Arctic Cat 2013 Wildcat Service Manual Download Page 99 | Manualshive

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GZ226

12. Place the key into the keyway in the crankshaft; then

wipe all oil from the crankshaft surface and rotor/fly-

wheel bore and install the rotor/flywheel onto the

crankshaft aligning the keyway with the key. Secure

with the nut (coated with red Loctite #271) tightened

to 105 ft-lb.

GZ225

13. Install the starter driven and counter gear shafts (D)

into the crankcase (longer shaft to the front); then

install the starter countershaft gear (C), starter driven

gear (A), and bushing (B) making sure the chamfered

gear teeth on the countershaft gear are directed out-

ward.

GZ224A

14. Install the starter motor with a new O-ring lightly

lubricated with grease; then tighten the mounting cap

screws to 8 ft-lb.

GZ251

15. Using Seal Protector Tool, install the outer magneto

cover using a new gasket and secure with the cap

screws. Using the pattern shown, tighten to 112 in.-lb.

GZ212B

Right-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.



NOTE: The engine/transmission does not have to

be removed from the frame for this procedure.

Removing Right-Side

Components

A. CVT Cover
B. Drive Clutch
C. Driven Clutch
D. Inner Clutch Cover

1. Remove the cap screws securing the CVT cover; then using

a rubber mallet, gently tap on the cover tabs to loosen the

cover. Account for a gasket and two alignment pins.

CAUTION

Make sure the one-way starter clutch is properly
engaged with the starter ring gear before installing and
tightening the rotor/flywheel nut or damage to the
clutch assembly could occur.



AT THIS POINT

To service any one specific component, only limited dis-
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.

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Summary of Contents for 2013 Wildcat

Page 1: ......

Page 2: ...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 A CAUTION identi fies unsafe practices which may result in vehicle related damage Follow the directive because it deals with the possibility of damaging part or parts of the ve...

Page 3: ......

Page 4: ...ry 129 RPM Limiter 130 Testing Electrical Components 130 Accessory Receptacle Connector 130 Brakelight Switch 130 Engine Coolant Temperature ECT Sensor 131 Fan Motor 131 Power Distribution Module PDM 131 Ignition Coil 132 Manifold Absolute Pressure Inlet Air Temperature MAP IAT Sensor 132 Speed Sensor 133 Electronic Power Steering EPS 133 Ignition Switch 134 Headlight Switch 135 Drive Select Switc...

Page 5: ... 250 ohms brown white to green white Less than 1 ohm brown white to green white Crankshaft Position Sensor AC Voltage 2 0 or more brown white to green white AC Generator Output no load 75 AC volts 5000 RPM black to black Ignition Timing 10 BTDC 1500 RPM VALVES AND GUIDES Valve Face Diameter intake exhaust 31 6 mm 27 9 mm Valve Tappet Clearance intake cold engine max exhaust 0 1016 mm 0 1524 mm Val...

Page 6: ...Bearing Support Bracket Frame 20 27 Input Shaft Assembly Gear Case Housing 23 31 DRIVE TRAIN COMPONENTS cont Part Part Bolted To Torque ft lb N m Secondary Drive Gear Nut Secondary Drive Gear 4 6 Pinion Housing Differential Housing 23 31 Thrust Button Gear Case Cover 8 11 Differential Housing Cover Differential Housing 23 31 Lock Collar Differential Housing 125 170 Hub Axle min 250 340 Oil Drain P...

Page 7: ...lt life Gasoline Oil Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 Wildcat or 91 Wildcat X minimum octane regular unleaded In many areas oxygenates are added to the gasoline Oxygenated gasolines containing up to 10 ethanol or 5 methane are acceptable gasolines When using ethanol blended gasoline it is not necessary to add a gasoline antifreeze since ethanol will prevent the ...

Page 8: ...haust system with a clean cloth 5 Apply light oil to the plungers of the shock absorbers 6 Tighten all nuts bolts cap screws and screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts cap screws and bolts are tightened to specifications 7 Fill the cooling system to the bottom of the stand pipe in the radiator neck with pro...

Page 9: ...necessary 8 Tighten all nuts bolts cap screws and screws making sure all calibrated nuts cap screws and bolts are tight ened to specifications 9 Check tire pressure Inflate to recommended pressure as necessary 10 Make sure the steering moves freely and does not bind 11 Check the spark plugs Clean or replace as necessary CAUTION The ignition switch must be in the OFF position prior to installing th...

Page 10: ... Timing Light 0644 296 Valve Clearance Adjuster 0444 255 Item Initial Service After Break In First Month or 100 Miles Daily Monthly 100 Miles Every 3 Months 300 Miles Every 6 Months 500 Miles Annually 1500 Miles As Needed Battery I I C Fuses I R Air Filter I I R Valve Tappet Clearance I I A Engine Compression I Spark Plugs I I I R 4000 Mi or 18 Mo Muffler Spark Arrester C R Gas Hoses I I R 2 Yrs T...

Page 11: ...filter element Do not twist foam to remove oil 6 Attach the foam filter to the inner filter screen WC140 7 Clean any dirt or debris from inside the air cleaner Be sure no dirt enters the throttle body 8 Place the foam filter onto the filter frame then install in the air filter housing Position the filter frame on top 9 Install the air filter housing cover and secure with the retaining clips CHECKI...

Page 12: ...he valve adjuster dial D While holding the valve adjuster handle in place rotate the valve adjuster dial counterclockwise until proper valve tappet clearance is attained NOTE Refer to the appropriate specifications in Feeler Gauge Procedure sub section for the proper valve tappet clearance NOTE Rotating the valve adjuster dial counter clockwise will open the valve tappet clearance by 0 05 mm 0 002...

Page 13: ...rings see Engine Transmission Spark Plugs A light brown insulator indicates the plug is correct A white or dark insulator indicates that the engine may need to be serviced To maintain a hot strong spark keep the plug free of carbon ATV 0051 Adjust the gap to 0 5 0 6 mm 0 019 0 024 in ATV0052E When installing a spark plug be sure to tighten it securely A new spark plug should be tightened 1 2 turn ...

Page 14: ...ew oil filter Tighten securely 6 Install the engine drain plug and tighten to 16 ft lb Pour the specified amount of the recommended oil in the filler hole Install the oil level stick filler plug 7 Start the engine while the vehicle is outside on level ground and allow it to idle for a few minutes 8 Turn the engine off and wait approximately one min ute 9 Unscrew the oil level stick and wipe it wit...

Page 15: ... 5 Pour the appropriate amount of recommended lubri cant into the fill hole 6 Install the fill plug and tighten to 16 ft lb NOTE If the lubricant is contaminated with water inspect the drain plug fill plug and or bladder Driveshaft Coupling The following drive system components should be inspected periodically to ensure proper operation A Spline lateral movement slop B Coupling cracked damaged or ...

Page 16: ...ghts 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 0740 647 NOTE There should be an average operating load on the vehicle when adjusting the headlight aim 2 Measure the distance from the floor...

Page 17: ...ke System CHECKING BLEEDING The hydraulic brake system has been filled and bled at the factory To check and or bleed a hydraulic brake system use the following procedure 1 With the master cylinder in a level position check the fluid level in the reservoir If the level in the reservoir is not above the MIN add DOT 4 brake fluid PR095 2 Depress the brake pedal several times to check for a firm brake...

Page 18: ...ey show excessive wear Check the thickness of each of the brake pads as follows 1 Remove a front wheel 2 Measure the thickness of each brake pad PR242 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 A Remove the wheel B Remove the cap screws secur...

Page 19: ...sing a rubber mallet gently tap on the cover tabs to loosen the cover Remove the cover 2 Remove the nut securing the movable drive face then remove the face Account for the flat washer and spacer NOTE Keep the drive face plate in contact with the drive face when removing or installing the drive face to prevent the rollers from falling out CD963 CD966A 3 Install one of the V belt cover cap screws i...

Page 20: ...3 NOTE Drive belts require a break in period see Break in Procedure Drive Belt in the General Informa tion Section REMOVING 1 Raise the rear of the vehicle just enough to unload the rear suspension weight off the shock absorbers 2 Remove the right rear shock absorber then loosen the clamp securing the cooling exhaust duct to the boot WC599 3 Remove the cap screws securing the CVT cover and air fil...

Page 21: ...ew drive belt in place on the drive clutch then making sure the match marks are aligned install the movable sheave on the driven clutch WC667 WC595 2 Secure the driven clutch with the cap screw A washer B and alignment shim s C then tighten to 60 ft lb WC741A 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...

