The oil pump on the Arctic Cat Wildcat X engine is located inside the crankcase. It includes a gerotor assembly and an oil pump cover, which are installed and secured in the crankcase with two cap screws.

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Summary of Contents for Arctic Cat WILDCAT X

Page 1 SERVICE MANUAL ® ® ® www.arcticcat.com www.arcticcat.com...
Page 2: Table Of Contents
2016 Wildcat X/4X Service Manual Table Of Contents General Information/Foreword.......... 2 Installing Right-Side Components ........70 Center Crankcase Components ........71 Specifications..............2 Separating Crankcase Halves ..........71 Torque Specifications ............3 Torque Conversions (ft-lb/N-m) .......... 4 Disassembling Crankcase Half.........72 Servicing Center Crankcase Components .......74 Drive Belt Break-In Procedure ...........
Page 3: General Information/Foreword
SAE Approved 80W-90 Hypoid Lubricant When replacement of parts is necessary, use only genuine Belt Width 32 mm (1.25”) Arctic Cat parts. They are precision-made to ensure high Brake Fluid DOT 4 quality and correct fit. Refer to the appropriate Illustrated Taillight/Brakelight...
Page 4: Torque Specifications
CAMSHAFT AND CYLINDER HEAD SUSPENSION COMPONENTS (Rear) Cam Lobe Height (min) 34.18 mm Sway Bar Bracket Frame Sway Bar Link Sway Bar Arm Camshaft Journal Oil Clearance (max) 0.07 mm Sway Bar Link Lower Trailing Arm Camshaft Journal Holder(right & center) 21.94-22.04 mm Inside Diameter (left)
Page 5: Torque Conversions (Ft-Lb/N-M)
DRIVE TRAIN COMPONENTS (cont) Torque Conversions Torque Part Part Bolted To ft-lb N-m (ft-lb/N-m) Oil Fill/Level Plug Front Differential - Rear Drive Wheel (aluminum lug nut) Hub (20 ft-lb increments) Wheel (black lug nut) Hub (20 ft-lb increments) Bead Lock (Limited) Wheel ft-lb ft-lb...
Page 6: Preparation For Storage
3. Either drain the gas tank or add a fuel stabilizer to the gas in the gas tank. CAUTION 4. Change the engine oil. Do not use white gas. Only Arctic Cat approved gaso- line additives should be used. 5. Plug the hole in the exhaust system with a clean cloth.
Page 7 5. Check the coolant level and add properly mixed 8. Check the tire pressure. Inflate to recommended coolant as necessary. pressure as necessary. 6. Charge the battery; then install. Connect the battery 9. Tighten all nuts, bolts, cap screws, and screws mak- cables making sure to connect the positive cable ing sure all calibrated nuts, cap screws, and bolts are tightened to specifications.
Page 8: Periodic Maintenance/Tune-Up
 NOTE: Foam Filter Cleaner and Foam Filter Oil cian when performing service procedures in this section. are available from Arctic Cat. Refer to the current Special Tools Catalog for the appro- priate tool description. 4. Dry both filter components.
Page 9: Valve/Tappet Clearance
CHECKING AND CLEANING DRAINS CHECKING 1. Inspect the drain beneath the main housing for debris Using a feeler gauge, check each valve/tappet clearance. or liquid. Remove and clean the drain bulb if con- If clearance is not within specifications, loosen the jam taminated.
Page 10: Testing Engine Compression
A. Battery is fully charged and in good health. B. Starter cranks engine over (normal speed). C. Gauge is functioning properly. D. Throttle in the full-open position. E. Valve/tappet clearance correct. F. Engine warmed up. G. Intake not restricted.  NOTE: To service top-side components, see Engine/Transmission.
Page 11: Muffler/Spark Arrester
A new spark plug should be tightened 1/2 turn once the washer contacts the cylinder head. A used spark plug should be tightened 1/8-1/4 turn once the washer contacts the cylinder head. Muffler/Spark Arrester Clean the spark arrester using the following procedure. ! WARNING Wait until the muffler cools to avoid burns.
Page 12: Front Differential - Rear Drive Lubricant
11. Remove the oil level stick; the oil level must be within the operating range but not exceeding the upper mark. WC020A 2. If low, add SAE approved 80W-90 hypoid gear lube as necessary. To change the lubricant, use the following procedure. GZ461A CAUTION 1.
Page 13: Headlight - Taillight/Brakelight
Headlight - Taillight/Brakelight  NOTE: The LEDs are not replaceable. The entire assembly must be replaced as a component. To replace the headlight assembly, use the following pro- cedure. 1. With the hood removed, remove the wiring harness connector from the back of the headlight. WC099A 2.
Page 14: Shift Lever/Shift Cable
2. Loosen adjuster nut (A) and jam nut (B) and adjust the cable as necessary to obtain park in the full aft position of the shift lever and low range full forward. Tighten the jam nut securely. WC361A Shift Lever/Shift Cable WC348C CHECKING Hydraulic Brake System...
Page 15 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 rear brake pads, use the following pro- cedure.
