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WT263

6. Release the spring clip securing the headlight bulb;

then remove the bulb.

WT264

INSTALLING HEADLIGHT ASSEMBLY

1. Install the headlight bulb making sure each tab is posi-

tioned correctly and that it cannot rotate clockwise.

Secure the bulb with the spring.

WT264A

2. Install the rubber seal so that it is fully seated.

WT262

3. Starting with the interior mounting stud, install the

headlight assembly into position.

WT269A



NOTE: Applying lubricant to the studs will aid in

assembly.

4. With the interior stud in place in the grommet, work

the exterior stud into position.



NOTE: It may be necessary to lightly pull on the

exterior bracket to insert the exterior mounting stud.

WT270

5. Secure the headlight with the existing screws.

6. Connect the wiring harness and install the front

fender; then install the grille.

7. Check and adjust headlight aim (see Periodic Mainte-

nance section).

REMOVING TAILLIGHT/BRAKELIGHT



NOTE: The LED taillights are not replaceable. The

entire assembly must be replaced as a component.

Содержание Wildcar Trail

Страница 1: ...ROV SERVICE MANUAL 2014 WILDCAT TRAIL...

Страница 2: ...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 i...

Страница 3: ...ponents 59 Servicing Bottom Side Components 63 Installing Bottom Side Components 65 Servicing Left Side Components 68 Installing Engine 72 Fuel Lubrication Cooling 77 Throttle Body 77 Gas Tank 79 Gas...

Страница 4: ...Ignition Coil Resistance primary Less than 1 ohm Ignition Coil Primary Voltage Battery Voltage Stator Coil crankshaft position sensor Resistance AC generator 100 150 ohms Less than 1 ohm Crankshaft Po...

Страница 5: ...8 Carrier Bearing Bracket Frame 20 27 Carrier Bearing Set Screw Front Shaft 6 8 Pinion Housing Differential Housing 23 31 Differential Housing Cover Differential Housing 23 31 Hub Axle Knuckle 200 270...

Страница 6: ...bricant meets all of the lubri cation requirements of this vehicle FILLING GAS TANK Since gasoline expands as its temperature rises the gas tank must be filled to its specified capacity only Expan sio...

Страница 7: ...e the bat tery clean the battery posts and 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 correctl...

Страница 8: ...ming Light 0644 296 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 F...

Страница 9: ...o not twist foam to remove oil 6 Attach the foam filter to the inner filter screen WT179 7 Clean any dirt or debris from inside the air cleaner Be sure no dirt enters the throttle body 8 Place the foa...

Страница 10: ...Servicing Top Side Components Spark Plugs A light brown insulator indicates the plug is correct A white or dark insulator indicates that the engine may need to be ser viced To maintain a hot strong sp...

Страница 11: ...ended 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 wa...

Страница 12: ...ws Tighten all nuts bolts and cap screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts bolts and cap screws are tightened...

Страница 13: ...bly into position WT269A NOTE Applying lubricant to the studs will aid in assembly 4 With the interior stud in place in the grommet work the exterior stud into position NOTE It may be necessary to lig...

Страница 14: ...ng 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 0748 285 NOTE There should be an average operating loa...

Страница 15: ...rocedure watch the reservoir very closely to make sure there is always a sufficient amount of brake fluid If the fluid level gets low in the reservoir refill the reservoir before the bleeding procedur...

Страница 16: ...ke pads are properly burnished To properly burnish the brake pads use the following procedure 1 Choose an area large enough to safely accelerate the vehi cle to 30 mph and to brake to a stop 2 Acceler...

Страница 17: ...lt on the drive clutch then making sure the X marks are aligned install the alignment shims if applicable and stationary sheave on the driven clutch WT517A WT200A 2 Using an appropriate strap or oil f...

Страница 18: ...d be checked periodically for damage bends cracks deterioration broken components and missing components Front Bumper REMOVING 1 Remove the hood and grille see Hood and Grille 2 Disconnect the headlig...

Страница 19: ...ING HOOD 1 Turn the two quarter turn fasteners counterclockwise and remove hood WT226A 2 Insert the hood tabs into the grille and lay the hood down flat Turn both of the fasteners clockwise secur ing...

