Arctic Cat Wildcar Trail Service Manual
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Arctic Cat Wildcar Trail Service Manual

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2014
SERVICE MANUAL
[ROV]

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Do you have a question about the Wildcar Trail and is the answer not in the manual?

Questions and answers

Leo brunette
May 5, 2025

My side x side doesn’t want to shift at all. When I parked it the last time I drove it it was fine

0
1 comments:
Mr. Anderson
May 18, 2025

Improper shifting in an Arctic Cat Wildcat Trail side by side could be caused by:

1. Attempting to change drive positions while the vehicle is moving or on uneven terrain.
2. Not pressing the brake when shifting drive positions.
3. Accelerating while in park, which can damage the drive belt.
4. Worn or damaged components such as shift forks, shift shaft rail, shift drum cam, or gears with nicks, cracks, or wear.
5. Overheated or worn brake components affecting vehicle control.

Proper shifting requires the vehicle to be stationary, on level ground, and the brake applied.

This answer is automatically generated

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Summary of Contents for Arctic Cat Wildcar Trail

  • Page 1 2014 SERVICE MANUAL [ROV]...
  • Page 2 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to fol- low the directive because it deals with the possibility of serious personal injury or even death.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General Information ..............2 Gas/Vent Hoses............... 80 Oil Filter/Oil Pump..............80 General Specifications............... 2 Oil Cooler................. 80 Torque Specifications..............3 Oil Flow Chart ................81 Torque Conversions (ft-lb/N-m)..........4 Liquid Cooling System ............. 82 Drive Belt Break-In Procedure ........... 4 Radiator ...................

  • Page 4: General Information

    Connecting Rod (small end bore) (max) 18.044 mm Gasoline (recommended) 87 Octane Regular Unleaded Crankshaft Runout (max) 0.03 mm Engine Oil (recommended) Arctic Cat ACX All Weather Specifications subject to change without notice. Synthetic Front Differential Lubricant SAE Approved 80W-90 Hyp- Transaxle Lubricant...

  • Page 5: Torque Specifications

    DRIVE TRAIN COMPONENTS Torque Torque Specifications Part Part Bolted To ft-lb N-m Engine/Transaxle Mounting Transaxle Bracket***** Front Differential Differential Bracket Carrier Bearing Bearing Bracket Torque (ft-lb) Tolerance Carrier Bearing Bracket Frame 0-15 ±20% Carrier Bearing Set Screw** Front Shaft 16-39 ±15% Pinion Housing Differential Housing...

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

    RECOMMENDED ENGINE OIL Torque Conversions The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil, which has been specifically (ft-lb/N-m) formulated for use in this Arctic Cat engine. Although Arctic Cat ACX All Weather synthetic engine oil is the only oil recommended for use in this engine, use of any API certified SM 0W-40 oil is acceptable.

  • Page 7: Genuine Parts

    Start the engine and allow it to CAUTION idle. Using Arctic Cat Engine Storage Preserver, rap- The ignition switch must be in the OFF position prior to idly inject the preserver into the air filter opening for a installing the battery or damage may occur to the igni- period of 10 to 20 seconds;...

  • Page 8: Periodic Maintenance/Tune-Up

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

  • Page 9: Lubrication Points

     NOTE: Foam Filter Cleaner and Foam Filter Oil are available from Arctic Cat. Lubrication Points 4. Dry both filter components. 5. Put the foam filter in a plastic bag; then pour in air fil- It is advisable to lubricate certain components periodically ter oil and work the filter.

  • Page 10: Spark Plugs

    WT021 ATV-0051 1. Remove the spark plug wires from the spark plugs. CAUTION 2. Using compressed air, blow any debris from around Before removing a spark plug, be sure to clean the area the spark plugs. around the spark plug. Dirt could enter engine when removing or installing the spark plug.

  • Page 11: Engine Oil - Filter

     NOTE: If the screen or gasket is damaged in any 4. Using the Oil Filter Wrench and a ratchet handle (or a socket or box-end wrench), remove the old oil filter. way, it must be replaced.  NOTE: Clean up any excess oil after removing the filter. 2.

  • Page 12: Nuts/Bolts/Cap Screws

     NOTE: Removing the front fender will aid in replac- ing the headlight assembly. 2. Remove the headlight adjustment cap screw. WT025A 2. If low, add Arctic Cat Transaxle Fluid as necessary. Tighten the fill/level plug to 16 ft-lb. To change the lubricant, use the following procedure. WT065A 1.
  • Page 13 WT263 WT262 6. Release the spring clip securing the headlight bulb; 3. Starting with the interior mounting stud, install the then remove the bulb. headlight assembly into position. WT264 WT269A INSTALLING HEADLIGHT ASSEMBLY  NOTE: Applying lubricant to the studs will aid in assembly.
  • Page 14 1. Remove the fasteners securing the facia to the storage box. WT260 2. Connect the wiring harness and secure the facia using WT101A the existing fasteners. Tighten securely. 2. Disconnect the wiring harness. 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.

  • Page 15: Hydraulic Brake System

    WT065A WT045A  NOTE: During the bleeding procedure, watch the reservoir very closely to make sure there is always a Hydraulic Brake System sufficient amount of brake fluid. If the fluid level gets low in the reservoir, refill the reservoir before the bleeding procedure is continued.

  • Page 16: Burnishing Brake Pads

    3. If thickness of either brake pad is less than 1.0 mm (0.039 in.), the brake pads must be replaced. Burnishing Brake Pads  NOTE: The brake pads should be replaced as a set. 4. To replace the brake pads, use the following procedure. Brake pads must be burnished to achieve full braking effective- A.
  • Page 17 WT200A WT183A 2. Using an appropriate strap or oil filter wrench (3 5/8”) 5. Remove the stationary sheave and V-belt and any belt to hold the driven clutch and ensuring the splines of the threads or debris in the clutch housing or sheaves. sheave and input shaft are engaged, secure the clutch with the cap screw and washer.