Page 16: Burnishing Brake Pads
2. Remove the right rear shock absorber; then loosen the clamp securing the cooling exhaust duct to the boot. WC610  NOTE: It will be necessary to retract the pistons to accommodate new pads. It may be necessary to open the bleed screw slightly.
Page 17 WC667 WC810 6. Remove the movable sheave and V-belt and any belt threads or debris in the CVT housing or sheaves. WC810A 2. Secure the driven clutch with the cap screw (A), washer (B), and alignment shim(s) (C); then tighten to 60 ft-lb.
Page 18: Steering/Body/Controls
2. Remove two side fender screws (C), one on left and one on right located above and behind the headlight Steering/Body/Controls assemblies. 3. Reach up through the front fender wells and remove two fender screws (D) from the rear of the hood and The following steering components should be inspected remove the hood.
Page 19: Steering Wheel
WC347A WC342A 2. Remove the hose clamp from the gasoline filler neck 2. Secure with the machine screws and tighten securely. and disconnect the filler hose. 3. Remove the plug or tape from the gas filler hose and connect the hose to the gasoline filler neck and secure with the hose clamp.
Page 20: Steering Assembly
WC321 WC242A 4. Remove the U-clamp; then remove the bracket. Steering Assembly 5. Loosen the Allen-head cap screw securing the steer- ing rack input coupler to the shaft; then remove four cap screws securing the EPS mounting bracket to the frame.
Page 21 7. Remove the steering flex-shaft support bracket; then slide the EPS unit upwards and to the rear until clear of the steering rack input coupler. WC254A WC247A 8. Remove the steering flex-shaft coupler from the EPS unit; then maneuver the assembly past the brake hoses and out of the vehicle.
Page 22 REMOVING RACK AND PINION ASSEMBLY 1. Remove the hood and grille; then remove the EPS assembly. 2. Remove the front differential assembly (see Drive and Brake Systems). 3. Remove the cotter pins and nuts securing the tie rods to the steering rack. WC252A ...
Page 23: Steering Shaft
WC279 WC260A 3. Install the upper mounting bracket in the frame and Inspecting secure with new “patch-lock” cap screws. Tighten to 1. Inspect the input shaft splines for excessive wear or 20 ft-lb. signs of misalignment. 2. Inspect the slide mechanism for pitting, excessive wear, or worn bushings.
Page 24 WC330 WC335 4. Remove four upper dash mounting screws and block 7. Remove the upper and lower snap rings from steer- the dash to the rear. ing shaft; then work the steering shaft out of the upper steering support housing and remove from the vehicle.
Page 25 5. Install the steering flex-shaft coupler onto the EPS input shaft aligning the flat-splined segment of the shaft to the slot in the coupler; then install the U-clamp on the lower sheering shaft housing and secure with two nuts. Tighten to 7 ft-lb. WC341A 2.
Page 26: Steering Knuckles
7. Install the upper tilt-steering link pivot bolt and tighten to 10 ft-lb; then install the steering wheel. 8. Remove the block and secure the upper dash screws; then install the hood and grille. Steering Knuckles REMOVING AND DISASSEMBLING 1. Secure the vehicle on a support stand to elevate the wheel;...
Page 27: Checking/Adjusting Front Wheel Alignment
 4. Install the tie rod end and secure with the nut (coated NOTE: If the hub plate cannot be fully installed due with red Loctite #271). Tighten to 55 ft-lb; then to misalignment of the hub nut, tighten the nut until install a new cotter pin and spread the pin.
Page 28: Accelerator Pedal
INSTALLING Align the mounting holes with the holes in the splash panel and secure with the two torx-head screws and nuts; then snap the throttle cable holding grommet into the actuator arm. Shift Lever REMOVING 1. Remove the seats; then remove the battery cover and shift lever handle.
Page 29: Shift Cable
4. Place the lower cable housing end into the mounting bracket on the engine and finger tighten jam nut (D); Shift Cable then connect cable (E) to the shift arm and install the E-clip (C). 5. Install any necessary cable ties as marked during removal;...
Page 30: Cargo Box
2. Install the rear body panel. Seats REMOVING/INSTALLING (X) 1. To remove a seat, pull the seat lock lever up. Raise the rear of the seat and tilt it forward. WC898A 2. Slide the muffler assembly clear of the holder pins. Account for the grafoil seal.
Page 31: Doors
WC722A WC133A 4. To install a rear seat, place into position with the seat CHECKING/ADJUSTING (X Limited) support; then secure with the cap screws and tighten 1. Loosen the screws on the hinge plate to raise or to 15 ft-lb. lower the door-to-latch contact or to move the door forward or backward.
Page 32 ROV-810 ROV-809 2. Align the roof over the top of the ROPS. Install the P-clamps in the proper locations onto the ROPS. 3. Secure the roof to the P-clamps using the cap screws, washers, and new lock nuts.  NOTE: The lip of the roof faces the rear of the vehicle. ROV-812 WC812...
Page 33: 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 34: Engine/Transmission
Magneto Rotor Remover Set 0444-254  Piston Pin Puller 0644-328 NOTE: Arctic Cat recommends the use of new gas- Secondary Drive Gear Holder 0444-253 kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. Spanner Wrench...