Страница 20: ...WT241A WT227A 5 Loosen the gas tank filler hose clamp and slide it down towards the tank WT244 6 Remove the panel from the frame while also pulling on the filler hose Seal off the hose to prevent obj...

Страница 21: ...tubes WT486 INSTALLING REAR BODY PANELS 1 If removed install the clutch air intake tube through the left rear body opening and secure it with the plate and existing cap screws Tighten securely WT484A...

Страница 22: ...tall the left rear fender and secure it with the exist ing hardware 7 Install the tabs of the body panel into the slots in side panel then insert the plastic insert into the gas tank filler hose Tight...

Страница 23: ...Make sure the bottom of the side panel is on the outside of the inner splash panel WT212 2 Secure the side panel using the existing cap screws and push pins Tighten all hardware to 60 in lb Dash Swit...

Страница 24: ...o the dash until they snap into place WT341 2 Connect the 12 volt accessory plug ignition switch and LCD gauge 3 With the steering shaft slid through the dash install the dash and secure it with the e...

Страница 25: ...sh pins Install the engine access panel and secure with the quarter turn screw WT281B 3 Install the shifter knob so the P is facing forward then tighten the jam nut to 12 ft lb 4 Install the seats Rac...

Страница 26: ...catching 4 Check for loose cap screws on rack and pinion housing 5 Check for seal damage or lubricant leaks NOTE The steering assembly rack and pinion is not repairable and must be replaced as an asse...

Страница 27: ...nd steering wheel for installing purposes WT298A NOTE Any time steering components are disas sembled all connecting components should be marked for proper alignment during assembling 2 Remove the hair...

Страница 28: ...e the tilt assembly out of the steering shaft WT349 NOTE Only the tilt assembly is a serviceable item If the shaft is damaged it must be replaced INSPECTING 1 Check the splines for wear or signs of tw...

Страница 29: ...the wheel then remove the wheel 2 Remove the nut securing the hub 3 Remove the brake caliper 4 Remove the hub assembly 5 Remove the cotter pin from the tie rod end and remove the tie rod end from the...

Страница 30: ...4 Install the tie rod end and secure with the nut coated with red Loctite 263 Tighten to 30 ft lb then install a new cotter pin and spread the pin NOTE During assembling new cotter pins should be ins...

Страница 31: ...and rear The front measurement should be 3 6 mm 1 8 1 4 in greater than the rear measurement toe out WT292A To adjust the wheel alignment use the following procedure 1 Center the steering rack then u...

Страница 32: ...ss the accelerator pedal completely and pull rearward on the cable end There should not be any free play and the tension sleeve should not be com pressed WT099B 3 To adjust the throttle cable locate t...

Страница 33: ...r knob and seats Make sure the seats lock securely in place Shift Cable REMOVING 1 Remove the seats and center console 2 Remove the E clip securing the shift cable to the transaxle WT439B 3 While hold...

Страница 34: ...USTING 1 Remove the seats shifter knob engine access panel and center console WT281B 2 With the transmission in neutral loosen the jam nut A and adjust the cable until there is a small amount of free...

Страница 35: ...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 With the gasket in pl...

Страница 36: ...k securely in place Seats REMOVING INSTALLING 1 To remove a seat pull the seat lock lever up Raise the rear of the seat and tilt it forward WT003A 2 To install a seat slide the front of the seat into...

Страница 37: ...sen or out tighten WT108A Floor REMOVING 1 Remove the seats engine access panel and center console 2 Remove the fasteners securing the floor to the frame WT344A CLEANING AND INSPECTING 1 Clean any deb...

Страница 38: ...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 p...

Страница 39: ...10 hours or 200 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...

Страница 40: ...fective 4 ECM defective 5 Fuel injector obstructed 6 Valve clearance out of adjustment 1 Drain gas replace with clean gas 2 Clean replace plug s 3 Replace stator coil 4 Replace ECM 5 Replace fuel inje...

Страница 41: ...place with clean gas 2 Drain excess oil change oil 3 Replace service rings cylinder 4 Replace cylinder head 5 Replace cylinder 6 Replace valves 7 Replace seals Problem Engine lacks power Condition Rem...

