Arctic Cat WILDCAT/X Service Manual
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Arctic Cat WILDCAT/X Service Manual

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2014
SERVICE MANUAL
[ROV]

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Leslie Brustad
May 19, 2025

Is it required to oil a New air filter on Artic Cat Wildcat 700?

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1 comments:
Mr. Anderson
May 23, 2025

Yes, it is necessary to oil a new air filter for the Arctic Cat Wildcat 700 if it is a foam filter. Foam filters should be oiled before use to improve filtration performance and trap dust effectively.

This answer is automatically generated

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Dave
May 29, 2025

2016, while cat X 1000 is the oil and the transmission mission fluid the same.

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Summary of Contents for Arctic Cat WILDCAT/X

  • Page 1 2014 SERVICE MANUAL [ROV]...
  • Page 2 FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2014 Arctic Cat Wildcat models (see cover). The complete manual is designed to aid service personnel in service-oriented applica- tions. This manual is divided into sections. Each section covers a specific vehicle component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions.

  • Page 3: Table Of Contents

    Troubleshooting................33 Front Differential ................127 Engine/Transmission ..............34 Driveshaft (Wildcat 4/4X)............139 Troubleshooting................35 Drive Axles ................142 Removing Engine/Transmission (Wildcat/X) ....... 37 Rear Gear Case ................145 Removing Engine/Transmission (Wildcat 4/4X) ......41 Hub....................151 Top-Side Components ..............46 Hydraulic Brake Caliper (Wildcat)..........153 Left-Side Components ..............

  • Page 4: General Information

    738.9 kg (1629 lb) - Wildcat 4 Valve Seat Angle 45° +15’/+30’ ROPS Tested Curb Weight 981 kg (2162 lb) - Wildcat/X Valve Face Radial Runout (max) 0.2 mm 1265 kg (2789 lb) - Wildcat 4/4X Valve Spring Free Length (min) 38.7 mm...

  • Page 5: Torque Specifications

    DRIVE TRAIN COMPONENTS Torque Torque Specifications Part Part Bolted To ft-lb N-m Rear Drive/Gear Case Frame Drive Coupler (Front) Drive Flange Drive Coupler (Rear) Drive Flange Torque (ft-lb) Tolerance Front Differential Frame/Differential Bracket 0-15 ±20% Set Screw** (Wildcat 4/4X) Carrier Bearing in.-lb 16-39 ±15%...

  • Page 6: Torque Conversions (Ft-Lb/N-M)

    ENGINE/TRANSMISSION (cont) Gasoline - Oil - Lubricant Air Filter Housing Engine Ground Wire Engine Stator Coil Magneto Cover (New) Stator Coil Magneto Cover (Original) RECOMMENDED GASOLINE *w/Red Loctite #263***w/Green Loctite #270 **w/Red Loctite #271 ****w/“Patch-Lock” The recommended gasoline to use is 87 (Wildcat/Wildcat *****w/Primer #7649 and Loctite #277 4) or 91 (X/4X) minimum octane regular unleaded.

  • Page 7: Genuine Parts

    FILLING GAS TANK 5. Apply light oil to the plungers of the shock absorbers. 6. Tighten all nuts, bolts, cap screws, and screws. Make ! WARNING sure rivets holding components together are tight. Always fill the gas tank in a well-ventilated area. Never Replace all loose rivets.

  • Page 8: Periodic Maintenance/Tune-Up

    SPECIAL TOOLS Periodic Maintenance/ A number of special tools must be available to the techni- cian when performing service procedures in this section. Tune-Up Refer to the current Special Tools Catalog for the appropri- ate tool description. Description This section has been organized into sub-sections showing Compression Tester Kit 0444-213 common maintenance procedures.

  • Page 9: Lubrication Points

     NOTE: The engine must be cold for this procedure.  NOTE: On the Wildcat/X, the seats, left-side seat belt and anchor, left-side heat shroud and shield, cargo box, and rear body panel must be removed for this pro- cedure.

  • Page 10: Testing Engine Compression

    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 11: Spark Plugs

     NOTE: On the Wildcat/X, the seats and rear body panel must be removed and the radiator tilted rearward for this procedure.  NOTE: On the Wildcat 4/4X, the rear seats and rear body panel must be removed and the radiator tilted rear- ward for this procedure.

  • Page 12: Engine/Transmission Oil - Filter

    2. Remove the spark arrester screen; then using a suit- able brush, clean the carbon deposits from the screen taking care not to damage the screen. PR078A 4. Using the Oil Filter Wrench and a ratchet handle (or a socket or box-end wrench), remove the old oil filter. ...

  • Page 13: 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 14 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 15: 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 16 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 17: Burnishing Brake Pads

    WC611A PR242 B. Remove the caliper and pads from the vehicle. 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.

  • Page 18: Replacing V-Belt

    2. Accelerate to 30 mph; then depress the brake pedal to decelerate to 0-5 mph. 3. Repeat procedure 20 times until brake pads are burnished. Replacing V-Belt REMOVING 1. Raise the rear of the vehicle just enough to unload the rear suspension (weight off the shock absorbers).
  • Page 19 WC741A WC667 3. Place the alignment pins and new gasket on the clutch housing; then install the CVT cover/air filter bracket and secure with the cap screws. Tighten in a crisscross pat- tern to 8 ft-lb. 4. Connect the exhaust duct and tighten the boot clamp securely.

