2014 Wildcat Trail Service

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WILDCAT TRAIL

2014

SERVICE MANUAL

[ROV]

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2014 Arctic
Cat Wildcat Trail. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific vehicle component or system and, in addition to the
standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual
as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.
The service technician should become familiar with the operation and construction of each component or system by
carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient
with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.
All Arctic Cat publications and decals display the words Warning, Caution, Note, and At This Point to emphasize
important information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of serious personal injury or even death. A CAUTION identifies 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 vehicle. The symbol  NOTE: identifies supplementary information worthy of particular attention. The symbol  AT THIS POINT directs the technician to certain and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic
Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.

May 2014

TABLE OF CONTENTS
General Information ..............................................................2
General Specifications............................................................... 2
Torque Specifications................................................................. 3
Torque Conversions (ft-lb/N-m).................................................. 4
Drive Belt Break-In Procedure ................................................... 4
Gasoline - Oil - Lubricant ........................................................... 4
Genuine Parts............................................................................ 5
Preparation For Storage ............................................................ 5
Preparation After Storage .......................................................... 5

Periodic Maintenance/Tune-Up ............................................6
Periodic Maintenance Chart ...................................................... 6
Lubrication Points ...................................................................... 7
Air Filter ..................................................................................... 7
Testing Engine Compression ..................................................... 7
Spark Plugs ............................................................................... 8
Muffler/Spark Arrester................................................................ 8
Engine Oil - Filter ....................................................................... 9
Front Differential - Transaxle Lubricant ...................................... 9
Nuts/Bolts/Cap Screws ............................................................ 10
Headlight/Taillight-Brakelight.................................................... 10
Hydraulic Brake System........................................................... 13
Burnishing Brake Pads ............................................................ 14
Replacing V-Belt ...................................................................... 14

Steering/Frame/Controls ....................................................16
Front Bumper ........................................................................... 16
Hood and Grille........................................................................ 17
Body Panels............................................................................. 17
Center Console........................................................................ 22
Rack and Pinion Assembly ...................................................... 23
Steering Wheel ........................................................................ 25
Steering Shaft .......................................................................... 26
Steering Knuckles.................................................................... 27
Checking/Adjusting Front Wheel Alignment............................. 29
Accelerator Pedal..................................................................... 29
Shift Lever................................................................................ 30
Shift Cable ............................................................................... 31
LCD Gauge.............................................................................. 32
Exhaust System....................................................................... 33
Cargo Box ................................................................................ 33
Seats........................................................................................ 34
Doors ....................................................................................... 34
Floor......................................................................................... 35
Troubleshooting ....................................................................... 36

Engine ..................................................................................37
Troubleshooting ....................................................................... 38
Removing Engine .................................................................... 40
Top-Side Components ............................................................. 45
Removing Top-Side Components ............................................ 45
Servicing Top-Side Components ............................................. 48
Bottom-Side Components........................................................ 59
Removing Bottom-Side Components ...................................... 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/Vent Hoses....................................................................... 80
Oil Filter/Oil Pump.................................................................... 80
Oil Cooler................................................................................. 80
Oil Flow Chart .......................................................................... 81
Liquid Cooling System ............................................................. 82
Radiator ................................................................................... 82
Thermostat .............................................................................. 84
Fan........................................................................................... 85
Water Pump ............................................................................. 85
Fuel Pump/Fuel Level Sensor.................................................. 87
Troubleshooting ....................................................................... 88

Electrical System ................................................................ 89
Battery ..................................................................................... 89
Accessory Receptacle/Connector ........................................... 90
Brakelight Switch ..................................................................... 90
Engine Coolant Temperature (ECT) Sensor ............................ 91
Fan Motor................................................................................. 91
Power Distribution Module (PDM)............................................ 91
Ignition Coils ............................................................................ 92
EFI Sensors/Components........................................................ 92
Speed Sensor .......................................................................... 94
Ignition Switch.......................................................................... 94
Headlight Switch ...................................................................... 94
Drive Select Switch.................................................................. 94
Reverse Override Switch ......................................................... 95
Front Drive Actuator................................................................. 95
Stator Coil ................................................................................ 95
Starter Motor............................................................................ 96
Starter Relay............................................................................ 96
Engine Control Module (ECM)................................................. 97
Regulator/Rectifier ................................................................... 97
Headlights................................................................................ 97
Taillight-Brakelight.................................................................... 97
Tilt Sensor................................................................................ 98
Throttle Position Sensor (TPS) ................................................ 98
EFI Diagnostic System ............................................................ 99
RPM Limiter ........................................................................... 103
Troubleshooting ..................................................................... 104

Drive and Brake Systems................................................. 105
Front Drive Actuator............................................................... 105
Front Differential .................................................................... 106
Drive Axles............................................................................. 119
Transaxle ............................................................................... 121
Driveshaft/Carrier Bearing ..................................................... 136
Hub ........................................................................................ 139
Hydraulic Brake Caliper ......................................................... 141
Master Cylinder Assembly ..................................................... 144
Troubleshooting ..................................................................... 146

Suspension ....................................................................... 147
Shock Absorbers ................................................................... 147
Front A-Arms ......................................................................... 157
Rear A Arms .......................................................................... 161
Front Sway Bar ...................................................................... 164
Rear Sway Bar....................................................................... 164
Wheels and Tires................................................................... 165
Troubleshooting ..................................................................... 165

General Information
NOTE: Some photographs and illustrations used in
this manual are used for clarity purposes only and are
not designed to depict actual conditions.
NOTE: Whenever a part is worn excessively, cracked,
or damaged in any way, replacement is necessary.
NOTE: Never reuse a lock nut. Once a lock nut has
been removed, it must be replaced with a new lock nut.

General Specifications
CHASSIS
449 kg (990 lb)
817 kg (1802 lb)
280.6 cm (110.5 in.)
163.3 cm (64.3 in.)
127 cm (50 in.)
25 x 8-12R (Front)
25 x 10-12R (Rear)
Tire Inflation Pressure
0.98 kg/cm² (14 psi)
MISCELLANY
Spark Plug Type
NGK CR8EB
Spark Plug Gap
0.6-0.8 mm (0.023-0.031 in.)
Gas Tank Capacity
28 L (7.4 U.S. gal.)
Coolant Capacity
3.1 L (3.2 U.S. qt)
Front Differential Capacity
200 ml (6.8 fl oz)*
Transaxle Capacity
1.2 L (1.2 U.S. qt)*
Engine Oil Capacity
2.8 L (3.0 U.S. qt) - Overhaul
3.34 L (3.4 U.S. qt) - Change
Gasoline (recommended)
87 Octane Regular Unleaded
Engine Oil (recommended)
Arctic Cat ACX All Weather
Synthetic
Front Differential Lubricant
SAE Approved 80W-90 Hypoid
Transaxle Lubricant
Arctic Cat Synthetic Transaxle
Fluid
Belt Width
31.3 mm (1.23”)
Brake Fluid
DOT 4
Taillight/Brakelight
High Intensity LED
Headlight
Halogen
COOLING SYSTEM
Cooling Fan On
203° F (95° C)
Cooling Fan Off
194° F (90° C)
ELECTRICAL SYSTEM
Spark Plug Cap
5000 ohms
Ignition Coil Resistance(primary)
Less than 1 ohm
Ignition Coil Primary Voltage
Battery Voltage
Stator Coil (crankshaft position sensor) 100-150 ohms
Resistance(AC generator)
Less than 1 ohm
Crankshaft Position Sensor
1.5 AC Volts or more
AC Generator Output (no load)
65 AC volts @ 4000 RPM
Ignition Timing
10° BTDC @ 1500 RPM
Dry Weight (approx)
ROPS Tested Curb Weight
Length (overall)
Height (overall)
Width (overall)
Tire Size

* Visible at plug threads.

VALVES AND GUIDES
(intake) 31.6 mm
(exhaust) 27.9 mm
Valve/Tappet Clearance
(intake) 0.16 mm
(cold engine) (max)
(exhaust) 0.22 mm
Valve Guide/Stem
(intake) 0.08 mm
Clearance (max)
(exhaust) 0.10 mm
Valve Guide Inside Diameter (max)
4.532 mm
Valve Head Thickness (min)
2.3 mm
Valve Seat Angle
45° +15’/+30’
Valve Spring Free Length (min)
38.7 mm
Valve Spring Tension @ 31.5 mm
19.0 kg (42 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min)
36.5 mm
Camshaft Journal Oil Clearance (max) 0.07 mm
Camshaft Journal Holder(right & center) 21.94-22.04 mm
Inside Diameter
(left) 17.44-17.48 mm
Camshaft Journal Outside(right & center) 21.96-21.98 mm
Diameter
(left) 17.48-17.53 mm
Camshaft Runout (max)
0.05 mm
Cylinder Head/Cover Distortion (max)
0.05 mm
CYLINDER, PISTON, AND RINGS
Piston/Cylinder Clearance
0.14mm
Cylinder Bore (max)
76.965 mm
Piston Diameter 10 mm from Skirt End 76.825 mm
Piston Ring Free End Gap (min) (1st/2nd) 12.5 mm
Bore x Stroke
76.9 x 75.3 mm
Cylinder Trueness (max)
0.05 mm
Piston Ring End Gap
(1st/2nd) 0.65 mm
- Installed (max)
(oil) 0.85 mm
Piston Ring to Groove Clearance (max) 0.1 mm
Piston Ring Groove Width
(1st/2nd) 1.202-1.204 mm
(oil) 2.501-2.503 mm
Piston Ring Thickness
(1st/2nd) 1.170-1.195 mm
Piston Pin Bore (max)
18.018 mm
Piston Pin Outside Diameter (min)
17.984 mm
CRANKSHAFT
Connecting Rod (small end bore) (max) 18.044 mm
Crankshaft Runout (max)
0.03 mm
Valve Face Diameter

Specifications subject to change without notice.

DRIVE TRAIN COMPONENTS

Torque Specifications
Torque (ft-lb)

Part

Tolerance

0-15

±20%

16-39

±15%

40+

±10%

EXHAUST COMPONENTS
Part

Part Bolted To

Exhaust Pipe Flange
Spark Arrester
Heat Shield
Heat Shield
O2 Sensor

Engine
Muffler
Frame
Manifold
Manifold

Torque
ft-lb N-m
8
6
48 in.-lb
10
20

10
8
6
14
27

15
20
20
8
25
20

20
27
27
11
34
27

35
40
35
30
35
25
35
20
20

48
54
48
40
48
34
48
27
27

35
20
35
35
35
35
20

48
27
48
48
48
48
27

25
25
25
37
25
10
20
25
25

34
34
34
50
34
14
27
34
34

8
20
20
8
40
40
40
5
60
35
60
60
10
20
8
20
20

11
27
27
11
54
54
54
7
81
48
81
81
14
27
11
27
27

BRAKE COMPONENTS
Brake Disc
Brake Hose
Brake Hose
Brake Hose
Master Cylinder
Caliper

Hub
Caliper
Master Cylinder
Frame
Frame
Knuckle

SUSPENSION COMPONENTS (Front)
A-Arm (Upper)
A-Arm (Lower)
Knuckle
Knuckle
Shock Absorber
Shock Absorber
Sway Bar Mount
Sway Bar
Sway Bar Link

Frame
Frame
Ball Joint
Tie Rod End
Frame
A-Arm
Frame
Sway Bar Link
A-Arm

SUSPENSION COMPONENTS (Rear)
Sway Bar Mount
Sway Bar
A-Arm
Shock Absorber (Lower)
Shock Absorber (Upper)
Knuckle
Sway Bar Link

Frame
Sway Bar Link
Frame
A-Arm
Frame
A-Arm
A-Arm

STEERING COMPONENTS
Steering Wheel
Rack and Pinion Assembly
Rack and Pinion Bracket
Tie Rod*
Jam Nut
Tilt Steering Link
Tilt Steering
Intermediate Shaft
Intermediate Shaft

Steering Shaft
Frame
Frame
Rack and Pinion Assembly
Tie Rod
Frame
Frame
Rack and Pinion
Shaft Adjuster

CHASSIS/ROPS ASSEMBLY
Door Latch Bracket
Door Hinge
Shift Lever
Shift Cable
Front ROPS Tube
Front ROPS Tube
Rear ROPS Tube
Cargo Box
Seat Belt Retractor
Seat Belt Shoulder
Seat Belt Buckle
Seat Belt Anchor
Accelerator Pedal Bracket
Accelerator Pedal
Throttle Cable
Brake Pedal
Front Bumper

Frame
Frame
Shift Mount Bracket
Shift Axle Arm
Frame
Rear ROPS Tube
Frame
Frame
Frame
ROPS Hoop
Frame
Frame
Splash Panel
Accelerator Pedal Bracket
Throttle Body
Frame
Frame

Engine/Transaxle Mounting
Bracket*****
Front Differential
Carrier Bearing
Carrier Bearing Bracket
Carrier Bearing Set Screw**
Pinion Housing
Differential Housing Cover***
Hub
Detent Plug
Speed Sensor
Oil Drain Plug
Oil Fill Plug
Drain Plug
Fill Plug
Wheel (steel)
Wheel (aluminum)

Part Bolted To
Transaxle
Differential Bracket
Bearing Bracket
Frame
Front Shaft
Differential Housing
Differential Housing
Axle/Knuckle
Transaxle
Rear Transaxle
Front Differential
Front Differential
Transaxle
Transaxle
Hub (20 ft-lb increments)
Hub (20 ft-lb increments)

Torque
ft-lb N-m
75

102

38
52
35
48
20
27
6
8
23
31
23
31
200
270
20
27
10
14
45 in.-lb 5
16
22
18
24
18
24
40
54
80
108