Страница 42: ...the cap screws securing the rear splash panels to the frame WT488A WT489A WT362A 2 Remove the left rear wheel then remove the outer clutch cover Retain the cap screws WT182A 3 Remove the cap screw sec...

Страница 43: ...ther tube and loosen the air intake clamp WT405A WT311A NOTE Removing the intake boot with air box will aid in installation 7 Loosen the throttle body clamp WT316A 8 Remove and discard the top patch l...

Страница 44: ...alling inside 11 Remove the ISC connector A MAP IAT connector B and the TPS connector C then loosen the clamp securing the throttle body to the intake manifold Leave it connected to the throttle cable...

Страница 45: ...nal position in the engine Tighten securely 16 Remove the spark plug caps A Disconnect the cam position sensor B coil connectors C and oxygen O2 sensor D WT405B NOTE Leave the oxygen O2 sensor in the...

Страница 46: ...and discard the lock nuts on the transaxle mounting plate WT225A 22 Loosen the jam nut A then loosen the adjuster nut B but do not remove it from plate WT412A 23 Remove the cap screws securing the tra...

Страница 47: ...ecuring the cylinder head cover Account for rubber washers and silicone held gaskets ROV1 005A ROV1 001A 2 Remove the two fasteners securing the starter motor ROV1 116A 3 Remove the magneto and timing...

Страница 48: ...n remov ing the camshaft holder ROV1 010 NOTE The camshaft holder and cylinder head have matching code numbers and must remain a set KC548A KC549A 7 Lift on the chain and remove both camshafts and spr...

Страница 49: ...ng care not to let the pistons fall against the cyl inder remove the cylinder and account for two dowel pins Remove and discard the base gasket 15 Using a suitable pick remove the circlip from the pis...

Страница 50: ...with the present shim size to obtain the recommended replacement shim Cleaning Inspecting Valve Cover NOTE If the valve cover cannot be trued the cylin der head assembly must be replaced 1 Wash the ca...

Страница 51: ...49 KCINTAKE TAPPET CLEARANCE TABLE INTAKE...

Страница 52: ...50 KCEXHAUST TAPPET CLEARANCE TABLE EXHAUST...

Страница 53: ...Apply grease to the inside surface of new valve seals then place a lower spring seat A and valve guide seal B over each valve guide WT582A 2 Insert each valve into its original location 3 Install eac...

Страница 54: ...or 0 85 mm oil WT586 Measuring Piston Pin Outside Diameter and Piston Pin Bore 1 Measure the piston pin outside diameter at each end and in the center If measurement is less than 17 894 mm the piston...

Страница 55: ...s sure move the cylinder head 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 Correct any high spots before a...

Страница 56: ...a 320 grit ball hone NOTE To produce the proper 60 cross hatch pat tern use a low RPM drill 600 RPM at the rate of 30 strokes per minute If honing oil is not available use a lightweight petroleum bas...

Страница 57: ...g the intake side of the engine and slide the piston pin through the piston then install the other piston circlip 3 Repeat steps 1 and 2 for the other piston 4 Install a new base gasket and the two do...

Страница 58: ...ening the head bolts 13 With a light film of engine assembly grease applied to the tappets install the correct shim B and tappet A to each valve of the cylinder head as noted dur ing disassembling WT4...

Страница 59: ...rews to 15 ft lb WT153 19 With the engine at TDC and each cam timing mark properly aligned place each camshaft holder on the proper camshaft NOTE Each holder has an In and Ex WT156A 20 Install the fas...

Страница 60: ...ming sensor with O ring lightly coated with grease WT165 26 Install the timing inspection and magneto plugs Tighten the timing inspection plug to 10 ft lb and the magneto plug to 11 ft lb WT166A 27 In...

Страница 61: ...el pins and two longer fasteners for assembly purposes ROV1 048 3 Remove the chain by pulling it down through the crankcase and out the PTO side 4 Remove the fastener securing the chain guide to the c...

Страница 62: ...tarter gear 7 Remove the cap screw securing the rotor flywheel to the crankshaft Account for a washer and install the crankshaft protector KC545 8 Using the flywheel puller remove the flywheel KC546 9...

