155 GC009A GC015 5. Place the pinion housing with new gasket onto the dif- 2. Using a T-40 torx wrench, remove the cap screws ferential housing; then secure with existing cap securing the differential cover. Account for and make screws. Tighten to 23 ft-lb. note of the ID tag location for assembling purposes.
  • Page 156 KX175 KX181 5. Remove the left differential bearing flange assembly Disassembling Pinion Gear and account for a shim. Mark the shim as left-side. 1. Remove the internal snap ring securing the pinion bearing in the housing. KX177 WC430 2. Using the Pinion Gear/Shaft Removal Tool and a ham- mer, remove the pinion gear from the gear case hous- ing.
  • Page 157 CC879 CC884 4. Remove any reusable parts from the gear case hous- 3. Using a propane torch, heat the gear case housing to ing; then discard the housing and lock collar. approximately 200° F; then install the pinion assem- bly. Assembling Pinion Gear 4.
  • Page 158 Backlash  NOTE: Always set backlash prior to any other shim- ming. 1. Install the existing shim or a 0.051-0.055-in. shim on the gear case side of the ring gear assembly. GC033A 4. Install the existing shim or a 0.063 in. shim on the cover side of the ring gear;...
  • Page 159 6. Zero the dial indicator; then while holding the pinion stationary, rock the ring gear assembly forward and back and record the backlash. Backlash must be 0.011-0.015 in. If backlash is within specifications, proceed to Ring Gear End-Play. If backlash is not within specifications, increase shim thickness to increase backlash or decrease shim thickness to decrease backlash.
  • Page 160 GC036B CF275A 5. Making sure the O-ring is properly positioned on the  NOTE: The spider and ring gear assembly must be differential housing cover assembly, install the cover replaced as a complete unit. with existing cap screws (coated with green Loctite #270).
  • Page 161  NOTE: If a new housing is being installed, tighten the cap screws to 28 ft-lb. CF278 CAUTION Make sure the tool is free of nicks or sharp edges or CD103 damage to the seal may occur. 3. Repeat steps 1-2 for the opposite side. INSTALLING DIFFERENTIAL 1.
  • Page 162  NOTE: To secure the clamp, use Hose Clamp Pliers. 7. Using new O-rings with clean grease applied, install the front drive actuator on the differential and tighten the three mounting screws securely. Connect the front drive actuator connector. 8. Apply fresh multi-purpose grease to the splines; then install the front axles into the differential pushing in on the axle shafts to seat the splines into the differential.

  • Page 163: Drive Axles

    Drive Axles REMOVING/INSTALLING DRIVE AXLES  NOTE: For removing/installing a rear drive axle, see Rear Gear Case or Front Differential in this section. CLEANING AND INSPECTING AXLES  NOTE: Always clean and inspect the drive axle com- ponents to determine if any service or replacement is WC303A necessary.
  • Page 164 5. Remove the rear axles from the rear drive gear case by pushing the axle shaft toward the gear case and pull- ing the CV/spline shaft out. Account for one O-ring on each axle shaft. WC240B PR729C 6. Remove the two lower lateral links from the frame; then remove the lower rear gear case mounting cap screw.
  • Page 165 RING GEAR/THRUST BUTTON Removing 1. Remove the cap screws securing the gear case cover to the gear case; then remove the ring gear. 2. Remove the thrust button from the gear case cover (left-hand threads). Account for a shim. Inspecting 1.
  • Page 166 4. If clearance is not as specified, repeat steps 1 and 2 using thicker (clearance too great) or thinner (clear- ance too small) until correct specification is reached. REAR DRIVE INPUT SHAFT/ HOUSING Removing/Disassembling 1. Remove the cap screws securing the rear drive input shaft/housing to the rear gear case;...
  • Page 167 Cleaning and Inspecting 1. Wash all parts in parts cleaning solvent and dry with compressed air. ! WARNING Always wear safety glasses when working with com- pressed air. 2. Clean all gasket material and sealant from mating sur- faces. 3. Inspect bearings, shafts, and housing for excessive wear, cracks, or discoloration.
  • Page 168  NOTE: It is critical to apply molybdenum grease to all splines of all driveshafts. WC296A 7. Install the upper left lateral link and secure with a bolt and nut. Tighten to 40 ft-lb. WC767A 3. With the spring in the rear driveshaft, lower the gear case and slide it onto the engine output shaft making sure the boot slips over the splined shaft;...