Page 35: Troubleshooting
Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Gasoline bad 1. Drain gas - replace with clean gas 2. Valve clearance out of adjustment 2. Adjust clearance 3. Valve guides worn 3.
Page 36: Engine
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 37: 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 38: Crankcase
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 the clamps. Coolant can remain in the radia- tor. WC352A 10. Remove the gas tank hold-down and gas tank; then remove the gas tank cradle.
Page 39 WC146A WC204A 15. Remove the air filter housing support bracket; then free the air filter housing from the inlet boot and remove from the vehicle. WC206A 18. Remove the engine ground cable. WC365A 16. Disconnect the gas line connectors from the fuel rails and electrical connectors from the injectors;...
Page 40  NOTE: It may be necessary to use a hoist to slightly raise the rear of the vehicle to free the link from the frame weldment. 24. Remove two through-bolts and one cap screw secur- ing the rear drive gear case; then reattach the lateral link and remove the hoist if used.
Page 41: Top-Side Components
WC172B WC174A Top-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 ...
Page 42 4. Remove all cap screws except the two top-side cap screws next to the spark plug. These will keep the alignment pins in place. Note the two rubber washers on the remaining cap screws. 5. Remove the valve cover. Account for and note the orientation of the cylinder head plug.
Page 43 GZ155 GZ408 8. Bend the washer tabs down and remove the two cap 10. Remove the five nuts securing the cylinder head to screws securing the sprocket to the camshaft; then the cylinder; then remove the four cylinder head cap drop the sprocket off the camshaft being careful not screws and washers.
Page 44: Crankcase (Step 1)
GZ161 GZ141A 12. 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 compres- sion stroke; then repeat steps 2-11 on the other cylin- der head. AT THIS POINT ...
Page 45: Servicing Top-Side Components
CAUTION Servicing Top-Side When removing the cylinder, be sure to support the pis- Components ton to prevent damage to the crankcase and piston. 16. Using an awl, remove one piston-pin circlip. 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.
Page 46 If valves, valve guides, or valve seats require servicing or 2. Remove each ring by working it toward the dome of replacement, Arctic Cat recommends the components be the piston while rotating it out of the groove. taken to a qualified machine shop for servicing.
Page 47 Inspecting Piston 1. Inspect the piston for cracks in the piston pin, dome, and skirt areas. 2. Inspect the piston for seizure marks or scuffing. 3. Inspect the perimeter of each piston for signs of excessive “blowby.” Excessive “blowby” indicates worn piston rings or an out-of-round cylinder.
Page 48 Cleaning/Inspecting Cylinder Head CAUTION The cylinder head studs must be removed for this pro- cedure. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber being careful not to nick, scrape, or damage the com- bustion chamber or the sealing surface.
Page 49 CAUTION Water or parts-cleaning solvent must be used in con- junction with the wet-or-dry sandpaper or damage to the sealing surface may result. CC390D 7. If any measurement exceeds the limit, replace the cylinder and piston. Inspecting Cam Chain Guide 1.
Page 50: Installing Top-Side Components
2. The lobe heights must be greater than minimum specifications. Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced. ...
Page 51: Cylinder Head
GZ142 GZ161A 4. Loosely install the two nuts securing the cylinder to 7. Place a new head gasket into position on the cylin- the crankcase. der. Place the alignment pins into position; then place the head assembly into position on the cylinder ...
Page 52  11. With the timing inspection plug removed and the NOTE: Note the position of the alignment marks on front chain held tight, use a cap screw to rotate the the end of the camshaft. They must be parallel to the crankshaft until the front piston is at TDC indicated valve cover mating surface.
Page 53 18. Rotate the crankshaft until the first cap screw (from step 16) can be tightened; then tighten to 10 ft-lb. Bend the tab to secure the cap screw. 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.
Page 54 21. With the cam lobes directed down (toward the pis- D. Recessed side of the sprocket directed toward the ton), maneuver the camshaft/sprocket assembly cam lobes. through the chain and towards its seating position; E. Camshaft alignment pin and sprocket alignment hole then loop the chain over the sprocket.
Page 55 GZ193 GZ162A 26. Rotate the crankshaft until the first cap screw (from 29. Remove the cap screw from the end of the chain ten- step 24) can be addressed; then tighten to 10 ft-lb. sioner; then using a flat-blade screwdriver, rotate the Bend the tab to secure the cap screw.
Page 56 GZ201 GZ206  NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. 35. Install the valve cover cap screws with rubber wash- ers; then install the remaining cap screws. Tighten only until snug. CD471 32.
Page 57: 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- assembly of components may be necessary.
Page 58 5. With the flywheel key removed, remove the starter 8. Remove the water pump. Account for an O-ring. ring-gear and spacer washer.  NOTE: The water pump is a non-serviceable com- ponent and must be replaced as a complete assembly. 9.
Page 59: 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 rollers. If bearing is damaged, it must be replaced. H2-022A 13. Remove the snap ring securing the speed sensor trig- ger to the shaft;...
Page 60 FI576A FI580 INSPECTING STATOR COIL/ MAGNETO COVER ASSEMBLY 1. Inspect the stator coil for burned or discolored wir- ing, 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 61: 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. If installing the existing magneto cover, tighten the cap screws to 13 ft-lb. If installing a new mag- neto cover, tighten the cap screws to 15 ft-lb.