Страница 63: ...emove the oil pan and account for two dowel pins and a gasket NOTE Using a rubber mallet will aid in the removal of the oil pan 16 Remove the oil pressure relief and oil screen Account for a rubber se...

Страница 64: ...crankshaft from the case 22 Remove the cap screws securing the connecting rods together ROV1 083A ROV1 084 NOTE Note the color coding on the bearings for assembling purposes NOTE Keep both the top an...

Страница 65: ...ing broken or missing hold down clips or loose cap screws 2 Inspect the bearings in the magneto housing for dis coloration roughness when rotated and secure fit in bearing bores REPLACING STATOR COIL...

Страница 66: ...The mark will be a number 1 or 2 located on the side sur face of rod as shown Determine the replacement bearing color by following the table KC527A The crank cases go with a grade mark The mark will...

Страница 67: ...ritical to ensure the lines between the two connecting rod halves match in a straight line 3 In the top crankcase apply a suitable assembly lubri cant to the six plain bearing tops and bottoms then ca...

Страница 68: ...KC550A NOTE The longer bolt is installed just to the right of the oil filter 8 Rotate the engine again and using a twelve point socket tighten the connecting rods to 22 ft lb then to 36 ft lb and fina...

Страница 69: ...Install a new gasket and two dowel pins ROV1 100A NOTE The two longer fasteners go in the dowel pin locations 13 Install the oil pan Tighten the cap screws to 8 ft lb ROV1 069 14 With the O rings and...

Страница 70: ...l onto the crankshaft and secure with the cap screw Tighten to 60 ft lb KC545 19 Using a gasket scraper clean off the existing gasket and case from the MAG cover Using a new gasket and dowel pins inst...

Страница 71: ...acement is necessary 1 Using parts cleaning solvent wash grease dirt and foreign matter off all components dry with com pressed air 2 Remove any drive belt dust accumulation from the stationary sheave...

Страница 72: ...A DRIVEN CLUTCH Disassembling 1 Remove the stationary sheave from the movable sheave Account for the shims WT526 WT191 2 In the stationary sheave using a suitable tool remove the E clips securing the...

Страница 73: ...taining plate C in the moveable sheave then place in a suitable driven clutch compression tool and fin ger tighten the wing nut WT527 3 Secure the spring retaining plate with the existing cap screws a...

Страница 74: ...nment must be corrected add or remove the appropriate alignment shim p n 1423 189 1 02 mm or p n 1423 219 0 51 mm 3 Repeat steps 1 and 2 as required until correct align ment is achieved NOTE To instal...

Страница 75: ...of the trans axle so they are joined together Push the front axles rear ward until the front differential mounting holes are properly aligned Tighten the clamp securely WT424A 8 Remove the clamps fro...

Страница 76: ...osition sensor C WT396A 12 Remove the three cap screws from the PTO side of the engine and install the clips securing the starter cable and the gasline hose Tighten the cap screws to 9 ft lb Install t...

Страница 77: ...x bracket E with the cap screw and tighten to 5 ft lb WT478A 17 Remove the towels from the intake manifold and install the fuel rail Account for two O rings Tighten the existing cap screws B to 8 ft l...

Страница 78: ...crews Install the push pins securing the wiring harness to the left side splash panel WT364A 24 Install the rear body panels and the side panels see Steering Frame Controls 25 Install the seat belt as...

Страница 79: ...ssary see Periodic Maintenance Tune Up Throttle Body 1 Turn the ignition switch to the OFF position then remove the ignition key 2 Remove the rear body panels and the cargo box 3 Remove the clamp on t...

Страница 80: ...ully into the boot Secure with worm clams and tighten securely WT567A WT566A 12 Connect the ISC connector A MAP IAT connector B and the TPS connector C WT397A 13 Install the air filter housing in plac...

Страница 81: ...iscard the lock nuts securing the right side frame tube WT365A 6 Remove the four cap screws securing the seat base to the frame WT359A 7 Remove the remaining cap screws securing the frame tubes to the...

Страница 82: ...t show 6 68 8 44 kg cm2 95 120 psi 5 With the engine running at 3000 RPM and the coolant at approximately 195 F cooling fan cycling the pressure gauge must show 5 27 6 68 kg cm2 75 95 psi 6 Remove the...