  • Page 169: Hub

    15. Pour in the recommended gear case lubricant and check to ensure the lubricant is one inch below threads in fill/level hole. Install and tighten the fill/level plug to 16 ft-lb. REMOVING 1. Secure the vehicle on a support stand to elevate the wheel;...
  • Page 170 INSTALLING 1. Secure the brake disc to the hub with the four cap screws coated with red Loctite #271. Tighten to 15 ft-lb. 2. Install the hub assembly onto the axle; then apply Loctite primer and red Loctite #277 to the axle threads.

  • Page 171: Hydraulic Brake Caliper

    6. Remove the vehicle from the support stand. PR237A Hydraulic Brake Caliper ! WARNING Arctic Cat recommends only authorized Arctic Cat Wild- cat dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- trol causing severe injury or death.
  • Page 172 PR713A PR715 PR715 PR717A 2. Press the piston into the caliper housing using hand ! WARNING pressure only. Completely seat the piston; then wipe Make sure to hold the towel firmly in place or the piston off any excessive brake fluid. could be ejected from the housing causing injury.

  • Page 173: Master Cylinder Assembly

    PR719C PR239 4. Install the caliper onto the caliper holder making sure 6. Place the brake caliper assembly into position and the caliper and holder are correctly oriented. secure with new “patch-lock” cap screws. Tighten the  NOTE: It is very important to apply silicone grease caliper to 20 ft-lb.

  • Page 174: Troubleshooting

    Inspecting 1. Inspect the master cylinder push rod and clevis for wear, bending, or elongation of clevis holes. 2. Inspect the push rod boot for tears or deterioration. 3. Inspect the reservoir for cracks and leakage. 4. Inspect the brake hose for cracks and deterioration and the condition of the banjo-fittings.

  • Page 175: Suspension

    Suspension The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods bent, pitted, or damaged. B. Reservoirs damp or leaking. C. Shock absorber body damaged, punctured, or leaking. D. Shock absorber eyelets broken, bent, or cracked. WC284 E.
  • Page 176  NOTE: The upper A-arms can be removed without removing the hub or knuckle. If the technician’s objective is to remove the upper A-arms, proceed to step 6. PR193 7. Tap the ball joints out of the knuckle; then remove the knuckle.
  • Page 177 WC359 WC303A 2. Install the A-arm assemblies into the frame mounts 10. Secure the brake caliper to the knuckle with two new and secure with the cap screws. Only finger-tighten at “patch-lock” cap screws. Tighten to 20 ft-lb. this time. 3.

  • Page 178: Rear Trailing Arms

    6. Remove the sway bar link; then remove the nut from the front trailing arm cross-mount through-bolt but do Rear Trailing Arms not remove the bolt at this time. REMOVING 1. Lift and support the vehicle on support stands that allow access to the rear suspension with the rear tires off the floor.

  • Page 179: Wheels And Tires

    10. Remove the support stands and lower to the floor. Wheels and Tires TIRE SIZE ! WARNING Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable vehicle operation. WC306B The Wildcat is equipped with low-pressure tubeless tires 4.

  • Page 180: Troubleshooting

    4. Inspect each tire for cuts, wear, missing lugs, and ! WARNING leaks. Do not mix tire tread patterns. Use the same pattern type INSTALLING on front and rear. Failure to heed warning could cause poor handling qualities of the vehicle and could cause Install the wheel;...