  • Page 20: Steering/Frame/Controls

    2. Remove two side fender screws (C), one on left and one on right located above and behind the headlight Steering/Frame/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 21: Electronic Power Steering (Eps)

    INSTALLING 1. Place the rear body panel onto the vehicle making sure the outer front mounting tabs are located behind the splash panel. WC346A WC342A 2. Secure with the machine screws and tighten securely. 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 22 WC241A WC246A 3. Unplug the two connectors from the EPS unit; then 6. Remove the mounting screw securing the brake line remove four cap screws and two lock nuts from the support bracket to the EPS mounting bracket. steering flex-shaft clamp bracket and clamp. 7.
  • Page 23 2. Mark the ends of the EPS input and output shafts to corre- spond 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. WC251A WC254A WC252A...

  • Page 24: Rack And Pinion Assembly

    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. WC247A 10. Connect the two electrical connectors and check EPS operation.

  • Page 25: Steering Wheel

    5. Install the front differential assembly (see Drive System). 6. Install the EPS assembly. 7. Install the hood and grille. Steering Wheel REMOVING 1. Remove the steering wheel cover; then match mark the steering shaft and steering wheel. WC279A 2. Secure the bracket to the frame with four cap screws and ...

  • Page 26: Steering Shaft

    Steering Shaft REMOVING 1. Remove the steering wheel. 2. Remove the hood and grille. 3. Remove the upper pivot bolt on the steering tilt link and drop the tilt link down clear of the dash. WC328A 6. Remove the steering shaft from the EPS by pulling straight away from the input shaft.
  • Page 27 INSPECTING 4. Install the upper steering housing collar onto the tilt housing and tighten the nuts to 20 ft-lb. 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.

  • Page 28: Steering Knuckles

    CLEANING AND INSPECTING 6. Install the upper steering flex-shaft hold-down strap and secure with the cap screw. Tighten to 50 in.-lb. 1. Clean all knuckle components. 2. Inspect the bearing for pits, scoring, rusting, or prema- ture wear. 3. Inspect the knuckle for cracks, breaks, or galling of the bearing surface.

  • Page 29: Checking/Adjusting Front Wheel Alignment

    Wildcat WC271 WC268A 4. Install the tie rod end and secure with the nut (coated X/Wildcat 4/4X with red Loctite #271). Tighten to 55 ft-lb; then install a new cotter pin and spread the pin.  NOTE: During assembling, new cotter pins should be installed.

  • Page 30: Accelerator Pedal

    Mark the center-line of the front tires at the front and rear of the tire; then using a tape measure, measure and record Accelerator Pedal the distance between the marks at the front and rear. The front measurement should be 6 mm (1/4 in.) greater than the rear measurement (toe-out).

  • Page 31: 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 32: Exhaust System

    2. Install the rear body panel. 1. Remove the four exhaust springs at the muffler/ exhaust pipe juncture. Seats REMOVING/INSTALLING (Wildcat/X) 1. To remove a seat, pull the seat lock lever up. Raise the rear of the seat and tilt it forward. WC153A 2.

  • Page 33: Doors

    4. To install a rear seat, place into position with the seat support engaging the floor bolts; then install the flange nuts and tighten securely. Doors CHECKING/ADJUSTING (Wildcat/X) WC133A The doors and latches are adjustable for proper latching/ CHECKING/ADJUSTING unlatching.

  • Page 34: Roof (X Limited)

    2. Loosen the screws on the latch plate to move the latch forward or backward. After adjustment, tighten securely. Roof (X Limited) REMOVING/INSTALLING 1. Turn the clamps away from the ROPS and remove the roof. WC556A WC803 WC799A CHECKING/ADJUSTING (X Limited) 1.

  • Page 35: 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 36: Engine/Transmission

    SPECIAL TOOLS Engine/Transmission 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. This section has been organized into sub-sections which show a progression for the complete servicing of the Arc- Description tic Cat Wildcat engine/transmission.

  • Page 37: 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 38 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 39: Removing Engine/Transmission (Wildcat/X)

    Removing Engine/ Transmission (Wildcat/X) 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 informa- tion. 1. Drive or lift the vehicle onto wheel ramps or other lift that WC186 supports vehicle by its wheels;...
  • Page 40 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 41 14. Loosen the inlet boot (A); then remove the crankcase breather hose (B) and the inlet air duct (C). WC204A WC146A 15. Remove the air filter housing strap; then free the air filter housing from the inlet boot and remove from the vehicle. WC206A 18.
  • Page 42  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 43: Removing Engine/Transmission (Wildcat 4/4X)

    Removing Engine/ Transmission (Wildcat 4/ 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. Remove the rear seats; then remove the battery cover WC172B and disconnect the negative battery cable.
  • Page 44 WC186 WC153A 6. Remove the cargo box; then disconnect the gasline 9. Remove the two cargo box supports; then remove the hose connector from the fuel pump and separate the heat shield leaving the rear coil attached to the radia- fuel pump/level sensor connector.
  • Page 45 WC201A WC192 14. Loosen the inlet boot (A); then remove the crankcase breather hose (B) and the inlet air duct (C). WC193 12. Remove the radiator mounting screws; then discon- nect the coolant hoses from the engine and remove the WC146A radiator from the vehicle being careful not to release 15.
  • Page 46 17. Remove the ECT connector (A), front coil primary con- 20. Remove the E-clip (A); then loosen the jam nut (B) nector (B), TPS connector (C), MAP/IAT connector (D), and slide the shift cable out of the mounting bracket and ISC connector (E); then tie the engine harness out of and off the shift arm (C).
  • Page 47 WC172A WC170 26. Remove the rear drive coupler boot; then lift the  NOTE: It may be necessary to use a hoist to slightly engine slightly and work the rear drive gear case and engine rearward enough to clear the front drive cou- raise the rear of the vehicle to free the link from the pler and drop the driveshaft down.