Page 22: ...ls and lubricating all internal components when servicing the engine transmission SPECIAL TOOLS A number of special tools must be available to the techni cian when performing service procedures in this section Refer to the current Special Tools Catalog for the appropri ate tool description NOTE Special tools are available from the Arctic Cat Service Department Description p n Seal Protector Tool 0...

Page 23: ...lace ECM 4 Replace fuel injector 5 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance excessive 2 Valve spring s weak broken 3 Rocker arm rocker arm shaft worn 4 Camshaft worn 1 Adjust clearance 2 Replace spring s 3 Replace arm shaft 4 Replace camshaft Problem Engine noisy Noise seems to come from piston Condition Remedy 1 Piston cylinder worn 2 Combus...

Page 24: ...ed 2 Piston rings cylinder worn 3 Valve guides worn 4 Cylinder wall scored 5 Valve stems worn 6 Stem seals defective 1 Drain excess oil change oil 2 Replace service rings cylinder 3 Replace guides 4 Replace cylinder 5 Replace valves 6 Replace seals Problem Engine lacks power Condition Remedy 1 Valve clearance incorrect 2 Valve springs weak 3 Valve timing incorrect 4 Piston ring s cylinder worn 5 V...

Page 25: ...p screws from the front output drive flange then remove the starter cable WC187A WC187B 5 Remove all nuts and screws securing the rear body panel then loosen the gas tank fill hose clamp and remove the cover forward through the ROPS tubes Seal the fill hose to prevent contamination of gas or vapor escaping WC186 6 Remove the cargo box then disconnect the gasline hose connector from the fuel pump a...

Page 26: ...il primary connector then clamp off the coolant hoses at the water pump and thermostat outlet Do not remove the hoses yet WC350A WC192 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 the clamps Coolant can remain in the radiator WC197A 13 Remove the CVT cooling outlet duct then rem...

Page 27: ...rs from the fuel rails and electrical connectors from the injectors then remove the mounting screws and remove the fuel rails and injectors WC203A 17 Remove the ECT connector A front coil primary connector B TPS connector C MAP IAT connec tor D and ISC connector E then tie the engine har ness out of the way WC204A WC206A 18 Remove the engine ground cable WC211A 19 Loosen the throttle body boot cla...

Page 28: ...emove the upper rear lateral link pivot bolt then drop the link down to allow removal of the rear drive gear case through bolt WC169A WC170 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 u...

Page 29: ...the spring WC767A WC174A Installing Engine Transmission NOTE Arctic Cat recommends new gaskets and O rings be installed whenever servicing the vehicle 1 Install the front exhaust pipe onto the engine with a new grafoil gasket but do not torque then using a suitable engine hoist and equalizer sling lower the engine into the vehicle 2 Apply a liberal amount of molybdenum grease to the rear output sp...

Page 30: ...ighten the through bolts to 38 ft lb and the cap screw to 20 ft lb WC170A 7 Coat the threads of all three Allen head cap screws secur ing the front drive coupler flange with blue Loctite 243 and tighten to 40 ft lb then connect the starter cable WC187A 8 Crimp the clamp onto the rear drive coupler boot WC172B 9 Connect the speed sensor D stator connector E and the CKP sensor F then install the gea...

Page 31: ...n the CVT housing and tighten to 6 ft lb then connect and secure the throttle body inlet air boot A crankcase breather hose B and inlet air duct C Tighten the inlet air boot clamp to 30 in lb and install the air filter housing strap WC146A 16 Install the CVT cooling outlet duct then with a new grafoil gasket install the rear exhaust pipe and cap screws loosely 17 Install the radiator fan assembly ...

Page 32: ...allowing air to bleed from the loosened filler cap then loosen the bleed screw on the water pump allowing air trapped in the engine to escape Top off coolant and tighten all bleed points securely WC354A WC205A 24 Install the cargo box then remove the cap from the gas fill hose and place the rear body panel into posi tion Secure the gas tank fill hose to the filler neck and secure with the clamp 25...

Page 33: ...onents which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to removed from the frame for this procedure Removing Top Side Components A Valve Cover Rocker Arms B Cylinder Head Camshaft 1 Remove the timing inspection plug spark plugs and magneto housing cover then install the 10 mm cap scre...

Page 34: ...the tension Remove the two cap screws securing the tensioner adjuster assembly and remove the assembly Account for a gasket GZ200 5 Using an awl rotate the C ring in its groove until it is out of the cylinder head then remove the C ring NOTE Care should be taken not to drop the C ring into the crankcase GZ155 6 Bend the washer tabs down and remove the two cap screws securing the sprocket to the ca...

Page 35: ...guide GZ151 GZ161 10 If the remaining cylinder head is to be serviced apply tension to the loose timing chain and rotate the second cylinder to top dead center of the compression stroke then repeat steps 2 9 on the other cylinder head C Cylinders D Pistons NOTE Steps 1 10 in the preceding sub section must precede this procedure 11 Remove the cap screws securing the water hose union to the cylinder...

Page 36: ...er NOTE Support the connecting rod with rubber bands or a piece of hose to avoid damaging the rod or install a suitable connecting rod holder GZ146A AT THIS POINT To service cylinder see Servicing Top Side Compo nents sub section CAUTION When removing the cylinder be sure to support the pis ton to prevent damage to the crankcase and piston CAUTION Do not allow the connecting rod to go down inside ...

Page 37: ...al location of each valve set for use during installation Return each valve set to its original location during installation 1 Using a valve spring compressor compress the valve springs and remove the valve cotters Account for an upper spring retainer CC132D 2 Remove the valve seal and the lower remaining spring seat Discard the valve seal CC136D NOTE The valve seals must be replaced 3 Remove the ...

Page 38: ...n must not exceed spec ifications Measuring Valve Guide Inside Diameter 1 Insert a suitable bore gauge 1 2 way into each valve guide bore and record the measurement 2 Acceptable inside diameter range must be within specifications 3 If a valve guide is out of tolerance it must be replaced Servicing Valves Valve Guides Valve Seats If valves valve guides or valve seats require servicing or replacemen...

Page 39: ... Using the sharpened ring as a tool clean carbon from the ring grooves 3 Using a non metallic carbon removal tool remove any carbon buildup from the dome of the piston 4 Inspect the piston for cracks in the piston pin dome and skirt areas 5 Inspect the piston for seizure marks or scuffing 6 Inspect the perimeter of each piston for signs of exces sive blowby Excessive blowby indicates worn piston r...

Page 40: ...ract this measurement from the measurement in step 1 The difference clearance must be within specifications Installing Piston Rings 1 Install the expander spring making sure the ends are aligned on the wire then install the oil ring with the ring gap 90 from the spring gap and the marking E TOP directed toward the top of the piston GZ168 GZ169A 2 Install the second compression ring with the markin...

Page 41: ...pair the surface using a cylinder hone see Inspecting Cylinder in this sub section 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 ...

Page 42: ... the camshaft and note runout maximum toler ance must not exceed specifications Measuring Camshaft Lobe Height 1 Using a calipers measure each cam lobe height ATV1013A 2 The lobe heights must not exceed minimum specifica tions Inspecting Camshaft Bearing Journal 1 Inspect the bearing journal for scoring seizure marks or pitting 2 If excessive scoring seizure marks or pitting is found the cylinder ...

Page 43: ...be replaced Installing Top Side Components A Pistons B Cylinders 1 Install the piston on the connecting rod making sure the circlip on each side is fully seated in the piston NOTE The piston should be installed so the arrow points toward the exhaust of the respective cylinder GZ166 2 Place the two alignment pins into position Place the cyl inder gasket into position with a drop of silicone sealant...

Page 44: ...ead D Valve Cover NOTE Steps 1 5 in the preceding sub section must precede this procedure 6 Place the chain guide into the cylinder GZ161A 7 Place a new head gasket into position on the cylinder Place the alignment pins into position then place the head assembly into position on the cylinder while guiding the cam chain through the cylinder head GZ151 8 Apply a light coat of grease to the cylinder ...

Page 45: ...ton maneuver the camshaft sprocket assembly through the chain and towards its seating position then loop the chain over the sprocket NOTE Note the position of the alignment marks on the end of the camshaft They must be parallel with the valve cover mating surface If rotating the cam shaft is necessary for alignment rotate the sprocket inside the chain until the alignment pin can be engaged in the ...

Page 46: ...e cam lobes directed down toward the piston maneuver the camshaft sprocket assembly through the chain and towards its seating position then loop the chain over the sprocket NOTE Note the position of the alignment marks on the end of the camshaft They must slightly favor the exhaust side of the cylinder If rotating the camshaft is necessary for alignment rotate the sprocket inside the chain until t...

