Arctic Cat WILDCAT/X Service Manual Download Page 127

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125

Troubleshooting

Problem: Spark absent or weak

Condition

Remedy

Ignition coil

defective

Spark plug(s)

defective

CKP sensor

defective

ECM

defective

1. Replace ignition coil
2. Replace plug(s)
3. Replace CKP sensor
4. Replace ECM

Problem: Spark plug fouled with carbon

Condition

Remedy

Gasoline

incorrect

Air cleaner element

dirty

Spark plug(s)

incorrect (too cold)

Valve seals

cracked - missing

Oil rings

worn - broken

1. Change to correct gasoline
2. Clean element
3. Replace plug(s)
4. Replace seals
5. Replace rings

Problem: Spark plug electrodes overheat or burn

Condition

Remedy

Spark plug(s)

incorrect (too hot)

Engine

overheats

Spark plug(s)

loose

1. Replace plug(s)
2. Service cooling system
3. Tighten plug(s)

Problem: Battery does not charge

Condition

Remedy

Lead wires/connections

shorted - loose - open

Stator coils

shorted - grounded - open

Regulator/rectifier

shorted

1. Repair - replace - tighten lead wires
2. Replace stator coils
3. Replace regulator/rectifier

Problem: Battery charges, but charging rate is below the specification

Condition

Remedy

Lead wires

shorted - open - loose (at terminals)

Stator coils

grounded - open

Regulator/rectifier

defective

Cell plates (battery)

defective

1. Repair - tighten lead wires
2. Replace stator coils
3. Replace regulator/rectifier
4. Replace battery

Problem: Magneto overcharges

Condition

Remedy

Battery

short circuited

Regulator/rectifier

defective

Regulator/rectifier

poorly grounded

1. Replace battery
2. Replace regulator/rectifier
3. Clean - tighten ground connection

Problem: Charging unstable

Condition

Remedy

Lead wire

intermittently shorting

Magneto

internally shorted

Regulator/rectifier

defective

1. Replace lead wire
2. Replace stator coil
3. Replace regulator/rectifier

Problem: Starter does not engage

Condition

Remedy

Battery charge

low

Switch contacts

defective

Starter motor brushes

not seating

Starter relay

defective

Wiring connections

loose - disconnected

Start-in-gear/neutral relay

defective

1. Recharge - replace battery
2. Replace switch
3. Replace starter
4. Replace relay
5. Connect - tighten - repair connections
6. Replace relay

Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates)

Condition

Remedy

Charging rate

too low - too high

Battery

discharged

1. Replace battery
2. Charge battery

Problem: Battery discharges too rapidly

Condition

Remedy

Charging system (charging operation)

not set properly

Cell plates

overcharged - damaged

Battery

short-circuited

Electrical load

too high

1. Check AC generator - regulator/rectifier - circuit connections
2. Replace battery - correct charging system
3. Replace battery
4. Reduce load

Problem: Battery polarity reversed

Condition

Remedy

Battery

incorrectly connected

1. Reverse connections - replace battery

Summary of Contents for WILDCAT/X

Page 1: ...ROV SERVICE MANUAL 2014 WILDCAT X WILDCAT 4 4X...

Page 2: ...t 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 pers...

Page 3: ...enter Crankcase Components 79 Separating Crankcase Halves 79 Disassembling Crankcase Half 80 Servicing Center Crankcase Components 82 Assembling Crankcase Half 89 Joining Crankcase Halves 90 Installin...

Page 4: ...nkshaft position sensor Resistance AC generator 150 250 ohms Less than 1 ohm Crankshaft Position Sensor AC Voltage 2 0 or more AC Generator Output no load 75 AC volts 5000 RPM Ignition Timing 10 BTDC...

Page 5: ...Differential Bracket 38 52 Set Screw Wildcat 4 4X Carrier Bearing 75 in lb 8 5 Center Front Driveshaft Wildcat 4 4X Front Driveshaft 40 54 Center Rear Driveshaft Wildcat 4 4X Rear Driveshaft 40 54 Ca...