  • Page 181: Steering/Frame/Controls

    Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Steering wheel secure. B. Steering has equal and complete full-left and full- right capability. C. Steering sector mounting bolts tight. WC241A D. Ball joints not worn, cracked, or damaged. 3.
  • Page 182 2. Mark the ends of the EPS input and output shafts to correspond with the flat-splined segment; then align the flat-splined segment of the output shaft with the slot in the rack input coupler and install the EPS into the vehicle. WC246A 6.

  • Page 183: Rack And Pinion Assembly

    WC251A WC247A 10. Connect the two electrical connectors and check EPS operation. 11. Install the hood and grille. Rack and Pinion Assembly REMOVING 1. Remove the hood and grille; then remove the EPS assem- bly (see Electronic Power Steering (EPS) in this section). WC252A 2.
  • Page 184 5. Remove four cap screws securing the rack and pinion assembly to the frame; then rotate the rack and pinion assembly to the rear and out of the frame from either side. WC279A 2. Secure the bracket to the frame with four cap screws and tighten to 20 ft-lb.

  • Page 185: Steering Wheel

    5. Install the front differential assembly (see under Drive System - Front Differential). 6. Install the EPS assembly (see Electronic Power Steer- ing (EPS) in this section). 7. Install the hood and grille. Steering Wheel REMOVING 1. Remove the steering wheel cover; then match mark WC321 the steering shaft and steering wheel.
  • Page 186 WC247A WC337A INSPECTING 1. Check that the steering flex-shaft rotates freely in the housing with no sticking or binding. 2. Check the splines for wear or any signs of twisting. 3. Check the housing for cuts, cracks, or kinks. 4. If the assembly is serviceable, remove the flex-shaft and lubricate with the appropriate lubricant;...

  • Page 187: Steering Knuckles

    WC324A WC242 4. Install the upper steering housing collar onto the tilt 6. Install the upper steering flex-shaft hold-down strap housing and tighten the nuts to 20 ft-lb. and secure with the cap screw. Tighten to 50 in.-lb. WC339A WC247A 5.
  • Page 188 WC271 PR289 7. Tap the ball joint end out of the knuckle; then slide the 2. Install the knuckle to the lower ball joint and secure axle out of the knuckle. with a new “patch-lock” cap screw. Tighten to 35 ft- 8.

  • Page 189: Checking/Adjusting Front Wheel Alignment

    WC281 WC317A 6. Engage the hub nut into the Belleville washer on the  NOTE: If the hub plate cannot be fully installed due convex side; then with the concave side of the washer to misalignment of the hub nut, tighten the nut until directed toward the hub, install the nut and washer.

  • Page 190: Hood

    3. Reach up through the front fender wells and remove two fender screws (D) from the rear of the hood and remove the hood. INSTALLING 1. Lay the hood in place on the frame; then install the rear fender screws (D). 2.

  • Page 191: Accelerator Pedal

    Accelerator Pedal REMOVING Dislodge the throttle cable holding grommet from the actu- ator arm; then remove two torx-head screws and nuts securing the accelerator pedal assembly to the splash panel and remove the accelerator pedal. WC344A 3. Lift the rear body panel off and remove forward between the ROPS uprights;...

  • Page 192: Shift Cable

    REMOVING 1. Remove the seats, battery cover, and center console. 2. Remove the nut (A) from the shift arm pivot bolt: then loosen the jam nut (B) and lift the cable upward out of the mounting bracket slot. 3. Remove the E-clip (C); then loosen jam nut (D) and slide the cable (E) out of the mounting bracket.

  • Page 193: Exhaust System

    3. Remove the nuts securing the gauge assembly to the dash; then unplug the multi-pin connector and remove Cargo Box the gauge from the vehicle. 4. Place the new gauge into the dash panel opening; then place the gauge holder over the mounting screws and secure with the nuts.

  • Page 194: Troubleshooting

    Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.
  • Page 195 NOTES...

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