ENGINE
Front Rubber Mount
Front Rubber Mount
Transaxle Rubber Mount
Front Engine Mount
Rear Engine Mount
Adjuster Nut
Transaxle Mounting Bracket
Transaxle Mounting Bracket
Crankcase Half (6 mm)
Crankcase Half (8 mm)
Cylinder Head (Cap Screw)*
Cylinder Head Cover
Driven Clutch
Drive Clutch
Magneto Cover
Tappet Cover
Oil Pump
Rotor/Flywheel
Cam Sprocket**
Inner Clutch Cover
Camshaft Holder*
Shifter Housing
Starter Motor
Outer Clutch Cover
Intake Boot Clamp
Starter One-Way Clutch**
Fuel Rail
Air Filter Housing
Ground Wire
Stator Coil
Oil Drain Plug
Drain Plug
Cam Chain Tensioner
Connecting Rod
Oil Crossover Tube
Cylinder Head (Side)
Oil Filter Union
Phase Plate
Timing Inspection Plug
Magneto Plug
Oil Hose Fitting
PTO-Side Cover
Tensioner Cap
Upper Chain Guide
Oil Cooler Hose
Coolant Hose
Coolant Hose
Bypass Hose

Engine Mounting Bracket
Frame
Frame
Engine
Frame
Engine/Transaxle Mounting Bracket
Transaxle
Rubber Mount
Crankcase Half
Crankcase Half
Crankcase(step 1)
(step 2)
(final)
Cylinder Head
Input Shaft
Crankshaft
Crankcase
Valve Cover
Crankcase
Crankshaft
Camshaft
Engine
Cylinder Head
Crankcase
Crankcase
Inner Cover
Intake Boot
Rotor/Flywheel
Engine
Frame
Engine
Magneto Cover
Engine
Clutch Cover
Cylinder Head
Connecting Rod(step 1)
(step 2)
(final)
Crankcase
Crankcase
Crankcase
Sprocket
Magneto Cover
Magneto Cover
Crankcase
Crankcase
Tensioner
Cylinder Head
Oil Cooler/Engine
Coolant Pipe
Water Pump/Cylinder
Thermostat Coolant Pipe

20
25
20
35
40
15
37
25
7
21
22
29
36
7
35
60
7
7
8
60
7
8
7
8
8
5
30 in.-lb
20
6
5
7
11
20
50 in.-lb
15
22
36
45
13.5
7
20
7
10
8
25
7
15
7
35 in.-lb
40 in.-lb
35 in.-lb
15 in.-lb

*w/Oil **w/Red Loctite #271 ***w/Green Loctite #270
****w/“Patch-Lock” *****w/Anti-Seize

27
34
27
48
54
20
50
34
9.5
28
29
39
49
9.5
48
81
9.5
9.5
10
81
9.5
11
9.5
11
11
5.5
3.4
27
8
7
9.5
15
27
5.5
20
29
49
60
18
9.5
27
9.5
17
11
34
9.5
20
9.5
4
4.5
4
1.7

RECOMMENDED ENGINE OIL

Torque Conversions
(ft-lb/N-m)
ft-lb
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

N-m
1.4
2.7
4.1
5.4
6.8
8.2
9.5
10.9
12.2
13.6
15
16.3
17.7
19
20.4
21.8
23.1
24.5
25.8
27.2
28.6
29.9
31.3
32.6
34

ft-lb
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50

N-m
35.4
36.7
38.1
39.4
40.8
42.2
43.5
44.9
46.2
47.6
49
50.3
51.7
53
54.4
55.8
57.1
58.5
59.8
61.2
62.6
63.9
65.3
66.6
68

ft-lb
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75

N-m
69.4
70.7
72.1
73.4
74.8
76.2
77.5
78.9
80.2
81.6
83
84.3
85.7
87
88.4
89.8
91.1
92.5
93.8
95.2
96.6
97.9
99.3
100.6
102

ft-lb
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100

N-m
103.4
104.7
106.1
107.4
108.8
110.2
111.5
112.9
114.2
115.6
117
118.3
119.7
121
122.4
123.8
125.1
126.5
127.8
129.2
130.6
131.9
133.3
134.6
136

Drive Belt Break-In
Procedure
New drive belts require a break-in period of approximately
25 miles. During this period, drive the vehicle for 25 miles
at 3/4 throttle or less while varying throttle position (but
not exceeding 40 mph). By varying throttle position, the
exposed cord on the side of a new belt will be conditioned
allowing the drive belt to gain its optimum flexibility and
will extend drive belt life.

Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 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
accumulation of moisture in the fuel system.

CAUTION
Do not use white gas. Only Arctic Cat approved gasoline additives should be used.

The recommended oil to use is Arctic Cat ACX All
Weather synthetic engine oil, which has been specifically
formulated for use in this Arctic Cat engine. Although
Arctic Cat ACX All Weather synthetic engine oil is the
only oil recommended for use in this engine, use of any
API certified SM 0W-40 oil is acceptable.

OILCHARTJ

RECOMMENDED FRONT
DIFFERENTIAL LUBRICANT
The recommended lubricant is Arctic Cat Gear Lube or an
equivalent gear 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.

CAUTION
Any lubricant used in place of the recommended lubricant could cause serious front differential damage.

RECOMMENDED TRANSAXLE
LUBRICANT
The recommended transaxle lubricant is Arctic Cat Synthetic Transaxle Fluid. This lubricant meets all of the lubrication requirements of this vehicle.

CAUTION
Any lubricant used in place of the recommended lubricant could cause serious transaxle damage.

FILLING GAS TANK

! WARNING
Always fill the gas tank in a well-ventilated area. Never
add fuel to the gas tank near any open flames or with
the engine running. DO NOT SMOKE while filling the
gas tank.

Since gasoline expands as its temperature rises, the gas
tank must be filled to its specified capacity only. Expansion room must be maintained in the tank particularly if
the tank is filled with cold gasoline and then moved to a
warm area.

! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the engine to
cool before filling the gas tank.

Tighten the gas tank cap securely after filling the tank.

! WARNING
Do not over-fill the gas tank.

Genuine Parts
When replacement of parts is necessary, use only genuine Arctic Cat parts. They are precision-made to ensure high quality
and correct fit. Refer to the appropriate Illustrated Parts Manual for the correct part number, quantity, and description.

Preparation For Storage
CAUTION
Prior to storing the vehicle, it must be properly serviced
to prevent rusting and component deterioration.

1. Clean the seat cushion (cover and base) with a damp
cloth and allow it to dry.
2. Clean the vehicle thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire vehicle.
Allow it to dry thoroughly. DO NOT get water into
any part of the engine or air intake.
3. Either drain the gas tank or add Fuel Stabilizer to the
gas in the gas tank. Remove the air filter housing
cover and air filter. Start the engine and allow it to
idle. Using Arctic Cat Engine Storage Preserver, rapidly inject the preserver into the air filter opening for a
period of 10 to 20 seconds; then stop the engine.
Install the air filter and housing cover.

CAUTION
If the interior of the air filter housing is dirty, clean the
area before starting the engine.

4. Plug the exhaust hole in the exhaust 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 properly mixed coolant.

8. Disconnect the battery cables; then remove the battery, clean the battery posts and cables, and store in a
clean, dry area.
9. Store the vehicle indoors in a level position.

CAUTION
Avoid storing outside in direct sunlight and avoid using
a plastic cover as moisture will collect on the vehicle
causing rusting.

Preparation After
Storage
Taking the vehicle out of storage and correctly preparing it
will assure many miles and hours of trouble-free riding.
1. Clean the vehicle thoroughly.
2. Clean the engine. Remove the cloth from the exhaust
system.
3. Check all control wires and cables for signs of wear or
fraying. Replace if necessary.
4. Change the engine oil and filter.
5. Check the coolant level and add properly mixed coolant as necessary.
6. Charge the battery; then install. Connect the battery
cables.

CAUTION
The ignition switch must be in the OFF position prior to
installing the battery or damage may occur to the ignition system.

CAUTION
Connect the positive battery cable first; then the negative.

7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight, and
headlight aim; adjust or replace as necessary.
8. Tighten all nuts, bolts, cap screws, and screws making
sure all calibrated nuts, cap screws, and bolts are tightened 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.

SPECIAL TOOLS

Periodic Maintenance/
Tune-Up

A number of special tools must be available to the technician when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appropriate tool description.
Description

This section has been organized into sub-sections showing
common maintenance procedures.

p/n

Compression Tester Kit

0444-213

Oil Filter Wrench

0644-389

Timing Light

0644-296

NOTE: Special tools are available from the Arctic
Cat Service Department.

Periodic Maintenance
Chart
A = Adjust I = Inspect C = Clean L = Lubricate R = Replace T = Tighten
Item
Battery
Fuses
Air Filter
Valve/Tappet Clearance
Engine Compression
Spark Plugs
Muffler/Spark Arrester
Gas Hoses
Throttle Cable Ends/Accelerator Pedal Pivot
Engine Oil/Filter
Front Differential Lubricant
Transaxle Lubricant
Tires/Air Pressure
Steering Components
V-Belt
Suspension (Ball joint boots, drive axle boots
front and rear, tie rods, differential and rear
drive bellows)
Nuts/Bolts/Cap Screws
Ignition Timing
Headlight/Taillight-Brakelight
Switches
Shift Lever
Gauge/Indicators
Frame/Welds
Electrical Connections
Complete Brake System
Brake Pads
Brake Fluid
Brake Hoses
Coolant/Cooling System
Wheel Lug Nuts

Initial Service After
Every 3
Every 6
Break-In (First
Daily Monthly Months (300 Months (500 Annually
(100 Miles)
(1500 Miles)
Month or 100 Miles)
Miles)
Miles)
I

As
Needed

C
R
R
A

I
I*

I
I

R (4000 Mi
or 18 Mo)
R
R (2 Yrs)
A-R
A/R
R
R
(2000Mi)
R
R
R
R

C
I
I
R
R
R

I
I

I
I
I
I

I
I

C-L
R*/R**/R***
I
I

I
l

A
I

I
I

I
I
I
I
I
T

R
R
A-L
R

I
I

l
l
I*
I
I

C
R
R (2 Yrs)
R (4 Yrs)
R (2 Yrs)

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

NOTE: Foam Filter Cleaner and Foam Filter Oil are
available from Arctic Cat.

Lubrication Points

4. Dry both filter components.

It is advisable to lubricate certain components periodically
to ensure free movement. Apply light oil to the components using the following list as reference.
A. Accelerator Pedal Pivot/Cable Ends
B. Brake Pedal Pivot

5. Put the foam filter in a plastic bag; then pour in air filter oil and work the filter.
NOTE: Apply oil to the inner filter; then carefully
squeeze excessive oil from the filter element. Do not
twist foam to remove oil.

6. Attach the foam filter to the inner filter screen.

C. Shift Cable

Air Filter
CLEANING AND INSPECTING FILTER

CAUTION
Failure to inspect the air filter frequently if the vehicle is
used in dusty, wet, or muddy conditions can damage
the engine.

1. Unsnap the five fasteners securing the air filter housing cover and remove the cover.

WT179

CAUTION
A torn air filter can cause damage to the vehicle engine. Dirt
and dust may get inside the engine if the element is torn.
Carefully examine the element for tears before and after
cleaning it. Replace the element with a new one if it is torn.

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
the air filter on the filter rod and install the filter knob.
Tighten securely.

WT006A

2. Remove the air filter knob; then remove the air filter.

9. Install the air filter housing cover and secure with the
retaining clips.

CHECKING AND CLEANING DRAINS
1. Inspect the drain beneath the main housing for debris
or liquid. Remove and clean the drain bulb if contaminated.
2. Wipe any accumulation of oil or gas from the filter
housing and drain.

Testing Engine
Compression

WT176A

NOTE: Do not attempt to remove the inner foam
from the wire mesh. It is part of the filter frame.

3. Fill a wash pan larger than the filter with a non-flammable cleaning solvent; then dip the inner filter and
outer foam medium in the solvent and wash them.

NOTE: The engine should be warm (operating temperature) and the battery fully charged for an accurate
compression test.
NOTE: The access panel must be removed for this
procedure.

WT021

1. Remove the spark plug wires from the spark plugs.
2. Using compressed air, blow any debris from around
the spark plugs.

! WARNING

ATV-0051

CAUTION
Before removing a spark plug, be sure to clean the area
around the spark plug. Dirt could enter engine when
removing or installing the spark plug.

Always wear safety glasses when using compressed air.

3. Remove the spark plugs; then attach the spark plug wires
to the plugs and ground the plugs on the cylinder heads
well away from the spark plug holes.
4. Attach the Compression Tester Kit.
5. While holding the throttle in the full-open position, crank
the engine over with the electric starter until the gauge
stops climbing (five to 10 compression strokes). Compression should be as shown in the chart.
PSI (WOT)
Cylinder #1/Cylinder #2

185

6. If compression is abnormally low, verify the following:
A. Starter cranks engine over (normal speed).
B. Gauge is functioning properly.
C. Throttle in the full-open position.
D. Valve/tappet clearance correct.
E. Engine warmed up.
7. If compression is still low, check for blown cylinder head
gasket, valve leakage, or worn piston rings or cylinder
(see Engine – 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 serviced. To maintain a hot, strong spark, keep the plug free of
carbon. Adjust the gap to 0.6-0.8 mm (0.023-0.031 in.).

ATV-0052

When installing a spark plug, be sure to tighten it securely. A
new spark plug should be tightened 1/2 turn once the washer
contacts the cylinder head. A used spark plug should be tightened 1/8-1/4 turn once the washer contacts the cylinder head.

Muffler/Spark Arrester
Clean the spark arrester using the following procedure.

! WARNING
Wait until the muffler cools to avoid burns.

1. Remove the spark arrester screen; then using a suitable brush, clean the carbon deposits from the screen
taking care not to damage the screen.

WT005A

NOTE: If the screen or gasket is damaged in any
way, it must be replaced.

2. Install the spark arrester assembly and gasket and
secure with the cap screws. Tighten the cap screws to
72 in.-lb.

Engine Oil - Filter

4. Using the Oil Filter Wrench and a ratchet handle (or a
socket or box-end wrench), remove the old oil filter.
NOTE: Clean up any excess oil after removing the filter.