  • Page 48: Top-Side Components

    GZ026 WC174A  NOTE: Timing marks on the rotor/flywheel are stamped with an “F” (front cylinder) and “R” (rear cyl- Top-Side Components inder) adjacent to the mark.  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components.
  • Page 49 GZ126A GZ405 4. Remove all cap screws except the two top-side cap 7. Using an awl, rotate the C-ring in its groove until it is screws next to the spark plug. These will keep the out of the cylinder head; then remove the C-ring. alignment pins in place.
  • Page 50 CC266D GZ151  NOTE: Loop the chain over the cylinder head and secure it to keep it from falling into the crankcase. GZ161 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 compression stroke;...
  • Page 51 14. Remove the two nuts securing the cylinder to the crankcase. GZ144 AT THIS POINT  GZ141A 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. 16.
  • Page 52 CAUTION CAUTION Do not allow the connecting rod to go down inside the Water or parts-cleaning solvent must be used in con- crankcase. If the rod is down inside the crankcase and junction with the wet-or-dry sandpaper or damage to the crankshaft is rotated, severe damage will result.
  • Page 53 3. Rotate the valve in the V blocks. 4. Maximum runout must not exceed specifications. Measuring Valve Guide/Valve Stem Deflection (Wobble Method) 1. Mount a dial indicator and base on the surface plate; then place the cylinder head on the surface plate. 2.
  • Page 54 2. Acceptable outside diameter must be at or above specifications. Installing Valves 1. Apply grease to the inside surface of the valve seals; then place a lower spring seat and valve guide seal over each valve guide. CC400D Cleaning/Inspecting Piston 1.
  • Page 55 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 56 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 57 CC127D CC283D 5. Wash the cylinder in parts-cleaning solvent. 2. Rotate the camshaft and note runout; maximum run- out must not exceed specifications. 6. 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 58 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 59 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 60 GZ132B GZ130 9. Loosely install the five cylinder head nuts.  NOTE: At this point, oil the camshaft bearings, cam 10. In a crisscross pattern, tighten the four cylinder head lobes, and the three seating journals on the cylinder. cap screws (from step 8) initially to 20 ft-lb; then 13.
  • Page 61 GZ190B GZ195 A. Piston still at top-dead-center. 17. Keeping tension on the opposite cam chain, rotate the crankshaft until the second cap screw securing the B. Camshaft lobes directed down (toward the piston). sprocket to the camshaft can be installed; then install the cap screw (threads coated with red Loctite #271) C.
  • Page 62 Wildcat/ Wildcat 4 CORRECT GZ059 FW-014 20. With the alignment pin installed in the rear camshaft, X/4X loosely place the cam sprocket (with the recessed side facing the cam shaft lobes) onto the camshaft. At this point, do not “seat” the sprocket onto the shaft. CORRECT GZ519 INCORRECT...
  • Page 63 B. Camshaft lobes directed down (toward the piston). C. Camshaft alignment marks parallel to the valve cover mating surface. D. Recessed side of the sprocket directed toward the cam lobes. E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned. CAUTION If any of the above factors are not as stated go back to step 19 and carefully proceed.
  • Page 64 28. Install the cylinder head plugs in the cylinder heads 31. Using a flat-blade screwdriver, rotate the adjuster with the open end facing downward and toward the screw inside the tensioner counterclockwise until the inside. tensioner spring bears tension; then install the cap screw into the end of the chain tensioner.

  • Page 65: Left-Side Components

    GZ533 GZ208 34. Lubricate the camshaft journals and lobes with 39. Install the spark plugs and timing inspection plug; engine oil; then place the valve cover into position. then remove the cap screw from the crankshaft and install the crankcase end cap. ...
  • Page 66 GZ212A GZ216 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.
  • Page 67 GZ218 H2-019C 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 68: Servicing Left-Side Components

    GZ250 FI572 REPLACING STARTER CLUTCH ASSEMBLY Servicing Left-Side 1. Remove the cap screws securing the one-way clutch Components assembly to the flywheel; then remove from the fly- wheel. INSPECTING STARTER CLUTCH/ GEAR 1. Place the starter clutch gear onto the rotor/flywheel and attempt to rotate the starter clutch gear clockwise.
  • Page 69 REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR 1. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft position sen- sor, and two cap screws from the harness hold-down. 2. Lift the rubber grommet out of the housing; then remove the stator coil/crankshaft position sensor.