Страница 83: ...ts and the oil inlet and out let for cracks or bends INSTALLING 1 Place the oil cooler into position and secure with the existing hardware Tighten securely 2 Connect the oil hoses and secure with the...

Страница 84: ...OVING 1 Remove the hood and grille 2 Using appropriate clamps close off the coolant hoses to the radiator and the oil hoses to the oil cooler WT455 WT459 3 Using an appropriate Allen wrench remove the...

Страница 85: ...cool ant into a suitable container WT458 NOTE If the radiator will be replaced transfer the cooling fan and oil cooler to the new radiator INSTALLING 1 Place the assembled radiator studs into the mou...

Страница 86: ...The thermostat is located on the right side in a housing in line with the coolant hose behind the muffler NOTE Removing the muffler will aid in removing 1 Drain a couple of cups of coolant from the w...

Страница 87: ...ator 2 Remove the fan assembly from the radiator INSTALLING 1 Position the fan assembly on the radiator then secure with existing hardware NOTE The fan wiring must be directed downward 2 Install the r...

Страница 88: ...vidually press in the bearings WT573 4 Install the impeller in place and secure with a washer and E clip 5 Install the magneto cover and secure with the cap screws Tighten the screws to 11 ft lb 6 Ins...

Страница 89: ...the FUEL relay by swapping with another relay If the pump runs replace the FUEL relay 7 If the pump still is inoperative proceed to REMOV ING REMOVING 1 Remove the passenger seat NOTE The power suppl...

Страница 90: ...he fuel pump 4 Install the passenger seat Troubleshooting FULL EMPTY Problem Starting impaired Condition Remedy 1 Gas contaminated 2 Throttle cable too tight 1 Drain gas tank and fill with clean gas 2...

Страница 91: ...ded 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 stops and sho...

Страница 92: ...the Maintenance Charge Indicator D will illuminate NOTE For optimal charge and performance leave the charger connected to the battery for a minimum 1 hour after the Maintenance Charge Indicator D illu...

Страница 93: ...ound The fan should operate WT558A NOTE Fan motor resistance checks are not recom mended Resistance values change with the motor commutator position Power Distribution Module PDM FUSES RELAYS NOTE To...

Страница 94: ...onnect the coil connector Connect the red tester lead to one coil terminal then connect the black tester lead to the other coil terminal 2 Resistance must be less than 1 ohm NOTE If the meter does not...

Страница 95: ...er head 1 Remove the cargo box 2 Disconnect the sensor WT405D NOTE For this test the meter must be in OHMS position 3 On the sensor side of connector connect the black nega tive test lead to one black...

Страница 96: ...t the main 30 amp fuse the battery or the main wiring harness 4 Connect the red meter lead to the brown black wire then with the black lead grounded turn the ignition switch to the ON position The met...

Страница 97: ...itch 30 amp fuse and wir ing connections prior to testing the actuator VOLTAGE 1 Locate the 4 wire connector for the front drive actua tor above the differential then connect the red meter lead to the...

Страница 98: ...tarter 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 VOLTAGE Perform this test on the starter m...

Страница 99: ...sition and wait for 10 seconds 3 Release the accelerator pedal and wait an additional 10 seconds 4 Turn the key to the OFF position and allow the gauge to shut off Regulator Rectifier The regulator re...

Страница 100: ...onnected 1 Connect the three wire plug to the sensor then remove the right side mounting screw securing the sensor to the frame 2 Select DC Voltage on the multimeter 3 Connect the red tester lead to t...

Страница 101: ...al 10 seconds 4 Turn the key to the OFF position and allow the gauge to shut off EFI Diagnostic System DIGITAL GAUGE The digital gauge can be used as a diagnostic tool for many of the DTC s displayed...

Страница 102: ...eit or Celsius DTC P0112 P0113 P0114 Usage Verify correct output of IAT sensor NOTE After engine has been running IAT readings will be higher than outside air temperature due to engine and engine comp...

Страница 103: ...st be cleared as noted in the code chart Code Fault Description Possible Cause Fault Recovery C0063 Tilt Sensor Circuit High Sensor or interconnect harness shorted to battery power Correct condition C...