5. Apply oil to a new filter O-ring 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 recommended oil in
the filler hole. Install the oil level stick/filler plug.

OIL - FILTER

CAUTION

Change the engine oil and oil filter at the scheduled intervals. The engine should always be warm when the oil is
changed so the oil will drain easily and completely.
1. Park the vehicle on level ground; then remove the
access panel.

Any oil used in place of the recommended oil could cause
serious engine damage. Do not use oils which contain
graphite or molybdenum additives. These oils can
adversely affect clutch operation. Also, not recommended
are racing, vegetable, non-detergent, and castor-based oils.

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 minute.
9. Unscrew the oil level stick and wipe it with a clean
cloth.
10. Install the oil level stick and thread into the engine
case.
NOTE: The oil level stick should be threaded into
the case for checking the oil level.

WT037A

11. Remove the oil level stick; the oil level must be within
the operating range but not exceeding the upper mark.

2. Remove the oil level stick/filler plug.

WT066A
WT035A

3. Remove the drain plug from the bottom of the engine
and drain the oil into a drain pan.

CAUTION
Do not over-fill the engine with oil. Always make sure
that the oil level is not above the upper mark.

12. Inspect the area around the drain plug and oil filter for
leaks.

Front Differential Transaxle Lubricant
To check front differential lubricant, use the following procedure.
WT294A

1. Remove the level plug; lubricant should be level with
the bottom threads.
9

Headlight/TaillightBrakelight
HEADLIGHT BULB REPLACEMENT
1. Remove the wiring harness connector from the back
of the headlight.
2. Remove the rubber seal; then release the retaining
clip. Remove the bulb.
WT041A

2. If low, remove the fill plug and add lubricant until it
appears at the level plug threads. Tighten the fill plug
to 16 ft-lb and the level plug to 45 in.-lb.
To check transaxle lubricant, use the following procedure.
1. Remove the fill/level plug; the lubricant level should
be level with the bottom of the plug threads.

3. Install the new bulb; then attach the retaining clip and
press on the rubber boot.
4. Connect the wiring harness.
5. Adjust the headlight using the Checking/Adjusting
Headlight Aim instructions in this sub-section.

REMOVING HEADLIGHT ASSEMBLY
1. Remove the grille.
NOTE: Removing the front fender will aid in replacing the headlight assembly.

2. Remove the headlight adjustment cap screw.

WT025A

2. If low, add Arctic Cat Transaxle Fluid as necessary.
Tighten the fill/level plug to 16 ft-lb.
To change the lubricant, use the following procedure.
1. Place the vehicle on level ground.
2. Remove each drain and fill plug.

WT065A

3. Remove the inner cap screw securing the rear of the
headlight assembly.

3. Drain the lubricant into a drain pan.
4. After all the lubricant has been drained, install the
drain plug and tighten to 16 ft-lb.
5. Pour the appropriate amount of recommended lubricant 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.

Nuts/Bolts/Cap Screws
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 to specifications.

WT272

4. Push the headlight assembly inward towards the radiator and lift slightly on the exterior bracket until the
mounting stud is free; then remove the headlight
assembly.
5. Remove the rubber seal at the rear of the headlight
assembly.

WT263

WT262

6. Release the spring clip securing the headlight bulb;
then remove the bulb.

3. Starting with the interior mounting stud, install the
headlight assembly into position.

WT264

WT269A

INSTALLING HEADLIGHT ASSEMBLY
1. Install the headlight bulb making sure each tab is positioned correctly and that it cannot rotate clockwise.
Secure the bulb with the spring.

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.

WT264A

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

REMOVING TAILLIGHT/BRAKELIGHT
NOTE: The LED taillights are not replaceable. The
entire assembly must be replaced as a component.
11

1. Remove the fasteners securing the facia to the storage box.

WT260
WT101A

2. Disconnect the wiring harness.

2. Connect the wiring harness and secure the facia using
the existing fasteners. Tighten securely.

CHECKING/ADJUSTING HEADLIGHT
AIM
The headlights can be adjusted vertically. The geometric
center of the HIGH beam light zone is to be used for vertical aiming.
1. Position the vehicle on a level floor so the headlights
are approximately 6.1 m (20 ft) from an aiming surface (wall or similar aiming surface).

WT222

3. Remove the lock nuts securing the taillight to the facia.

0748-285

NOTE: There should be an average operating load
on the vehicle when adjusting the headlight aim.

2. Measure the distance from the floor to the mid-point
of each headlight.
WT259A

INSTALLING TAILLIGHT/
BRAKELIGHT
1. Install the new taillight into the facia using new lock
nuts. Tighten to 36 in.-lb.

3. Using the measurements obtained in step 2, make horizontal marks on the aiming surface.
4. Switch on the lights. Make sure the HIGH beam is on.
DO NOT USE LOW BEAM.
5. Observe each headlight beam aim. Proper aim is when
the most intense beam is 5 cm (2 in.) below the horizontal mark on the aiming surface.
6. Remove the front grille; then loosen the cap screw and
move the headlight assembly up or down as required.
Tighten to 60 in.-lb.

WT065A

Hydraulic Brake 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 vehicle in a level position and the tires properly inflated, check the fluid level in the reservoir. If
the level in the reservoir is not above the MIN, add
DOT 4 brake fluid.

WT045A

NOTE: During the bleeding procedure, 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 procedure is continued.

D. Repeat step C until the brake pedal is firm.
E. At this point, perform step B, C, and D on the left
rear bleed screw; then move to the right front bleed
screw and follow the same procedure. Finish with
the left front bleed screw.
4. Carefully check the entire hydraulic brake system
that all hose connections are tight, the bleed screws
are tight, the protective caps are installed, and no
leakage is present.

CAUTION
This hydraulic brake system is designed to use DOT 4
brake fluid only. If brake fluid must be added, care must be
taken as brake fluid is very corrosive to painted surfaces.

INSPECTING HOSES
Carefully inspect the hydraulic brake hoses for cracks or
other damage. If found, the brake hoses must be replaced.

CHECKING/REPLACING PADS
WT012A

2. Depress the brake pedal several times to check for a firm
brake. If the brake is not firm, the system must be bled.
3. To bleed the brake system, use the following procedure:
A. Remove the cover and fill the reservoir with DOT
4 brake fluid.

The clearance between the brake pads and brake discs is
adjusted automatically as the brake pads wear. The only
maintenance that is required is replacement of the brake
pads when they 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.

B. Install and secure the cover; then slowly press the
brake pedal several times.
C. Install one end of a clear hose onto the bleed screw
farthest from the cylinder (right rear) and direct the
other end into a container; then while holding
slight pressure on the brake pedal, open the bleed
screw and watch for air bubbles. Close the bleed
screw before releasing the brake pedal. Repeat this
procedure until no air bubbles are present.

WT220

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 procedure.
A. Remove the cap screws securing the caliper holder to
the knuckle; then remove the pads from the caliper.

Burnishing Brake Pads
Brake pads must be burnished to achieve full braking effectiveness. Braking distance will be extended until brake pads are
properly burnished. To properly burnish the brake pads, use the
following procedure.

! WARNING
Failure to properly burnish the brake pads could lead to
premature brake pad wear or brake loss. Brake loss can
result in severe injury.

1. Choose an area large enough to safely accelerate the vehicle to 30 mph and to brake to a stop.
2. Accelerate to 30 mph; then depress the brake pedal to
decelerate to 0-5 mph.
3. Repeat procedure 20 times until brake pads are burnished.
WT221

B. Install the new brake pads.
C. Secure the caliper holder to the knuckle with new
“patch-lock” cap screws. Tighten to 20 ft-lb.

Replacing V-Belt
NOTE: If a clutch or any clutch component has been
replaced or the technician is unsure of shim quantity/
placement, clutch offset must be verified (see Engine
- Servicing Left-Side Components).
NOTE: Drive belts require a break-in period (see Break-in
Procedure - Drive Belt in the General Information Section).

CAUTION
Failure to properly break-in a new drive belt will result in
premature belt failure.

REMOVING
WT287A

5. Install the wheel; then using a crisscross pattern, tighten
the wheel nuts in 20 ft-lb increments to a final torque of 40
ft-lb (steel wheel) or 80 ft-lb (aluminium wheel).
6. Burnish the brake pads (see Burnishing Brake Pads in this
section).

1. Raise the rear of the vehicle just enough to unload the rear
suspension (weight off the shock absorbers).
2. Remove the left rear tire.
3. Remove the cap screws securing the outer clutch cover;
then remove the outer clutch cover.

BRAKE DISC
Using a micrometer, measure the thickness of the brake disc in
the contact surface. If thickness is 0.125-in. or less, the disc must
be replaced. To replace the brake disc, see Drive System – Hub.

WT182A

4. Remove the cap screw securing the driven clutch to
the output shaft. Account for the washer.

WT183A

5. Remove the stationary sheave and V-belt and any belt
threads or debris in the clutch housing or sheaves.
NOTE: If removing the stationary sheave, account
for the alignment shims in the moveable sheave (see
Servicing Left-Side Components in the Engine section for proper shimming).

WT200A

2. Using an appropriate strap or oil filter wrench (3 5/8”)
to hold the driven clutch and ensuring the splines of the
sheave and input shaft are engaged, secure the clutch
with the cap screw and washer. Tighten to 35 ft-lb.

WT202

3. Install the clutch cover and secure with the cap screws.
Tighten to 50 in.-lb.
WT186A

INSTALLING
1. Making sure the directional arrows on the belt are aligned
with engine rotation, place the drive belt 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.

WT182A

4. Install the left rear tire. Tighten in a crisscross pattern
in 20 ft-lb increments to 40 ft-lb (steel wheel) or 80 ftlb (aluminum wheel).

WT517A

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

WT454

4. Remove the cap screws from both sides securing the
front fenders to the frame.

E. Tie rods not bent or cracked.
F. Knuckles not worn, cracked, or damaged.
G. Cotter pins not damaged or missing.
H. Steering wheel tilt locks securely.
The frame and welds should 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 headlights.

WT453A

5. Remove the cap screws (A, B, and C) and discard the
lock nuts from (A). Remove the bumper.

WT548A

WT463

3. Using a suitable prying tool, pry the clips out from
between the wiring harness and the frame. Press the
clips downward to remove from frame.

INSTALLING
1. Place the bumper frame into position place and with
the existing cap screws and new lock nuts (A), fingertighten at this point.

WT548A

2. Install the lower bumper cap screws (C); then tighten
the upper and lower bumper cap screws to 20 ft-lb.
3. Install the cap screws and nuts securing the radiator to
the frame (B). Tighten to 8 ft-lb.

WT251

REMOVING GRILLE
Remove the fasteners securing the grille; then remove the
grille.

4. Install the cap screws securing the front fenders to the
frame; then tighten securely.
5. Connect the headlights.
6. Using the existing cap screws, secure the grille and
tighten securely.
7. Install the hood and secure with the quarter-turn fasteners

Hood and Grille
WT256A

REMOVING/INSTALLING HOOD

CLEANING AND INSPECTION GRILLE

1. Turn the two quarter-turn fasteners counterclockwise
and remove hood.

Clean any dirt or debris from the grille webbing. This
helps air flow to the radiator and oil cooler.

INSTALLING GRILLE
Place the grille into position and secure it using the existing cap screws. Tighten all hardware to 60 in.-lb.

Body Panels
REMOVING REAR BODY PANELS
1. Remove the seats.
WT226A

2. Remove the push pins and cap screws securing the
rear fenders.

2. Insert the hood tabs into the grille and lay the hood
down flat. Turn both of the fasteners clockwise securing the hood.

WT241A

WT209A

! WARNING
The heat deflector under the right-rear fender has sharp
edges and can cause serious injury if care is not taken.

3. Remove the cap screws securing the taillight/brakelight assembly to the frame and disconnect the harness.

WT227A

5. Loosen the gas tank filler hose clamp and slide it
down towards the tank.

WT101A

WT244

6. Remove the panel from the frame while also pulling
on the filler hose. Seal off the hose to prevent objects
from entering the hose.
WT222

4. Remove the fasteners securing the right rear body
panel.

WT246

7. Remove the air pre-filter cover.
18

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

WT028A

8. Loosen the clamp securing the clutch air intake tube to
engine; then pry the tube off of engine. Account for
the clamp.
WT484A

2. Install the tabs of the body panel into the slots in the
side panel; then route the air intake clutch tube to the
engine.

WT487A

9. Remove the fasteners securing the left rear body panel.

WT490

WT250A

10. Remove the panel with the air/clutch intake tubes.
WT486

3. With the panel tabs in place, press the panel towards
the frame and maneuver the air intake tube inside the
boot.

WT486

7. Install the tabs of the body panel into the slots in side
panel; then insert the plastic insert into the gas tank
filler hose. Tighten the clamp and install the gas cap.

WT485

4. Secure the panel to the frame and pre-filter cover with
the existing cap screws and push pins.
WT245

8. Secure the panel to the frame with the existing cap
screws and push pins.

WT488A

WT491A

WT489A

5. Install the clutch intake tube onto the engine and
secure it with the clamp. Tighten securely.
WT489A

9. Install the right rear fender and secure with the existing hardware; then install the seats.

WT487A

6. Install the left rear fender and secure it with the existing hardware.
20

WT209A

REMOVING SIDE PANELS
To remove a side panel, remove the cap screws and push
pins securing the side panel to the frame; then remove the
panel.

WT212

2. Secure the side panel using the existing cap screws
and push pins. Tighten all hardware to 60 in.-lb.

Dash/Switches
REMOVING
1. Remove the steering wheel (see Steering Wheel in this
section).
2. Remove the top steering tilt assembly cap screw and
discard the nut.

WT257A

INSTALLING SIDE PANELS
1. To install a side panel, install the side panel tabs into
the front upper side panel slots.