Page 6: ...ar lube which is SAE approved 80W 90 hypoid This lubricant meets all of the lubrication requirements of the Arctic Cat vehicle front differential and rear drive ENGINE TRANSMISSION cont Air Filter Hou...

Page 7: ...cables and store in a clean dry area 9 Store the vehicle indoors in a level position Preparation After Storage Taking the vehicle out of storage and correctly preparing it will assure many miles and h...

Page 8: ...44 296 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 N...

Page 9: ...any dirt or debris from inside the air cleaner Be sure no dirt enters the throttle body 8 Install the filter in the air filter housing Position the filter frame on top 9 Install the air filter housing...

Page 10: ...ter handle with one of the marks on the valve adjuster dial D While holding the valve adjuster handle in place rotate the valve adjuster dial counterclockwise until proper valve tappet clearance is at...

Page 11: ...components see Engine Transmission 7 Pour approximately 30 ml 1 fl oz of oil into the spark plug holes reattach the gauge and retest compression 8 If compression increases to normal service the piston...

Page 12: ...g and check to make sure it is positioned correctly then install the new oil filter Tighten securely 6 Install the engine drain plug and tighten to 16 ft lb Pour the specified amount of the recommende...

Page 13: ...e 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...

Page 14: ...hts 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...

Page 15: ...e 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...

Page 16: ...s 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...

Page 17: ...open the bleed screw slightly C Install the new brake pads then secure the caliper and pads to the knuckle with the anchor bolts Tighten to 35 ft lb and install the E clips 6 Install the wheel then us...

Page 18: ...lutch to the transmission input shaft Account for the washer and alignment shim s WC810 WC597 6 Remove the movable sheave and V belt and any belt threads or debris in the CVT housing or sheaves WC809...

Page 19: ...screws Tighten in a crisscross pat tern to 8 ft lb 4 Connect the exhaust duct and tighten the boot clamp securely 5 Install the rear shock absorber and secure with the cap screws Tighten the upper ca...

Page 20: ...ove two fender screws D from the rear of the hood and remove the hood INSTALLING 1 Lay the hood in place on the frame then install the rear fender screws D 2 Install the two side fender screws C then...

Page 21: ...ely 3 Remove the plug or tape from the gas filler hose and connect the hose to the gasoline filler neck and secure with the hose clamp Tighten securely Electronic Power Steering EPS NOTE Thoroughly tr...

Page 22: ...line support bracket to the EPS mounting bracket 7 Remove the steering flex shaft support bracket then slide the EPS unit upwards and to the rear until clear of the steering rack input coupler WC247A...

Page 23: ...ft aligning the flat splined segment of the shaft to the slot in the coupler WC251A WC252A NOTE The flex shaft coupler must engage com pletely covering the majority of the splines of the input shaft 6...

Page 24: ...rear and out of the frame from either side WC260A WC279 INSPECTING 1 Inspect the input shaft splines for excessive wear or signs of misalignment 2 Inspect the slide mechanism for pitting excessive we...

Page 25: ...ked for proper alignment during assembling 2 Remove the hairpin clip from the steering shaft then remove the nut securing the steering wheel and remove the steering wheel INSPECTING 1 Inspect the stee...

Page 26: ...rear WC329A 5 Remove the steering shaft housing support hold down strap then remove the U clamp from the lower steer ing shaft support WC247A WC328A 6 Remove the steering shaft from the EPS by pullin...

Page 27: ...led slide the shaft into the upper steering support housing WC341A 2 From under the dash install the lower snap ring onto the steering shaft WC337A 3 Install the wave washer and flat washer onto the u...

Page 28: ...ball joint in the knuckle WC271 7 Tap the ball joint end out of the knuckle then slide the axle out of the knuckle 8 Remove the cap screw securing the lower ball joint to the knuckle and remove the kn...