Page 62 H2-019 H2-020 6. Install the shift cam plate onto the shift cam shaft and 9. Install the gear position switch; then align and install secure with the cap screw. Tighten to 8 ft-lb. the shift select arm to the shift shaft using the match marks as a guide.
Page 63: Right-Side Components
GZ249 GZ224A 16. Install the starter motor with a new O-ring lightly lubricated with grease; then tighten the mounting cap screws to 8 ft-lb. GZ226 14. Place the key into the keyway in the crankshaft; then wipe all oil from the crankshaft surface and rotor/fly- wheel bore and install the rotor/flywheel onto the GZ251 17.
Page 64: Removing Right-Side Components
Removing Right-Side Components A. CVT Cover B. Drive Clutch C. Driven Clutch D. Inner Clutch Cover 1. Remove the cap screws securing the CVT cover; then using a rubber mallet, gently tap on the cover tabs to loosen the cover. Account for a gasket and WC664A two alignment pins.
Page 65: Servicing Right-Side Components
GZ527 WC657 Servicing Right-Side Components DRIVE CLUTCH Disassembling  NOTE: Note the timing marks (X) on the cover, spi- der, and movable sheave. These must be aligned when assembling the drive clutch for balance purposes. 1. Loosen the machine screws securing the cover. Remove every other cap screw from the cover;...
Page 66 FC083 WC650 4. Secure the drive clutch to the holder using the clutch  bolt and washer. NOTE: Applying heat to the spider threaded area will aid in clutch disassembly. The heat will loosen the Loctite used during assembly. 7. Remove the drive clutch from the clutch holder. 8.
Page 67  NOTE: If the needle bearing is washed, re-pack the bearing with hi-temp molybdenum wheel bearing grease. 2. Remove any drive belt dust accumulation from the stationary sheave, movable sheave, and bushings using parts-cleaning solvent only. CAUTION Do not use steel wool or a wire brush to clean compo- nents having a bushing;...
Page 68: Driven Clutch
8. Align the match marks (X) and install the clutch cover and secure with six cap screws. Tighten using a crisscross pattern to 120 in.-lb. WC635 3. Remove the E-clips securing the cam rollers to the spider; then remove the thrust washer and roller. WC653A DRIVEN CLUTCH Disassembling...
Page 69 4. Place the roller onto the spider (beveled side of roller facing in); then install the thrust washer and E-Ring. WC626 Assembling WC677A 1. Install the roller and thrust washer in place with the 5. Place the insert and spider onto the bearing assembly. washer toward the outside of sheave.
Page 70 8. Using an appropriate driven clutch compressor tool, install the cam making sure all marks are aligned. Tighten the screws to 11 ft-lb. GZ440A 2. Inspect the bearing (B) for smooth rotation and no discoloration or scoring. 3. Inspect the gear (C) for chipped or missing teeth, WC686 excessive hub wear, or excessive wear in the drive WATER PUMP DRIVE ASSEMBLY...
Page 71: Installing Right-Side Components
With the gasket and alignment pins in position, install the clutch cover and secure with the existing cap Installing Right-Side screws. Tighten to 8 ft-lb. 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.
Page 72: Center Crankcase Components
WC739 WC809 10. If offset adjustment is necessary, place the transmis- sion in park. Remove the driven clutch cap screw (A), washer (B), and any shims (C). If belt clearance is too small, add additional shims to gain the desired clearance.
Page 73: Disassembling Crankcase Half
H2-012A GZ269A  NOTE: Do not disassemble these assemblies unless service is required. If disassembled, secondary gear sets will have to be reset for backlash and gear contact (see Servicing Center Crankcase Components sub-section). 4. Remove one cap screw from the right-side crankcase and eight cap screws from the left-side crankcase;...
Page 74 GZ474A GZ463A 4. Remove the snap ring securing the oil pump driven  NOTE: To aid in installing, it is recommended the gear (D) to the oil pump driveshaft; then remove the assemblies are kept together and IN ORDER. gear. Account for a drive pin and washer. 1.
Page 75: Servicing Center Crankcase Components
6. Remove two cap screws securing the oil pump in the crankcase and remove the oil pump. Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS Initial Set-Up  NOTE: If the secondary output driven shaft is replaced or disassembled, the initial set-up must be performed to establish correct gear tooth contact.
Page 76 MT012 MT016A 6. To adjust tooth contact, use the following chart to correctly shim the driven shaft. Tooth Contact Shim Correction Contact at Top Increase Shim Thickness Contact at Root Decrease Shim Thickness 7. After correct tooth contact is established, proceed to Checking Backlash in this sub-section.
Page 77 Correcting Backlash 2. Inspect the crankcase for scoring, discoloration, or cracks in the gerotor bore. If scored, crankcase  NOTE: If backlash measurement is within the assembly must be replaced. acceptable range, no correction is necessary. 1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thinner shim.
Page 78 GZ354A GZ356 6. Remove the oil seal from the oil pump cover. GZ363 3. With the outer rotor reference dot directed toward the GZ365 oil pump cover, install the rotor onto the inner rotor. 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.