Страница 104: ...mshaft Angle Sensor Intermittent Erratic Sensor or interconnect harness intermittent Correct condition P0480 Fan Relay Control Circuit Relay erratic or intermittent Correct condition P0484 Fan Relay C...

Страница 105: ...proached see table When the RPM limiter is acti vated it could be misinterpreted as a high speed mis fire Gear Reverse Park High Neutral Low Fail Safe Mode Incorrect ECU Gauge P0630 Warranty Registrat...

Страница 106: ...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...

Страница 107: ...front differential input housing With the engine stopped and the ignition switch in the ON position a momentary whirring sound can be heard each time the drive select switch is shifted If no sound is...

Страница 108: ...then tighten the cap screw on the driveshaft side to 36 in lb WT532A NOTE It is important to tighten this cap screw while the others are loose to ensure proper seating of the actuator 5 Tighten the r...

Страница 109: ...pers WT287A 7 Remove the hub nut and discard the cotter key WT328A 8 Remove and discard the patch lock cap screw securing the shock absorber to the upper A arm and retain the washer Remove the shock a...

Страница 110: ...boot on the output shaft of the front differential WT422A 15 Pull the front differential forward until the driveshaft splines are free from the differential WT502 16 Remove the differential from the v...

Страница 111: ...nt for a spacer GC010 5 Remove the snap ring securing the input shaft bearing then place the pinion housing in a press and remove the bearing GC011 AF984 KX219 Assembling Input Shaft 1 Place the pinio...

Страница 112: ...input shaft into the pinion housing then secure in the bearing with a circlip GC009A 5 Place the pinion housing with new gasket onto the dif ferential housing then secure with existing cap screws Tig...

Страница 113: ...osition of parts for assembling purposes KX175 5 Remove the left differential bearing flange assembly and account for a shim Mark the shim as left side KX177 KX178 6 Place the differential with the op...

Страница 114: ...le parts from the gear case hous ing then discard the housing and lock collar Assembling Pinion Gear 1 Install the bearing onto the pinion shaft Install the pinion shaft collar CC882 CC883 2 Place the...

Страница 115: ...case then while holding the pinion stationary rock the ring gear forward and back to determine if any backlash exists If no backlash exists install a thicker shim and recheck GC036A 3 Install the bear...

Страница 116: ...s to decrease backlash NOTE Higher backlash settings usually result in quieter gear operation GC037A Ring Gear End Play After correcting backlash ring gear end play can be adjusted To adjust end play...

Страница 117: ...as a complete unit 3 Assemble the fork and sliding collar into the cover assembly then install the left bearing flange bearing assembly and seat firmly into the cover CF266A CF267A 4 Apply a light co...

Страница 118: ...cap screws to 28 ft lb CD103 CD110 Removing Installing Axle Seal NOTE This procedure can be performed on a rear gear case 1 Remove the seal using a seal removal tool CC899 NOTE Prior to installing th...

Страница 119: ...go between the mounting brackets and the front differential on the left side of the differential 4 Install the boot clamp securing the boot to the output shaft of the front differential WT422A 5 Inst...

Страница 120: ...OTE During assembly new cotter pins should always be used NOTE If the cotter pin cannot be inserted due to misalignment of the hole and the slots in the nut always tighten the nut until it is properly...

Страница 121: ...hub nut and discard the cotter key WT328A 5 Remove and discard the upper ball joint cap screw and rotate the knuckle downward away from the drive axle 6 Place a drain pan under the vehicle to contain...

Страница 122: ...4 NOTE Steps 1 3 can be used to replace the out board boot ASSEMBLING AXLES 1 Install the inner boot with the small clamp making sure the ends of the clamp are positioned correctly NOTE The boot is po...

Страница 123: ...brake disc into position in the steer ing knuckle followed by an 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...

Страница 124: ...nsaxle 4 Using an appropriate seal installer and protector install a new seal so it seats flush with the case 0 5 mm deep TA110 Front Output Seal NOTE The transaxle must be removed for this pro cedure...

Страница 125: ...ce the vehicle securely on a support stand 2 Remove the hood wheels seats center console floor and driveshaft 3 Remove the E clip connecting the shift cable to the transaxle Remove the shift cable bra...