  • Page 18: Steering/Frame/Controls

    Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Steering wheel secure. B. Steering has equal and complete full-left and full- right capability. C. Steering sector mounting bolts tight. D. Ball joints not worn, cracked, or damaged. WT454 4.

  • Page 19: Hood And Grille

    WT548A WT251 2. Install the lower bumper cap screws (C); then tighten REMOVING GRILLE the upper and lower bumper cap screws to 20 ft-lb. Remove the fasteners securing the grille; then remove the 3. Install the cap screws and nuts securing the radiator to grille.
  • Page 20 WT241A WT209A ! WARNING The heat deflector under the right-rear fender has sharp edges and can cause serious injury if care is not taken. 3. Remove the cap screws securing the taillight/brake- light assembly to the frame and disconnect the har- ness.
  • Page 21 INSTALLING REAR BODY PANELS 1. If removed, install the clutch air intake tube through the left rear body opening and secure it with the plate and existing cap screws. Tighten securely. WT028A 8. Loosen the clamp securing the clutch air intake tube to engine;...
  • Page 22 7. Install the tabs of the body panel into the slots in side panel; then insert the plastic insert into the gas tank filler hose. Tighten the clamp and install the gas cap. WT485 4. Secure the panel to the frame and pre-filter cover with the existing cap screws and push pins.
  • Page 23 WT209A WT212 2. Secure the side panel using the existing cap screws REMOVING SIDE PANELS and push pins. Tighten all hardware to 60 in.-lb. To remove a side panel, remove the cap screws and push pins securing the side panel to the frame; then remove the panel.

  • Page 24: Center Console

    WT014A WT341 5. Disconnect the LCD gauge, ignition switch, and 12- 2. Connect the 12-volt accessory plug, ignition switch, volt accessory plug. and LCD gauge. 3. With the steering shaft slid through the dash, install the dash and secure it with the existing fasteners. 4.

  • Page 25: Rack And Pinion Assembly

    2. Loosen the jam nut below the shifter knob; then unscrew the shifter knob. WT281B 3. Install the shifter knob so the “P” is facing forward; then tighten the jam nut to 12 ft-lb. WT274A 3. Remove the fasteners securing the center console; 4.
  • Page 26 5. Support the steering rack assembly in a suitable bench  NOTE: The steering assembly (rack and pinion) is vise; then remove the clamp (A) and cut the cable tie not repairable and must be replaced as an assembly; (B). Slide the boot to the center of the tie rod. however, the tie rods and boots are replaceable.

  • Page 27: Steering Wheel

    WT298A WT569  NOTE: Any time steering components are disas- 4. Center the tie rods in the steering rack assembly and align the white paint line on the pinion with the white sembled, all connecting components should be paint line on the rack housing. marked for proper alignment during assembling.

  • Page 28: Steering Shaft

    Steering Shaft REMOVING 1. Remove the steering wheel and hood; then remove the dash. 2. Remove and discard the cap screws and lock nuts securing the steering tilt assembly to the frame. WT594 7. Slide the tilt assembly out of the steering shaft. WT346 3.

  • Page 29: Steering Knuckles

    3. Install the tilt assembly onto the steering shaft and 4. Remove the hub assembly. secure it with new cap screws and lock nuts. Tighten 5. Remove the cotter pin from the tie rod end and to 20 ft-lb. remove the tie rod end from the knuckle. 6.
  • Page 30 2. Inspect the bearing for pits, scoring, rusting, or premature wear. 3. Inspect the knuckle for cracks, breaks, or galling of the bearing surface. ASSEMBLING AND INSTALLING 1. Using a suitable press and driver, press the bearing into the knuckle until firmly seated; then install the snap ring.

  • Page 31: Checking/Adjusting Front Wheel Alignment

    WT287A WT292A 9. Install the wheel; then using a crisscross pattern, To adjust the wheel alignment, use the following procedure: tighten the wheel nuts in 20 ft-lb increments to a final 1. Center the steering rack; then using an open-end torque factor of 40 ft-lb (steel wheel) or 80 ft-lb (alu- wrench to hold the tie rod (B), loosen the right-side minium wheel).

  • Page 32: Shift Lever

    WT099B WT099C 3. To adjust the throttle cable, locate the in-line cable adjuster beneath the clutch cover; then slide the pro- tective sleeve upward from the adjuster. WT288A INSTALLING Align the mounting holes with the holes in the splash panel WT081A and secure with the two torx-head screws and new lock nuts;...

  • Page 33: Shift Cable

    WT281B WT439B 2. Remove the cap screw from the shift cable pivot bolt 3. While holding the nut (B), loosen the jam nut (A) and (A), remove the axle bolt (B), and account for plastic remove the shift cable from the transaxle. inserts (C).

  • Page 34: Lcd Gauge

    WT276A WT276A 3. Once the proper adjustment is achieved, tighten the INSTALLING jam nut to 20 ft-lb. 1. Install the new shift cable in place noting the routing from removing. Secure to the transaxle with the E-clip and jam nut. Finger-tighten the jam nut at this point. 2.

  • Page 35: Exhaust System

    INSPECTING MUFFLER 1. Inspect muffler externally for cracks, holes, and dents. 2. Inspect the muffler internally by shaking the muffler back and forth and listening for rattles or loose debris inside the muffler.  NOTE: For additional details on cleaning the muffler/ spark arrester, see Periodic Maintenance/Tune-Up.

  • Page 36: Seats

    WT234A WT229 5. Remove the fasteners securing the upper rear body 3. Secure the cargo box with self tapping screws and panel to the cargo box. tighten to 5 ft-lb. 4. Install the LED taillight assembly. 5. Install the rear fenders; then install the seats making sure they lock securely in place.