Page 29: ...ghten the hub nut to 250 ft lb WC303A 7 Secure the brake caliper to the knuckle with the two new patch lock cap screws Tighten to 20 ft lb WC268A WC606 8 Install the hub plate making sure it fits comp...

Page 30: ...lodge 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 P...

Page 31: ...o be replaced 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 th...

Page 32: ...s 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 posi...

Page 33: ...ange nuts and tighten securely Doors CHECKING ADJUSTING Wildcat X The doors and latches are adjustable for proper latching unlatching 1 To raise or lower door to latch contact or to move the door forw...

Page 34: ...ward or backward After adjustment tighten securely WC801A WC798A 2 Loosen the screws on the latch plate to move the latch forward or backward After adjustment tighten securely Roof X Limited REMOVING...

Page 35: ...ings 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 Conditio...

Page 36: ...00 miles are most critical to the life of this ROV Proper operation during this break in period will help assure maximum life and performance from the ROV Instruct the customer to follow the proper br...

Page 37: ...ace 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...

Page 38: ...d 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 Re...

Page 39: ...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 th...

Page 40: ...ry 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...

Page 41: ...then remove the mounting screws and remove the fuel rails and injectors WC203A 17 Remove the ECT connector A front coil primary connec tor B TPS connector C MAP IAT connector D and ISC connector E the...

Page 42: ...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 la...

Page 43: ...serve the note introducing each sub section for this important information 1 Remove the rear seats then remove the battery cover and disconnect the negative battery cable 2 Remove the rear center cons...

Page 44: ...Remove the springs from the exhaust pipe to muffler connectors and remove the muffler Account for two grafoil seals WC153A 9 Remove the two cargo box supports then remove the heat shield leaving the...

Page 45: ...ws securing the air filter mounting bracket to the CVT housing WC200A WC201A 14 Loosen the inlet boot A then remove the crankcase breather hose B and the inlet air duct C WC146A 15 Remove the air filt...

Page 46: ...able attached WC210A 20 Remove the E clip A then loosen the jam nut B and slide the shift cable out of the mounting bracket and off the shift arm C WC362A 21 Disconnect the speed sensor connector D st...

Page 47: ...lizer sling sup port the engine then remove the engine through bolts front first followed by the rear WC172A 26 Remove the rear drive coupler boot then lift the engine slightly and work the rear drive...

Page 48: ...neto housing cover then install the 10 mm cap screw left hand threads in the crankshaft and rotate the desired cylinder to top dead center of the com pression stroke GZ027 GZ026 NOTE Timing marks on t...

Page 49: ...the tensioner clockwise to remove the tension Remove the two cap screws securing the tensioner adjuster assembly and remove the assembly Account for a gasket GZ405 7 Using an awl rotate the C ring in...

Page 50: ...guide GZ151 GZ161 12 If the remaining cylinder head is to be serviced apply tension to the loose timing chain and rotate the second cylinder to top dead center of the compression stroke then repeat st...

Page 51: ...n Pin Puller remove the piston pin Account for the opposite side circlip Remove the piston NOTE It is advisable to remove the opposite side circlip prior to using the puller NOTE Support the connectin...

Page 52: ...nents 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 CC132D 2 Remove the...

Page 53: ...ator contact point against the outside edge of the valve face Zero the indicator CC131D 3 Push the valve from side to side then from top to bot tom 4 Maximum wobble deflection must not exceed spec ifi...

Page 54: ...iston while rotating it out of the groove CC400D Cleaning Inspecting Piston 1 Using a soft wire brush clean carbon from the ring grooves 2 Using a non metallic carbon removal tool remove any carbon bu...

Page 55: ...btract this measurement from the measurement in step 1 The difference clearance must not exceed specifications Installing Piston Rings 1 Install the expander spring making sure the ends are aligned on...

Page 56: ...ing solvent 2 Inspect the cylinder for pitting scoring scuffing warpage and corrosion If marks are found repair the surface using a cylinder hone see Inspecting Cylinder in this sub section 3 Place th...