Страница 126: ...ring the gear position switch Gently pry the switch off the shift rail and account for the wave washer 5 Remove the screws securing the case halves together 6 While prying the two halves apart with an...

Страница 127: ...afts simultaneously TA059 6 Place the transaxle upright on the bench and dump any remaining fluid into the pan 7 With the transaxle flat on the bench remove the four screws securing the pinion gear as...

Страница 128: ...1 Inspect the bearings for free and smooth turning If either bearing does not turn freely it must be replaced TA016 2 Inspect the gear teeth for nicks cracks chips or signs of wear If any are present...

Страница 129: ...must be replaced E Idler Shaft 1 Inspect the bearings for free and smooth turning If either bearing does not turn freely it must be replaced TA033 2 Inspect the gear teeth for nicks cracks chips or s...

Страница 130: ...lls into the shift drum groove Install the washer to retain the spring TA122A 7 While holding pressure on the washer rotate the cam counterclockwise to lock the cam onto the shift drum TA040 8 Install...

Страница 131: ...y are present the shaft must be replaced TA052 TA053 4 Inspect the dogs for nicks cracks chips or signs of wear If any are present the dog must be replaced TA054 H Input Shaft 1 Inspect the bearings f...

Страница 132: ...e pinion assembly must be replaced Turn the pinion gear by hand If any sticking or binding is observed the bearing must be replaced Use the following procedure 1 Using an awl pry the plug from the cas...

Страница 133: ...est shim and install the snap ring If the snap ring will not fit in the groove remove the shim and install the next size smaller shim Continue until the snap ring can be installed 2 With the appropria...

Страница 134: ...sting shim and install a new thicker shim from shim kit TA102 8 If backlash measurement is more than specified remove the existing shim and install a thinner shim NOTE Continue to remove measure and i...

Страница 135: ...he shift fork pins face the installer NOTE Engage all four shafts before seating them simultaneously into the case NOTE Ensure the chain stays engaged in the sprocket teeth NOTE The shift shaft rail s...

Страница 136: ...detent over the shift drum aligning the appropriate splines of the detent with the shaft splines and the dot facing up TA134A 10 Install an appropriate bearing seal protector tool onto the bearing of...

Страница 137: ...nput shaft turn the bell crank to the correct position TA012C TA138A TA137A TA012B 16 Using an appropriate seal installer gently install a new plug over the pinion gear assembly so it fully seats past...

Страница 138: ...e lower cap screw on the front left shock and slide the shock off of the upper A arm Discard the cap screw but retain the washer WT323A 4 Rotate the steering rack all the way to the right then remove...

Страница 139: ...Slide the driveshaft off of the transaxle WT426 9 Remove the clamp behind the carrier bearing and slide the rear driveshaft rearward Remove the rear driveshaft WT421B 10 Remove the front boot clamp s...

Страница 140: ...ed surfaces with emery cloth to ensure a smooth surface WT438 1 Slide the carrier bearing onto the shaft with the set screws facing down towards the longer end of the driveshaft making sure it is past...

Страница 141: ...l cap screws washers and new lock nuts Tighten to 38 ft lb WT425 9 With the steering rack turned all the way to the right install the front left upper A arm cap screw washer and new lock nut Tighten t...

Страница 142: ...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 the...

Страница 143: ...Caliper REMOVING DISASSEMBLING 1 Secure the vehicle on a support stand to elevate the wheel then remove the wheel 2 Drain the brake fluid from the caliper hose and mas ter cylinder through the bleed...

Страница 144: ...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...

Страница 145: ...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...

Страница 146: ...tubing over the front left brake caliper bleeder valve and direct the other end into a container Remove the master cylinder cover then open the bleeder valve Allow the brake fluid to drain until the r...

Страница 147: ...ition of the banjo fittings INSTALLING 1 Place the master cylinder into position and secure with cap screws Tighten to 25 ft lb WT513A 2 Install the pivot pin and secure with a new cotter pin then con...

Страница 148: ...t improper 3 Bearing damaged 4 Gears worn chipped 5 Splines worn 1 Adjust backlash 2 Adjust contact 3 Replace bearing 4 Replace gears 5 Replace shaft s Problem Braking poor Condition Remedy 1 Pad worn...