Page 47: ...1027 23 Install the first cap screw threads coated with red Loctite 271 securing the sprocket and tab washer to the camshaft Tighten only until snug GZ195 24 Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed then install the cap screw threads coated with red Loctite 271 and tighten to 11 ft lb Bend the tab to secure the cap screw GZ193 CD465 25...

Page 48: ...ten sioner as the adjuster screw is rotated clockwise The adjuster shaft tension will be released in step 30 29 Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the two cap screws CD469 30 Using a flat blade screwdriver rotate the adjuster screw inside the tensioner counterclockwise until the tensioner spring bears tension then install the cap sc...

Page 49: ...O rings are properly installed Tighten the cap screws to 9 ft lb GZ208 38 If removed install the spark plugs Tighten securely Left Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to be...

Page 50: ... priate crankshaft protector into the crankshaft H2 018 4 Install Magneto Rotor Remover Set and loosen the rotor flywheel then remove the crankshaft protector and rotor flywheel from the crankshaft Account for the flywheel key GZ216 GZ217 5 With the flywheel key removed remove the starter ring gear and spacer washer GZ226 GZ249 6 Remove the hose clamps from the water pump then remove the coolant h...

Page 51: ...ift cover to the crankcase then remove the gear shift cover Account for a gasket H2 013A 10 Remove the nut A from the shift cam stopper sup port B then remove the cam stopper spring C Account for a flat washer D cam stopper F and shim E H2 019C 11 Remove the cap screw securing the shift cam plate to the shift cam shaft and remove the shift cam plate then remove the shift shaft H2 022A 12 Remove th...

Page 52: ... surfaces missing rollers or discoloration If any of the above conditions exist replace the starter clutch assembly FI572 REPLACING STARTER CLUTCH ASSEMBLY 1 Remove the cap screws securing the one way clutch assembly to the flywheel then remove from the fly wheel FI570 2 Thoroughly clean the rotor flywheel then install the new starter one way clutch and secure with the cap screws after applying a ...

Page 53: ... 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 Account for and note the position of the harness hold down under the crankshaft position sensor H2 017A H2 027 3 Install the new stator coil assembly and secure with three cap screws using a drop of red Loctite 271 on each Tighten according to the c...

Page 54: ...the trigger and counter shaft splines and install the trigger Secure with a flat washer and outer snap ring H2 023 GZ254 4 If removed install the shim E and cam stopper F then with the cam stopper support B in place install the spring C washer D and nut A Tighten to 8 ft lb FW 017B GZ256 5 Install the shift cam stopper spring onto the shift cam stopper and secure with a flat washer and nut Tighten...

Page 55: ... spacer washer if applicable properly positionned install the water pump Secure using the two existing cap screws GZ230A NOTE The longer cap screw goes on the top of the water pump 10 Install the coolant hoses and secure with the hose clamps 11 Install the spacer washer on the crankshaft then install the starter ring gear GZ249 GZ226 12 Place the key into the keyway in the crankshaft then wipe all...

Page 56: ... to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to be removed from the frame for this procedure Removing Right Side Components A CVT Cover B Driven Clutch C Clutch Cover D Centrifugal Clutch 1 Remove the cap screws securing the CVT cover then using a rubber mallet gently tap on the cover tabs to loosen the cover A...

Page 57: ... remove the V belt housing Account for two alignment pins GZ433A 7 Remove the cap screws securing the clutch cover then using a rubber mallet carefully remove the cover Account for two alignment pins GZ433B NOTE The one way bearing is not utilized on the Wildcat GZ434B 8 Using a hydraulic press remove the clutch housing assembly from the clutch cover Account for the left fixed drive spacer and an ...

Page 58: ... discoloration If any shoe is damaged replace the centrifugal clutch INSPECTING CLUTCH HOUSING 1 Inspect the clutch housing for burns grooving cracks or uneven wear 2 If the housing is damaged in any way the housing must be replaced DRIVEN CLUTCH ASSEMBLY NOTE The driven clutch is a non serviceable com ponent If the clutch faces cam ramps or face bush ing are worn or loose the clutch must be repla...

Page 59: ...r and secure with the snap ring flat side away from the bearing GZ441 2 Install the gear onto the driveshaft noting correct ori entation from step 1 of disassembling GZ442 3 Install the two snap rings on the driveshaft flat side away from the gear Installing Right Side Components 1 Install the clutch shoe assembly and secure with the flange nut threads coated with red Loctite 271 Tighten to 221 ft...

Page 60: ...ure with the nut coated with red Loctite 271 Tighten to 165 ft lb GZ066 8 Slide the fixed drive face onto the clutch shaft 9 Spread the faces of the driven clutch by threading in a cap screw then when the faces are separated insert the belt and push down between the faces GZ065A 10 Place the V belt into position on the driven clutch and over the front shaft GZ085 NOTE The arrows on the V belt shou...

Page 61: ...ater pump drive housing cover and tighten the cap screws to 8 ft lb GZ437A Center Crankcase Components NOTE This procedure cannot be done with the engine transmission in the frame Complete Remov ing procedures for Top Side Left Side and Right Side must precede this procedure NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to servi...

Page 62: ...ed If disassembled second ary gear sets will have to be reset for backlash and gear contact see Servicing Center Crankcase Com ponents sub section 4 Remove one cap screw from the right side crankcase and eight cap screws from the left side crankcase then using a rubber mallet separate the crankcase halves leaving all components in the right side case Account for a thrust washer on the crankshaft a...

Page 63: ...n remove the drive idler GZ299A 3 Remove the snap ring securing the water pump idler shaft C in the crankcase then remove the shaft and bearings GZ463A 4 Remove the snap ring securing the oil pump driven gear D to the oil pump driveshaft then remove the gear Account for a drive pin and washer GZ463B 5 Remove the shift fork shaft E then remove the gear shift shaft assembly F Account for a flat wash...

Page 64: ...o establish correct gear tooth contact If only the secondary output driveshaft or secondary output driven gear are replaced proceed to Correct ing Backlash in this sub section 1 Install a new bearing A onto the secondary driven shaft B making sure the bearing locating groove is directed away from the driven gear splines MT011A 2 Using a suitable press install the driven gear C on the shaft until t...

Page 65: ...o Checking Backlash in this sub section Checking Backlash 1 Install the drive bevel gear assembly and driven bevel gear output shaft assembly into the crankcase bottom cover 2 Mount the dial indicator so the tip is contacting a tooth on the secondary drive bevel gear FW 008 3 Firmly hold the bearing down and while rocking the drive bevel gear back and forth note the maximum backlash reading on the...

Page 66: ...mp cover then remove the gerotor set shaft and pin see Disassembling Crankcase Half in this sub section 2 Inspect the crankcase for scoring discoloration or cracks in the gerotor bore If scored crankcase assem bly must be replaced GZ357 3 Inspect the gerotor set for scoring discoloration or cracks then using a feeler gauge check the inner to outer rotor clearance If measurements exceed specifi cat...

Page 67: ...e outer rotor reference dot directed toward the oil pump cover install the rotor onto the inner rotor GZ360 4 Place a new O ring seal on the outside of the oil pump cover The oil pump assembly is now ready for assem bly into the crankcase GZ362 CRANKSHAFT ASSEMBLY NOTE The crankshaft and connecting rod is a non serviceable assembly If any component is out of specification the assembly must be repl...

Page 68: ... exceed specifications NOTE Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 3 4 Measuring Crankshaft Web to Web 1 Using a calipers measure the distance from the out side edge of one web to the outside edge of the other web H2 005 2 Acceptable width range must be within specifications COUNTERSHAFT GZ281A Disassembling 1 ...

Page 69: ...e the washer and gear GZ314 5 Remove the reverse driven washer then remove the low driven gear locking washer GZ320 GZ319 GZ318A 6 Remove the low driven gear Account for a bearing bushing and thrust washer GZ316 Assembling 1 From the drive gear end install a thrust washer bush ing and bearing then install the low driven gear and washer ...

Page 70: ...19B GZ320B 3 Install the reverse driven bushing and bearing then install the reverse driven gear GZ286A GZ287 4 Install the outer reverse driven washer then secure the reverse driven gear assembly with a snap ring GZ288A GZ314 5 Install the reverse driven gear dog onto the counter shaft and secure with a snap ring ...