WT338A

3. Remove the door latches and discard the cap screws.

WT211

NOTE: Make sure the bottom of the side panel is on
the outside of the inner splash panel.

WT010

4. Remove the fasteners and push pins securing the dash
to the frame.

WT014A

WT341

5. Disconnect the LCD gauge, ignition switch, and 12volt accessory plug.

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 existing fasteners.
4. Using new “patch-lock” cap screws, install the door
latches. Adjust the doors (see Doors in this section);
then tighten to 8 ft-lb.
5. Using a new lock nut, install the tilt assembly and
tighten to 10 ft-lb.

WT336A

6. Using an appropriate tool, push the bottom dash tabs
in; then push the top tabs in and press the rocker
switches through the dash. Disconnect the rocker
switches and remove the dash.

WT338A

6. Install the steering wheel (see Steering Wheel in this
section).

Center Console
REMOVING
WT337A

1. Remove the seats and engine access panel.

INSTALLING
1. Install the switches into the appropriate locations.
Push the switches into the dash until they snap into
place.

WT037A

2. Loosen the jam nut below the shifter knob; then
unscrew the shifter knob.

WT281B

WT274A

3. Remove the fasteners securing the center console;
then remove the console.

3. Install the shifter knob so the “P” is facing forward;
then tighten the jam nut to 12 ft-lb.
4. Install the seats.

Rack and Pinion
Assembly
REMOVING
1. Secure the vehicle on a support stand to elevate the
front of the vehicle; then remove the front wheels.
2. Remove and discard the cotter pin from the tie rod end
and remove the tie rod from the knuckle.
WT281A

INSTALLING
1. Install the center console over the passenger handhold making sure the reverse override switch is connected and the front tab is properly inserted under the
floor plastic.

WT330A

3. Remove the steering wheel, dash, and steering shaft.
4. Remove the cap screws securing the rack and pinion
to the frame and remove from either side. Discard the
lock nuts.

WT286A

2. Secure the console with the existing cap screws and
push pins. Install the engine access panel and secure
with the quarter-turn screw.

WT369A

5. Support the steering rack assembly in a suitable bench
vise; then remove the clamp (A) and cut the cable tie
(B). Slide the boot to the center of the tie rod.

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. With the threads coated with red Loctite #271, install
the tie rod into the rack and tighten with a crow-foot to
37 ft-lb.

WT373A

6. While holding tie rod end (A), loosen jam nut (B) and
remove the tie rod end (A).

WT370A

NOTE: Always attach the crow-foot to the torque
wrench with the open end 90° to the torque wrench
handle to ensure accurate torque application.

WT366A

7. Remove the inner tie rod from rack.

PR528A

2. Install the boot onto the rack and secure with the
clamp and nylon ties.

WT367

INSPECTING
1. Inspect the input shaft splines for excessive wear or signs
of misalignment.
2. Inspect the slide mechanism for pitting, excessive wear, or
worn bushings.
3. Rotate the input shaft from center to full left and right
checking for any binding or catching.
4. Check for loose cap screws on rack and pinion housing.
5. Check for seal damage or lubricant leaks.

WT373A

3. With the jam nuts on the inner tie rod, install the tie
rod ends on to the inner tie rods. Do not tighten at this
point.

WT298A

WT569

4. Center the tie rods in the steering rack assembly and
align the white paint line on the pinion with the white
paint line on the rack housing.

NOTE: Any time steering components are disassembled, all connecting components should be
marked for proper alignment during assembling.

5. Install the rack and pinion assembly into the vehicle;
then using new lock nuts, secure to the frame and
tighten to 25 ft-lb.

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 steering wheel for cracks, missing padding, or broken spokes.
2. Inspect the splines for wear.
3. Check that the steering wheel is not bent.

INSTALLING
1. Install the steering wheel aligning the two match marks;
then secure the steering wheel. Tighten to 25 ft-lb.

WT369A

6. Install the steering shaft, dash, and steering wheel.
7. Tighten the tie rod jam nut 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.

8. Install the tie rod ends into the hubs; then with the
threads coated in red Loctite #271, tighten the castle
nuts to 55 ft-lb and secure with a new cotter pin.
9. Install the wheels and adjust front wheel alignment
(see Checking/Adjusting Front Wheel Alignment).
10. Remove the vehicle from the support stand.

Steering Wheel
REMOVING
1. Remove the steering wheel cover; then mark the steering shaft and steering wheel for installing purposes.

WT297

NOTE: If the hole in the steering shaft does not
align with the slots in the nut, tighten the nut slightly
until the next slot aligns with the hole.

Steering Shaft
REMOVING
1. Remove the steering wheel and hood; then remove the
dash.
2. Remove and discard the cap screws and lock nuts
securing the steering tilt assembly to the frame.
WT594

7. Slide the tilt assembly out of the steering shaft.

WT346

3. Remove the push pins securing the rubber boot to the
splash panel.
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 twisting.
2. Check the U-joints for any clicking or binding. If present, the shaft must be replaced.
3. Check the tilt assembly for cracks or broken welds.

INSTALLING
WT343A

4. Remove the lower cap screw and discard the lock nut
securing the steering shaft to the rack and pinion.

1. Slide the steering shaft through the splash panel. With
both white lines on the rack and pinion aligned with
the gap in the lower knuckle on the steering shaft,
slide the steering shaft onto the splines.

WT345A

5. Remove the steering shaft through the splash panel.
6. Remove the snap ring. Account for the two washers.

WT348

2. Using the existing cap screw and new lock nut, secure
the steering shaft to the rack and pinion assembly.
Tighten to 25 ft-lb.

3. Install the tilt assembly onto the steering shaft and
secure it with new cap screws and lock nuts. Tighten
to 20 ft-lb.

4. Remove the hub assembly.
5. Remove the cotter pin from the tie rod end and
remove the tie rod end from the knuckle.
6. Remove the upper cap screw securing the ball joint in
the knuckle.
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 knuckle.

WT351

4. Install the wave washer and washer; then install the
snap ring securing the shaft in place.

WT329A

9. Remove the snap ring securing the bearing in the
knuckle; then press the bearing out of the knuckle.

WT593

5. Install the rubber boot in place around the steering
shaft and secure with the existing push pins.

WT326

10. Using a suitable press, remove the bearing from the
knuckle.

WT343

6. Install the dash; then install the steering wheel and
hood.

Steering Knuckles
REMOVING AND DISASSEMBLING
1. Secure the vehicle on a support stand to elevate the
wheel; then remove the wheel.
2. Remove the nut securing the hub.

WT327

CLEANING AND INSPECTING
1. Clean all knuckle components.

3. Remove the brake caliper.
27

2. Inspect the bearing for pits, scoring, rusting, or premature
wear.
3. Inspect the knuckle for cracks, breaks, or galling of
the bearing surface.

ASSEMBLING AND INSTALLING
1. Using a suitable press and driver, press the bearing
into the knuckle until firmly seated; then install the
snap ring.

WT329A

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 installed.

5. Install the hub assembly onto the axle; then secure the
hub using the hub nut.
WT327

WT451
WT331

2. Install the knuckle to the lower ball joint and secure with a
new “patch-lock” cap screw. Tighten to 35 ft-lb.

6. Tighten the hub nut to 200 ft-lb; then install a new cotter pin and spread the pin making sure the side of the
pin is flush to the hub nut.

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.

WT275

NOTE: During assembly, new cotter pins should
always be used.
WT332

NOTE: If the cotter pin cannot be inserted due to
misalignment of the hole and the slots in the nut,
always tighten the nut until it is properly aligned.

7. Secure the brake caliper to the knuckle with the two
new “patch-lock” cap screws. Tighten to 20 ft-lb.
28

WT287A

9. Install the wheel; then using a crisscross pattern,
tighten the wheel nuts in 20 ft-lb increments to a final
torque factor of 40 ft-lb (steel wheel) or 80 ft-lb (aluminium wheel).
10. Remove the vehicle from the support stand.

WT292A

To adjust the wheel alignment, use the following procedure:
1. Center the steering rack; then using an open-end
wrench to hold the tie rod (B), loosen the right-side
and left-side jam nuts (A).

Checking/Adjusting Front
Wheel Alignment
NOTE: All measurements and adjustments must be
made with the vehicle unloaded.
NOTE: Make sure the white alignment marks of the
steering rack are aligned.
WT039A

CAUTION
Always use a wrench to hold the tie rod ends when loosening or tightening the jam nuts or damage to the boots
could occur.

2. Turn the left-side and right-side tie rods (B) in equal
increments to achieve the proper toe-out; then tighten
to 25 ft-lb.

Accelerator Pedal
WT080A

Mark the center-line of the front tires at the front and rear
of the tire; then using a tape measure, measure and record
the distance between the marks at the front and rear. The
front measurement should be 3-6 mm (1/8-1/4 in.) greater
than the rear measurement (toe-out).

REMOVING
Dislodge the yellow nylon bushing of the throttle cable
from the actuator arm; then remove two torx-head screws
and nuts securing the accelerator pedal assembly to the
splash panel and remove the accelerator pedal.

WT099C

WT099B

3. To adjust the throttle cable, locate the in-line cable
adjuster beneath the clutch cover; then slide the protective sleeve upward from the adjuster.

WT288A

INSTALLING
Align the mounting holes with the holes in the splash panel
and secure with the two torx-head screws and new lock nuts;
then tighten to 10 ft-lb. Snap the throttle cable bushing into
the actuator arm.

WT081A

4. Loosen the jam nut (A) and turn the adjuster (B)
clockwise to increase free-play or counterclockwise to
decrease.

CHECKING CABLE FREE-PLAY
1. Check cable free-play by grasping the cable at the top
of the accelerator pedal and lightly pulling rearward to
remove slack. Free-play should be 1-2 mm (0.0400.080 in.).

WT082A

5. Tighten the jam nut securely and slide the protective
sleeve over the adjuster making sure the sleeves overlap over the seal.
WT099A

2. Depress 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 compressed.

Shift Lever
REMOVING
1. Remove the seats, shifter knob, and center console.

WT281B

WT439B

2. Remove the cap screw from the shift cable pivot bolt
(A), remove the axle bolt (B), and account for plastic
inserts (C).

3. While holding the nut (B), loosen the jam nut (A) and
remove the shift cable from the transaxle.

WT296A

4. Remove the cap screw and lock nut securing the shift
cable to the shift arm. Discard the nut.

WT225B

3. Remove the shift lever.

INSTALLING
1. Connect the shift cable to the shift arm with the pivot
bolt and new lock nut. Tighten to 8 ft-lb.
2. Place the shift lever into position and secure with the
axle bolt, plastic inserts, and new lock nut. Tighten to
20 ft-lb.
3. Install the center console, shifter knob, and seats.
Make sure the seats lock securely in place.

Shift Cable
WT296B

REMOVING
1. Remove the seats and center console.
2. Remove the E-clip securing the shift cable to the
transaxle.

5. Cut the plastic wire ties securing the cable to frame
noting their locations for installing.
6. Loosen the jam nut (A) securing the shift cable on the
shifter bracket and remove the shift cable noting the
cable location for installing.

WT276A

INSTALLING

WT276A

3. Once the proper adjustment is achieved, tighten the
jam nut to 20 ft-lb.

1. Install the new shift cable in place noting the routing from
removing. Secure to the transaxle with the E-clip and jam
nut. Finger-tighten the jam nut at this point.
2. Install the shift cable end to the shifter bracket and secure
with the cap screw, new lock nut, and jam nuts.
3. Install any necessary cable ties as marked during removing; then adjust the shift cable (see ADJUSTING in this
sub-section). After cable is properly adjusted, tighten the
jam nuts to 20 ft-lb.
4. Install the center console and seats. Make sure the
seats lock securely in place.

ADJUSTING
1. Remove the seats, shifter knob, engine access panel,
and center console.

WT342

NOTE: After the jam nuts are secure, check the shift
cable again for proper adjustment.

4. Install the center console and engine access panel.
5. Install the shifter knob and tighten the jam nut to 12 ft-lb.

WT281B

2. With the transmission in neutral, loosen the jam nut
(A) and adjust the cable until there is a small amount
of free-play in the shift lever moving forward and
backward while still in neutral.

WT274A

6. Install the seats. Make sure the seats lock securely in
place

LCD Gauge
REMOVING/INSTALLING
To remove the gauge, pull out on one side of it; then disconnect the multi-pin connector and remove the gauge.

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

INSTALLING MUFFLER
1. With the gasket in place, place the muffler onto the
holder pins and slide into position.
WT339

To install the gauge, connect the multi-pin connector and
press the gauge into the dash.
NOTE: Ensure the rubber mounting ring is oriented
correctly on the tab and seats fully through the dash.

WT293A

NOTE: Starting with the upper rear pin will aid in
installing.

2. Secure the muffler to the exhaust pipe with the two
exhaust springs.
WT601A

Cargo Box

Exhaust System

REMOVING

REMOVING MUFFLER

1. Remove the seats and rear fenders.

1. Remove the two exhaust springs at the muffler/
exhaust pipe juncture.

2. Remove the LED taillight assembly.
3. Remove the fasteners securing the upper rear body
panel to the splash guard.

WT295

! WARNING
The heat deflector under the right-rear fender has sharp
edges and can cause serious injury if care is not taken.

WT229A

4. Remove the fasteners securing the cargo box.

2. Slide the muffler assembly clear of the holder pins.
Account for the exhaust gasket.
33

WT234A

WT229

5. Remove the fasteners securing the upper rear body
panel to the cargo box.

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

Seats
REMOVING/INSTALLING
1. To remove a seat, pull the seat lock lever up. Raise the
rear of the seat and tilt it forward.
WT230A

WT003A
WT231A

INSTALLING
1. Secure the upper rear body panel to the cargo box and
tighten the cap screws to 15 in.-lb.
2. Install the cargo box into position so the upper body
panel is over the top of splash guard; then tighten the
cap screws to 5 ft-lb.

2. To install a seat, slide the front of the seat into the seat
retainers and push down firmly on the rear of seat. The
seat should automatically lock into position.