  • Page 70: Installing Left-Side Components

    Installing Left-Side Components 1. Thoroughly clean all gasket material and sealant from mating surfaces. 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.
  • Page 71 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 72: 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 73: Servicing Right-Side Components

    3. Remove the cap screw (left-hand threads) securing the drive clutch assembly; then using an appropriate clutch puller, remove the drive clutch. GZ500A 9. Using a suitable press, remove the seal and bearing simultaneously from the clutch cover. WC666A 4. Remove the drive belt. 5.
  • Page 74 GZ529 WC658 3. Remove the windage plate; then position the drive 2. Remove the cover, spring, and nylon shift stop. clutch over an appropriate clutch holder.  NOTE: The holder should either be secured in a vise or bolted to a sturdy work bench. WC657 FC083 4.
  • Page 75 MS405 WC651A Cleaning and Inspecting 6. Using a small torch, heat the threaded area of the spi- der. Place an appropriate spider removal tool over the  NOTE: If any components other than flyweights, pins, heated spider and break the spider loose by turning it spring, needle bearings, rollers, and thrust washers are clockwise (left-hand threads).
  • Page 76 1. Place the cam arms, thrust washers, and cam arm 5. Secure the cam arm pins with new lock nuts and pivot pins (pivot pin heads opposite direction of rota- tighten to 48 in.-lb. tion) into the moveable drive sheave and secure with 6.
  • Page 77 WC627 WC636 WC626 WC635 3. Remove the E-clips securing the cam rollers to the Assembling spider; then remove the thrust washer and roller. 1. Install the roller and thrust washer in place with the washer toward the outside of sheave. WC628 ...
  • Page 78 3. Place the sheaves together lining up the “X” marks. WC672 7. Place the spring and spider into the movable sheave WC811 making sure all marks are aligned. 4. Place the roller onto the spider (beveled side of roller facing in); then install the thrust washer and E-Ring. WC678 8.

  • Page 79: Installing Right-Side Components

    GZ442 GZ441 2. Remove the snap ring securing the bearing in the 2. Install the gear onto the driveshaft noting correct ori- water pump drive cover; then remove the bearing entation (from step 1 of disassembling). using an appropriate blind bearing remover. GZ442 3.
  • Page 80 GZ532A GZ501  NOTE: It is critical to verify the seal on the bearing faces the clutch cover seal before pressing in a new bearing. 3. Secure the bearing in the clutch cover using the exist- ing bearing retainers and machine screws (threads coated with blue Loctite #242).

  • Page 81: Center Crankcase 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. Separating Crankcase Halves 1. Remove the oil strainer cap; then remove the oil strainer.

  • Page 82: Disassembling Crankcase Half

    GZ448A GZ272B Disassembling Crankcase Half  NOTE: For steps 1-8, refer to illustration GZ474A. GZ269A  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).
  • Page 83 GZ299A DE677A 3. Remove the snap ring securing the water pump idler shaft (C) in the crankcase; then remove the shaft and bearings. GZ276 6. Remove two cap screws securing the oil pump in the crankcase and remove the oil pump. GZ463A 4.

  • Page 84: Servicing Center Crankcase Components

    8. Remove the reverse idler gear (I), shaft bushing, and two washers. MT011B 3. If installing the existing shaft, start with the shims removed during disassembly or if installing a new shaft, GZ279 start with approximately 1.0 mm shims at point (D); then install the output driveshaft bearing (E) making sure the ...
  • Page 85  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 86 GZ358 5. Inspect the oil pump driveshaft and drive pin for GZ393B excessive wear or grooving. Replace as required. OIL PUMP ASSEMBLY Disassembling and Inspecting 1. Remove the oil pump cover; then remove the gerotor set, shaft, and pin (see Disassembling Crankcase Half in this sub-section).

  • Page 87: Crankshaft Assembly

    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 88 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crank- CAUTION shaft. 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.
  • Page 89 GZ313A GZ318A 4. Remove the snap ring securing the reverse driven gear 6. Remove the low driven gear. Account for a bearing, and washer; then remove the washer and gear. bushing, and thrust washer. GZ314 GZ316 5. Remove the reverse driven washer; then remove the Assembling low driven gear locking washer.
  • Page 90 2. Install the low driven gear locking washer; then install the inner reverse driven gear washer. GZ288A GZ319B GZ314 5. Install the reverse driven gear dog onto the counter- shaft and secure with a snap ring. GZ320B 3. Install the reverse driven bushing and bearing; then install the reverse driven gear.

  • Page 91: Assembling Crankcase Half

    GZ283B GZ463A 7. Install the drive gear washer and the shift forks. The 4. Install the countershaft gear onto the countershaft and countershaft is now ready for installation. secure with a snap ring (flat-side away from the gear). Assembling Crankcase Half 1.

  • Page 92: Joining Crankcase Halves

    GZ332 GZ280B GZ333 GZ336 7. Install the gear shift shaft into the crankcase making sure 9. Engage the shift forks into the gear shift shaft and the flat washer is in place on the right case end and the push the shift fork shaft into the crankcase. spacer on the gear shift stop end.
  • Page 93 GZ340 GZ342 2. Coat both sides with engine oil; then install the spacer 5. Tighten the 6 mm cap screws to 8 ft-lb and the 8 mm washer on the crankshaft with the radius directed cap screws to 20 ft-lb using the pattern shown and toward the crankshaft.

  • Page 94: Installing Engine/Transmission (Wildcat/X)

    Components, and to Installing Top-Side Components. GZ452A H2-012A Installing Engine/ Transmission (Wildcat/X)  NOTE: Arctic Cat recommends new gaskets and O- rings be installed whenever servicing the vehicle. GZ451 9. Carefully place the lower crankcase cover onto the joined 1. Install the front exhaust pipe onto the engine with a new grafoil gasket but do not torque;...
  • Page 95 WC187A WC173A 8. Crimp the clamp onto the rear drive coupler boot. 3. Holding the engine rearward, lift the front drive shaft and loosely install at least one cap screw; then work the engine down into the mounting brackets. 4. Install the engine mounting through-bolts with flat washer, rear first;...
  • Page 96 10. Making sure the tab on the throttle body aligns and 12. Install the fuel rail with fuel injectors and secure with fully engages the alignment slot on the intake boot, the cap screws. Tighten to 6 ft-lb. install the throttle body and tighten the clamp nut to 13.