  • Page 37: Floor

    Floor REMOVING 1. Remove the seats, engine access panel, and center console. 2. Remove the fasteners securing the floor to the frame. WT110A 2. Close the door to ensure it latches securely. If not, loosen the fasteners and adjust the latch up or down until the door latches securely.

  • Page 38: 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 39: Engine

    V Blocks 0644-535 Clutch Alignment Bar 0544-027  NOTE: Arctic Cat recommends the use of new gas- Clutch Puller 0744-080 kets, lock nuts, and seals and lubricating all internal  NOTE: Special tools are available from the Arctic components when servicing the engine.

  • Page 40: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Gasoline bad - contaminated 1. Drain gas - replace with clean gas 2. Valve clearance out of adjustment 2. Adjust clearance 3. Valve guides worn 3.
  • Page 41 Problem: Engine idles poorly Condition Remedy 1. Gasoline bad - contaminated 1. Drain gas - replace with clean gas 2. Valve clearance incorrect 2. Adjust clearance 3. Valve seating poor 3. Replace valves/cylinder head 4. Valve guides defective 4. Replace cylinder head 5.

  • Page 42: Removing Engine

    Removing Engine Many service procedures can be performed without removing the engine from the frame. Closely observe the note introducing each sub-section for this important infor- mation.  NOTE: To remove the engine, the taillight assembly, left side panel, and left rear body panel must be removed (see Steering/Frame/Controls).
  • Page 43 WT186A WT405A 5. Remove and retain the cap screws securing the inner clutch cover ; then with the air outlet duct connected to the inner clutch cover, remove the cover as an assem- bly. Account for the rubber O-rings on both sides of the cover.
  • Page 44 WT313A WT400  NOTE: Plug the holes with paper towels to keep contaminates from falling inside. 11. Remove the ISC connector (A), MAP/IAT connector (B), and the TPS connector (C); then loosen the clamp securing the throttle body to the intake manifold. Leave it connected to the throttle cable and set the throttle body off to the side.
  • Page 45  NOTE: After removing the cap screws, install them in their original position in the engine. Tighten securely. 16. Remove the spark plug caps (A). Disconnect the cam position sensor (B), coil connectors (C), and oxygen (O2) sensor (D). WT403A 14.
  • Page 46 19. Remove the coolant hose connecting the water pump 22. Loosen the jam nut (A); then loosen the adjuster nut to the cylinder. (B) but do not remove it from plate. WT412A WT410A 23. Remove the cap screws securing the transaxle to the engine plate;...

  • Page 47: Top-Side Components

    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  To service any one specific component, only limited dis- ROV1-116A assembly of components may be necessary.
  • Page 48 KC520 KC549A 7. Lift on the chain and remove both camshafts and  NOTE: Take care not to drop the fasteners down into sprockets; then using a suitable holder, hook the engine. chain and let it hang over the side of the head. 6.
  • Page 49 12. Remove the cylinder head making sure not to let the chain fall down into engine. Account for two dowel pins. ROV1-015A CAUTION Do not use an impact tool to remove the head bolts or ROV1-040A damage to the cam shaft journals could occur. 13.

  • Page 50: Servicing Top-Side Components

    4. To select the correct replacement shim for an out-of- specification clearance, note the three-digit number on the surface of the existing shim; then refer to the appropriate Tappet Shim Selection Table (Exhaust or Intake) on the following pages and use this procedure: A.
  • Page 51 TAPPET CLEARANCE TABLE - INTAKE KCINTAKE...
  • Page 52 TAPPET CLEARANCE TABLE - EXHAUST KCEXHAUST...
  • Page 53 Removing Valves  NOTE: Index all valves, springs, and cotters to their original position when removing. When installing, all valve components should be installed in their origi- nal position. 1. Using a valve spring compressor, compress the valve springs and remove the valve cotters. Account for an upper spring retainer.
  • Page 54 ATV-1070 CC400D 2. Insert an inside dial indicator into the piston pin bore. Inspecting Piston The diameter must not exceed 18.018 mm. Take two measurements to ensure accuracy. 1. Inspect the piston for cracks in the piston pin, dome, and skirt areas. 2.
  • Page 55 CYLINDER/CYLINDER HEAD ASSEMBLY  NOTE: If the cylinder/cylinder head cannot be trued, they must be replaced as an assembly. 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 combustion WT589...
  • Page 56 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Cor- rect any high spots before assembly by continuing to move the cylinder in a figure eight motion until a uni- form bright metallic finish is attained.
  • Page 57  NOTE: If the journals are worn, replace the camshaft. Installing Top-Side Components  NOTE: Arctic Cat recommends new gaskets be WT131 8. Install the chain guide so it is seated at the top and used when assembling the engine.
  • Page 58 WT134 WT471A 11. Install the cap screws (threads coated with oil) with the 14. Install the two outside fasteners and tighten to 7 ft-lb. two longer bolts going in the dowel pin locations. WT143A WT142A 15. Making sure the chain stays on the crankshaft 12.
  • Page 59 WT156A WT147 20. Install the fasteners and in the order shown, tighten to 17. Install the intake cam shaft; then install the chain 7 ft-lb. around the sprocket so the intake timing mark is par- allel with the head surface. WT156 21.
  • Page 60 23. Install the rubber gasket onto the head cover and install onto the head. WT166A 27. Install the thermostat housing. WT162A  NOTE: Applying a small bead of silicone between the head cover and rubber gasket will aid in assembling. 24.