Page 79: Shaft
CRANKSHAFT ASSEMBLY  NOTE: The crankshaft and connecting rod is a non-serviceable assembly. If any component is out of specification, the assembly must be replaced. Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore;...
Page 80 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 81 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 82: 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 83: Crankcase
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 and the spacer on the gear shift stop end.
Page 84: 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 85 GZ342 GZ269A 5. Tighten the 6 mm cap screws to 8 ft-lb and the 8 mm cap screws to 21 ft-lb using the pattern shown and turning the shafts frequently to ensure there is no binding.  NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs.
Page 86: Installing Engine/Transmission
20 ft-lb. Engine/Transmission  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 87 WC187A WC362A 8. Crimp the clamp onto the rear drive coupler boot. 10. Install the heat shield; tighten the fasteners to 20 ft-lb. 11. Making sure the tab on the throttle body aligns and fully engages the alignment slot on the intake boot, install the throttle body and tighten the clamp nut to 30 in.-lb;...
Page 88 16. Set the air filter housing into place and secure with the three screws on the CVT housing and tighten to 6 ft-lb; then connect and secure the throttle body inlet air boot (A), crankcase breather hose (B), and inlet air duct (C).
Page 89 WC899A WC354A 25. Install the cargo box; then remove the cap from the gas fill hose and place the rear body panel into posi- tion. Secure the gas tank fill hose to the filler neck and secure with the clamp. 26.
Page 90: 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. ! WARNING Whenever the gasline hoses are removed (other than for pressure testing), the battery must be disconnected to prevent inadvertent activation of the electronic fuel pump.
Page 91: Gas Tank
WC215A WC206B 4. Remove the holding strap and move the radiator INSTALLING back into position and secure with the mounting 1. Connect the throttle cable to the throttle arm; then screws. Tighten securely. install the throttle cable housing to the throttle body 5.
Page 92: Oil Pump
Oil Pump  NOTE: Whenever internal engine components wear excessively or break and whenever oil is contami- nated, the oil pump should be replaced. TESTING OIL PUMP PRESSURE  NOTE: The engine must be warmed up to operating temperature (cooling fan cycling) for this test. 1.
Page 93: Oil Cooler
2. Connect the oil hoses and secure with the hose clamps. Tighten securely. 3. Install the hood. Liquid Cooling System When filling the cooling system, use premixed Arctic Cat WC357A Antifreeze. While the cooling system is being filled, air 5. Clamp the coolant hoses off; then loosen the coolant pockets may develop;...
Page 94 WC193 WC919B 4. Install the cargo box (see Steering/Body/Controls).  NOTE: Note the routing of hoses and location of any ties used to secure hoses to frame. 5. Pour the proper mixture and quantity of coolant into the radiator filler loosening the radiator cap to allow 6.
Page 95: Thermostat
Thermostat Water Pump  REMOVING NOTE: The water pump is a non-serviceable com- ponent. It must be replaced as an assembly.  NOTE: The thermostat is located in a housing REMOVING in-line with the upper radiator hoses under the radia- tor/fan assembly.
Page 96: Troubleshooting
4. Fill the cooling system with appropriate mixed cool- CAUTION ant and install the radiator cap. After operating the Wildcat for the initial 5-10 minutes, 5. Start the engine and check for coolant leaks; then add stop the engine, allow the engine to cool down, and coolant if necessary to proper level.
Page 97: Electrical System
 switches are activated. NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 for charging or the CTEK Multi  NOTE: For absolute accuracy, all tests should be US 3300 for battery maintenance charging.
Page 98: Electronic Power Steering (Eps)
CATT II, EPS replace- form to operator expectations, bring the battery to an ment is not necessary. Follow the instructions under authorized Arctic Cat dealer for further troubleshoot- "Fault Recovery Method" to correct the malfunction. ing.
Page 99 Code Fault Description Fault Condition Possible Cause EPS Fault Recovery Method C1309 Temperature Above 120° EPS internal 120° C over-temp condition Clean the EPS housing and cooling fins. EPS will auto-recover when internal has been detected temperature drops below 115° C C1310 Vehicle Speed High Vehicle speed signal received by the EPS Intermittent main harness wires, defective...
Page 100: Ignition Switch
4. With the ignition off, disconnect the battery leads 2. Connect the red tester lead to the orange wire and the from the battery. Carefully remove the connector black tester lead to ground. from the ECM. Disconnect the 8-pin connector from 3.
Page 101: Accessory Receptacle/Connector
 NOTE: To check ignition timing, the seats and cen- ter console must be removed. 1. Attach the Timing Light to the spark plug high ten- sion lead; then remove the timing inspection plug from the left-side crankcase cover. 2. Start the engine and using the RPM function on the speedometer/tachometer, run at 1500 RPM;...
Page 102: Fan Motor
2. Using an ohmmeter, the following readings must be 4. Depress the reverse override switch. The meter must observed (± 5%). show less than 1 DC volt. Fan Motor This component can be tested using the CATT II. Utilize the Test screen. ...