  • Page 97: Installing Engine/Transmission (Wildcat 4/4X)

    18. Connect the fan connectors, rear spark plug cap, and 24. Install the cargo box; then remove the cap from the gas fill rear coil primary connector. hose and place the rear body panel into position. Secure the gas tank fill hose to the filler neck and secure with the 19.
  • Page 98 WC169A WC172B 6. Install the lower front through-bolt and the rear lower 9. Connect the speed sensor (D), stator connector (E), cap screw securing the rear drive gear case; then with and the CKP sensor (F); then install the gear shift new lock nuts, tighten the through-bolts to 38 ft-lb, cable onto the shift arm (C) and secure with the E-clip and the cap screw to 20 ft-lb.
  • Page 99 13. Connect the gas line connectors to the fuel rails and the electrical connectors to the fuel injectors. WC164A WC203A 14. Place the inlet air duct into position; then install the CVT intake cooling duct and secure with the clamp. WC210A 11.
  • Page 100 19. Install the gas tank cradle and gas tank and secure with the hold down bracket; then connect the fuel hose and fuel pump/fuel level sensor connector. 20. Install the heat shield and secure with the appropriate fasteners; then install the cargo box supports and secure with the cap screws and new lock nuts.

  • Page 101: 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 102: Gas Tank

    WC215A WC206B 4. Remove the holding strap and move the radiator back INSTALLING 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 103: 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 104: Oil Cooler

    Oil Cooler REMOVING 1. Remove the hood. 2. Loosen the clamps securing the oil hoses to the oil cooler; then place an absorbent towel under the con- nection and remove the hoses. 3. Remove the cap screws from the oil cooler mountings and remove the oil cooler.

  • Page 105: 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 106: 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 107: 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 108 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 109: 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 110: Electrical System

    Loss of battery charge may be caused by ambient temper- ature, ignition OFF current draw, corroded terminals, self Electrical System discharge, frequent start/stops, and short engine run times. Frequent winch usage, snowplowing, extended low RPM operation, short trips, and high amperage accessory usage are also reasons for battery discharge.

  • Page 111: Rpm Limiter

     NOTE: The maintainer/charger will charge the bat- tery to 95% capacity at which time the Maintenance RPM Limiter Charge Indicator (D) will illuminate and the main- tainer/charger will change to pulse/float mainte- nance. If the battery falls below 12.9 DC volts, the ...

  • Page 112: Engine Coolant Temperature (Ect) Sensor

     NOTE: If the meter shows no battery voltage, trou- bleshoot the fuse, switch, or the main wiring harness. Fan Motor  NOTE: If the meter shows battery voltage, the main wiring harness is good; proceed to test the switch/ ...

  • Page 113: Ignition Coil

    RESISTANCE 2. Set the meter selector to the DC Voltage position. 3. Connect the black tester lead to ground. CAUTION 4. Using the red tester lead, contact each end of the fuse Always disconnect the battery when performing resis- holder connector terminals individually. tance tests to avoid damaging the multimeter.

  • Page 114: Speed Sensor

    3. Connect the black tester lead to the gray/white wire and 1. Disconnect the three-wire connector from the speed sensor the red tester lead to the green/black wire. The meter harness or from the speed sensor; then remove the Allen- should read 4.5-5.5 DC volts.
  • Page 115 Code Fault Description Fault Condition Possible Cause EPS Fault Recovery Method C1301 Over Current EPS internal over-current condition Internal EPS Condition Correct EPS condition* has been detected C1302 Excessive Current Error EPS internal current measurement Internal EPS Condition Correct EPS condition* error has been detected C1303 Torque Sensor Range EPS internal torque sensor range...

  • Page 116: Ignition Switch

    The following tests may aid in troubleshooting when the ignition switch is ON and no EPS assistance is present: Headlight Switch  NOTE: The EPS assembly is not serviceable and must not be disassembled or EPS warranty will be voided. Make sure to thoroughly troubleshoot the entire system VOLTAGE before replacing the EPS assembly.

  • Page 117: Reverse Override Switch

    VOLTAGE  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. 1. Connect the black tester lead to the black wire; then turn the ignition switch to the ON position.

  • Page 118: Starter Motor

    VOLTAGE (AC Generator - Regulated 2. Connect the red tester lead to the brown/white wire; then connect the black tester lead to the green/white Output) wire. The meter reading must be within specification. 1. Set the meter selector to the DC Voltage position. AC VOLTAGE 2.

  • Page 119: Starter Relay

     NOTE: If the starter engages and more than one volt is indicated by the multimeter, replace the starter relay. If no “click” is heard and the multimeter contin- ues to indicate battery voltage, proceed to step 4. 4. Disconnect the two-wire plug from the starter relay; then connect the red tester lead to the green wire and the black tester lead to the black wire.

  • Page 120: Headlights

    2. Connect the red tester lead to the positive battery post 1. Set the meter selector to the DC Voltage position. and the black tester lead to the negative battery post. 2. Connect the red tester lead to the red/blue wire; then 3.