  • Page 61: Bottom-Side Components

    WT170A ROV1-048 3. Remove the chain by pulling it down through the crankcase and out the PTO side. Bottom-Side 4. Remove the fastener securing the chain guide to the Components crankcase.  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 62 ROV1-108A KC543 10. Remove the starter idler gear and shaft.  NOTE: Account for the different-lengthed fasteners for assembling purposes.  NOTE: If the technician’s objective is to service or replace the flywheel or starter gear, proceed to the step 7; if not, continue to disassemble the bottom side components without removing the flywheel or starter gear.
  • Page 63 ROV1-064 ROV1-070A 13. Remove the fasteners connecting the top case half to the bottom case half. ROV1-068 17. Remove the oil passage tube and oil level stick. ROV1-077A  NOTE; The fastener just above the oil filter is longer than the others. 14.
  • Page 64 19. Pull the case halves apart and note the six plain bear- ings in each case half.  NOTE: Using a rubber mallet will aid in separating the case halves. ROV1-084  NOTE: Note the color coding on the bearings for assembling purposes.

  • Page 65: Servicing Bottom-Side Components

    ROV1-111 FI572 26. Remove the mechanical seal from the cover and the INSPECTING STATOR COIL/ ceramic mating seal from the impeller. MAGNETO COVER ASSEMBLY 1. Inspect the stator coil for burned or discolored wiring, Servicing Bottom-Side broken or missing hold-down clips, or loose cap screws.
  • Page 66 ZJ058A KC527A 2. Rotate the crankshaft slowly. Crankshaft Connecting Rod Bearing Inserts Color Mark Mark Choice 3. The reading must be 0.002 in. or crankshaft repair- Black ing/replacing will be necessary. Green Green Main Bearings Check the main bearings for signs of pitting, scratches, The crank cases go with a grade mark.

  • Page 67: Installing Bottom-Side Components

    ROV1-085 KC531A  NOTE: It is critical to ensure the lines between the Balancer Shaft Bearing Inserts Color Crankcase Mark Mark Choice two connecting rod halves match in a straight line. Yellow 3. In the top crankcase, apply a suitable assembly lubri- Green cant to the six plain bearing tops and bottoms;...
  • Page 68 ROV1-090A ROV1-091A 6. Install the bottom end of the crankcase and install the exist-  NOTE: Rotating the crankshaft will aid in lining up ing eleven cap screws and washers. Tighten to 21 ft-lb. the fasteners. 9. Install the oil crossover tube. Tighten to 13.5 ft-lb. ROV1-078A ...
  • Page 69 ROV1-096 ROV1-069 11. Install the oil screen pickup grommet with the flat side of 14. With the O-rings and dowel pins in the proper loca- the rubber facing up; then install the oil screen so the high tions, install and secure the oil pump with the appropri- side faces the oil filter to make it level with the oil pan ate fasteners.

  • Page 70: Servicing Left-Side Components

    15. Install the starter idler gear and pin with the smaller gear facing outward. KC545 19. Using a gasket scraper, clean off the existing gasket and case from the MAG cover. Using a new gasket ROV1-065A and dowel pins, install the cover making sure the cool- 16.
  • Page 71  NOTE: To remove left-side components, see Engine - Removing Engine. DRIVE CLUTCH Disassembling  NOTE: Note the timing marks (X) on the cover, spider, and movable sheave. These must be aligned when assembling the drive clutch for balance purposes. 1.
  • Page 72 WT521 WT191 2. In the stationary sheave using a suitable tool, remove  NOTE: Grasp the moveable sheave and lift it the E-clips securing the rollers. upward; then release it. It must move freely and not bind at any point. 2.
  • Page 73 WT189 WT527 4. Remove the spring retaining plate cup and spring. 3. Secure the spring retaining plate with the existing cap screws and tighten it to 11 ft-lb. WT523 WT189 Assembling 4. Put shims in the movable sheave with the thicker shim towards the movable sheave.

  • Page 74: Installing Engine

    3. Repeat steps 1 and 2 as required until correct align- ment is achieved.  NOTE: To install left-side components, see Engine – Installing Engine. Installing Engine  NOTE: The driveshaft must be secured to the trans- axle before the engine is installed. 1.
  • Page 75 WT407 WT475 7. Align the rear driveshaft with the output shaft of the trans- CAUTION axle so they are joined together. Push the front axles rear- ward until the front differential mounting holes are Care should be taken to install the tool over the output properly aligned.
  • Page 76 12. Remove the three cap screws from the PTO side of the engine and install the clips securing the starter cable and the gasline hose. Tighten the cap screws to 9 ft-lb. Install the starter cable on the starter and tighten securely.
  • Page 77 WT403A WT404A 15. Install the muffler and account for the gasket. Secure 18. Secure the gasline hose to the fuel rail. using the two exhaust springs. WT402 19. Connect the air filter housing to the throttle body and WT295 16. Install the throttle body into the intake manifold and secure it with the worm clamp.
  • Page 78 21. Install the engine breather tube and secure it with the 23. Install the rear splash panels and secure them with the clamp. cap screws. Install the push pins securing the wiring harness to the left-side splash panel. WT405A WT364A 24.

  • Page 79: Fuel/Lubrication/Cooling

    Fuel/Lubrication/Cooling ! 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. ! WARNING Whenever any maintenance or inspection is performed WT314A on the fuel system during which there may be fuel leak- ...
  • Page 80 WT315A WT566A 7. Remove the air filter housing. 12. Connect the ISC connector (A), MAP/IAT connector (B), and the TPS connector (C). 8. Remove the ISC connector (A), MAP/IAT connector (B), and TPS connector (C); then disconnect the throt- tle cable (D). WT397A 13.

  • Page 81: Gas Tank

    6. Remove the four cap screws securing the seat base to the frame. WT314A 17. Install the cargo box and rear body panels.  NOTE: If the throttle body, ECM, TPS, or ISC are WT359A replaced, the EFI system must be synchronized. Use 7.

  • Page 82: Gas/Vent Hoses

    5. Place the battery into position and connect the battery  NOTE: If oil pressure is lower than specified, check cables (negative cable first). Tighten the cables securely. for an oil leak, clogged oil filter, or defective oil pump. 6. Install the floor and battery access panel. ...