Page 103: Power Distribution Module (Pdm)
VOLTAGE (Taillight) 5. The meter must show battery voltage from one side of the connector terminal ends.  NOTE: Perform this test at the socket end of the  taillight-brakelight harness (pigtail). The ignition NOTE: Battery voltage will be indicated from only switch must be in the ON position and either high one side of the fuse holder connector terminal;...
Page 104 CRANKSHAFT POSITION SENSOR 1. Disconnect the sensor connector from the sensor located on top of the throttle body. 1. Set the meter selector to the OHMS position. 2. Select DC Voltage on the tester and turn the ignition 2. Connect the red tester lead to the brown wire; then switch to the ON position.
Page 105: Speed Sensor
SPEED SENSOR Component data can be retrieved using the CATT II. Uti- lize the Sensor Data screen.  NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this section). ...
Page 106 4. Check for any flashing DTC (Diagnostic Trouble 3. Test the fuel level sensor by connecting a multimeter (A) Code) on the digital gauge. A disconnected or faulty to the fuel level sensor leads (B); then select OHMS. The tilt sensor will cause the fuel pump not to run and a multimeter should show 5 ohms at full fuel position (C) code to flash.
Page 107: Tilt Sensor
Output Voltage  NOTE: Needle adapters will be required on the mul- timeter leads as the following tests are made with the sensor connected. 1. Connect the three-wire plug to the sensor; then remove the right-side mounting screw securing the sensor to the frame.
Page 108 Testing 3. Using a multimeter, connect the black tester lead to the center socket (GND) on the analyzer and the red 1. Remove the seats and rear body panel; then remove tester lead to the white socket (VAR); then select the the two top radiator mounting cap screws and tilt the DC Voltage position.
Page 109: Stator Coil
RPM Limiter Component data can be retrieved using the CATT II. Utilize the Sensor Data screen. NOTE: The vehicle is equipped with an ECM that cuts fuel spray and spark when maximum RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire. Incorrect Warranty Gear...
Page 110: Starter Motor
 NOTE: If the meter showed no battery voltage, inspect the main fuse, ground connections, starter Starter Motor motor lead, battery voltage (at the battery), or starter solenoid.  NOTE: The starter motor is not a serviceable com- ponent. If the motor is defective, it must be replaced. Starter Relay REMOVING 1.
Page 111: Efi Diagnostic System
This EFI system has a built-in feature that will only allow an ECM of the same part number to be used in these models. Do not attempt to substitute an ECM from a dif- ferent model as the system will not allow it to start. Error codes can be cleared by following the procedures located in the EFI Diagnostic System sub-section in this section.
Page 112 Coolant (COOL) Diagnostic Mode Tachometer (tACH) Diagnostic Mode EFI032 EFI030 Display: Engine coolant temperature as measured by the Display: Engine RPM ECT sensor. DTC: P0336, P0337, P0339 DTC: P0116, P0117, P0118, P0119 Usage: Verify engine speed signal from the following. Usage: Monitor coolant temperature to verify the follow- ing.
Page 113 TPS (tPS) Diagnostic Mode DTC: P0112, P0113, P0114 Usage: Verify correct output of IAT sensor.  NOTE: After engine has been running, IAT read- ings will be higher than outside air temperature due to engine and engine compartment heat as well as intake manifold heating.
Page 114 Code Fault Description Possible Cause Fault Recovery C0063 Tilt Sensor Circuit High Sensor or interconnect harness shorted to battery power Correct condition* C0064 Tilt Sensor Circuit Low/SG/Open Sensor or interconnect harness open or shorted to chassis ground Correct condition* C1263 Backup/Reverse-Light Circuit Open Bulb has failed or is disconnected or interconnect harness is open Correct condition*...
Page 115 Code Fault Description Possible Cause Fault Recovery P0601 ECM CAN Communication Shutdown Intermittent CAN connections or unstable CAN conditions have caused Correct CAN the ECM to temporarily shutdown CAN communication communication issue* P0615 Starter Relay Circuit Start switch/button, starter relay, gear switch or interconnect harness Correct condition* erratic or intermittent P0616...
Page 116: Troubleshooting
Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace stator coil 4. ECM defective 4. Replace ECM 5. Pick-up coil defective 5.
Page 117: Drive And Brake Systems
Drive and Brake Systems GENERAL INFORMATION The die-cast aluminum housings have been assembled with thread-rolling screws (trilobular). When assembling with these screws, start the screws carefully into the housing; then use the following torque values. Size New Housing Reassembled Housing WC938A 3.
Page 118: Front Differential
Front Differential REMOVING 1. Remove the forward belly panel (X) or seats and center console (4X); then drain the lubricant 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.
Page 119 7. Push in on the axle shaft while pulling outward on the axle coupler and remove the axle assembly from the differential. WC608 5. Holding the upper A-arm/ball joint down into the knuckle, remove and discard the retaining cap screw. PR729C 8.
Page 120 WC267A GC004A 10. Remove the front drive actuator from the differen- 2. Using a rubber mallet, remove the housing. Account tial; then remove the front boot clamp from the front for a gasket. Remove the fork, collar, and spring. drive coupler and slide the boot off. Note the location of all the components for assem- bling purposes.
Page 121 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 existing snap ring making sure the sharp edge of the snap ring faces to the outside.