Page 71: ...l pump gerotor assembly and oil pump cover in the crankcase and secure with two cap screws Coat the threads with red Loctite 271 and tighten securely to 8 ft lb GZ305 2 Install a flat washer drive pin and drive gear onto the oil pump shaft then secure with a snap ring flat side away from the gear GZ347 3 Install the countershaft into the crankcase and secure with the snap ring flat side away from ...

Page 72: ...scard the input shaft seal then install the input shaft through the case half FW 023 FW 025 7 Apply a generous amount of molybdenum grease to the sholder of the shaft just past the splines FW 027 8 Place a new seal on the input shaft by carefully sliding it over the shoulder of the input shaft and pressing it into the case half FW 029 FW 031 9 Install the gear shift shaft into the crankcase making...

Page 73: ...r installation to the left side crankcase Joining Crankcase Halves 1 Using rubber bands support the connecting rods to align with the cylinder bores GZ340 2 Coat both sides with engine oil then install the spacer washer on the crankshaft with the radius directed toward the crankshaft GZ341 3 Install the two alignment pins then apply a thin bead of silicone sealant to the crankcase mating surface A...

Page 74: ...ing or sticking occurs GZ457A NOTE Cap screw number eight 8 is installed from the right side NOTE If the secondary drive driven assemblies have been disassembled refer to Servicing Center Crankcase Components sub section for proper gear tooth contact and backlash 6 Install the locating ring in the crankcase assembly then install the secondary driven shaft assembly and secondary drive assembly maki...

Page 75: ...nd the 8 mm cap screws to 20 ft lb GZ447 10 Install the oil screen then apply a thin bead of silicone sealant to the oil strainer cap and secure with the cap screws Tighten to 8 ft lb AT THIS POINT After completing center crankcase components proceed to Installing Right Side Components to Installing Left Side Components and to Installing Top Side Components ...

Page 76: ... components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to removed from the frame for this procedure Removing Top Side Components A Valve Cover Rocker Arms B Cylinder Head Camshaft 1 Remove the timing inspection plug spark plugs and magneto housing cover then install the 10 mm cap...

Page 77: ...the tension Remove the two cap screws securing the tensioner adjuster assembly and remove the assembly Account for a gasket GZ200 5 Using an awl rotate the C ring in its groove until it is out of the cylinder head then remove the C ring NOTE Care should be taken not to drop the C ring into the crankcase GZ155 6 Bend the washer tabs down and remove the two cap screws securing the sprocket to the ca...

Page 78: ...guide GZ151 GZ161 10 If the remaining cylinder head is to be serviced apply tension to the loose timing chain and rotate the second cylinder to top dead center of the compression stroke then repeat steps 2 9 on the other cylinder head C Cylinders D Pistons NOTE Steps 1 10 in the preceding sub section must precede this procedure 11 Remove the cap screws securing the water hose union to the cylinder...

Page 79: ...er NOTE Support the connecting rod with rubber bands or a piece of hose to avoid damaging the rod or install a suitable connecting rod holder GZ146A AT THIS POINT To service cylinder see Servicing Top Side Compo nents sub section CAUTION When removing the cylinder be sure to support the pis ton to prevent damage to the crankcase and piston CAUTION Do not allow the connecting rod to go down inside ...

Page 80: ...al location of each valve set for use during installation Return each valve set to its original location during installation 1 Using a valve spring compressor compress the valve springs and remove the valve cotters Account for an upper spring retainer CC132D 2 Remove the valve seal and the lower remaining spring seat Discard the valve seal CC136D NOTE The valve seals must be replaced 3 Remove the ...

Page 81: ...n must not exceed spec ifications Measuring Valve Guide Inside Diameter 1 Insert a suitable bore gauge 1 2 way into each valve guide bore and record the measurement 2 Acceptable inside diameter range must be within specifications 3 If a valve guide is out of tolerance it must be replaced Servicing Valves Valve Guides Valve Seats If valves valve guides or valve seats require servicing or replacemen...

Page 82: ...ring and snap it into two pieces then grind the end of the old ring to a 45 angle and to a sharp edge 2 Using the sharpened ring as a tool clean carbon from the ring grooves 3 Using a non metallic carbon removal tool remove any carbon buildup from the dome of the piston 4 Inspect the piston for cracks in the piston pin dome and skirt areas 5 Inspect the piston for seizure marks or scuffing 6 Inspe...

Page 83: ...piston diameter at a point 15 mm 0 6 in above the piston skirt at a right angle to the piston pin bore Subtract this measurement from the measurement in step 1 The difference clearance must be within specifications Installing Piston Rings 1 Install the expander spring making sure the ends are aligned on the wire then install the oil ring with the ring gap 90 from the spring gap and the marking E T...

Page 84: ...orrosion If marks are found repair the surface using a cylinder hone see Inspecting Cylinder in this sub section 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 ...

Page 85: ...iston Measuring Camshaft Runout NOTE If the camshaft is out of tolerance it must be replaced 1 Place the camshaft on a set of V blocks then position the dial indicator contact point against the shaft and zero the indicator CC283D 2 Rotate the camshaft and note runout maximum toler ance must not exceed specifications Measuring Camshaft Lobe Height 1 Using a calipers measure each cam lobe height ATV...

Page 86: ...iston on the connecting rod making sure the circlip on each side is fully seated in the piston NOTE The piston should be installed so the arrow points toward the exhaust of the respective cylinder GZ166 2 Place the two alignment pins into position Place the cyl inder gasket into position with a drop of silicone sealant at the front and rear crankcase junction then place a pis ton holder or suitabl...

Page 87: ... light coat of grease to the cylinder head cap screw threads and washers then install the cap screws Tighten only until snug GZ132B 9 Loosely install the five cylinder head nuts 10 In a crisscross pattern tighten the four cylinder head cap screws from step 8 to 20 ft lb then 30 ft lb and finally 37 ft lb then tighten the 8 mm nut from step 9 to 18 ft lb Using a crisscross pattern tighten the 6 mm ...

Page 88: ...shaft properly aligned to the head NOTE On the Wildcat X the marks should be paral lel with the valve cover mating surface FW 012 NOTE On the Wildcat the marks must slightly favor the intake side of the cylinder FW 013 14 Seat the cam sprocket onto the camshaft making sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket then place the camshaft sprocket assembly onto...

Page 89: ...neuver the camshaft sprocket assembly through the chain and towards its seating position then loop the chain over the sprocket NOTE Note the position of the alignment marks on the end of the camshaft If rotating the camshaft is necessary for alignment rotate the sprocket inside the chain until the alignment pin can be engaged in the sprocket with the camshaft properly aligned to the head NOTE On t...

Page 90: ...asher onto the sprocket making sure it covers the pin in the alignment hole ATV 1027 23 Install the first cap screw threads coated with red Loctite 271 securing the sprocket and tab washer to the camshaft Tighten only until snug GZ195 24 Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed then install the cap screw threads coated with red Loctite...

Page 91: ...screwdriver rotate the adjuster screw inside the tensioner clockwise until the screw bottoms CD501 NOTE The adjuster shaft will be drawn into the ten sioner as the adjuster screw is rotated clockwise The adjuster shaft tension will be released in step 30 29 Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the two cap screws CD469 30 Using a flat ...

Page 92: ...ms and adjuster screws must not have pressure on them 34 Install the top side cap screws with rubber washers then install the remaining cap screws Tighten only until snug CC003D 35 In a crisscross pattern starting from the center and working outward tighten the cap screws on both valve covers to 8 5 ft lb 36 Adjust valve tappet clearance see Periodic Mainte nance Tune Up 37 Place the tappet covers...

Page 93: ...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 GZ224A NOTE The starter is not serviceable and must be replaced as a complete assembly 3 Remove the rotor flywheel nut then install the appro priate crankshaft protector into the crankshaft H2 018 4 Install Magn...

Page 94: ...t for an O ring NOTE The water pump is a non serviceable compo nent and must be replaced as a complete assembly 9 Remove the cap screws securing the gear shift cover to the crankcase then remove the gear shift cover Account for a gasket H2013A 10 Remove the nut A from the shift cam stopper sup port B then remove the cam stopper spring C Account for a flat washer D cam stopper F and shim E H2 019C ...

Page 95: ...nspect the starter clutch gear for chipped or missing teeth or discoloration scoring of the clutch surface Inspect the bearing for loose worn or discolored roll ers If bearing is damaged it must be replaced FI569 3 Inspect the one way bearing for chipped surfaces missing rollers or discoloration If any of the above conditions exist replace the starter clutch assembly FI572 REPLACING STARTER CLUTCH...