Page 57: ...ars breaks or chips 2 If the chain guide is damaged it must be replaced 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...

Page 58: ...gain If it is still out of tolerance replace the cylinder head Inspecting Camshaft Spring Drive Pin Front Camshaft Only 1 Inspect the spring and drive pin for damage CF061A CF060A 2 If damaged the cam...

Page 59: ...and tighten the clamp C Cylinder Head 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...

Page 60: ...ide facing the cam shaft lobes onto the camshaft At this point do not seat the sprocket onto the shaft 732 307B GZ130 NOTE At this point oil the camshaft bearings cam lobes and the three seating journ...

Page 61: ...stall the cap screw threads coated with red Loctite 271 and tighten to 11 ft lb Bend the tab to secure the cap screw GZ193 18 Rotate the crankshaft until the first cap screw from step 16 can be tighte...

Page 62: ...chain over the sprocket NOTE Note the position of the alignment marks on the end of the camshaft They should be parallel with the plane of the cylinder head If rotating the cam shaft is necessary for...

Page 63: ...haft 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...

Page 64: ...e the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the two cap screws CD469 31 Using a flat blade screwdriver rotate the adjuster screw inside the tension...

Page 65: ...nspection plug then remove the cap screw from the crankshaft and install the crankcase end cap NOTE Apply grease to the end cap to aid in instal lation Left Side Components NOTE For efficiency it is p...

Page 66: ...appro 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 cranksh...

Page 67: ...move 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 pl...

Page 68: ...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...

Page 69: ...L CRANKSHAFT POSITION SENSOR 1 Remove the three cap screws securing the stator coil two cap screws securing the crankshaft position sen sor and two cap screws from the harness hold down 2 Lift the rub...

Page 70: ...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 install the shim E...

Page 71: ...ly coated with grease and prop erly positioned 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...

Page 72: ...ose 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 C...

Page 73: ...ns WC662A NOTE Only the clutch cover bearing and seal are servicable If any other component of the cover is damaged the cover must be replaced 8 Remove and retain the two machine screws and bear ing r...

Page 74: ...odels with a shift stop proceed to step 3 GZ529 3 Remove the windage plate then position the drive clutch over an appropriate clutch holder NOTE The holder should either be secured in a vise or bolted...

Page 75: ...essed air NOTE If the needle bearing is washed re pack the bearing with hi temp molybdenum wheel bearing grease 2 Remove any drive belt dust accumulation from the stationary sheave movable sheave and...

Page 76: ...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...

Page 77: ...spring and movable sheave 5 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 In...

Page 78: ...er 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 co...

Page 79: ...ive 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 from the bearing GZ441 2 Install...

Page 80: ...ghten to 8 ft lb GZ528A 5 Making sure the alignment pins are correctly installed place a bead of silicone sealant on the mating surfaces of the V belt housing and install the housing Using new patch l...

Page 81: ...ps 8 11 until proper clearance is achieved 13 Place the CVT cover gasket into position then with the two alignment pins in position install the cover and secure with the cap screws Tighten the cap scr...

Page 82: ...the right side case Account for a thrust washer on the crankshaft and flat washers on gear shift shaft countershaft and reverse idler Note the location of two alignment pins GZ454A GZ272B Disassembli...

Page 83: ...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 washer and a spacer DE677A GZ276 6 Remove two...

Page 84: ...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 U...

Page 85: ...m 0 005 0 015 in Correcting Backlash NOTE If backlash measurement is within the acceptable range no correction is necessary 1 If backlash measurement is less than specified remove an existing shim mea...

Page 86: ...or cracks then using a feeler gauge check the inner to outer rotor clearance If measurements exceed specifi cations the gerotor set must be replaced GZ355 4 Inspect the oil pump cover for scoring dis...

Page 87: ...Diameter 1 Insert a snap gauge into the upper connecting rod small end bore then remove the gauge and measure it with micrometer CC290D 2 Maximum diameter must not exceed specifications Measuring Conn...