Page 122 GC009A GC015 5. Place the pinion housing with new gasket onto the 2. Using a T-40 torx wrench, remove the cap screws differential housing; then secure with existing cap securing the differential cover. screws. Tighten to 23 ft-lb. 3. Using a plastic mallet, tap lightly to remove the dif- ...
Page 123 KX177 WC430 2. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing. KX178 6. Place the differential with the open side down; then lift the housing off the spider assembly. Account for shim(s) and mark as right-side.
Page 124 Shimming Procedure/Shim Selection Case-Side Shims (Backlash) 0402-405 0.051 0402-406 0.055 0402-407 0.059 0402-408 0.063 0402-409 0.067 Cover-Side Shims (Ring Gear End-Play) CC882 1402-074 0.051 1402-075 0.055 1402-076 0.059 1402-077 0.063 1402-078 0.067 It is very important to adjust bevel gears for the proper running tolerances.
Page 125 GC036B GC036A 5. Place the appropriate Backlash Measuring Tool into 3. Install the bearing flange onto the gear case cover the splines of the ring gear and install a dial indicator making sure the alignment/locating pin engages the making sure it contacts the gauge at a 90° angle and locating hole in the cover;...
Page 126 GC037A GC031A Ring Gear End-Play After correcting backlash, ring gear end-play can be adjusted. To adjust end-play, use the following proce- dure. 1. Secure the gear case in a holding fixture with the cover side up; then install a dial indicator contacting the ring gear axle flange.
Page 127 CF266A CC892 7. Install the shift fork assembly making sure the fork leg is facing upward. Apply a small amount of oil to the gasket; then install the gasket. CF267A 4. Apply a light coat of Loctite #598 to the O-ring; then install it on the assembled cover assembly making sure to seat the O-ring completely down around the CC893...
Page 128 CD110 WC277 2. Apply molybdenum grease to the splines and install Removing/Installing Axle Seal the forward driveshaft into the differential splined  NOTE: This procedure can be performed on a rear coupler; then install the three Allen-head bolts in the driveshaft coupler and tighten to 50 ft-lb.
Page 129 WC266A PR729C 5. On the X, secure the carrier bearing support bracket 9. Install the axles into the knuckles; then swing the to the frame with four cap screws and tighten to 20 knuckles vertical and engage the ball joint shanks ft-lb.
Page 130: Driveshaft (4X)
Driveshaft (4X) REMOVING/DISASSEMBLING 1. Remove the front and rear seats. WC303A 12. Install the brake calipers/pads and secure with new “patch-lock” cap screws. Tighten to 20 ft-lb. WC722A 2. Remove the battery access panel, shift knob, front and rear console, and front seat belts. Make sure to disconnect the reverse override switch and the front and rear accessory plugs.
Page 131  NOTE: Inspect the rubber coupler for deteriorating rubber or augured holes. WC713 8. Remove the screws and nuts from the rear bearing assembly. Accounting for an O-ring on the splined WC703 end of the shaft. 5. Loosen the set screws on the front and rear bearing 9.
Page 132 WC710 WC697A 13. On the front driveshaft by the front differential, 4. Place the rear driveshaft in position; then using new remove the rear-most boot clamp. Account for an Allen-head screws, connect the front and rear cou- O-ring on the splined end of the shaft. plers.
Page 133: Drive Axles
WC722A WC268A 9. Install the front seats. 4. Remove the hub assembly. 5. Leaving the lower trailing arm connected to the knuckle, remove the upper trailing arm and lateral Drive Axles links from the knuckle; then move the top of the knuckle outward and rotate forward to disengage the axle from the axle bearing.
Page 134 PR729C CF337 2. Place the end of the CV joint into a vise as shown. REMOVING FRONT DRIVE AXLE  NOTE: For removing a front drive axle, see Front Differential in this section. CLEANING AND INSPECTING AXLES  NOTE: Always clean and inspect the drive axle components to determine if any service or replace- ment is necessary.
Page 135 3. Connect the upper trailing arm and secure but do not tighten; then connect the lower lateral link and upper lateral links to the knuckle. Tighten the upper trailing arm cap screw and the lateral link bolts to 40 ft-lb. ATV-1048 3.
Page 136: Rear Gear Case
8. Install the wheels and using a crisscross pattern, tighten the wheel nuts in 20 ft-lb increments to a final torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum wheel w/black nuts), or 80 ft-lb (aluminum wheel w/chrome nuts). INSTALLING FRONT DRIVE AXLE 1.
Page 137 AT THIS POINT  On the 4X if the technician’s objective is to remove the rear driveshaft, release the clamp securing the shaft to the gear case; then slide the shaft from the gear case. WC170B 4. Remove the lower frame gear case bracket; then remove the left upper lateral link and the upper rear gear case through-bolt.
Page 138 GC057A GZ392 2. Place the ring gear with selected shim into the cover and measure the ring gear to thrust button clearance with a thickness gauge. Clearance should be 0.020-0.040 in. GZ176A GC058A 3. If clearance is as specified, remove the ring gear and thrust button;...
Page 139  NOTE: The clutch pack is not a serviceable compo- nent. If worn, discolored, or damaged in any way, it must be replaced. Assembling/Installing 1. Install a new bearing into the input housing and secure with the snap ring (flat side directed away from bearing).