Page 96: ... 1 Inspect the stator coil for burned or discolored wiring broken or missing hold down clips or loose cap screws 2 Inspect the bearings in the magneto housing for dis coloration roughness when rotated and secure fit in bearing bores 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...

Page 97: ...th clean engine oil then install the oil filler cover into the crankcase and secure with the cap screws Tighten to 8 ft lb GZ250 3 Clean the countershaft and trigger splines thoroughly and install the inner snap ring onto the shaft then apply green Loctite 620 to the trigger and counter shaft splines and install the trigger Secure with a flat washer and outer snap ring H2 023 GZ254 4 If removed in...

Page 98: ... the shift shaft seal in the shifter housing then using a new gasket install the shifter housing and secure with the cap screws Tighten in a crisscross pattern to 8 ft lb H2 013A 9 With the O ring and spacer washer if applicable properly positionned install the water pump Secure using the two existing cap screws GZ230A NOTE The longer cap screw goes on the top of the water pump 10 Install the cool...

Page 99: ...cap screws Using the pattern shown tighten to 112 in lb GZ212B Right 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 NOTE The engine transmission does not have to be removed from the frame for this procedure Removing Right Side...

Page 100: ...6A 4 Remove the drive belt 5 Remove and discard the cap screws securing the V belt housing to the crankcase then remove the V belt housing Account for two alignment pins GZ433A 6 Remove the cap screws securing the clutch cover then using a rubber mallet carefully remove the cover Account for two alignment pins GZ246B 7 Using a suitable press remove the clutch housing from the clutch cover Discard ...

Page 101: ...vable sheave These must be aligned when assembling the drive clutch for balance purposes 1 Loosen the machine screws securing the cover Remove every other cap screw from the cover then while firmly holding the cover remove the three remaining screws equally WC659 WC658 2 Remove the cover spring and nylon shift stop WC657 WC656A 3 Remove the windage plate then position the drive clutch over an appr...

Page 102: ... assembly must be replaced MS405 Cleaning and Inspecting NOTE If any components other than flyweights pins spring needle bearings rollers and thrust washers are damaged or worn clutch replacement is necessary 1 Using parts cleaning solvent wash grease dirt and foreign matter off all components dry with com pressed air NOTE If the needle bearing is washed re pack the bearing with hi temp molybdenum...

Page 103: ...ads of the stationary sheave and spider Tighten the spider to 265 ft lb WC641 WC642 NOTE Allow the Loctite to cure at room tempera ture for 24 hours NOTE Grasp the moveable sheave and lift it upward then release it It must move freely and not bind at any point 4 With the head of each cam arm pin positioned away from the direction of the drive clutch rotation install the cam arms NOTE The drive clu...

Page 104: ...he E clips securing the cam rollers to the spider then remove the thrust washer and roller WC628 NOTE The relief in the roller is directed towards the spider 5 Remove the spring and movable sheave 6 Using a suitable punch remove the roller pin securing the roller axle in movable sheave then drive out the axle and account for a thrust washer WC627 WC626 Assembling 1 Install the roller and thrust wa...

Page 105: ...g in then install the thrust washer and E Ring WC677A 5 Place the insert and spider onto the bearing assembly WC670 6 Insert the bearing assembly with spider insert into the spider making sure to line up the x marks WC672 7 Place the spring and spider into the movable sheave making sure all marks are aligned WC678 8 Using an appropriate driven clutch compressor tool install the cam making sure all...

Page 106: ...oring or discoloration GZ440A 2 Inspect the bearing B for smooth rotation and no dis coloration or scoring 3 Inspect the gear C for chipped or missing teeth excessive hub wear or excessive wear in the drive pin slot 4 Inspect the drive pin D and driveshaft E for exces sive wear or looseness Assembling 1 Install the bearing in the water pump drive cover and secure with the snap ring flat side away ...

Page 107: ...ing bearing retainers and machine screws threads coated with blue Loctite 242 Tighten to 8 ft lb GZ508 4 Press the clutch housing assembly into the clutch cover until it is seated against the bearing GZ512 5 Install a new O ring into a new fixed drive face spacer then apply a thin coat of grease to the inner O ring and outside sealing surface of the spacer and place over the clutch housing assembl...

Page 108: ...eler gauge flat against the sheave Check for slight resis tance with gauge between sheave and belt WC739 11 If offset adjustment is necessary place the transmis sion in park Remove the driven clutch cap screw A washer B and any shims C If belt clearance is too small add additional shims to gain the desired clear ance If belt clearance is too large remove shims to gain the desired clearance 12 Inst...

Page 109: ...secondary drive assembly then remove the secondary driven shaft assembly and set aside Account for one locating ring GZ448A 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 4 Remove one cap screw from the right side crankcase and ...

Page 110: ...crankcase GZ298 2 Remove the snap ring securing the water pump drive idler B to the idler shaft then remove the drive idler GZ299A 3 Remove the snap ring securing the water pump idler shaft C in the crankcase then remove the shaft and bearings GZ463A 4 Remove the snap ring securing the oil pump driven gear D to the oil pump driveshaft then remove the gear Account for a drive pin and washer GZ463B ...

Page 111: ... section Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS Initial Set Up NOTE If the secondary output driven shaft is replaced or disassembled the initial set up must be performed to establish correct gear tooth contact If only the secondary output driveshaft or secondary output driven gear are replaced proceed to Correct ing Backlash in this sub section 1 Install a new bearing A...

Page 112: ...s lay out dye Rotate the shafts through several rotations in both directions Gear contact should extend from the root to the top of the gear teeth MT016A 6 To adjust tooth contact use the following chart to cor rectly shim the driven shaft 7 After correct tooth contact is established proceed to Checking Backlash in this sub section Checking Backlash 1 Install the drive bevel gear assembly and driv...

Page 113: ...er install the secondary drive gear nut threads coated with red Loctite 263 and tighten to 200 ft lb The output drive assembly is now ready for installa tion GZ393B 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 2 Inspect the crankcase for scoring discoloration or cracks in th...

Page 114: ... side GZ359 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 GZ356 GZ363 3 With the outer rotor reference dot directed toward the oil pump cover install the rotor onto the inner rotor GZ360 4 Place a new...

Page 115: ...onnecting Rod Big End Side to Side 1 Push the lower end of the connecting rod to one side of the crankshaft journal 2 Using a feeler gauge measure the gap between the connecting rod and crankshaft journal 3 Acceptable gap range must be within specifications Measuring Crankshaft Runout 1 Place the crankshaft on a set of V blocks 2 Mount a dial indicator and base on the surface plate Position the in...

Page 116: ...12 3 Remove the reverse driven gear dog GZ313A 4 Remove the snap ring securing the reverse driven gear and washer then remove the washer and gear GZ314 5 Remove the reverse driven washer then remove the low driven gear locking washer GZ320 GZ319 CAUTION When disassembling the countershaft care must be taken to note the direction each major component dog gear faces If a major component is installed...

Page 117: ...ring then install the low driven gear and washer GZ317A GZ318 2 Install the low driven gear locking washer then install the inner reverse driven gear washer GZ319B GZ320B 3 Install the reverse driven bushing and bearing then install the reverse driven gear GZ286A GZ287 4 Install the outer reverse driven washer then secure the reverse driven gear assembly with a snap ring ...

Page 118: ... and the shift forks The countershaft is now ready for installation Assembling Crankcase Half 1 Install the oil pump gerotor assembly and oil pump cover in the crankcase and secure with two cap screws Coat the threads with red Loctite 271 and tighten securely to 8 ft lb GZ305 2 Install a flat washer drive pin and drive gear onto the oil pump shaft then secure with a snap ring flat side away from t...

Page 119: ...ump and countershaft gears 6 Install the driveshaft then with a flat washer on each end of the reverse idler assembly install into the crankcase GZ332 GZ333 7 Install the gear shift shaft into the crankcase making sure the flat washer is in place on the right case end and the spacer on the gear shift stop end DE677A GZ335 8 Place the larger flat washer on the drive gear end of the countershaft and...

Page 120: ...ed toward the crankshaft GZ341 3 Install the two alignment pins then apply a thin bead of silicone sealant to the crankcase mating surface NOTE When applying silicone make sure to keep clear of all oil galleys and ports Do not over apply sil icone GZ345C 4 Carefully join the crankcase halves by placing the left side crankcase onto the assembled right side Secure with the cap screws eight left side...

Page 121: ...ar tooth contact and backlash 6 Install the locating ring in the crankcase assembly then install the secondary driven shaft assembly and secondary drive assembly making sure the locating ring and bearing engage correctly GZ269A GZ448A 7 Make sure the locating pins on the front and rear bear ings are correctly seated in the crankcase 8 Install two alignment pins into the upper crankcase assembly th...