  • Page 83: Oil Flow Chart

    2. Wash the cooling fins using a garden hose and hot, soapy water and a soft brush. 3. Inspect all mounting brackets and the oil inlet and out- let for cracks or bends. INSTALLING 1. Place the oil cooler into position and secure with the existing hardware.

  • Page 84: Liquid Cooling System

    Liquid Cooling System When filling the cooling system, use premixed Arctic Cat Antifreeze. While the cooling system is being filled, air pockets may develop; therefore, open the bleed screw on the thermostat housing to allow air to bleed from the cooling system.
  • Page 85 WT456A WT461 7. Using a suitable prying tool, pry the clips out from 10. Disconnect the radiator fan and remove the radiator/ between the wiring harness and the frame; then push oil cooler from the vehicle. Drain the remaining cool- the clips downward to remove them from the frame.

  • Page 86: Thermostat

    WT459A WT535 4. Install the lower bumper cap screws and tighten the 3. Remove the hose from the bottom of the thermostat upper and lower bumper cap screws to 20 ft-lb. housing and push out of the way. WT547 WT460A 4.

  • Page 87: Fan

    3. Inspect all coolant hoses, connections, and clamps for 1. Using appropriate clamps, close-off the coolant hose deterioration, cracks, and wear. before and after the water pump.  NOTE: All coolant hoses and clamps should be replaced every four years or 4000 miles. INSTALLING 1.
  • Page 88 WT571 WT576A 6. Using an appropriate press, remove the two bearings. CAUTION Only apply pressure to the center race of the seal while installing to avoid damaging the seal. 2. Using a section of 1” pipe, press in the mechanical seal.

  • Page 89: Fuel Pump/Fuel Level Sensor

     NOTE: The two longer cap screws go in the dowel 3. Turn the ignition switch to the ON position. The fuel pressure should build until the pump shuts off. Pres- pin locations. sure should read 3.0 kg-cm (43 psi). 7.

  • Page 90: Troubleshooting

    FULL WT550B WT552A 2. Secure the pump assembly with the mounting screws and tighten securely in a crisscross pattern. EMPTY WT551B  NOTE: If readings are erratic, clean the resistor wiper and resistor with clean alcohol and retest. If WT552B 3.

  • Page 91: Electrical System

    EFI diagnostic system and digi- tal gauge (see EFI Diagnostic System in this section  NOTE: Arctic Cat recommends the use of the CTEK for more information). Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging.

  • Page 92: Accessory Receptacle/Connector

    Charging The switch connectors are spade-type connectors on the  NOTE: Arctic Cat recommends the use of the CTEK side of the master cylinder. Multi US 800 or the CTEK Multi US 3300 for battery  NOTE: The ignition switch must be in the ON position.

  • Page 93: Engine Coolant Temperature (Ect) Sensor

    1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to one terminal; then con- nect the black tester lead to the other terminal. 3. When the pedal is depressed, the meter must show less than 1 ohm.

  • Page 94: Ignition Coils

    1. Disconnect the coil connector. Connect the red tester lead to one coil terminal; then connect the black tester lead to the other coil terminal. 2. Resistance must be less than 1 ohm.  NOTE: If the meter does not show as specified, replace ignition coil.
  • Page 95 2. Connect the red tester lead to the brown wire; then 1. Remove the cargo box. connect the black tester lead to the white wire. The 2. Disconnect the sensor. meter reading must be 100-150 ohms. 3. Set the meter selector to the AC Voltage position. ...

  • Page 96: Speed Sensor

    3. Meter must show battery voltage. Speed Sensor  NOTE: If the meter shows no battery voltage, trou- bleshoot the main 30 amp fuse, the battery, or the main wiring harness.  NOTE: Preliminary checks may be performed on this 4.

  • Page 97: Reverse Override Switch

    Front Drive Actuator  NOTE: With the engine stopped and the ignition switch in the ON position, a momentary “whirring” sound must be noticeable each time the drive select switch is moved to 2WD and 4WD. Test the switch, 30 amp fuse, and wir- ing connections prior to testing the actuator.

  • Page 98: Starter Motor

    VOLTAGE 1. Set the meter selector to the DC Voltage position. Perform this test on the starter motor positive terminal. To 2. Connect the red tester lead to the positive battery post; access the terminal, slide the boot away. then connect the black tester lead to the negative bat- tery post.

  • Page 99: Engine Control Module (Ecm)

     NOTE: Make sure the ignition switch is in the ON posi- tion and the transmission is in park. Regulator/Rectifier  NOTE: Verify there are no loose or corroded connec- tions on the battery and/or starter relay. The regulator/rectifier is secured to the coolant overflow 3.

  • Page 100: Tilt Sensor

    1. Set the meter selector to the DC Voltage position. 2. Select DC Voltage on the multimeter. 2. Connect the red tester lead to the red/blue wire; then 3. Connect the red tester lead to the blue/brown wire and connect the black tester lead to the black wire. the black tester lead to the pink/black wire;...

  • Page 101: Efi Diagnostic System

     NOTE: If the vehicle is in warranty, removing or adjusting the TPS will void warranty. If the TPS is tested out of specification, the throttle body must be replaced. If the vehicle is out of warranty, the TPS can be adjusted.
  • Page 102 Coolant (COOLANT) MAP (AIR PRESS) WT591 WT602 Display: Engine coolant temperature as measured by the Display: MAP in millibars and in./Hg. ECT sensor. DTC: P0107, P0108 DTC: P0116, P0117, P0118, P0119 Usage: Verify barometric pressure signal correct. Usage: Monitor coolant temperature to verify the follow- ing.
  • Page 103 Fuel Sensor (FUEL) Speedometer (SPEED) WT545 WT543 Display: Fuel level signal from the fuel level sensor. Display: Vehicle speed signal. DTC: C1400, C1401, C1402 DTC: P0500 Usage: Check output of the fuel level sensor.* Usage: Verify speedometer sensor signal from the fol- 1.
  • Page 104 Code Fault Description Possible Cause Fault Recovery P0117 ECT Sensor Circuit Low/SG Sensor or interconnect harness shorted to chassis ground Correct condition* P0118 ECT Sensor Circuit High/Open/SP Sensor or interconnect harness open or shorted to battery power Correct condition* P0119 ECT Sensor Circuit Intermittent Sensor or interconnect harness intermittent Correct condition* P0121 TPS Range/Performance...