Doors
CHECKING/ADJUSTING
NOTE: The ROPS must be fully installed whenever
adjusting the doors in any way.

Inspect the doors for broken or bent tubes, hinges, or
latches. Make sure the latches engage and lock securely; if
not, us the following instructions.
1. Open the door to ensure it swings freely. If not, loosen
the two top fasteners and adjust door as necessary
until it swings freely. Tighten the fasteners securely.

Floor
REMOVING
1. Remove the seats, engine access panel, and center
console.
2. Remove the fasteners securing the floor to the frame.

WT110A

2. Close the door to ensure it latches securely. If not,
loosen the fasteners and adjust the latch up or down
until the door latches securely. Tighten the fasteners
securely.
3. With the door closed, ensure the rubber bumper contacts the latch. To adjust, turn the bumper in (loosen)
or out (tighten).

WT344A

CLEANING AND INSPECTING
1. Clean any debris from underneath the floor.
2. Inspect the floor for any cracks or holes.

INSTALLING
1. Install the floor into position and secure it with the
existing cap screws. Tighten securely.
WT108A

2. Install the center console, engine access panel, and
seats. Make sure the seats lock securely in place.

Troubleshooting
Problem: Handling too heavy or stiff
Condition
1.
2.
3.
4.
5.

Front wheel alignment incorrect
Lubrication inadequate
Tire inflation pressure incorrect
Tie rod ends seizing
Linkage connections seizing

Problem: Steering oscillation
Condition
1.
2.
3.
4.
5.
6.
7.
8.

Tires inflated unequally
Wheel(s) wobbly
Wheel hub cap screw(s) loose - missing
Wheel hub bearing worn - damaged
Tie rod ends worn - loose
Tires defective - incorrect
A-arm bushings damaged
Bolts - nuts (frame) loose

Problem: Steering pulling to one side
Condition
1.
2.
3.
4.
5.

Tires inflated unequally
Front wheel alignment incorrect
Wheel hub bearings worn - broken
Frame distorted
Shock absorber defective

Problem: Steering impaired
Condition
1. Tire pressure too high
2. Steering linkage connections worn
3. Cap screws (suspension system) loose

Problem: Tire wear rapid or uneven
Condition
1. Wheel hub bearings worn - loose
2. Front wheel alignment incorrect

Problem: Steering noise
Condition
1. Caps screws - nuts loose
2. Wheel hub bearings broken - damaged
3. Lubrication inadequate

Problem: Rear wheel oscillation
Condition
1.
2.
3.
4.
5.
6.
7.

Rear wheel hub bearings worn - loose
Tires defective - incorrect
Wheel rim distorted
Wheel hub cap screws loose
Rear suspension lateral link bushing worn
Trailing arm bushings worn
Rear suspension lateral link loose

Remedy
1.
2.
3.
4.
5.

Adjust alignment
Lubricate appropriate components
Adjust pressure
Replace tie rod ends
Repair - replace connections

Remedy
1.
2.
3.
4.
5.
6.
7.
8.

Adjust pressure
Replace wheel(s)
Tighten - replace cap screws
Replace bearing
Replace - tighten tie rod ends
Replace tires
Replace bushings
Tighten bolts - nuts

Remedy
1.
2.
3.
4.
5.

Adjust pressure
Adjust alignment
Replace bearings
Repair - replace frame
Replace shock absorber

Remedy
1. Adjust pressure
2. Replace connections
3. Tighten cap screws

Remedy
1. Replace bearings
2. Adjust alignment

Remedy
1. Tighten cap screws - nuts
2. Replace bearings
3. Lubricate appropriate components

Remedy
1.
2.
3.
4.
5.
6.
7.

Replace bearings
Replace tires
Replace wheel
Tighten cap screws
Replace bushing
Replace bushings or link
Tighten nut or replace

SPECIAL TOOLS

Engine
This section has been organized into sub-sections which
show a progression for the complete servicing of the Arctic Cat Wildcat Trail engine.

p/n

Magneto Rotor Remover Set

0444-254

To service bottom-side components, the engine must be
removed from the frame. To service top-side or left-side
components, the engine does not have to be removed from
the frame.

Piston Pin Puller

0644-328

Spanner Wrench

0444-240

Surface Plate

0644-016

V Blocks

0644-535

NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal
components when servicing the engine.

Clutch Alignment Bar

0544-027

Clutch Puller

0744-080

NOTE: A new ROV and an overhauled ROV engine
require a “break-in” period. The first 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 the proper break-in procedure
as described in the Operators Manual.

NOTE: Special tools are available from the Arctic
Cat Service Department.

Troubleshooting
Problem: Engine will not start or is hard to start (Compression too low)
Condition
Remedy
1.
2.
3.
4.
5.
6.
7.

Gasoline bad - contaminated
Valve clearance out of adjustment
Valve guides worn
Valves mistimed
Piston rings worn - broken
Cylinder bore worn
Starter motor cranks too slowly - does not turn

1.
2.
3.
4.
5.
6.
7.

Drain gas - replace with clean gas
Adjust clearance
Replace cylinder head
Retime engine
Replace rings
Replace cylinder
See Electrical System

Problem: Engine will not start or is hard to start (No spark)
Condition
Remedy
1.
2.
3.
4.
5.
6.

Spark plug(s) fouled
Spark plug(s) wet
Magneto defective
ECM defective
Ignition coil defective
High-tension lead open - shorted

1.
2.
3.
4.
5.
6.

Clean - replace plug(s)
Clean - dry plug(s)
Replace stator coil
Replace ECM
Replace ignition coil
Replace high tension lead

Problem: Engine will not start or is hard to start (No fuel reaching the fuel injector)
Condition
Remedy
1.
2.
3.
4.

Gas tank vent hose obstructed
Fuel hose obstructed
Fuel screens obstructed
Fuel pump defective

Problem: Engine stalls easily
Condition
1.
2.
3.
4.
5.
6.

Gasoline bad - contaminated
Spark plug(s) fouled
Magneto defective
ECM defective
Fuel injector obstructed
Valve clearance out of adjustment

Problem: Engine noisy (Excessive valve chatter)
Condition
1. Valve clearance excessive
2. Valve spring(s) weak - broken
3. Camshaft worn

1.
2.
3.
4.

Clean vent hose
Clean - replace hose
Clean - replace inlet screen
Replace fuel pump

Remedy
1.
2.
3.
4.
5.
6.

Drain gas - replace with clean gas
Clean - replace plug(s)
Replace stator coil
Replace ECM
Replace fuel injector
Adjust clearance

Remedy
1. Adjust clearance
2. Replace spring(s)
3. Replace camshaft

Problem: Engine noisy (Noise seems to come from piston)
Condition
Remedy
1.
2.
3.
4.

Piston - cylinder worn
Combustion chamber carbon buildup
Piston pin - piston pin bore worn
Piston rings - ring groove(s) worn

1.
2.
3.
4.

Replace - service piston - cylinder
Clean cylinder head and piston
Replace - service pin - replace connecting rod
Replace rings - piston

Problem: Engine noisy (Noise seems to come from timing chain)
Condition
Remedy
1. Chain stretched
2. Sprockets worn
3. Tension adjuster malfunctioning

1. Replace chain
2. Replace sprockets
3. Repair - replace adjuster

Problem: Engine noisy (Noise seems to come from crankshaft)
Condition
Remedy
1. Main bearing worn - burned
2. Lower rod-end bearing worn - burned
3. Rotor/flywheel loose

1. Replace bearing
2. Replace bearing
3. Tighten - replace flywheel - crankshaft

Problem: Engine noisy (Noise seems to come from crankcase)
Condition
Remedy
1.
2.
3.
4.

Gears worn - chipped
Splines worn
Bearings worn
Bushing worn

1.
2.
3.
4.

Replace gears
Replace shaft(s)
Replace bearings
Replace bushing

Problem: Engine idles poorly
Condition

Remedy

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Gasoline bad - contaminated
Valve clearance incorrect
Valve seating poor
Valve guides defective
Magneto defective
ECM defective
Spark plug(s) fouled - gap too wide
Ignition coil defective
Fuel injector obstructed
Throttle body dirty

Problem: Engine runs poorly at high speed
Condition
1.
2.
3.
4.
5.
6.
7.
8.
9.

Gasoline bad - contaminated
High RPM “cut out” against RPM limiter
Valve springs weak
Valve timing incorrect
Cams worn
Spark plug gap too narrow
Ignition coil defective
Air cleaner element obstructed
Fuel hose obstructed

Problem: Exhaust smoke dirty or heavy
Condition
1.
2.
3.
4.
5.
6.
7.

Gasoline bad - contaminated
Engine oil overfilled - contaminated
Piston rings - cylinder worn
Valve guides worn
Cylinder wall scored
Valve stems worn
Stem seals defective

Drain gas - replace with clean gas
Adjust clearance
Replace valves/cylinder head
Replace cylinder head
Replace stator coil
Replace ECM
Adjust gap - replace plug(s)
Replace ignition coil
Replace fuel injector
Clean bore and ISA passages

Remedy
1.
2.
3.
4.
5.
6.
7.
8.
9.

Drain gas - replace with clean gas
Shift into higher gear - decrease speed
Replace springs
Retime engine
Replace cams
Adjust gap
Replace ignition oil
Clean element
Clean - prime hose

Remedy
1.
2.
3.
4.
5.
6.
7.

Drain gas - replace with clean gas
Drain excess oil - change oil
Replace - service rings - cylinder
Replace cylinder head
Replace cylinder
Replace valves
Replace seals

Problem: Engine lacks power
Condition

Remedy

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Gasoline bad - contaminated
Valve clearance incorrect
Valve springs weak
Valve timing incorrect
Piston ring(s) - cylinder worn
Valve seating poor
Spark plug fouled
Spark plug gap incorrect
Fuel injector obstructed
Air cleaner element obstructed
Engine oil overfilled - contaminated
Intake manifold leaking air
Cam chain worn

Drain gas - replace with clean gas
Adjust clearance
Replace springs
Time camshaft
Replace - service rings - cylinder
Repair seats
Clean - replace plug
Adjust gap - replace plug
Replace fuel injector
Clean element
Drain excess oil - change oil
Tighten - replace manifold
Replace cam chain - sprockets

Problem: Engine overheats
Condition

Remedy

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Carbon deposit (piston crown) excessive
Oil low
Octane low - gasoline poor
Oil pump defective
Oil filter obstructed
Intake manifold leaking air
Coolant level low
Fan malfunctioning
Fan relay malfunctioning
Thermostat stuck - closed
Radiator hoses - cap damaged - obstructed
Fan fuse(s) blown

Clean piston
Add oil
Drain - replace gasoline
Replace pump
Replace filter
Tighten - replace manifold
Fill - examine system for leaks
Check fan fuse - replace fan
Replace fan relay
Replace thermostat
Clear obstruction - replace hoses - cap
Replace fuse(s)

Removing Engine
Many service procedures can be performed without
removing the engine from the frame. Closely observe the
note introducing each sub-section for this important information.
NOTE: To remove the engine, the taillight assembly,
left side panel, and left rear body panel must be
removed (see Steering/Frame/Controls).
NOTE: The vehicle must be supported on an appropriate stand for this procedure.

1. Remove the rear cargo box and rear fenders; then
remove the cap screws securing the rear splash panels
to the frame.

WT182A

3. Remove the cap screw securing the driven clutch to
the output shaft; then remove the stationary sheave of
the driven clutch along with the belt. Account for a
flat washer.

WT183A
WT488A

4. Remove the cap screw securing the drive clutch.
Using an appropriate clutch puller, remove the drive
clutch. Remove the driven pulley moveable sheave.

WT489A

WT186B

NOTE: When removing the stationary sheave,
account for the alignment shims (see Installing LeftSide Components in the Engine section for proper
shimming).

WT362A

2. Remove the left-rear wheel; then remove the outer
clutch cover. Retain the cap screws.
40

WT186A

WT405A

5. Remove and retain the cap screws securing the inner
clutch cover; then with the air outlet duct connected to
the inner clutch cover, remove the cover as an assembly. Account for the rubber O-rings on both sides of
the cover.

WT311A

NOTE: Removing the intake boot with air box will
aid in installation.

7. Loosen the throttle body clamp.
WT443A

WT316A
WT442A

AT THIS POINT
If the technician's objective is to service the left-side
components, no further disassembling is necessary.
Proceed to Servicing Left-Side Components in this
section.

8. Remove and discard the top “patch-lock” fasteners
securing the air box; then remove and retain the lower
air box cap screws and grommets.

6. Remove the clamp on the breather tube and loosen the
air intake clamp.

WT313A

WT400

NOTE: Plug the holes with paper towels to keep
contaminates from falling inside.

11. Remove the ISC connector (A), MAP/IAT connector
(B), and the TPS connector (C); then loosen the clamp
securing the throttle body to the intake manifold.
Leave it connected to the throttle cable and set the
throttle body off to the side.

WT315A

9. Remove the air filter housing; then remove the gasoline hose from the fuel rail.

WT397A

12. Remove the springs securing the exhaust pipe to the
muffler; then remove muffler.

WT402

10. Disconnect the injectors (A). Remove and retain the
cap screws (B) securing the fuel rail to the intake manifold.

WT295

13. Remove the cap screws securing the heat shield to the
exhaust pipe; then carefully remove the heat shield
leaving the oxygen (O2) sensor in the exhaust pipe.

WT404A

NOTE: After removing the cap screws, install them
in their original position in the engine. Tighten
securely.

16. Remove the spark plug caps (A). Disconnect the cam
position sensor (B), coil connectors (C), and oxygen
(O2) sensor (D).

WT403A

14. Remove the exhaust pipe. Account for two exhaust
gaskets.

WT405B

NOTE: Leave the oxygen (O2) sensor in the exhaust
pipe.