Page 122: ...cone sealant to the oil strainer cap and secure with the cap screws Tighten to 8 ft lb H2 012A AT THIS POINT After completing center crankcase components proceed to Installing Right Side Components to Installing Left Side Components and to Installing Top Side Components ...

Page 123: ...ery cover and disconnect the battery 3 Remove the rear body panel then remove the cargo box 4 Remove the two screws securing the heat shield to the radiator cooling fan assembly WC351B 5 Remove the two upper radiator support mounting screws then while holding the heat shield away from the radiator tip the radiator back and secure with an appropriate holding strap such as a tarp strap WC212 6 Remov...

Page 124: ...5 Secure the heat shield and rear coil to the radiator then install the cargo box 6 Install the rear body panel and secure with the appro priate fasteners then connect the negative battery cable and install the battery cover and seats Gas Tank REMOVING 1 Remove the seats and battery cover then disconnect the negative battery cable 2 Remove the rear body panel and cap off or tape the gas filler hos...

Page 125: ...Remove the oil hose from the fitting nearest the oil fil ter base WC222A 2 Using a suitable T fitting connect Oil Pressure Test Kit to the oil fitting and hose Tighten all clamps securely NOTE Some oil seepage may occur when installing the oil pressure gauge Wipe up oil residue with a cloth 3 Place the transmission in park and start the engine Allow the engine to warm up to operating temperature w...

Page 126: ... coolant pipe or the water pump housing to allow air to bleed from the cooling system When clear coolant no bub bles is present tighten the bleed screw securely then fill the cooling system to the bottom of the stand pipe in the radiator neck Run the engine for five minutes after the initial fill shut the engine off and then top off the cooling system to the bottom of the stand pipe in the radiato...

Page 127: ...te locations WC180B 4 Install the cargo box see Steering Frame Controls 5 Pour the proper mixture and quantity of coolant into the radiator filler loosening the radiator cap to allow air to escape while filling WC354A 6 Start the engine and allow it to warm up while check ing for leaks then shut the engine off and check cool ant level Adjust as required 7 Remove the cap from the gas tank fill hose...

Page 128: ...nt hoses from the water pump then remove two cap screws securing the water pump to the crankcase GZ230A NOTE Always use a large container and have suffi cient floor drying material available when draining the coolant in case of coolant spillage 2 Remove the water pump from the engine INSTALLING 1 Install a new O ring onto the water pump and lightly coat with clean engine oil GZ252C 2 Install the w...

Page 129: ... power supply wiring to the fuel pump could be checked by reconnecting the battery nega tive cable and using a multimeter set to DC volts then check for battery voltage by turning the ignition to ON and checking between the black and red wires Disconnect the negative battery cable when finished 3 Disconnect the fuel pump fuel level sender connector then wrap a shop towel around the gasline connect...

Page 130: ...o latch in place then connect the two wire connector A INSTALLING 1 Carefully place the fuel pump assembly into the gas tank referencing orientation marks made during removal WC226 2 Secure the pump assembly with the mounting screws and tighten securely in a crisscross pattern WC226A 3 Connect the electrical connector and the gasline hose connector to the fuel pump then press the wiring har ness a...

Page 131: ...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 High RPM cut out against RPM limiter 1 Decrease RPM speed ...

Page 132: ...mmends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging Maintenance charging is required on all batteries not used for more than two weeks or as required by battery drain 800E 1 When charging a battery in the vehicle be sure the ignition switch is in the OFF position 2 Clean the battery terminals with a solution of baking soda and water NOTE The sealing s...

Page 133: ... full charge unplug the charger from the 110 volt electrical outlet RPM Limiter NOTE The Wildcat is equipped with an ECM that interrupts the ignition when maximum RPM is approached When the RPM limiter is activated it could be misinterpreted as a high speed misfire Testing Electrical Components All of the electrical tests should be made using the Fluke Model 77 Multimeter If any other type of mete...

Page 134: ...e reaches 40 C 104 F the meter should read approximately 1136 ohms 4 On the ECT sensor when the temperature reaches 100 C 212 F the meter should read approximately 155 ohms 5 If the readings are not as indicated the sensor must be replaced 6 Install the sensor and tighten securely 7 Connect the leads Fan Motor NOTE Preliminary checks may be performed on this component using the diagnostic mode on ...

Page 135: ...eld front cylinder Remove the rear body panel and cargo box to access the coils VOLTAGE Primary Coil 1 Set the meter selector to the DC Voltage position then disconnect the connector from the coil to be tested 2 Connect the red tester lead to the orange wire and the black tester lead to ground 3 Turn the ignition switch to the ON position The meter must show battery voltage RESISTANCE NOTE For the...

Page 136: ...ted then connect the red tester lead to the signal lead pin S 6 Slowly move the vehicle forward or backward the meter must show 0 and approximately 6 DC volts alternately NOTE If the sensor tests are within specifications the LCD gauge must be replaced see Steering Frame Controls To replace a speed sensor use the following procedure 1 Disconnect the three wire connector from the speed sensor harne...

Page 137: ...be approximately 10 5 DC volts Code Fault Description Possible Cause Recovery Method C1301 Over Current Internal EPS Condition Correct EPS condi tion then cycle key switch On Off On C1302 Excessive Current Error Internal EPS Condition Correct EPS condi tion then cycle key switch On Off On C1303 Torque Sen sor Range Fault Internal EPS Condition Correct EPS condi tion then cycle key switch On Off On...

Page 138: ...ges accord ing to the chart make sure the front drive actuator is plugged in then troubleshoot the switch ignition fuses battery connections or wiring harness Reverse Override Switch VOLTAGE NOTE To perform the following tests the ignition switch must be in the ON position and the transmis sion shifted into reverse gear 1 Connect the red meter lead to the black green wire and the black meter lead ...

Page 139: ...KP Sensor NOTE Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge see EFI Diagnostic System in this section VOLTAGE AC Generator Regulated Output 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the positive battery post then connect the black tester lead to the negative bat tery post 3 With the engine running at a c...

Page 140: ...hen install the starter into the crankcase Secure with two machine screws and wiring forms 2 Secure the positive cable to the starter motor with the nut 3 Connect the battery TESTING VOLTAGE Perform this test on the starter motor positive terminal To access the terminal slide the boot away NOTE The ignition switch must be in the ON posi tion and the shift lever in the NEUTRAL position 1 Set the me...

Page 141: ...or rectifier is replaced TESTING 1 Start engine and warm up to normal operating temper ature then connect a multimeter set at the DC Volt age position to the battery as follows 2 Connect the red tester lead to the positive battery post and the black tester lead to the negative battery post 3 Slowly increase RPM The voltage should increase with the engine RPM to a maximum of 15 5 DC volts NOTE If v...

Page 142: ...pler The seats and center console must be removed to access the sensor SUPPLY VOLTAGE 1 Disconnect the three wire connector from the sensor then select DC Voltage on the multimeter and connect the red tester lead to the orange wire C and the pink tester lead to the pink wire A CD706C 2 Turn the ignition switch to the ON position The mul timeter should read battery voltage If battery voltage is not...

Page 143: ... Turn the ignition switch to the ON position The meter should read approximately 5 0 DC volts PR538A NOTE If the meter does not read as specified check for poor connections at the ECM or open bro ken wires in the wiring harness 4 Turn the ignition switch to the OFF position 5 Select the OHMS position on the meter then perform the following resistance tests on the TPS A Pin B to ground infinity ope...

Page 144: ...n connect the harness to the TPS Analyzer Tool FI672 3 Using a multimeter connect the black tester lead to the white socket VAR on the analyzer and the red tester lead to the red socket SV then select the DC Voltage position FI676A 4 Adjust the TPS until a reading of 0 6 DC volt is obtained then tighten the screw securely Open and close the throttle and determine the reading returns to 0 6 DC volt...

Page 145: ...c Mode EFI032 Display Engine coolant temperature as measured by the ECT sensor DTC P0116 P0117 P0118 P0119 Usage Monitor coolant temperature to verify the following 1 ECT sensor signal 2 High Temperature indicator on 230 F 3 Thermostat opening approximately 180 F indi cated by a momentary drop or pause in the rising temperature reading 4 Left fan ON 185 F OFF 175 F right fan ON 195 F OFF 185 F A f...

Page 146: ...ECM CAN signal to EPS unit TPS tPS Diagnostic Mode EFI028 Display of TPS 0 closed 95 100 WOT DTC P0121 P0122 P0123 Usage Verify TPS signal and adjust throttle cable MAP bArO Diagnostic Mode EFI027 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 ar...