  • Page 105: Rpm Limiter

    RPM Limiter  NOTE: This vehicle is equipped with an ECM that interrupts the ignition when maximum RPM is approached (see table). When the RPM limiter is acti- vated, it could be misinterpreted as a high-speed mis- fire. Park/ Incorrect High/ Fail-Safe ECU/...

  • Page 106: 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 107: Drive And Brake Systems

    Drive and Brake Systems The following drive system components should be inspected periodically to ensure proper operation. A. Spline lateral movement (slop). B. Coupling cracked, damaged, or worn. C.Carrier bearing smooth rotation and bearing support tight. WT504A GENERAL INFORMATION 2. Remove the floor; then using a T-30 torx wrench, The die-cast aluminum housings have been assembled remove the mounting cap screw from the driveshaft with thread-rolling screws (trilobular).

  • Page 108: Front Differential

    WT531A WT532A INSTALLING  NOTE: It is important to tighten this cap screw while 1. Lubricate the O-rings on the actuator; then ensure all the others are loose to ensure proper seating of the mounting surfaces are clean and free of debris. actuator.
  • Page 109 WT500A WT498A 9. Remove and discard the upper ball joint cap screw and  NOTE: After all lubricant is drained, install the drain rotate the knuckle downward and away from the drive plug and tighten to 45 in.-lb. axle. 4. Remove the steering wheel and dash; then remove the steering post (see Steering/Frame/Controls).
  • Page 110 12. Cut the cable tie securing the actuator plug to the frame; then disconnect the actuator. WT502 16. Remove the differential from the vehicle from the left side. WT504A Disassembling Input Shaft  NOTE: Note the position of the cable ties for assem- 1.
  • Page 111 CD106 GC011 3. Remove the snap rings from the input shaft; then remove the input shaft from the pinion housing. AF984 GC009A 4. Using a seal removal tool, remove the input shaft seal. Account for a spacer. KX219 Assembling Input Shaft 1.
  • Page 112 GC011 KX209 2. Install the input shaft seal making sure it is fully seated in the edge of the housing. GC004A Disassembling Differential Assembly GC014  NOTE: This procedure can be performed on a rear 3. Lubricate the input shaft with High-Performance #2 gear case.
  • Page 113 KX174 KX178 6. Place the differential with the open side down; then  NOTE: If the cover is difficult to remove, pry on the lift the housing off the spider assembly. Account for cover in more than one recessed location. shim(s) and mark as right-side.
  • Page 114 WC430 CC882 2. Using the Pinion Gear/Shaft Removal Tool and a ham- mer, remove the pinion gear from the gear case hous- ing. CC883 2. Place the pinion assembly in a bearing puller; then install the bearing using a press. CC878 3.
  • Page 115 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. WC429 Shimming Procedure/Shim Selection Case-Side Shims (Backlash)
  • Page 116 GC036B GC037A 5. Place the Backlash Measuring Tool into the splines of Ring Gear End-Play the ring gear and install a dial indicator making sure it contacts the gauge at a 90° angle and on the index After correcting backlash, ring gear end-play can be mark.
  • Page 117 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. CF266A GC031A CF267A...
  • Page 118 CC892 CD110 7. Install the shift fork assembly making sure the fork leg Removing/Installing Axle Seal is facing upward. Apply a small amount of oil to the gasket; then install the gasket.  NOTE: This procedure can be performed on a rear gear case.
  • Page 119 INSTALLING 1. From the right side of vehicle, place the differential into the vehicle (actuator side down); then maneuver it into the mounting brackets. WT503A 6. Install the rack and pinion assembly. Using new lock nuts, secure it to the frame and tighten to 25 ft-lb. WT501 2.
  • Page 120 WT333 WT328A  NOTE: During assembly, new cotter pins should always be used.  NOTE: If the cotter pin cannot be inserted due to misalignment of the hole and the slots in the nut, always tighten the nut until it is properly aligned. 13.

  • Page 121: Drive Axles

    WT041A WT328A 16. Install the plugs (with O-rings); then tighten the fill 5. Remove and discard the upper ball joint cap screw and plug to 16 ft-lb and the level plug to 45 in.-lb. rotate the knuckle downward away from the drive axle.
  • Page 122 1. Using a clean towel, wipe away any oil or grease from the axle components. CF334  NOTE: Steps 1-3 can be used to replace the out- board boot. CD019 2. Inspect boots for any tears, cracks, or deterioration. ASSEMBLING AXLES ...