  • Page 121: Throttle Position Sensor (Tps)

    CD706C WC159A 2. Turn the ignition switch to the ON position. The mul- timeter should read battery voltage. If battery voltage Throttle Position Sensor is not indicated, check the 30-amp fuse, wiring har- (TPS) ness, or the ignition switch. 3. Remove the red tester lead and connect to the blue/ brown wire (B).

  • Page 122: Efi Diagnostic System

    FI672 EFI033A 3. Using a multimeter, connect the black tester lead to NOTE: The display on the gauge will display in the center socket (GND) on the analyzer and the red SAE (speedometer in MPH mode) or Metric (speed- tester lead to the white socket (VAR); then select the DC Voltage position.
  • Page 123 Fuel Sensor (FUEL) Diagnostic Mode EFI032 EFI031 *Fan Schedule: Left fan ON @ 185° F, OFF @ 175° F; Right fan ON @ Display: Fuel level signal from the fuel level sensor 195° F, OFF @ 185° F. (measured in ohms). *High Temperature REV Limiter 5000 RPM @ 230°...
  • Page 124 Speed (SPd) Diagnostic Mode Display: MAP in millibars (1013 millibars = 29.92 in. mercury). DTC: P0107, P0108 Usage: Verify barometric pressure signal correct. Note: Local barometric pressure is given in in./Hg (Inches of Mercury). 34 millibars are equal to 1 inch of mercury.

  • Page 125: Diagnostic Trouble Codes List

    Code List 1. Battery voltage with engine and accessories off (>12.2 VDC for fully charged). NOTE: Each of the following numerical codes will 2. Battery voltage with engine running (charging = 13.8 have a one-letter prefix of C, P, or U. A “C” prefix VDC or greater).
  • Page 126 Code Fault Description Possible Cause Fault Recovery P0485 Fan Relay Control Circuit Low/SG/Open Fan fuse has blown, fan relay removed, or interconnect harness Correct condition* shorted to chassis ground P0500 Vehicle Speed-Sensor Sensor circuit signal intermittent or missing Correct condition*, start and drive the vehicle* P0508 Idle Air Control System Circuit Low/SG...

  • Page 127: 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 128: 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 hous- ing; then use the following torque values. Size New Housing Reassembled Housing M6 (Torx T-30 Recess) 9 ft-lb 8 ft-lb PR189A...

  • Page 129: Front Differential

    Front Differential REMOVING 1. Remove the forward belly panel (Wildcat/X) or seats and center console (Wildcat 4/4X); 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 130 5. Holding the upper A-arm/ball joint down into the knuckle, remove and discard the retaining cap screw. PR729C 8. On the Wildcat/X from underneath the vehicle, remove the carrier bearing support bracket; then remove the bolts and nuts securing the carrier bearing to the bracket and remove the bracket.
  • Page 131 WC275A 11. From under the vehicle (Wildcat/X) or inside the vehi- GC015 cle (Wildcat 4/4X), slide the driveshaft to the rear suf- ficiently to allow differential to move to the rear 6-8 inches.
  • Page 132 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 133 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. screws. Tighten to 23 ft-lb. 3. Using a plastic mallet, tap lightly to remove the differ- ...
  • Page 134 KX177 WC430 2. Using the Pinion Gear/Shaft Removal Tool and a ham- mer, remove the pinion gear from the gear case hous- ing. 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 135 CC882 WC429 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) 1402-074 0.051 CC883 1402-075 0.055 2. Place the pinion assembly in a bearing puller; then install the bearing using a press. 1402-076 0.059 1402-077...
  • Page 136 2. Install the ring gear with shim in the gear case; then while holding the pinion stationary, rock the ring gear forward and back to determine if any backlash exists. If no backlash exists, install a thicker shim and recheck. GC036B 5.
  • Page 137 Assembling Differential Assembly 1. With the pinion gear and new bearings installed, place the selected (backlash) shim on the gear case side of the ring gear with the chamfered side toward the ring gear; then install into gear case/differential housing. GC037A Ring Gear End-Play After correcting backlash, ring gear end-play can be...
  • Page 138 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 liberal coat of grease 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 139 Tighten to 38 ft-lb. 2. Using Gear Case Seal Installer Tool, evenly press the seal into the cover bore until properly seated. WC276A 4. On the Wildcat/X, secure the carrier bearing to the CF278 carrier bearing support bracket with two bolts and CAUTION nuts.
  • Page 140 WC266A PR729C 5. On the Wildcat/X, secure the carrier bearing support 9. Install the axles into the knuckles; then swing the bracket to the frame with four cap screws and tighten knuckles vertical and engage the ball joint shanks into to 20 ft-lb.

  • Page 141: Driveshaft (Wildcat 4/4X)

    Driveshaft (Wildcat 4/4X) REMOVING/DISASSEMBLING 1. Remove the front and rear seats. WC303A 12. Install the brake calipers 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 142  NOTE: Inspect the rubber coupler for deteoriating rubber or augured holes. WC713 8. Remove the screws and nuts from the rear bearing assembly. Accounting for an O-ring on the splined end of the shaft. WC703 5. Loosen the set screws on the front and rear bearing 9.
  • Page 143 WC710 WC697A 12. 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 O- Allen-head screws, connect the front and rear cou- ring on the splined end of the shaft. plers.