Page 147: ...ling 13 5 VDC or greater 4 Battery voltage starter cranking 10 5 11 5 VDC DIAGNOSTIC TROUBLE CODES DTC If an EFI or related chassis component fails or an out of tolerance signal is detected by the ECM a diagnostic trou ble code DTC will be generated in the ECM and dis played on the LCD The DTC will be displayed alternately with a wrench icon or malfunction indicator light MIL The DTC will continue...

Page 148: ...485 ON K2 Fan Relay Control Circuit Low SG Open P0500 Gauge Direct Error Code N A Vehicle Speed Sensor P0508 ON C4 D3 D4 E4 Idle Air Control System Circuit Low SG P0509 ON C4 D4 Idle Air Control System Circuit High Open P0562 L1 System Voltage Low P0563 L1 System Voltage High P0601 N A ECM Memory Check Sum Error P0615 1 L3 Starter Relay Circuit P0616 ON L3 Starter Relay Circuit Low P0617 L3 Starte...

Page 149: ...eplace battery Problem Magneto overcharges Condition Remedy 1 Battery short circuited 2 Regulator rectifier defective 3 Regulator rectifier poorly grounded 1 Replace battery 2 Replace regulator rectifier 3 Clean tighten ground connection Problem Charging unstable Condition Remedy 1 Lead wire intermittently shorting 2 Magneto internally shorted 3 Regulator rectifier defective 1 Replace lead wire 2 ...

Page 150: ...ctrical Sys tem If the actuator runs constantly or makes squealing or grinding sounds the actuator must be replaced REMOVING 1 Select LOCK on the drive select switch then discon nect the connector on the actuator harness 2 Using a T 30 torx wrench remove the mounting cap screw from the driveshaft side of the actuator PR189A 3 Remove the mounting cap screw from above the actu ator on the suspension...

Page 151: ...rn the ignition switch to the ON position and check the operation by shifting the drive select switch sev eral times 7 Secure the wiring harness to the frame with a nylon cable tie then install the inner fender panel Front Differential REMOVING 1 Remove the forward belly panel then drain the lubri cant from the differential 2 Using an appropriate jack or lift raise the vehicle so the wheels are of...

Page 152: ...Push in on the axle shaft while pulling outward on the axle coupler and remove the axle assembly from the differential PR729C 8 From underneath the vehicle remove the carrier bear ing support bracket then remove the bolts and nuts securing the carrier bearing to the bracket and remove the bracket WC265A WC266A 9 Disconnect the drive line coupler by removing three nuts from the Allen head bolts the...

Page 153: ... bolts then slide the differential rearward and lay it on the right side Remove from the vehicle from either left or right side WC 277 Disassembling Input Shaft 1 Using a T 40 torx wrench remove the cap screws securing the pinion housing GC004A 2 Using a rubber mallet remove the housing Account for a gasket Remove the fork collar and spring Note the location of all the components for assembling pu...

Page 154: ...to the outside GC012 GC011 2 Install the input shaft seal making sure it is fully seated in the edge of the housing GC014 3 Lubricate the input shaft with High Performance 2 Molybdenum Disulphide Grease packing the boot ribs and splines then assemble allowing excess grease to freely escape Slight pressure on the boot will be pres ent during assembly Secure with new clamps NOTE Any time drive splin...

Page 155: ...ring the pinion housing Account for the coupler fork and spring differential only GC015 2 Using a T 40 torx wrench remove the cap screws securing the differential cover Account for and make note of the ID tag location for assembling purposes GC003 3 Using a plastic mallet tap lightly to remove the differ ential cover Account for an O ring KX174 NOTE If the cover is difficult to remove pry on the c...

Page 156: ...er assembly Account for shim s and mark as right side KX179 KX181 Disassembling Pinion Gear 1 Remove the internal snap ring securing the pinion bearing in the housing WC430 2 Using the Pinion Gear Shaft Removal Tool and a ham mer remove the pinion gear from the gear case hous ing CC878 3 Secure the pinion gear in a bearing puller then remove the pinion bearing using a press Account for a collar an...

Page 157: ... Procedure Shim Selection It is very important to adjust bevel gears for the proper running tolerances Gear life and gear noise are greatly affected by these tolerances therefore it is very important to properly adjust any gear set prior to final assembly The following procedure can be used on both front differ ential or rear drive gear case NOTE All bearings must be installed in the gear case and...

Page 158: ... bearing flange onto the gear case cover making sure the alignment locating pin engages the locating hole in the cover then make sure the bearing flange is completely seated in the cover GC032A GC033A 4 Install the existing shim or a 0 063 in shim on the cover side of the ring gear then place the assembled gear case cover onto the gear case and secure with three cap screws Tighten evenly using a c...

Page 159: ... the cover side up then install a dial indicator contacting the ring gear axle flange GC035 2 Zero the dial indicator then push the ring gear toward the dial indicator and release End play should be 0 004 0 008 in 3 To increase end play decrease the shim thickness To decrease end play increase the shim thickness NOTE Once proper backlash and end play are established the gear case can be assembled ...

Page 160: ...ifferential housing cover assembly install the cover with existing cap screws coated with green Loctite 270 Account for the ID tag Tighten the cap screws evenly to 23 ft lb NOTE Grease can be applied to the O ring for ease of assembling NOTE If a new housing is being installed tighten the cap screws to 28 ft lb 6 Install the shift fork shaft w spring into the housing making sure the shaft O ring i...

Page 161: ...erly seated CF278 3 Repeat steps 1 2 for the opposite side INSTALLING DIFFERENTIAL 1 Lay the differential assembly on its right side and place in the frame of the vehicle then turn it upright and maneuver into the mounting brackets WC277 2 Apply molybdenum grease to the splines and install the forward driveshaft into the differential splined coupler then install the three Allen head bolts in the d...

Page 162: ...ve actuator connector 8 Apply fresh multi purpose grease to the splines then install the front axles into the differential pushing in on the axle shafts to seat the splines into the differential PR729C 9 Install the axles into the knuckles then swing the knuckles vertical and engage the ball joint shanks into the knuckles While holding the ball joint securely in the knuckle secure with a new patch...

Page 163: ... stands and lower the vehicle Drive Axles REMOVING INSTALLING DRIVE AXLES NOTE For removing installing a rear drive axle see Rear Gear Case or Front Differential in this section CLEANING AND INSPECTING AXLES NOTE Always clean and inspect the drive axle com ponents to determine if any service or replacement is necessary 1 Using a clean towel wipe away any oil or grease from the axle components CD01...

Page 164: ...from the axle bearing WC282B WC286A 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 PR729C 6 Remove the two lower lateral links from the frame then remove the lower rear gear case mounting cap screw WC287A WC170B 7 Remove the lower frame gear case bracket then remove ...

Page 165: ...ssing or chipped teeth or discoloration 2 Inspect the thrust button for excessive wear or discol oration 3 Inspect the bearings for discoloration roughness or excessive wear NOTE For servicing bearings or seals see Front Differential in this section Installing Shimming NOTE Ring gear clearance must be adjusted prior to selecting shim for the thrust button 1 Install the thrust button with shim into...

Page 166: ...t shaft housing to the rear gear case then remove the input housing assembly GZ183 2 Remove the clutch pack from the clutch basket then remove the snap ring securing the clutch basket A to the input shaft B and remove the clutch basket GZ392 GZ176A GZ177 3 Remove the input shaft from the input housing then remove the oil seal GZ180 GZ182A 4 Remove the snap ring retaining the input bearing and usin...

Page 167: ...ith the housing GZ182A 3 Apply grease to the lips of the oil seal then install the input shaft into the input bearing and housing GZ179A 4 Install the clutch basket onto the input shaft and secure with the snap ring flat side directed outward then install the clutch pack into the basket GZ176 5 Using a new gasket install the assembled rear drive input shaft housing onto the rear drive gear case an...

Page 168: ... the bolts and new lock nuts Do not tighten at this time WC287A 6 In order tighten the lower frame gear case bracket mounting nuts A to 35 ft lb lower lateral link nuts B to 40 ft lb and the gear case cap screw C to 20 ft lb then tighten the nuts on lower front and upper rear through bolts to 38 ft lb WC296A 7 Install the upper left lateral link and secure with a bolt and nut Tighten to 40 ft lb W...