  • Page 123: Transaxle

    5. Set the parking brake; then turn the ignition switch to the ON position, select LOCK on the drive select switch. Turn the ignition switch to the OFF position. 6. Tighten the axle nut (from step 3) to 200 ft-lb; then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut.
  • Page 124 TA113 TA110 Front Output Seal  NOTE: The transaxle must be removed for this pro- cedure. 1. Using an awl and a mallet, pry the seal from the case taking care not to damage the seal bore. TA115 Input (Driven Clutch) Seal ...
  • Page 125 2. Remove the hood, wheels, seats, center console, floor, and driveshaft. 3. Remove the E-clip connecting the shift cable to the transaxle. Remove the shift cable bracket; then dis- connect the speed sensor and the gear position switch. TA130 Pinion Plug ...
  • Page 126 TA004 TA027 4. Remove the clip securing the gear position switch.  NOTE: Tip the transaxle towards the drain to get Gently pry the switch off the shift rail and account for any remaining fluid. the wave washer.  NOTE: Install the drain plug and tighten to 18 ft-lb. 5.
  • Page 127 TA059 TA028A 6. Place the transaxle upright on the bench and dump any 3. Remove the output gear assembly with bearings. remaining fluid into the pan. AT THIS POINT  If the pinion shaft and gear are not being serviced or replaced, no further disassembling is required.

  • Page 128: Servicing Components

    TA127 TA009 SERVICING COMPONENTS CAUTION  NOTE: If any bearing is removed, install a new bear- There is a ball bearing below the pinion seal. Use cau- ing using a suitable press. tion not to damage the bearing while removing the seal. ...
  • Page 129 TA036 TA034 3. Inspect the shaft gear teeth for nicks, cracks, chips, or 3. Inspect the shaft gear teeth for nicks, cracks, chips, or signs of wear. If any are present, the shaft must be signs of wear. If any are present, the shaft must be replaced.
  • Page 130 7. While holding pressure on the washer, rotate the cam counterclockwise to lock the cam onto the shift drum. TA039 4. Check the detent star (A) and shift drum gear (B) for nicks, cracks, chips, or signs of wear. If any are pres- TA040 ent, the detent star must be replaced.
  • Page 131 TA049 TA053 4. Inspect the dogs for nicks, cracks, chips, or signs of wear. If any are present, the dog must be replaced. TA050 TA054 H. Input Shaft 1. Inspect the bearings for free and smooth turning. If either bearing does not turn freely, it must be replaced. TA051 3.
  • Page 132 2. Inspect the sprocket teeth for nicks, cracks, chips, or 2. Remove the small inner snap ring and account for the signs of wear. If any are present, the sprocket must be shim. replaced. TA082A 3. With the aid of an assistant and using an appropriate TA043 3.
  • Page 133 BACKLASH AT THIS POINT  If the pinion shaft or gear were replaced or serviced, backlash must be checked. If not, proceed to ASSEM- BLING HALVES. 1. Install the pinion shaft into the case. With the appro- priate shim in place, secure with the snap ring. TA081 6.
  • Page 134 6. Acceptable backlash range is 0.076-0.241 mm (0.003- 0.0095 in.).  NOTE: If backlash measurement is within the acceptable range, no correction is necessary. 7. If backlash measurement is less than specified, remove the existing shim and install a new thicker shim (from shim kit).
  • Page 135 TA130 TA059 ASSEMBLING HALVES  NOTE: Make sure the shift fork pins face the installer. 1. Install the intermediate shaft and idler shaft into the  NOTE: Engage all four shafts before seating them case only partially. Do not seat the shafts completely simultaneously into the case.
  • Page 136  NOTE: Rotate the shift drum and the shift shaft to ensure the timing marks are correctly aligned. 9. Install the star detent over the shift drum aligning the appropriate splines of the detent with the shaft splines and the dot facing up. TA064 6.
  • Page 137 (approximately 1.0-1.5 mm deep). TA012C CORRECT TA135A 17. Add the appropriate amount of Arctic Cat Synthetic Transaxle Fluid to the transaxle; then install the fill plug and tighten to 18 ft-lb. INSTALLING 1. Using new lock nuts, secure the bracket to the rear of the transaxle.

  • Page 138: Driveshaft/Carrier Bearing

    WT430 WT323A 3. Install the shift cable bracket and tighten to 7 ft-lb. 4. Rotate the steering rack all the way to the right; then remove the upper cap screw securing the upper A-arm 4. Connect the shift cable to the transaxle and secure with the to the frame and remove it from the mounting brack- E-clip.
  • Page 139 WT421A WT426 7. Remove the front boot clamp securing the driveshaft 9. Remove the clamp behind the carrier bearing and slide the to the transaxle. rear driveshaft rearward. Remove the rear driveshaft. WT424A WT421B 10. Remove the front boot clamp securing the front differ- ...
  • Page 140 WT431A WT438 12. Remove the snap ring. 1. Slide the carrier bearing onto the shaft with the set screws facing down towards the longer end of the driveshaft making sure it is past the snap ring groove. Do not tighten the set screws at this time. WT434 13.

  • Page 141: Hub

    WT422A WT425 5. Apply molybdenum grease to the splines on both ends of 9. With the steering rack turned all the way to the right, the rear driveshaft and insert the rear driveshaft into the install the front left upper A-arm cap screw, washer, mating end of front driveshaft.
  • Page 142 4. Inspect the hub for pits, cracks, loose studs, or spline wear. REPLACING WHEEL STUDS 1. Secure the hub in a suitable holding fixture and remove the brake disc (if applicable). 2. Drive the damaged stud out of the hub; then place the new stud into the hub and thread on an appropriate flange nut.

  • Page 143: Hydraulic Brake Caliper

    8. Remove the vehicle from the support stand. Hydraulic Brake Caliper ! WARNING Arctic Cat recommends only authorized Arctic Cat Wild- WT325A cat dealers perform hydraulic brake service. Failure to 5. Install the hub assembly onto the axle. Install the properly repair brake systems can result in loss of con- brake caliper and secure with new “patch-lock”...
  • Page 144 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 145 PR715 PR719C 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 146: Master Cylinder Assembly

    WT514A PR239 6. Place the brake caliper assembly into position and secure with new “patch-lock” cap screws. Tighten the caliper to 20 ft-lb. 7. Place a new crush washer on each side of the brake hose fitting and install it on the caliper. Tighten to 20 ft-lb. 8.
  • Page 147 INSPECTING 2. Install the pivot pin and secure with a new cotter pin; then connect the switch. 1. Inspect the master cylinder push rod and clevis for wear, bending, or elongation of clevis holes. 3. Using four new crush washers installed on both sides of the banjo fitting, secure the banjo bolts into the 2.