Page 140 GZ176 WC295A 5. Using a new gasket, install the assembled rear drive 5. Install the lower lateral links and secure with the input shaft/housing onto the rear drive gear case and bolts and new lock nuts. Do not tighten at this time. secure with the three cap screws.
Page 141: Hub
Rear WC169A WC268 8. Apply molybdenum grease to the splines of the axle Front couplers and install the axles into the gear case; then install the rear drive axles (see Drive Axles in this section). 9. Pour in the recommended gear case lubricant and check to ensure the lubricant is one inch below threads in fill/level hole.
Page 142 WC303A PR250 3. Using a socket and ratchet handle, tighten the nut until the stud is fully drawn into the hub. WC769A 4. Install the hub plate making sure it fits completely over the nut and lies flat against the hub. PR252A INSTALLING 1.
Page 143: Hydraulic Brake Caliper
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. REMOVING/DISASSEMBLING (Front) 1. Secure the vehicle on a support stand to elevate the wheel;...
Page 144 WC725A PR238 REMOVING/DISASSEMBLING (Rear) 5. Remove the caliper holder from the caliper and dis- card the O-ring. 1. Secure the vehicle on a support stand to elevate the wheel; then remove the wheel. ! WARNING Never let brake fluid contact the eyes. Damage to the eyes will occur.
Page 145 PR717A PR715 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. 7.
Page 146  NOTE: It is very important to apply silicone grease 8. Fill the reservoir; then bleed the brake system (see to the O-rings and caliper bores prior to assembly. Periodic Maintenance/Tune-Up). ! WARNING Never use brake fluid from an open container or reuse brake fluid.
Page 147: Master Cylinder Assembly
WC692 WC609 3. Using silicon grease, lubricate the O-rings and install 6. Fill the reservoir; then bleed the brake system (see into the anchor bolt bores making sure the correct Periodic Maintenance/Tune-Up.) size of O-rings are installed in the correct locations 7.
Page 148 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 149: Troubleshooting Drive System
Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shaft serration worn - broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel Condition Remedy 1. Secondary drive - driven gear teeth broken 1.
Page 150: Suspension
DISASSEMBLING Suspension  NOTE: It is very important to measure the preload with a tape measure before disassembling in order to return the spring to the proper preload setting. The following suspension system components should be inspected periodically to ensure proper operation. A.
Page 151 WC904 WC909 4. Remove the snap ring from the spring retainer, and CHECKING/ADJUSTING RIDE HEIGHT remove the spring retainer and the snap ring. (X Limited/4X Limited)  NOTE: Ensure the vehicle is on level ground, the tires are properly inflated, and there is an average operating load in the vehicle.
Page 152 1. Loosen, but do not remove, the lock ring screw. Front WC912A 3. Adjust left and right spring as required. Model Front Rear WC778A Wildcat X EPS 13.75” 13.5” Rear Wildcat 4X 13.75” 13.5” Wildcat 4X LTD 13.75”...
Page 153 5. Remove the top spring. Rear 6. Clean all of the shock absorber components in a parts-cleaning solvent. 7. Inspect each shock rod for nicks, pits, rust, bends, and oil residue. 8. Inspect all of the spring retainers, shock rods, spring couplers, shock bodies, and eyelets for cracks, leaks, or bends.
Page 154: Front A-Arms
Front A-Arms REMOVING 1. Secure the vehicle on a support stand to elevate the front wheels; then remove the wheels and account for the hub plate.  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.
Page 155 INSTALLING Front 1. Apply Loctite Primer “T” to the A-arm socket; then apply green Loctite #609 to the entire outside diame- ter of the ball joint. Install the ball joint into the A-arm and secure with the snap ring. WC606 4.
Page 156: Rear Trailing Arms
7. Install the tie rod end and secure with the nut (coated with red Loctite #271). Tighten to 55 ft-lb; then install a new cotter pin and spread the pin to secure the nut.  NOTE: During assembly, new cotter pins should be installed.
Page 157 WC300 WC305A 4. Remove the hub nut and Belleville washer securing INSPECTING the hub. 1. Inspect the arm for any signs of metal fatigue, 5. Remove and discard the cap screws securing the cracked or broken welds, or severe dents or gouges. brake caliper to the knuckle and remove the caliper 2.
Page 158: Wheels And Tires
! WARNING washer directed toward the hub, install the nut and Use only Arctic Cat approved tires when replacing tires. washer. Keeping the nut and washer engaged, tighten Failure to do so could result in unstable vehicle opera- the hub nut to 250 ft-lb.
Page 159: Troubleshooting
CLEANING AND INSPECTING 1. Clean the wheels and hubs with parts-cleaning sol- vent. 2. Clean the tires with soap and water. 3. Inspect each wheel for cracks, dents, or bends. 4. Inspect each tire for cuts, wear, missing lugs, and leaks.
Page 160 ©2015 Arctic Cat Inc. Effective September 2015 Printed in U.S.A. ®™Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-660...

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Arctic Cat WILDCAT X Service Manual

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Fuel/Lubrication/Cooling

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