Страница 149: ...ers to the end of the threads and removing the retainer then remove the spring 2 Clean all shock absorber components in parts clean ing solvent 3 Inspect each shock rod for nicks pits rust bends and o...

Страница 150: ...the adjustment knobs clockwise while counting the number of clicks until the adjustment knob is fully closed or bottomed There are six clicks per full 360 revolution of the adjustment knob After notin...

Страница 151: ...taining wire into the groove between the cap and body FX063 FX062 5 Tap upward on body cap removal tool to release cap then depress the bearing assembly to full expose retaining wire FX061 FX060 6 Usi...

Страница 152: ...ody cap and body Remove any thread lock residue from the body and body cap using a wire brush and small pick FX055 FX054 9 Remove the O ring from the body cap then push the IFP out of body FX053 FX052...

Страница 153: ...washer FX044 FX043 14 Use Gas Shock Rod Body Clamping Tool to secure the shaft then apply sufficient heat to the eyelet to break the thread lock bond between the shaft and eye let FX042 FX041 15 Using...

Страница 154: ...638 to the shaft FX038 FX037 2 Tighten to 50 ft lb FX036 3 Assemble the shaft with eyelet washer and bumper NOTE Always lubricate seals and O rings with a thin layer of molybdenum grease before insta...

Страница 155: ...mpression valve stack FX028 FX027 8 Replace the O ring and bearing on the piston Install the piston making sure the compression side of piston is next to the compression shims FX026 FX025 9 Install th...

Страница 156: ...f the IFP must be decreased by 0 480 on the this shock absorber when the IFP depth is determined from the top of the body B Example 8 164 0 480 7 684 installed IFP depth NOTE Handle the body carefully...

Страница 157: ...re inserting Insert the shaft assembly into the oil slowly allowing air bubbles to escape FX013 FX012 16 Push the bearing assembly just past the retainer groove in the body then install the wire retai...

Страница 158: ...nflation Needle to the specified pressure for about 10 seconds the shaft should fully extend FX007 FX006 19 Inspect both ends of shocks for leaks Use rubber mal let to secure bearing cap assembly FX00...

Страница 159: ...6 Remove and discard the cap screws securing the ball joints to the knuckle WT329A 7 Tap the ball joints out of the knuckle then remove the knuckle 8 Remove and discard the cap screw securing the lowe...

Страница 160: ...d 13 Place the A arm in a bench vise and using an appro priate tool drive out and discard the bushings WT600 REMOVING LOWER NOTE Having the steering rack turned completely to the left and the clamp or...

Страница 161: ...ds cracks and worn bush ings 4 Inspect the ball joint mounting holes for cracks or damage 5 Inspect the frame mounts for signs of damage wear or weldment damage INSTALLING 1 Using a suitable press pre...

Страница 162: ...ith the axle going through the center of the knuckle rotate it upward and secure the upper A arm to the knuckle using a new patch lock cap screw Tighten the cap screws to 35 ft lb WT332 11 Install the...

Страница 163: ...upport stand that allows access to the rear suspension with the rear tires off of the floor Remove the wheels NOTE The upper A arm can be removed without removing the hub or the knuckle If it is the t...

Страница 164: ...the cap screws and nuts securing the lower A arm to the frame Discard the nuts WT445A 9 Remove the seals and sleeve WT444 NOTE Only remove the bushings if they must be serviced 10 Place the A arm in...

Страница 165: ...48B 5 Tighten cap screw A to 35 ft lb cap screw B to 35 ft lb cap screw C to 20 ft lb and cap screw D to 20 in lb 6 Using the existing cap screws and new lock nuts secure the knuckle to the upper and...

Страница 166: ...d secure it to the lower A arm links 2 Install the bushing retainers and bushings Finger tighten the cap screws only at this point WT324 2 Tighten the A arm links to 20 ft lb then tighten the sway bar...

Страница 167: ...tire repair kit or replace the tire Troubleshooting WARNING Use only Arctic Cat approved tires when replacing tires Failure to do so could result in unstable vehicle operation WARNING Always use the...

Страница 168: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2260 145...

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