  • Page 148: Troubleshooting

    Troubleshooting 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. Gear teeth broken 1. Replace gear(s) 2.

  • Page 149: Suspension

    INSTALLING Suspension 1. Place the shock absorber spring over the shock absorber, compress the spring, and install the retainer. 2. Place bushings and sleeves (where appropriate) into shock eyelet; then install shocks with two cap screws The following suspension system components should be and nuts.
  • Page 150 FX068 WT590A 1. Loosen the spring preload adjuster rings with spanner 4. If measurement is not as specified, use an appropriate wrenches. spanner wrench to adjust the left and right spring as required. FX067 2. Remove the spring retainer and spring. WT078B REBUILDING Inspection...
  • Page 151 FX064 FX061 4. Secure the shock eyelet in the vise and insert the nitro- gen needle. Fully depress the needle to release nitro- gen pressure from the shock. After installing the appropriate body cap removal tool, insert the retaining wire into the groove between the cap and body. FX060 6.
  • Page 152 FX057 FX053 FX056 FX052 8. Apply sufficient heat to the body cap to break down 10. Remove the lock nut. the thread lock bond between the body cap and body. Remove any thread lock residue from the body and body cap using a wire brush and small pick. FX049 11.
  • Page 153 FX047 FX042 12. Remove the piston assembly; then remove the com- pression valve stack and cable tie it together. 13. Remove the rubber washer, bearing assembly, bearing cap, bumper, and washer. FX041 15. Using a small pick, remove all seals and O-rings from the bearing cap and bearing assembly.
  • Page 154 ASSEMBLING 1. Apply Loctite Primer #7649 to the shaft. Allow proper curing time before applying green Loctite #638 to the shaft. FX035 FX038 FX034 4. Replace the wiper seal in the bearing cap. FX037 2. Tighten to 50 ft-lb. FX033 5.
  • Page 155 FX031 FX027 6. Using Shaft Bullet Tool, install the bearing cap assem- 8. Replace the O-ring and bearing on the piston. Install bly and bearing assembly. the piston making sure the compression side of piston is next to the compression shims. FX030 FX026 FX029...
  • Page 156 FX023 FX019 10. Replace the O-ring on the IFP. Apply a thin layer of  NOTE: When setting IFP depth, note the shock molybdenum grease to the body before installing the absorber IFP shuttles 0.480” during installation. IFP into the body with the IFP relief contour facing towards the top of the body.
  • Page 157 FX018 FX012 14. Verify the IFP depth is correct. Fill the body with 16. Push the bearing assembly just past the retainer specified oil 3/8” from top of body. Pass a propane groove in the body; then install the wire retainer. torch quickly over the body to eliminate any air bub- bles in oil.
  • Page 158 FX007 FX005 FX008 FX004 20. Install the body cap and eyelet bushings. 18. Secure the body with body clamps and ensure the shaft has room to fully extend when charged. Charge with nitrogen using Inflation Needle to the specified pressure for about 10 seconds; the shaft should fully extend.

  • Page 159: Front A-Arms

    FX001 WT330A 6. Remove and discard the cap screws securing the ball joints to the knuckle. Front A-Arms REMOVING UPPER 1. Lift and support the vehicle with a support stand to allow access to the front suspension. 2. Remove the front wheels. 3.
  • Page 160 WT334 WT600 10. Remove the snap ring securing the ball joint in the A- REMOVING LOWER arm. Remove ball joint.  NOTE: Having the steering rack turned completely to the left and the clamp orientated as shown will aid in removing the cap screw. WT496 ...
  • Page 161 INSTALLING 1. Using a suitable press, press in the new bushing. WT492A WT599 2. Place the A-arm in a bench vise and using a 16 mm reamer, ream out the bushings. WT493A 4. Remove the seals and sleeve and inspect for cracks, nicks, or tears.
  • Page 162 WT497 WT332 5. Install the lower A-arm into the frame mounts and 11. Install the tie rod end and secure it with the castle nut secure it with the cap screw and new lock nut. Finger- (coated with red Loctite #271). Tighten to 55 ft-lb; tighten only at this time.

  • Page 163: Rear A Arms

    WT498A WT418A 14. Tighten the cap screw securing the upper A-arm to the 3. Remove and discard the cotter pin from the hub nut; frame to 35 ft-lb. then remove nut and hub. 15. Using new “patch-lock” cap screws, secure the brake caliper to the brake disc.
  • Page 164 6. Remove the cap screw securing the lower A-arm to the hub. Discard the nut. WT444  NOTE: Only remove the bushings if they must be serviced. W446A  NOTE: The drive axle does not have to be removed 10. Place the A-arm in a bench vise and using an appro- for this procedure.
  • Page 165 2. Place the A-arm in a bench vise and using a 16 mm 6. Using the existing cap screws and new lock nuts, reamer, ream out the bushings. secure the knuckle to the upper and lower A-arms. Tighten to 35 ft-lb. ...

  • Page 166: Front Sway Bar

    11. Using new “patch-lock” cap screws, install the brake 2. Tighten the A-arm links to 20 ft-lb; then tighten the caliper and tighten to 20 ft-lb. sway bar link to 35 ft-lb. 12. Install the wheel and tighten the lug nuts to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels).

  • Page 167: Wheels And Tires

    ! WARNING 3. Inspect each wheel for cracks, dents, or bends. Use only Arctic Cat approved tires when replacing tires. 4. Inspect each tire for cuts, wear, missing lugs, and leaks. Failure to do so could result in unstable vehicle operation.
  • Page 168 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-145...

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