  • Page 144: Drive Axles

    Wildcat WC722A PR243A 9. Install the front seats. X/Wildcat 4/4X Drive Axles REMOVING REAR DRIVE AXLE 1. Secure the vehicle on a support stand to elevate the wheel; then remove the wheel and account for the hub plate. WC606 4. Remove the hub assembly. 5.
  • Page 145 WC282B CD019 2. Inspect boots for any tears, cracks, or deterioration.  NOTE: If a boot is damaged in any way, it must be replaced with a boot kit. DISASSEMBLING AXLES  NOTE: Only the boots are serviceable on the axles; if any other component is worn or damaged, the axle must be replaced.
  • Page 146 CF334 PR729C  NOTE: Steps 1-3 can be used to replace the out-  NOTE: To ensure proper axle seating, give it a light board boot. pull; the axle should remain “clipped” in place. ASSEMBLING AXLES 2. Swing the knuckles to the rear and fit the bearing over the ends of the axles.

  • Page 147: Rear Gear Case

    WC303A WC281 6. Install the brake calipers and secure with new “patch- 7. Install the wheel and tighten in a crisscross pattern in lock” cap screws. Tighten to 20 ft-lb. 20 ft-lb increments to 80 ft-lb. 7. Install the hub plate making sure it fits completely 8.
  • Page 148 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 149 WC169A WC743 9. Lay the gear case on its left side and remove from either side of the vehicle. Account for the spring and washer with the drive coupler. WC170C 8. Remove the lower front through-bolt; then remove the boot clamp on the input drive coupler and slide the gear case to the rear until drive coupler disengages.
  • Page 150 GZ392 GC057A 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 0.002- 0.004 in. GZ176A GC058A 3. If clearance is as specified, remove the ring gear and thrust button;...
  • Page 151  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 bear- ing).
  • Page 152 GZ176 WC295A 5. Using a new gasket, install the assembled rear drive 5. Install the lower lateral links and secure with the bolts input shaft/housing onto the rear drive gear case and and new lock nuts. Do not tighten at this time. secure with the three cap screws.

  • Page 153: Hub

    WC169A WC303A 8. Apply molybdenum grease to the splines of the axle 12. Install the brake calipers and secure with new “patch- couplers and install the axles into the gear case; then lock” cap screws. Tighten to 20 ft-lb. swing the knuckles to the rear and fit the bearing over 13.
  • Page 154 WC240B PR254A 2. Remove the Belleville washer and hub nut securing  NOTE: It may be necessary to heat the cap screws the hub. to loosen the Loctite. CLEANING AND INSPECTING 1. Clean all hub components. 2. Inspect all threads for stripping or damage. 3.

  • Page 155: Hydraulic Brake Caliper (Wildcat)

    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 156 3. Remove the brake hose from the caliper and close the bleed screw; then remove the caliper. 4. Compress the caliper holder against the caliper (oppo- site the O-ring side) and remove the outer brake pad; then remove the inner brake pad. PR713A PR237A ...
  • Page 157 PR719C PR715 4. Install the caliper onto the caliper holder making sure the caliper and holder are correctly oriented.  NOTE: It is very important to apply silicone grease to the O-rings and caliper bores prior to assembly. PR717A 2. Press the piston into the caliper housing using hand pressure only.

  • Page 158: Hydraulic Brake Caliper (X/Wildcat 4/4X)

     NOTE: Whenever brake components are removed, disassembled, or repaired where brake fluid is exposed to air, drain all fluid and replace with new DOT 4 brake fluid from an unopened container. Brake fluid readily absorbs moisture from the air signifi- cantly lowering the boiling point.
  • Page 159 ASSEMBLING/INSTALLING (Rear  NOTE: The O-ring is used for shipping purposes Brake) and provides no function in operation. 1. Install new seals into the brake caliper housing and apply 5. Remove the brake pads from the caliper. a liberal amount of DOT 4 brake fluid to the cylinder bore of the housing, seals, and brake piston.
  • Page 160 PR712 3. Apply high-temperature silicone grease (supplied with the PR238 O-ring kit) to the inside of the caliper holder bores and O- rings; then install the four O-rings into the caliper. PR239 6. Place the brake caliper assembly into position and secure PR719C with new “patch-lock”...

  • Page 161: Master Cylinder Assembly

    WC725A WC611A 2. Install the pistons into the caliper seating them com- pletely into the piston bore. WC609 6. Fill the reservoir; then bleed the brake system (see Peri- odic Maintenance/Tune-Up.) WC692 3. Using silicon grease, lubricate the O-rings and install into 7.

  • Page 162: Master Cylinder Assembly

    3. Remove the oil bolt securing the banjo-fittings to the master cylinder; then remove the master cylinder. Dis- card the three crush washers. CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the vehicle. Inspecting 1.