17. Remove the water pump drain plug and drain the coolant into a suitable pan.

WT398A

WT399A

NOTE: Opening the radiator cap will aid in draining
the coolant.
WT406A

15. Remove the positive cable from the starter; then
remove the three cap screws securing the positive
cable to the PTO cover leaving the clips on the cable.

WT414A

18. Remove the coolant hoses from the water pump and
thermostat housing. Disconnect the ECT connector
and tie the coolant pipe out of the way.

WT411

19. Remove the coolant hose connecting the water pump
to the cylinder.

WT410A

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 transaxle to the
engine plate; then remove the cap screws securing the
front of the engine to the frame.

WT399

20. Using appropriate clamps, clamp off oil lines and
remove them from the oil fittings.

WT 412B

WT394

WT407

21. Remove and discard the lock nuts on the transaxle
mounting plate.

24. Using a proper lifting device, remove the engine from
the vehicle.

WT225A

WT413

Top-Side Components
NOTE: For efficiency, it is preferable to remove and
disassemble only those components which need to
be addressed and to service only those components.
The technician should use discretion and sound
judgment.

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

ROV1-116A

3. Remove the magneto and timing inspection plug;
then turn the crankshaft to the TDC position.

NOTE: The engine does not need to be removed for
this procedure.

Removing Top-Side
Components
1. Remove the four cap screws securing the cylinder
head cover. Account for rubber washers and siliconeheld gaskets.
ROV1-012

ROV1-005A
ROV1-013

4. Remove the cam chain tensioner. Account for a gasket and the fasteners.

ROV1-001A

2. Remove the two fasteners securing the starter motor.

ROV1-002

5. Remove the chain guide.
45

KC520

KC549A

NOTE: Take care not to drop the fasteners down into
engine.

7. Lift on the chain and remove both camshafts and
sprockets; then using a suitable holder, hook the
chain and let it hang over the side of the head.

6. Remove the cap screws securing the intake and exhaust
camshaft retainers.
NOTE: Tapping on the end of the camshaft holder with
a rubber mallet opposite the sprocket will aid in removing the camshaft holder.

ROV1-019

8. On the right side of the head, remove the three cap
screws.

ROV1-010

NOTE: The camshaft holder and cylinder head have
matching code numbers and must remain a set.

ROV1-021A

9. Loosen the six head bolts securing the cylinder head
to the cylinder.

KC548A

12. Remove the cylinder head making sure not to let the
chain fall down into engine. Account for two dowel
pins.

ROV1-015A

CAUTION
Do not use an impact tool to remove the head bolts or
damage to the cam shaft journals could occur.

10. Using a needle nose pliers or magnet, remove the
head bolts. Note the location of the two longer bolts
for installing purposes. Account for the washers.

ROV1-040A

13. Remove the head gasket, chain guide, and two dowel
pins. Discard the head gasket.

ROV1-038
ROV1-020

11. Using a magnet or needle-nose pliers, carefully
remove the tappets (A) from the cylinder head and
account for the shims (B).

14. Taking care not to let the pistons fall against the cylinder, 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
piston; then push the piston pin out from the other
side.

WT471A

CAUTION
When removing the tappets, note the location of the tappet, the valve from which the tappet was removed, and
the shim number of the tappet or severe engine damage
may occur.

ROV1-043

NOTE: Only one piston circlip needs to be removed.

AT THIS POINT
If the technician’s objective is to measure valve/tappet clearance, proceed to Servicing Top-Side Components

4. To select the correct replacement shim for an out-ofspecification clearance, note the three-digit number on
the surface of the existing shim; then refer to the
appropriate Tappet Shim Selection Table (Exhaust or
Intake) on the following pages and use this procedure:
A. Find the Measured Tappet Clearance (from step 3)
in the left-side vertical column of the table.
B. Find the Present Shim Size (three-digit-number) at
the top-side horizontal column of the table.
C. Match the clearance in the vertical column with the
present shim size to obtain the recommended
replacement shim.
ROV1-044

16. Repeat step 15 for the other piston.

Cleaning/Inspecting Valve Cover
NOTE: If the valve cover cannot be trued, the cylinder head assembly must be replaced.

AT THIS POINT
To service center crankcase components only, proceed
to Removing Left-Side Components.

Servicing Top-Side
Components
MEASURING VALVE/TAPPET
CLEARENCE

1. Wash the camshaft holder in parts-cleaning solvent.
2. Place the camshaft holder on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light
pressure, move the camshaft holder 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 assembly by continuing to move the camshaft holder in a
figure eight motion until a uniform bright metallic finish is attained.

CAUTION

1. Rotate the engine two full revolutions.
NOTE: Rotating the engine two full revolutions will
ensure that any oil trapped in the tappet/shim is
purged to maintain an accurate clearance reading.

Do not remove an excessive amount of the sealing surface or damage to the camshaft will result. Always check
camshaft clearance when resurfacing the valve cover.

2. Rotate the engine until the camshaft lobe of the valve
being measured is directly away from the tappet.
3. Using an appropriate thickness gauge, measure and
record the intake and exhaust valve clearance of the
cylinder that is on the compression stroke; then rotate
the engine 360° and measure and record the valve
clearance of the other cylinder. Valve clearance must
be within specifications.
15°-25° C
(59°-77° F)

Valve Clearance (Cold)
Intake: 0.16 mm (0.006 in.)
Exhaust: 0.22 mm (0.009 in.)
WT581

CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to
the sealing surface may result.

VALVE ASSEMBLY
When servicing valve assembly, inspect valve seats, valve
stems, valve faces, and valve stem ends for pits, burn
marks, or other signs of abnormal wear.
NOTE: Whenever a valve is out of tolerance, it must
be replaced.
KC534A

TAPPET CLEARANCE TABLE INTAKE

KCINTAKE

TAPPET CLEARANCE TABLE EXHAUST

KCEXHAUST

Removing Valves
NOTE: Index all valves, springs, and cotters to their
original position when removing. When installing, all
valve components should be installed in their original position.

1. Using a valve spring compressor, compress the valve
springs and remove the valve cotters. Account for an
upper spring retainer.

WT582A

2. Insert each valve into its original location.
3. Install each valve spring (two per valve) with the closest
wound coils towards the cylinder head (down).

WT585

2. Using an appropriate tool, remove the valve seal (A)
and the lower remaining spring seat (B). Discard the
valve seal.

KC522

4. Place a spring retainer over the valve springs; then
using the valve spring compressor, compress the valve
springs and install the valve cotters (two per valve).

WT583A

3. Remove the valve springs; then invert the cylinder
head and remove the valves.

CAUTION
If valves are discolored or pitted or if the seating surface is worn, the valve must be replaced. Do not attempt
to grind the valves or severe engine damage may occur.
WT587

Measuring Valve Guide (Bore)
1. Insert a suitable bore gauge 1/2 way into each valve
guide bore and record the measurement.

NOTE: Apply a small amount of grease to the end of
the tool to hold the cotter.

2. Acceptable inside diameter range must be within
specifications.

PISTON ASSEMBLY

3. If a valve guide is out of tolerance, the cylinder head must
be replaced.

Installing Valves
1. 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.

NOTE: Whenever a piston or pin is out of tolerance,
it must be replaced.

Removing Piston Rings
1. Starting with the top ring, slide one end of the ring out
of the ring-groove.
2. Remove each ring by working it toward the dome of
the piston while rotating it out of the groove.
51

ATV-1070

CC400D

Inspecting Piston
1. Inspect the piston for cracks in the piston pin, dome,
and skirt areas.

2. Insert an inside dial indicator into the piston pin bore.
The diameter must not exceed 18.018 mm. Take two
measurements to ensure accuracy.

2. Inspect the piston for seizure marks or scuffing. If
observed, replace the piston.
3. Inspect the perimeter of each piston for signs of excessive “blowby.” Excessive “blowby” indicates worn
piston rings or an out-of-round cylinder.

Measuring Piston-Ring End Gap
(Installed)
1. Place each compression ring in the wear portion of the
cylinder. Use the piston to position each ring squarely in
the cylinder.
2. Using a feeler gauge, measure each piston-ring end gap.
Ring end gap must not exceed 0.65 mm (1st/2nd) or 0.85
mm (oil).

ATV-1069

Measuring Connecting Rod
(Small End Bore)
1. Insert a snap gauge into the upper connecting rod
small end bore; then remove the gauge and measure it
with micrometer.

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 pin must be replaced.

KC544

2. Maximum diameter must not exceed 18.044 mm. If
the diameter exceeds specification, the connecting rod
must be replaced (see Bottom Side Components in
this section).

Measuring Piston/Cylinder
Clearance
1. Measure the cylinder front to back in six places.

CYLINDER/CYLINDER HEAD
ASSEMBLY
NOTE: If the cylinder/cylinder head cannot be trued,
they must be replaced as an assembly.

Cleaning/Inspecting Cylinder Head

CAUTION
The cylinder head studs must be removed for this procedure.

WT589

2. Measure the corresponding piston diameter at a point
10 mm 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 not exceed 0.14 mm.

Installing Piston Rings
1. Install the rings (as shown).

1. Using a non-metallic carbon removal tool, remove any
carbon buildup from the combustion chamber being
careful not to nick, scrape, or damage the combustion
chamber or the sealing surface.
2. Inspect the spark plug hole for any damaged threads.
Repair damaged threads using a “heli-coil” insert.
3. Place the cylinder head on the surface plate covered
with #400 grit wet-or-dry sandpaper. Using light pressure, 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 assembly by continuing to move the cylinder head in a figure eight
motion until a uniform bright metallic finish is
attained.

CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to
the sealing surface may result.

Measuring Cylinder Head Distortion
1. Remove any carbon buildup in the combustion chamber.
2. Lay a straightedge across the cylinder head; then
using a feeler gauge, check the distortion between the
head and the straightedge.
3. Maximum distortion must not exceed 0.05 mm.

KC523
KC700RINGS

2. Rotate the rings so the ring gaps are orientated as
shown and oriented to the piston pin.

CAUTION
Incorrect installation of the piston rings will result in
engine damage.

Cleaning/Inspecting Cylinder
1. Wash the cylinder in parts-cleaning 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 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. Correct any high spots before assembly by continuing to
move the cylinder in a figure eight motion until a uniform bright metallic finish is attained.

CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to
the sealing surface may result.
WT579

7. If any measurement exceeds the limit, replace the cylinder and piston.

Inspecting Cam Chain Guide
1. Inspect cam chain guide for cuts, tears, 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.
WT580

4. Using a slide gauge and a dial indicator or a snap gauge,
measure the cylinder bore diameter in three locations
from top to bottom and again from top to bottom at 90°
from the first measurements for a total of six measurements. The trueness (out-of-roundness) is the difference
between the highest and lowest reading. Maximum trueness (out-of-roundness) must not exceed 0.1 mm. Cylinder bore must not exceed 76.965 mm.

1. Place the camshaft on a set of V blocks; then position
the dial indicator contact point against the shaft and
zero the indicator.

KC526

2. Rotate the camshaft and note runout; maximum runout must not exceed 0.05 mm.

Measuring Camshaft Lobe Height
1. Using a calipers, measure each cam lobe height.
KC524

5. Wash the cylinder in parts-cleaning solvent.
6. Inspect the cylinder for pitting, scoring, scuffing, and
corrosion. If marks are found, repair the surface using
a #320 grit ball hone.
NOTE: To produce the proper 60° cross-hatch pattern, 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-based oil. Thoroughly clean
cylinder after honing using soap and hot water. Dry
with compressed air; then immediately apply oil to
the cylinder bore. If the bore is severely damaged or
gouged, replace the cylinder.

ATV1013A

2. The lobe heights must be greater than 36.6 mm.

Inspecting Camshaft Bearing
Journal

7. Pull the chain up through the cylinder and slide the cylinder down onto the dowel pins.

1. Inspect the bearing journal for scoring, seizure marks,
or pitting.
2. If excessive scoring, seizure marks, or pitting is found,
the cylinder head assembly must be replaced.
NOTE: If the journals are worn, replace the camshaft.

Installing Top-Side
Components
NOTE: Arctic Cat recommends new gaskets be
used when assembling the engine.

1. Before installing on the connecting rod, install the
inside piston circlip into the piston making sure the
open end curve is in the piston opening.

WT131

8. Install the chain guide so it is seated at the top and
bottom.

WT132A

9. Install the two dowel pins and a new head gasket.
WT129A

2. Install the piston on the connecting rod making sure
the “IN” is facing 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 dowel pins.

WT133A

10. While pulling the chain up through the head, install the
head onto the cylinder accounting for the chain guide,
chain tensioner guide, and two dowel pins.

WT130A

5. Apply a generous amount of lubricant to both of the pistons and the inside of the cylinders.
6. Using an appropriate ring compressor, compress the
rings and slide the cylinder over the pistons.

WT134

11. Install the cap screws (threads coated with oil) with the
two longer bolts going in the dowel pin locations.

WT142A

12. In the order shown, tighten the head bolts to 22 ft-lb,
then to 29 ft-lb, and finally to 36 ft-lb.

WT142B

WT471A

14. Install the two outside fasteners and tighten to 7 ft-lb.

WT143A

15. Making sure the chain stays on the crankshaft
sprocket, rotate the engine to TDC.

WT145

NOTE: Care must be taken not to damage the cam
shaft journals while tightening 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 during disassembling.

WT144

16. Install the exhaust cam shaft; then install the chain
around the sprocket so the exhaust timing mark is
parallel with the head surface.
56

WT147

17. Install the intake cam shaft; then install the chain
around the sprocket so the intake timing mark is parallel with the head surface.

WT156A

20. Install the fasteners and in the order shown, tighten to
7 ft-lb.

WT156
WT151

18. Install the cam chain tensioner and tighten the cap
screws to 15 ft-lb.

21. Install the upper chain guide and tighten the fasteners
to 7 ft-lb.

WT159
WT153

19. With the engine at TDC and each cam timing mark
properly aligned, place each camshaft holder on the
proper camshaft.

22. Install the head wall fastener with the rubber washer
and steel cup.

NOTE: Each holder has an “In” and “Ex”.