Page 88: ...bling 1 Remove the shift forks noting the positions for assem bling then remove the high driven gear outer washer high driven gear high driven gear bearing high driven gear bushing and high driven gea...

Page 89: ...move 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 th...

Page 90: ...r 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 sec...

Page 91: ...side away from the gear GZ347 3 Install the countershaft into the crankcase and secure with the snap ring flat side away from the bearing GZ463A 4 Install the countershaft gear onto the countershaft a...

Page 92: ...l the countershaft assembly into the crankcase GZ280B GZ336 9 Engage the shift forks into the gear shift shaft and push the shift fork shaft into the crankcase GZ339 The right side crankcase is now re...

Page 93: ...ide and one right side GZ342 5 Tighten the 6 mm cap screws to 8 ft lb and the 8 mm cap screws to 20 ft lb using the pattern shown and turning the shafts frequently to ensure there is no binding NOTE R...

Page 94: ...to the oil strainer cap and secure with the cap screws Tighten to 8 ft lb H2 012A Installing Engine Transmission Wildcat X NOTE Arctic Cat recommends new gaskets and O rings be installed whenever serv...

Page 95: ...with the bolt and tighten a new lock nut to 40 ft lb WC169A 6 Install the lower front through bolt and the rear lower cap screw securing the rear drive gear case then with new lock nuts tighten the th...

Page 96: ...s to the fuel injectors WC203A 14 Place the inlet air duct into position then install the CVT intake cooling duct and secure with the clamp WC209A 15 Set the air filter housing into place and secure w...

Page 97: ...re with the clamp 25 Secure the rear body panel with the appropriate fasteners then pour in the prescribed engine oil and connect the neg ative battery cable Install the battery cover and seats 26 Sta...

Page 98: ...nd 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...

Page 99: ...9A 15 Set the air filter housing into place and secure with the three screws on the CVT housing and tighten to 6 ft lb then connect and secure the throttle body inlet air boot A crankcase breather hos...

Page 100: ...h the recommended coolant 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...

Page 101: ...ect 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 supp...

Page 102: ...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 t...

Page 103: ...emove 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...

Page 104: ...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 bott...

Page 105: ...e 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 whil...

Page 106: ...hen 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 co...

Page 107: ...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 an...

Page 108: ...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 as...

Page 109: ...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 Re...

Page 110: ...autions provided with the battery or battery maintainer charger Loss of battery charge may be caused by ambient temper ature ignition OFF current draw corroded terminals self discharge frequent start...

Page 111: ...battery will charge to 95 of its capacity at which time the Maintenance Charge Indicator D will illuminate NOTE For optimal charge and performance leave the charger connected to the battery for a min...

Page 112: ...re 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...

Page 113: ...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 these tests t...

Page 114: ...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 fo...

Page 115: ...auto recover when engine RPM signal returns to normal C1315 Engine RPM Faulty Engine RPM CAN signal received by the EPS incorrect or missing Broken main harness CAN wires or defective ECM EPS will aut...

Page 116: ...meter lead to the brown black wire then with the black lead grounded turn the ignition switch to the ON position The meter must show battery voltage 5 Connect the red meter lead to the yellow green w...

Page 117: ...amp fuse and wir ing connections prior to testing the actuator NOTE The differential must be in the unlocked position for this procedure VOLTAGE 1 Locate the 4 wire connector for the front drive actua...

Page 118: ...et the meter selector to the AC Voltage position 2 Connect the red tester lead to the brown white wire then connect the black tester lead to the green white wire 3 Crank the engine over using the elec...

Page 119: ...tage proceed to step 4 4 Disconnect the two wire plug from the starter relay then connect the red tester lead to the green wire and the black tester lead to the black wire PR297A 5 Depress the starter...

Page 120: ...connec tor in the left rear canopy tube at the juncture of the canopy tube and lower frame If battery voltage is shown on the meter replace the LED VOLTAGE Brakelight NOTE Perform this test at the so...