  • Page 163: 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 164: 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. WC618A E.
  • Page 165 FX181 FX178  NOTE: Throughout all procedures as a general rule, replace all volatile parts (seals, O-rings, bearings, etc.). Disassembling Shock Absorber 1. Remove the nylon ball from the reservoir cap with a pick. Slowly loosen the pellet retainer from the reservoir cap allowing nitrogen to escape from the reservoir before removing the retainer.
  • Page 166 FX174 FX170 FX173 FX169 5. Remove the retaining ring using a valve shim. Insert 7. Remove the screw and O-ring from the IFP. Remove the Piston Location (IFP) Tool and twist to lock it onto the IFP using the tool. the IFP.
  • Page 167 FX166 FX162 3. Inspect and clean the LSC/DSC blowout control with RESERVOIR - LCS REPLACEMENT the air nozzle and replace its O-rings. 1. Remove the reservoir with a spanner or strap wrench. Remove the LSC adjuster knob with a #10 torx-head bit.
  • Page 168 Disassembling Shaft Assembly 1. With the eyelet secured in vise, remove the lock nut from the end of the shaft with a 3/4” wrench. Remove the rebound valves. FX158 5. Use a small pick to remove Loctite residue from the threads on reusable components.
  • Page 169 FX149 FX145 5. Remove the spiral retaining rings with a small pick and press out the bearing. FX148 4. Remove the bearing and bearing assembly. FX144 FX147 FX143 6. Clamp the shaft with the Shaft Clamps. Apply heat to the eyelet and remove. FX146 ...
  • Page 170 Assembling 1. Apply green Loctite #638 to threads two threads up. Tighten the eyelet to 50 ft-lb. FX141 7. Clean any Loctite residue off the shaft and out of the eyelet. FX137 FX140 FX136 2. Insert the spiral retaining ring. Press the bearing into the eyelet.
  • Page 171 FX133 FX129 FX132 FX128 4. Clamp the eyelet; then install the Shaft Bullet Tool 6. Install the bearing cap assembly. Replace the U-cup and bumper. Remove the bearing cap seal with a small and the O-rings seal from the bearing assembly. pick.
  • Page 172 FX125 FX119 FX124 FX118 7. After lubricating the internal bore of the bearing 9. When using a bleeding shim, it should be kept in time assembly, install it on the shaft. Clean the compres- with the compression port. Install the piston compres- sion valve shims and install them.
  • Page 173 FX115 FX111 FX114 FX110 3. Tighten the LSC to 14 ft-lb or the DSC to 35 ft-lb. Assembling Shock Absorber 1. Apply green Loctite #638 to body threads two threads up, 360° around. Install a new O-ring body cap. FX109 FX113 FX108 4.
  • Page 174 FX107 FX103 FX1106 FX102 5. Install a new O-ring. Tighten the reservoir body to 30 7. Lubricate the IFP assembly with an appropriate grease ft-lb. and install the IFP. FX105 FX101 FX104 FX100 6. Replace the piston O-ring and bearing. Fill the reser- 8.
  • Page 175 FX099 FX095 FX098 FX094 9. Depress the IFP into the reservoir until it touches bot- 11. Work the shaft assembly up and down holding pres- tom. sure against the IFP. Insert the bearing assembly par- tially into the body; then rap the eyelet with a rubber mallet several times to eliminate air trapped in the pis- ton assembly.
  • Page 176 12. Quickly pass the torch over the assembly to raise and 14. Push down on the IFP to seat the bearing assembly. eliminate air bubbles. Slowly insert the bearing Remove the IFP screw. assembly into the body allowing air to escape. ...
  • Page 177 FX079 FX083 FX080 FX082 19. Insert the reservoir cap assembly and install the retain- 17. Replace the O-ring and pellet. ing wire. FX081 FX077 FX080 FX076 18. Install the pellet retainer and lubricate with an appro- 20. Charge the reservoir to designated pressure and priate grease.

  • Page 178: Shock Absorbers (Limited)

    FX071 FX075 23. Reset the spring preload. FX074 21. Inspect the bearing assembly and reservoir cap for FX070 leaks prior to installing the nylon ball and bearing cap. Shock Absorbers (Limited) REMOVING 1. Secure the vehicle to a support stand to elevate the wheels and release the load on the suspension.
  • Page 179 Rear Rear WC789C WC789B 3. Remove the spring retainer and spring support plates.  NOTE: Only the external parts are serviceable. If the shock absorber is damaged, it must be replaced. 1. Loosen, but do not remove, the lock ring screw. Front Front WC781A...

  • Page 180: Front A-Arms

    5. Remove the top spring. 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 181  NOTE: The upper A-arms can be removed without X/Wildcat 4/4X removing the hub or knuckle. If the technician’s objective is to remove the upper A-arms, proceed to step 6. WC606 Wildcat WC240B 2. Remove the hub nut and Belleville washer securing the hub.
  • Page 182 CLEANING AND INSPECTING 1. Clean all A-arm components in parts-cleaning solvent. 2. Clean the ball joint mounting hole of all residual Loc- tite, grease, oil, or dirt for installing purposes. 3. Inspect the A-arm for bends, cracks, and worn bush- ings.

  • Page 183: Rear Trailing Arms

    2. Remove the hub cap and lug nuts securing the wheel; then remove the hub plate. WC606 WC317 3. Place a jack stand or other support under the trailing arm; then remove the cap screw securing the lower shock eyelet to the arm. Account for a flat washer. X/Wildcat 4/4X WC611A 11.
  • Page 184 WC311 WC807A 2. Slide the trailing arm into the knuckle and secure with 7. Using a tarp strap or nylon straps, support the suspen- the nut. Tighten the nut to 60 ft-lb; then install a new sion/axle assembly and remove the support from roll-pin.

  • Page 185: Wheels And Tires

    CAUTION Do not mix tire tread patterns. Use the same pattern type on front and rear. Failure to heed warning could cause poor handling qualities of the vehicle and could cause excessive drive train damage not covered by warranty. WC303A 7.

  • Page 186: Troubleshooting

    Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring preload incorrect 1. Adjust preload 2. Spring(s) weak 2. Replace spring(s) 3. Shock absorber damaged 3. Replace shock absorber Problem: Suspension too stiff Condition Remedy 1. Spring preload incorrect 1. Adjust preload 2.
  • Page 187 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-865...

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