Page 169: ... plate cannot be fully installed due to misalignment of the nut tighten the nut until prop erly aligned and the plate is fully seated 14 Install the wheels then using a crisscross pattern tighten the wheel nuts in 20 ft lb increments to a final torque factor of 80 ft lb Install the hub caps 15 Pour in the recommended gear case lubricant and check to ensure the lubricant is one inch below threads i...

Page 170: ...et and ratchet handle tighten the nut until the stud is fully drawn into the hub PR252A 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 Install the brake caliper and secure with new patch lock cap screws Tighten to 20 ft l...

Page 171: ...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 NOTE If brake pads are to be returned to service do not allow brake fluid to contaminate them PR237A PR238 5 Remove the caliper holder from the caliper and dis card the O ring PR239B NOTE The O ring ...

Page 172: ...e piston surface for scoring discoloration or evidence of binding or galling 5 Inspect the caliper holder for wear or bending ASSEMBLING INSTALLING 1 Install new seals into the brake caliper housing and apply a liberal amount of DOT 4 brake fluid to the cylinder bore of the housing seals and brake piston PR715 PR717A 2 Press the piston into the caliper housing using hand pressure only Completely s...

Page 173: ...Remove the vehicle from the support stand and verify brake operation MASTER CYLINDER ASSEMBLY NOTE The master cylinder is a non serviceable component it must be replaced as an assembly Removing 1 Slide a piece of flexible tubing over one of the wheel bleeder valves and direct the other end into a con tainer Remove the reservoir cover then open the bleeder valve Allow the brake fluid to drain until...

Page 174: ...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 2 Propeller shaft serration worn broken 3 Coupling damaged 4 Coupling joint serration worn damaged 5 Front drive driven bevel gears broken damaged 6 Front differential gears pinions...

Page 175: ...railing arm Account for bushings and sleeves from each WC284 WC285 4 Completely remove pre load by turning the adjusters to the end of the threads and removing the retainer then remove the spring CLEANING AND INSPECTING 1 Clean all shock absorber components in parts clean ing solvent 2 Inspect each shock rod for nicks pits rust bends and oily residue 3 Inspect all springs spring retainers shock ro...

Page 176: ...t from the lower A arm 9 Remove the brakeline hose routing clips from the upper A arm then remove the cap screws securing the A arms to the frame 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 4 Inspect the ...

Page 177: ...sembly new cotter pins should be installed 8 Apply Loctite primer and red Loctite 277 to the threads of the axle 9 Engage the hub nut into the Belleville washer on the convex side then with the concave side of the washer directed toward the hub install the nut and washer Keeping the nut and washer engaged tighten the hub nut to 250 ft lb WC303A 10 Secure the brake caliper to the knuckle with two n...

Page 178: ...ugh bolt but do not remove the bolt at this time WC306A 7 Using a tarp strap or nylon straps support the suspen sion axle assembly and remove the support from under the trailing arm 8 Drive the roll pin out and remove the nut from the trailing arm rear knuckle pivot then remove the for ward cross mount bolt and remove the lower trailing arm WC305A INSPECTING 1 Inspect the arm for any signs of meta...

Page 179: ...ll the nut and washer Keeping the nut and washer engaged tighten the hub nut to 250 ft lb WC303A 7 Install the brake caliper and secure with new patch lock cap screws tightened to 20 ft lb 8 Install the hub plate making sure it fits completely over the nut and lies flat against the hub WC317A NOTE If the hub plate cannot be fully installed due to misalignment of the hub nut tighten the nut until p...

Page 180: ...fessionally NOTE Be sure all tires are the specified size and have identical tread pattern Troubleshooting WARNING 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 WARNING Do not operate the vehicle if tire damage exists Problem S...

Page 181: ...t the EPS system prior to replacing the EPS assembly see Electrical System as there are several possible external causes for system failure REMOVING NOTE Before removing the EPS ensure the front wheels and steering wheel are aligned to the front 1 Remove two cap screws and two fender screws secur ing the grille and remove the grille WC081C 2 Remove two fender screws behind the headlights and two f...

Page 182: ...n the EPS assem bly and it must be replaced as a complete assembly INSTALLING 1 Install the EPS mounting bracket onto the EPS unit and secure with the four cap screws Tighten to 35 ft lb 2 Mark the ends of the EPS input and output shafts to correspond with the flat splined segment then align the flat splined segment of the output shaft with the slot in the rack input coupler and install the EPS in...

Page 183: ...the lower bracket cap screws to 20 ft lb 9 Install the upper steering flex shaft hold down strap and tighten the cap screw to 50 in lb WC247A 10 Connect the two electrical connectors and check EPS operation 11 Install the hood and grille Rack and Pinion Assembly REMOVING 1 Remove the hood and grille then remove the EPS assem bly see Electronic Power Steering EPS in this section 2 Remove the front ...

Page 184: ...cant leaks NOTE The steering assembly rack and pinion is not repairable and must be replaced as an assembly however the tie rods and boots are replaceable INSTALLING 1 Place the rack and pinion assembly into the frame and guide the steering input shaft up through the shaft opening then rotate the assembly forward and into position on the front mounting bracket WC279A 2 Secure the bracket to the fr...

Page 185: ...el aligning the two match marks then apply a drop of red Loctite 271 to the threads of the nut and secure the steering wheel Tighten to 25 ft lb NOTE If a new steering wheel is being installed mark the wheel as close as possible to the old wheel mark then check for proper positioning with the front wheels straight forward 2 Install the hairpin clip on the steering shaft NOTE If the hole in the ste...

Page 186: ...g with no sticking or binding 2 Check the splines for wear or any signs of twisting 3 Check the housing for cuts cracks or kinks 4 If the assembly is serviceable remove the flex shaft and lubricate with the appropriate lubricant then rein stall in the housing INSTALLING 1 Making sure the lower snap ring is loosely on the steering shaft but not installed slide the shaft into the upper steering supp...

Page 187: ... lb WC247A 7 Install the upper tilt steering link pivot bolt and tighten to 10 ft lb then install the steering wheel see Steering Wheel in this section 8 Remove the block and secure the upper dash screws then install the hood and grille see Hood in this sec tion Steering Knuckles REMOVING AND DISASSEMBLING 1 Secure the vehicle on a support stand to elevate the wheel then remove the wheel and accou...

Page 188: ...STALLING 1 Using a suitable press and driver press the bearing into the knuckle until firmly seated then install the snap ring PR292A PR289 2 Install the knuckle to the lower ball joint and secure with a new patch lock cap screw Tighten to 35 ft lb 3 Slide the axle into the knuckle then install the upper ball joint and secure with a new patch lock cap screw Tighten to 35 ft lb WC272 WC271 4 Instal...

Page 189: ...nd plate is fully installed 9 Install the wheel using a crisscross pattern tighten the wheel nuts in 20 ft lb increments to a final torque fac tor of 80 ft lb 10 Remove the vehicle from the support stand Checking Adjusting Front Wheel Alignment NOTE All measurements and adjustments must be made with the vehicle unloaded Mark the center line of the front tires at the front and rear of the tire then...

Page 190: ...from the rear of the hood and remove the hood INSTALLING 1 Lay the hood in place on the frame then install the rear fender screws D 2 Install the two side fender screws C then place the grille on the vehicle and install the two machine screws B and fender screws A Tighten all fasteners securely Rear Body Panel REMOVING 1 Remove the seats then remove the machine screws securing the rear body panel ...

Page 191: ...or Pedal REMOVING Dislodge the throttle cable holding grommet from the actu ator arm then remove two torx head screws and nuts securing the accelerator pedal assembly to the splash panel and remove the accelerator pedal PR709 PR342C INSTALLING Align the mounting holes with the holes in the splash panel and secure with the two torx head screws and nuts then snap the throttle cable holding grommet i...

Page 192: ...ed accurately measure and record the distance between the adjuster nuts nuts opposite the jam nuts INSTALLING 1 Using the measurements from the existing cable adjust the adjuster nuts to the same length NOTE The shift cable will have to be adjusted but using the existing measurements will give a close starting point 2 From under the vehicle thread the new cable into position Do not tie cable tie p...

Page 193: ...ck 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 INSTALLING MUFFLER 1 Place the muffler onto the holder pins and slide into position 2 Secure the muffler to the exhaust pipe with the two exhaust springs Cargo Box REMOVING 1 Remove the rear body panel see Rear Body Panel in t...

Page 194: ...rings worn broken 4 Frame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Replace shock absorber Problem Steering impaired Condition Remedy 1 Tire pressure too high 2 Steering linkage connections worn 3 Cap screws suspension system loose 1 Adjust pressure 2 Replace connections 3 Tighten cap screws Problem Tire wear rapid or unev...

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