Page 121: ...the sensor 60 or more to the left and right observ ing the meter The meter should read 4 0 8 0 DC volts after approximately one second in the tilted position If the meter readings are not as specifie...

Page 122: ...ximately 10 seconds after which the letters dIAg will appear on the LCD momentarily followed by COOL EFI033A NOTE The display on the gauge will display in SAE speedometer in MPH mode or Metric speed o...

Page 123: ...N 185 F OFF 175 F right fan ON 195 F OFF 185 F A fan motor B fan relay C fan fuse D wiring connections 5 High Temperature Rev Limiter 5000 RPM 230 F Fuel Sensor FUEL Diagnostic Mode EFI031 Display Fue...

Page 124: ...in Hg Inches of Mercury 34 millibars are equal to 1 inch of mercury Example Gauge reading in the BARO mode 974 millibars thus 974 34 28 64 in Hg Second example Local barometer reading is 29 87 in Hg...

Page 125: ...nnect 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 Sensor...

Page 126: ...ter Relay Circuit High Start switch button starter relay or interconnect harness intermittent or shorted to battery power Correct condition P0630 VIN Not Programmed or Incompatible Verify the LCD gaug...

Page 127: ...place 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 rectifi...

Page 128: ...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...

Page 129: ...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 Dif...

Page 130: ...axle shaft while pulling outward on the axle coupler and remove the axle assembly from the differential PR729C 8 On the Wildcat X from underneath the vehicle remove the carrier bearing support bracke...

Page 131: ...upper and lower through 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 t...

Page 132: ...o 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 Greas...

Page 133: ...ousing 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 3 Using a plastic mallet tap lightly to remove t...

Page 134: ...e 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 be...

Page 135: ...y 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 g...

Page 136: ...gear case cover onto the gear case and secure with three cap screws Tighten evenly using a crisscross pattern GC036B 5 Place the appropriate Backlash Measuring Tool into the splines of the ring gear...

Page 137: ...ash and end play are established the gear case can be assembled see Assembling Differential Assembly in this sub sec tion CC888 Assembling Differential Assembly 1 With the pinion gear and new bearings...

Page 138: ...nly 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...

Page 139: ...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 th...

Page 140: ...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 kn...

Page 141: ...threads of the level hole then install the fill level plug and tighten to 16 ft lb 16 Install the hub caps then install the forward belly panel Remove the jack stands and lower the vehicle Driveshaft...

Page 142: ...r bearing assembly Accounting for an O ring on the splined end of the shaft 9 Remove the shaft then remove the remaining Allen head screws and nuts NOTE Inspect the rubber coupler for deteoriating rub...

Page 143: ...en the set screw at this time 3 Using the existing hardware connect the bearing housing to the frame Tighten to 35 ft lb Do not tighten set screws at this time WC697A 4 Place the rear driveshaft in po...

Page 144: ...WC304 3 Remove the brake caliper PR243A WC606 4 Remove the hub assembly 5 Remove the four cap screws securing the brake disc PR254A NOTE It may be necessary to heat the cap screws to loosen the Locti...

Page 145: ...eplacement is necessary 1 Using a clean towel wipe away any oil or grease from the axle components CD019 2 Inspect boots for any tears cracks or deterioration NOTE If a boot is damaged in any way it m...

Page 146: ...coupler to release the lock ring while pulling back on the CV coupler and slide the drive axle into place in the gear case PR729C NOTE To ensure proper axle seating give it a light pull the axle shou...

Page 147: ...axle nut Finger tighten at this time 4 Install the brake caliper on the steering knuckle using new patch lock cap screws Tighten to 20 ft lb 5 Set the parking brake then turn the ignition switch to th...

Page 148: ...rom 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 e...

Page 149: ...ds Account for a shim Inspecting 1 Inspect the ring gear for excessive wear missing or chipped teeth or discoloration 2 Inspect the thrust button for excessive wear or discol oration 3 Inspect the bea...