WT160

23. Install the rubber gasket onto the head cover and
install onto the head.

WT166A

27. Install the thermostat housing.
WT162A

NOTE: Applying a small bead of silicone between the
head cover and rubber gasket will aid in assembling.

24. Tighten the head cover fasteners in the order shown to
7 ft-lb with the rubber washers and steel cups.

WT168

NOTE: Apply a small amount of grease to the O-ring
before installing.

28. With the seal coated in grease, slide the PTO-side
cover over the crankshaft (with the two dowel pins).
WT163A

25. Install the cam timing sensor with O-ring (lightly
coated with grease).

WT169A

29. Install the fasteners and tighten to 7 ft-lb.
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.

NOTE: The two longer fasteners go in the dowel pin
locations.

WT170A

ROV1-048

3. Remove the chain by pulling it down through the
crankcase and out the PTO side.

Bottom-Side
Components

4. Remove the fastener securing the chain guide to the
crankcase.

NOTE: For efficiency, it is preferable to remove and
disassemble only those components which need to
be addressed and to service only those components.
The technician should use discretion and sound
judgment.

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

NOTE: The engine must be removed from the frame
for this procedure.

Removing Bottom-Side
Components

ROV1-056A

NOTE: If the water pump does not require servicing,
it does not have to be removed.

5. Remove the cap screws securing the water pump
cover to the crankcase. Account for two dowel pins
and an O-ring.

1. Remove the cap screws securing the PTO-side cover
to crankcase.

ROV1-054A

6. Remove the cap screws securing the MAG-side cover
to the crankcase. Account for two dowel pins and discard the gasket.
ROV1-045A

2. Using an appropriate puller if needed, remove the
PTO-side cover. Account for a gasket, two dowel pins,
and two longer fasteners for assembly purposes.

ROV1-108A

NOTE: Account for the different-lengthed fasteners
for assembling purposes.

KC543

10. Remove the starter idler gear and shaft.

NOTE: If the technician’s objective is to service or
replace the flywheel or starter gear, proceed to the
step 7; if not, continue to disassemble the bottom
side components without removing the flywheel or
starter gear.

7. Remove the cap screw securing the rotor/flywheel to
the crankshaft. Account for a washer and install the
crankshaft protector.

ROV1-065A

11. Remove the two cap screws securing oil pump.

KC545

8. Using the flywheel puller, remove the flywheel.

ROV1-063

12. Remove the oil pump leaving the chain on the top
sprocket. Account for two dowel pins and two O-rings.

KC546

9. Remove the starter gear leaving the flywheel key in
position.
ROV1-066

ROV1-064

ROV1-070A

13. Remove the fasteners connecting the top case half to
the bottom case half.

ROV1-068

17. Remove the oil passage tube and oil level stick.
ROV1-077A

NOTE; The fastener just above the oil filter is longer
than the others.

14. Rotate the engine and remove the cap screws securing
the oil pan to the crankcase.

ROV1-092A

18. Remove the fasteners and washers securing the bottom case half to the top case half.

ROV1-069A

15. Remove 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 seal under the oil pressure relief valve.
ROV1-078A

NOTE: Bolts 1-6 are longer than the other fasteners.

19. Pull the case halves apart and note the six plain bearings in each case half.
NOTE: Using a rubber mallet will aid in separating
the case halves.

ROV1-084

NOTE: Note the color coding on the bearings for
assembling purposes.
ROV1-088A

NOTE: Note the color coding on the bearings for
assembling purposes.

NOTE: Keep both the top and bottom of the connecting rod together as they are a matching set.

23. Remove the fasteners securing the stator and the crankshaft position sensor in place; then remove the stator.

20. Remove the counterbalance shaft from the case.

ROV1-059A
ROV1-080A

21. Remove the crankshaft from the case.

24. Remove the retaining ring and washer securing the
water pump to the case.

22. Remove the cap screws securing the connecting rods
together.

ROV1-115A

25. Remove the impeller.
ROV1-083A

ROV1-111

26. Remove the mechanical seal from the cover and the
ceramic mating seal from the impeller.

Servicing Bottom-Side
Components
INSPECTING STARTER CLUTCH/
GEAR
1. Place the starter clutch gear onto the rotor/flywheel and
attempt to rotate the starter clutch gear clockwise. It
should lock up to the rotor/flywheel. Rotate the gear counterclockwise and it should turn freely. If it moves or locks
up both ways, the starter clutch must be replaced.

FI572

INSPECTING STATOR COIL/
MAGNETO COVER ASSEMBLY
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 discoloration, 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
and the two cap screws securing the crankshaft position sensor.

2. Inspect the starter clutch gear for chipped or missing
teeth or discoloration/scoring of the clutch surface.
Inspect the bearing for loose, worn, or discolored rollers. If bearing is damaged, the gear must be replaced.

ROV1-059A

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 holddown under the crankshaft position sensor.
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.

3. Install the new stator coil assembly and secure with
three cap screws. Tighten the cap screws to 15 ft-lb.
4. Place the stator wire harness hold-down into position;
then install the crankshaft position sensor and secure
with two cap screws. Tighten securely.

CRANKSHAFT ASSEMBLY
Runout
1. Support the crankshaft using a set of V Blocks; use a
dial indicator to read crankshaft runout.
NOTE: The contact point of the dial indicator should
be on either side of the oil port hole of the center
crankshaft journal and to the outside of the oil port
hole on the MAG and PTO end of the crankshaft.
63

ZJ058A

2. Rotate the crankshaft slowly.
3. The reading must be 0.002 in. or crankshaft repairing/replacing will be necessary.

Main Bearings
Check the main bearings for signs of pitting, scratches,
wear, or damage. If any of these conditions are found, the
bearings must be replaced.

KC527A

Crankshaft
Mark
A
A
B
B

Connecting Rod
Mark
1
2
1
2

Bearing Inserts Color
Choice
Black
Green
Green
Red

The crank cases go with a grade mark. The mark will be
“A” or “B” located on the side surface of the case as
shown. Determine the replacement bearing color by following the table.

CAUTION
Always replace the bearings as a set; never replace one
side only or severe engine damage will occur

Bearing Selection
NOTE: This information is needed only if the crankshaft or the engine cases have been replaced or if the
connecting rod and main bearings are out of specifications.

Select the proper bearing inserts for the replacement in
accordance with the crankshaft mark.
KC538A

Crankshaft
Mark
A
A
B
B

Crankcase Mark
A
B
A
B

Bearing Inserts Color
Choice
Black
Green
Green
Red

The crank balancer goes with a grade mark. The mark will
be “A” or “B” located on the balancer shaft as shown.
Determine the replacement bearing color by following the
table.
KC539A

The connecting rods go with a grade number mark. The
mark will be a number “1” or “2” located on the side surface of rod as shown. Determine the replacement bearing
color by following the table.

KC531A

Balancer Shaft
Mark
A
A
B
B

Crankcase Mark
A
B
A
B

Bearing Inserts Color
Choice
Yellow
Green
Green
Brown

ROV1-085

NOTE: It is critical to ensure the lines between the
two connecting rod halves match in a straight line.

3. In the top crankcase, apply a suitable assembly lubricant to the six plain bearing tops and bottoms; then
carefully place the crankshaft into the crank case.

Installing Bottom-Side
Components
1. Using a suitable assembly lubricant, lubricate all bearing surfaces of the connecting rods.

ROV1-088A

4. Place the counterbalance shaft into the case making
sure the alignment marks on the counterbalance gear
and crankshaft are aligned.

ROV1-084A

2. Connect the mating halves of the connecting rod on
the crankshaft making sure the gear is on the right
hand side and the oil holes are facing the intake side.
Install the bolts (threads coated with oil); fingertighten only at this point.

ROV1-089A

5. Wipe off the sides of the case half; then apply a bead
of high-temp silicone to the sides of the case half.

ROV1-087A

ROV1-090A

6. Install the bottom end of the crankcase and install the existing eleven cap screws and washers. Tighten to 21 ft-lb.

ROV1-091A

NOTE: Rotating the crankshaft will aid in lining up
the fasteners.

9. Install the oil crossover tube. Tighten to 13.5 ft-lb.

ROV1-078A

NOTE: The longer fasteners go in the holes numbered one through six.

7. Rotate the engine to right-side up and install the remaining
crankcase cap screws and washers. Tighten the cap screws
(A) to 8 ft-lb and the cap screw (B) to 21 ft-lb.

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 finally to 45 ft-lb.

ROV1-092A

NOTE: Verify the correct positioning of the washers.

10. Place the rubber O-ring into the oil pressure relief valve
bore; then push the oil pressure relief valve until the Oring on the valve is past the chamfer.

ROV1-095

ROV1-096

ROV1-069

11. Install the oil screen pickup grommet with the flat side of
the rubber facing up; then install the oil screen so the high
side faces the oil filter to make it level with the oil pan
when installed.

14. With the O-rings and dowel pins in the proper locations, install and secure the oil pump with the appropriate fasteners. Tighten to 8 ft-lb.

ROV1-099A

ROV1-101A

12. Using a gasket scraper, clean off the old gasket from
the oil pan and case. Install a new gasket and two
dowel pins.

ROV1-063

ROV1-100A

NOTE: When installing the pump, the chain and
sprocket must be on the oil pump and counterbalance
shaft with the sprocket shoulder facing the oil pump.

NOTE: The two longer fasteners go in the dowel pin
locations.

13. Install the oil pan. Tighten the cap screws to 8 ft-lb.

ROV1-103A

15. Install the starter idler gear and pin with the smaller
gear facing outward.

KC545

ROV1-065A

16. Install the starter gear on the crankshaft with the
shoulder facing outwards.

19. Using a gasket scraper, clean off the existing gasket
and case from the MAG cover. Using a new gasket
and dowel pins, install the cover making sure the coolant pump shaft is aligned with the oil pump shaft.
Tighten to 7 ft-lb.
20. Install the chain guide and secure with the fastener.

ROV1-105

17. If the flywheel and starter gear were removed, install
the starter gear onto the crankshaft; then install the
flywheel key.

ROV1-107

21. With two dowel pins and the gasket in place, install
the PTO-side cover onto the crankcase and tighten to 7
ft-lb.

KC543

NOTE: Be sure to wipe any grease or oil from the
end of the crankshaft.

18. Install the flywheel onto the crankshaft and secure
with the cap screw. Tighten to 60 ft-lb.

ROV1-045A

Servicing Left-Side
Components
NOTE: The engine does not have to be removed
from the frame for this procedure.

NOTE: To remove left-side components, see Engine
- Removing Engine.

DRIVE CLUTCH
Disassembling
NOTE: Note the timing marks (X) on the cover, spider,
and movable sheave. These must be aligned when
assembling the drive clutch for balance purposes.

1. 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.
WT518A

Cleaning and Inspecting
NOTE: If any components other than flyweights, pins,
spring, thrust washers, or cover are damaged or worn,
clutch replacement is necessary.

1. Using parts-cleaning solvent, wash grease, dirt, and
foreign matter off all components; dry with compressed air.
2. Remove any drive belt dust accumulation from the
stationary sheave, movable sheave, and bushings
using parts-cleaning solvent only.
WC659

CAUTION
Do not use steel wool or a wire brush to clean components having a bushing; damage to the bushing will
result.

3. Inspect the cover for cracks or imperfections in the
casting.
4. Inspect the cam arm pins for wear or bends.
5. Inspect the bushing in the cover for wear, damage, or
cracks.
6. Inspect the spring for cracking or twisting.
7. Inspect the cam arms for grooves.
WT519

2. Remove the cover and spring.

Assembling

! WARNING
Never reuse the lock nuts on the cam arm pins.

1. Place the cam arms, thrust washers, and cam arm
pivot pins (pivot pin heads with the direction of rotation) into the moveable drive sheave and secure with
new lock nuts. Tighten to 48 in.-lb.
NOTE: The drive clutch rotates counterclockwise.

WC657

3. Remove the lock nuts (D) from the cam arm pivot pins
(B); then remove the pins and account for six thrust
washers (C) and three cam arms (A).

WT521

WT191

NOTE: Grasp the moveable sheave and lift it
upward; then release it. It must move freely and not
bind at any point.

2. In the stationary sheave using a suitable tool, remove
the E-clips securing the rollers.

2. Install the spring.
3. Align the match marks (X) and install the clutch cover
and secure with six cap screws. Tighten using a crisscross pattern to 120 in.-lb.

WT197

NOTE: The roller pins are not a serviceable item. If
they are damaged in any way, the stationary sheave
must be replaced.

WC653A

DRIVEN CLUTCH
Disassembling
1. Remove the stationary sheave from the movable
sheave. Account for the shims.

WT193A

3. Place the moveable sheave in an appropriate driven
clutch compression tool. Finger-tighten the wing nut
and remove the spring retaining plate.

WT526

WT189

4. Remove the spring retaining plate cup and spring.

WT527

3. Secure the spring retaining plate with the existing cap
screws and tighten it to 11 ft-lb.

WT523
WT189

Assembling
1. Install the roller (A) and flat washer (B); then secure
with the E-clip (C) on the roller pin.

4. Put shims in the movable sheave with the thicker shim
towards the movable sheave.

WT191A
WT198A

2. Install the spring (A), the cup (B), and the spring
retaining plate (C) in the moveable sheave; then place
in a suitable driven clutch compression tool and finger-tighten the wing nut.

5. Place the stationary sheave in the movable sheave
making sure the “X” timing marks are aligned.

WT526

3. Repeat steps 1 and 2 as required until correct alignment is achieved.
NOTE: To install left-side components, see Engine –
Installing Engine.

Installing Engine
NOTE: The driveshaft must be secured to the transaxle before the engine is installed.
WT194A

CLUTCH ALIGNMENT
NOTE: If a clutch or any clutch component has been
replaced or if the technician is unsure of shim quantity/placement, use the following procedure to check
and adjust clutch alignment.