Page 150: ...pecified repeat steps 1 and 2 using thicker clearance too great or thinner clear ance too small until correct specification is reached REAR DRIVE INPUT SHAFT HOUSING Removing Disassembling 1 Remove th...

Page 151: ...e clutch pack is not a serviceable compo nent If worn discolored or damaged in any way it must be replaced Assembling Installing 1 Install a new bearing into the input housing and secure with the snap...

Page 152: ...splined shaft then install the lower front and upper rear through bolts Do not tighten at this time NOTE Make sure all spacers are correctly located at the gear case mounting points 4 Install the boo...

Page 153: ...t and washer Keeping the nut and washer engaged tighten the hub nut to 250 ft lb WC303A 12 Install the brake calipers and secure with new patch lock cap screws Tighten to 20 ft lb 13 Install the hub p...

Page 154: ...2 Inspect all threads for stripping or damage 3 Inspect the brake disc if applicable for cracks or warping 4 Inspect the hub for pits cracks loose studs or spline wear REPLACING WHEEL STUDS 1 Secure t...

Page 155: ...e vehicle from the support stand Hydraulic Brake Caliper Wildcat REMOVING DISASSEMBLING 1 Secure the vehicle on a support stand to elevate the wheel then remove the wheel 2 Drain the brake fluid from...

Page 156: ...move four O rings from the brake caliper housing noting the location of the different sized O rings Dis card all seals O rings and crush washers CLEANING AND INSPECTING 1 Clean all caliper components...

Page 157: ...aliper 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 PR239C 5 Making sure brake...

Page 158: ...nce 2 Remove the brake hose from the caliper and close off the brake hose or place a suitable container under the end 3 If a front brake caliper is being removed remove the E clips on the inboard side...

Page 159: ...the brake caliper housings for scoring in the piston bores chipped seal ring grooves or signs of corrosion or discoloration 4 Inspect the piston surface for scoring discoloration or evidence of bindin...

Page 160: ...install it on the caliper Tighten to 20 ft lb 8 Fill the reservoir then bleed the brake system see Peri odic Maintenance Tune Up 9 Install the wheel then using a crisscross pattern tighten the wheel...

Page 161: ...en to 20 ft lb WC611A WC609 6 Fill the reservoir then bleed the brake system see Peri odic Maintenance Tune Up 7 Making sure the hub nut locking plate is properly seated install the wheel and tighten...

Page 162: ...s and deterioration and the condition of the banjo fittings Installing 1 Place the master cylinder into position then using three new crush washers secure the two banjo fittings to the master cylinder...

Page 163: ...eplace shaft 3 Replace coupling 4 Replace joint 5 Replace gear s 6 Replace gears pinions 7 Replace fuse drive select switch front drive actuator Problem Braking poor Condition Remedy 1 Pad worn 2 Brak...

Page 164: ...ads and removing the retainer then remove the spring WC618A 2 Clean all shock absorber components in parts cleaning solvent 3 Inspect each shock rod for nicks pits rust bends and oily residue 4 Inspec...

Page 165: ...the reservoir before removing the retainer FX180 FX1879 2 With the pellet removed depress the reservoir cap and remove the retaining ring from the reservoir with the aid of a valve shim Remove the re...

Page 166: ...ol and twist to lock it onto the IFP FX172 FX171 6 While pushing down on the tool pull up on the shock shaft to remove the shaft assembly FX170 FX169 7 Remove the screw and O ring from the IFP Remove...

Page 167: ...socket to remove the LCS or a deep 5 8 socket to remove the DSC FX163 FX162 3 Inspect and clean the LSC DSC blowout control with the air nozzle and replace its O rings FX160 FX161 4 Heat the body cap...

Page 168: ...y with Loctite Primer 7649 and set aside for assembling curing time is required on primed sur faces FX155 Disassembling Shaft Assembly 1 With the eyelet secured in vise remove the lock nut from the en...

Page 169: ...7 FX146 NOTE For assembling purposes lay the compo nents out in an orderly manner FX145 5 Remove the spiral retaining rings with a small pick and press out the bearing FX144 FX143 6 Clamp the shaft wi...

Page 170: ...s with Loctite Primer 7649 Wipe any excess primer off the shaft and set it aside FX138 Assembling 1 Apply green Loctite 638 to threads two threads up Tighten the eyelet to 50 ft lb FX137 FX136 2 Inser...

Page 171: ...umper Remove the bearing cap seal with a small pick FX131 FX130 5 Replace the bearing cap seal lubricating the internal bore with an appropriate grease FX129 FX128 6 Install the bearing cap assembly R...

Page 172: ...ipped with O rings replace the O ring s The piston faces may require some flat sand ing FX119 FX118 9 When using a bleeding shim it should be kept in time with the compression port Install the piston...

Page 173: ...up 360 around Install a new O ring body cap FX113 FX112 2 Insert the bushing into the body and clamp the body in the vise Tighten the body to 100 ft lb FX111 FX110 3 Tighten the LSC to 14 ft lb or the...

Page 174: ...reser voir body with designated shock oil FX103 FX102 7 Lubricate the IFP assembly with an appropriate grease and install the IFP FX101 FX100 8 Keep the palm of your hand over the Piston Location IFP...

Page 175: ...body Pass the torch quickly over the body to eliminate any air bubbles Insert the shaft assembly into the body FX095 FX094 11 Work the shaft assembly up and down holding pres sure against the IFP Inse...

Page 176: ...X091 FX090 13 Depress the bearing assembly just past the retaining wire groove Install the retaining wire FX089 FX088 14 Push down on the IFP to seat the bearing assembly Remove the IFP screw FX087 FX...

Page 177: ...1 FX080 18 Install the pellet retainer and lubricate with an appro priate grease FX079 FX080 19 Insert the reservoir cap assembly and install the retain ing wire FX077 FX076 20 Charge the reservoir to...

Page 178: ...bsorbers Limited REMOVING 1 Secure the vehicle to a support stand to elevate the wheels and release the load on the suspension 2 Remove the two cap screws and nuts securing each front shock absorber t...

Page 179: ...WC789A 2 Loosen the lock ring towards the top of the shock until there is no pressure on the springs WC778B WC789B 3 Remove the spring retainer and spring support plates WC781A WC793 4 Remove the mai...

Page 180: ...g retainer WC795 4 Install the shocks using the two cap screws and nuts Tighten the screws to 40 ft lb Rear 1 With the proper orientation slide the top spring and spring support plate up to the lock r...

Page 181: ...for the washer 5 Remove the cotter pin and nut securing the tie rod end to the knuckle then remove the tie rod end from the knuckle 6 Remove and discard the cap screws securing the ball joints to the...

Page 182: ...eyelet of the shock absorber to the lower A arm Tighten nut to 40 ft lb head side 5 Secure the A arm assemblies to the frame mounts from step 2 Tighten the cap screws to 40 ft lb 6 Install the knuckl...

Page 183: ...vehicle on support stands that allow access to the rear suspension with the rear tires off the floor 2 Remove the hub cap and lug nuts securing the wheel then remove the hub plate WC317 3 Place a jack...

Page 184: ...ross mount through bolt Tighten the nut to 60 ft lb WC311 2 Slide the trailing arm into the knuckle and secure with the nut Tighten the nut to 60 ft lb then install a new roll pin WC305A NOTE If the s...

Page 185: ...re from the rim CLEANING AND INSPECTING 1 Clean the wheels and hubs with parts cleaning solvent 2 Clean the tires with soap and water 3 Inspect each wheel for cracks dents or bends 4 Inspect each tire...

Page 186: ...worn 1 Adjust preload 2 Replace bushing Problem Suspension noisy Condition Remedy 1 Cap screws suspension system loose 2 A arm related bushings worn 1 Tighten cap screws 2 Replace bushings Problem Veh...

Page 187: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2259 865...

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Arctic Cat WILDCAT/X, Service Manual

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