1. Using a proper lifting device, install the front engine
mount studs into the engine mounting brackets. In the
chassis, install the new lock nuts but do not tighten at
this time.

1. With the drive clutch and driven clutch installed, position the Clutch Alignment Bar inside the sheaves of
the drive clutch and on the outside of the driven
clutch. Make sure not to damage or scratch the
sheaves.

WT515A

2. Align and install the cap screws securing the engine to
the transaxle. Account for a spacing washer (A).
Apply anti-seize compound to the threads of the
adjuster nut (B) but do not tighten at this time.

ROV374

2. The bar should just clear the outside edge of the stationary sheave of the driven clutch with a maximum
of 0.76 mm (0.030 in.) clearance. If the bar will not
clear the outside edge or clearance is more than the
specified amount, the alignment must be corrected.

WT474A

3. Using the appropriate center distance tool, install the
tool over the output shaft of the transaxle and using
the cap screw provided and secure it to the crankshaft.

ROV375

NOTE: If alignment 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).
72

WT475

CAUTION
Care should be taken to install the tool over the output
shaft and slide the tool evenly towards the crankshaft to
avoid damaging the shaft.

WT407

7. Align the rear driveshaft with the output shaft of the transaxle so they are joined together. Push the front axles rearward until the front differential mounting holes are
properly aligned. Tighten the clamp securely.

4. With the jam nut loosened towards the shoulder of the
adjuster nut, tighten the adjuster nut (A) to 10 ft-lb and
then the jam nut (B) to 15 ft-lb.

WT424A

8. Remove the clamps from the oil hoses and install
them onto the engine oil fittings. Secure with the
worm clamps.
WT477A

5. Install the new lock nuts and tighten them to 75 ft-lb.

WT394

9. Install the coolant hose (as noted when removing)
connecting the cylinder and the water pump.
WT225A

6. Tighten the front engine mounting lock nuts to 25 ft-lb.

12. Remove the three cap screws from the PTO side of the
engine and install the clips securing the starter cable
and the gasline hose. Tighten the cap screws to 9 ft-lb.
Install the starter cable on the starter and tighten
securely.

WT410A

WT414A

13. With the two gaskets in place, install the exhaust pipe.
Tighten to 8 ft-lb.

WT399B

10. Connect the coolant return hose (A), the coolant output hose (B), and the thermostat bypass hose (C).
Secure them with the hose clamps and connect the
ECT sensor (D).

WT406A

WT411A

11. Install the coil bracket to the frame and tighten securely.
Install the spark plug caps (A); then connect the coil
connectors (B) and the cam position sensor (C).

WT398A

14. Carefully thread the oxygen (O2) sensor plug in
through the heat shield. Install the heat shield onto the
exhaust pipe and tighten to 10 ft-lb. Connect the oxygen (O2) sensor.

WT396A

WT403A

15. Install the muffler and account for the gasket. Secure
using the two exhaust springs.

WT404A

18. Secure the gasline hose to the fuel rail.

WT402
WT295

16. Install the throttle body into the intake manifold and
tighten the clamp securely. Connect the ISC connector
(A), MAP/IAT connector (B), TPS connector (C), and
stator wires (D). Secure the air box bracket (E) with
the cap screw and tighten to 5 ft-lb.

19. Connect the air filter housing to the throttle body and
secure it with the worm clamp.

WT316A

20. Secure the bottom of the air filter housing with the
existing cap screws 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-lb and plug in the
injectors (A).

WT315A

21. Install the engine breather tube and secure it with the
clamp.

23. Install the rear splash panels and secure them with the
cap screws. Install the push pins securing the wiring
harness to the left-side splash panel.

WT405A
WT364A

24. Install the rear body panels and the side panels (see
Steering/Frame/Controls).
25. Install the seat belt assembly to the frame and tighten
to 60 ft-lb.
26. Install the vent hose, gasline hose, and fuel pump connector.
NOTE: Be sure to route the gasline hose and vent
hose through the hole on the right side splash panel.

WT313B

22. Install the air intake tube and secure it to the frame
and air filter housing with the worm clamp.

WT480

27. Install the cargo box and taillight assembly.

WT311A

WT408A

Fuel/Lubrication/Cooling
! WARNING
Whenever the gasline hoses are removed (other than for
pressure testing), the battery must be disconnected to
prevent inadvertent activation of the electronic fuel
pump.

! WARNING
Whenever any maintenance or inspection is performed
on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames,
etc., in the area.

SPECIAL TOOLS

WT314A

NOTE: Removing the intake boot with the air filter
housing will aid in installation.

4. Loosen the throttle body clamp.

p/n

Oil Pressure Test Kit

0644-495

Tachometer

0644-275

NOTE: Special tools are available from the Arctic
Cat Service Department.

TROUBLESHOOTING
1. Verify that the electric fuel pump is operating by listening for a “whirring” sound for approximately three
seconds after the ignition switch is turned to the ON
position. If no sound can be heard, see Fuel Pump/
Fuel Level Sensor in this section.

WT316A

5. Remove and discard the “patch lock” cap screws
securing the air intake housing bracket to the intake
manifold.

2. Check for a diagnostic trouble code (DTC) on the
LCD. If the light is flashing, see EFI Diagnostic System in Electrical System.
3. Make sure there is sufficient, clean gas in the gas tank.
4. Verify that the battery is sufficiently charged to crank
the engine over at normal speed.
5. Check the air filter housing and air filter for contamination. Clean or replace as necessary (see Periodic
Maintenance/Tune-Up).

Throttle Body
1. Turn the ignition switch to the OFF position; then
remove the ignition key.

WT313C

6. Remove and retain the lower cap screws and grommets.

! WARNING
Do not turn the ignition switch to the ON position with
the hoses removed. Gasoline will be pumped by the
electric fuel pump causing a safety hazard.

2. Remove the rear body panels and the cargo box.
3. Remove the clamp on the engine intake tube and
loosen the air intake clamp.
77

WT315A

7. Remove the air filter housing.
8. Remove the ISC connector (A), MAP/IAT connector
(B), and TPS connector (C); then disconnect the throttle cable (D).

WT566A

12. Connect the ISC connector (A), MAP/IAT connector
(B), and the TPS connector (C).

WT397A

WT397B

9. Loosen the clamp securing the throttle body to the
intake manifold; then remove the throttle body.
10. Connect the throttle cable to the throttle arm; then
install the throttle cable housing cover to the throttle
body. Secure with the screw.

13. Install the air filter housing in place and install the
outlet boot of the housing over the throttle body.
Secure with the clamp.
14. With the existing cap screws, grommets, and spacers,
secure the lower portion of air filter housing to the
frame. Tighten to 5 ft-lb.

11. Make sure the alignment tab on the throttle body
aligns with the slot in the intake boot and install the
throttle body fully into the boot. Secure with worm
clams and tighten securely.

WT315A

15. Using new “patch lock” cap screws, secure the air filter housing mount to the intake manifold (A). Tighten
to 5 ft-lb; then secure the mount to the air filter housing (B). Tighten to 36 in.lb.
WT567A

16. Install the engine intake tube and air intake to the air
filter housing and secure with the clamps.

6. Remove the four cap screws securing the seat base to
the frame.

WT314A

17. Install the cargo box and rear body panels.
NOTE: If the throttle body, ECM, TPS, or ISC are
replaced, the EFI system must be synchronized. Use
the following procedure.

WT359A

7. Remove the remaining cap screws securing the frame
tubes to the frame. Remove both frame tubes.

1. With the key off, depress accelerator pedal to Wide
Open Throttle (WOT).
2. Place the ignition key in the ON position 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.

Gas Tank
WT360

! WARNING
Whenever any maintenance or inspection is made on the fuel
system during which there may be fuel leakage, there should
be no welding, smoking, open flames, etc., in the area.

8. Slide the gas tank slightly forward and disconnect the
gasline hose, vent hose, and fuel pump; then remove
the gas tank.

REMOVING
1. Remove the seats, engine access panel, and center console.
2. Remove the floor and side panels.
3. Remove the battery access panel and battery.
4. Remove the right rear side panel and right rear fender.
5. Remove the cap screws and discard the lock nuts
securing the right side frame tube.
WT480A

INSTALLING
1. Place the gas tank into position; then connect the gasline
hose, vent hose, and fuel pump.
2. Place the two frame tubes into position and secure (but do
not tighten) with new “patch-lock” cap screws.
3. Install the remaining fasteners; then tighten all fasteners
securely.
4. Using new lock nuts, install the right side frame tube and
tighten securely.
WT365A

5. Place the battery into position and connect the battery
cables (negative cable first). Tighten the cables securely.
6. Install the floor and battery access panel.
7. Install the right rear side panel and the right rear fender.
8. Install the center console, engine access panel, and seats.

NOTE: If oil pressure is lower than specified, check
for an oil leak, clogged oil filter, or defective oil pump.
NOTE: If oil pressure is higher than specified, check
for too heavy engine oil weight (see General Information), clogged oil passage, or improper installation or
type of the oil filter.

REMOVING/DISASSEMBLING

Gas/Vent Hoses

1. Remove the oil pump from the engine (see Center
Crankcase Components in Engine).

Replace the gas hose every two years. Damage from aging
may not always be visible. Do not bend or obstruct the
routing of the vent hoses. Make certain the vent hoses are
securely connected and the opposite ends are always open.

2. Remove oil pump components from crankcase.

CLEANING AND INSPECTING
1. Clean all oil-pump components.
2. Inspect the rotors for scoring and gouges.

Oil Filter/Oil Pump

3. Inspect the driveshaft and driven sprocket for damage.
4. Inspect the crankcase for scoring, cracks, or damage.

NOTE: Whenever internal engine components wear
excessively or break and whenever oil is contaminated, the oil pump should be replaced.

ASSEMBLING/INSTALLING
1. Place the rotors into the crankcase making sure the
dowel pin is in the groove of the rotor.

TESTING OIL PUMP PRESSURE

2. Place the cover onto the crankcase.

NOTE: The engine must be warmed up to operating
temperature (cooling fan cycling) for this test.

3. Secure the pump with the two cap screws coated with
blue Loctite #243. Tighten to 8 ft-lb.

1. Remove the oil hose from the fitting nearest the oil filter
base.

Oil Cooler
REMOVING
1. Remove the hood and front bumper.
2. Using appropriate clamps, close-off both oil hoses.
3. Loosen the clamps securing the oil hoses to the oil
cooler; then place an absorbent towel under the connection and remove the hoses.

WT568A

2. Using a suitable “T” fitting, connect Oil Pressure Test Kit
to the lower 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 neutral and start the engine.
Set the speedometer/tachometer to RPM.
4. With the engine running at 3000 RPM and the coolant
at room temperature (approximately 70° F), the pressure gauge must 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 test kit from the vehicle and install the oil
hose. Tighten the clamps securely.
80

WT455

4. Remove the cap screws securing the oil cooler to the
radiator and remove the oil cooler.

2. Wash the cooling fins using a garden hose and hot,
soapy water and a soft brush.
3. Inspect all mounting brackets and the oil inlet and outlet 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 hose
clamps. Tighten securely.
3. Remove the oil hose close-off clamps.
WT549A

CLEANING AND INSPECTING
1. Prior to washing, inspect the oil cooler for signs of
leaks, oily dirt build-up, or plugged cooling fins.

4. Start the engine and allow it to run for approximately
two minutes. Verify engine oil level and add oil as
required.
5. Install the hood and front bumper.

Oil Flow Chart

oil_flow_wt

Liquid Cooling System
When filling the cooling system, use premixed Arctic Cat
Antifreeze. While the cooling system is being filled, air
pockets may develop; therefore, open the bleed screw on the
thermostat housing to allow air to bleed from the cooling
system. When clear coolant (no bubbles) 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 radiator neck.

WT452

NOTE: Opening the radiator cap will aid in draining
the radiator.

CAUTION
After operating the vehicle for the initial 5-10 minutes,
stop the engine, allow the engine to cool down, and
check the coolant level. Add coolant as necessary.

4. Disconnect the headlights.

Radiator
REMOVING
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.

WT463

5. Remove the cap screws securing each front fender to
the frame.

WT455

WT453A

6. Remove the cap screws securing the radiator to the
frame and disconnect the overflow bottle hose from
the top of the radiator.

WT459

3. Using an appropriate Allen wrench, remove the drain
plug from the bottom of the radiator and drain the
coolant into a suitable pan. Account for an O-ring on
the drain plug.
82

WT456A

WT461

7. Using a suitable prying tool, pry the clips out from
between the wiring harness and the frame; then push
the clips downward to remove them from the frame.

10. Disconnect the radiator fan and remove the radiator/
oil cooler from the vehicle. Drain the remaining coolant into a suitable container.

WT454A

WT458

8. Remove the cap screws securing the front bumper to
the frame. Discard the lock nuts.

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 mounting
holes on the radiator bracket. Connect the coolant
hoses and oil hoses; then secure them with the worm
hose clamps. Remove the close-off clamps.

WT459A

WT464

2. Connect the fan motor connector and connect the
overflow bottle hose to the radiator. Install the drain
plug with O-ring and tighten securely.
3. Install the bumper frame in place and using the existing cap screws and new lock nuts, finger-tighten only
at this time.
WT460A

9. Pull the bumper away from the vehicle.
83

WT459A

WT535

4. Install the lower bumper cap screws and tighten the
upper and lower bumper cap screws to 20 ft-lb.

3. Remove the hose from the bottom of the thermostat
housing and push out of the way.

WT460A

4. Remove the two cap screws securing the thermostat
housing together. Remove the thermostat.

WT547

5. Install the cap screws and nuts securing the radiator to
the frame. Tighten to 8 ft-lb.
6. Install the cap screws securing the front fenders to the
frame. Tighten securely and plug in the headlights.
7. Using the existing cap screws, secure the grille and
tighten securely.
8. Fill the radiator with the proper mixture of coolant
until there are no more air bubbles present and the
coolant level is above the cooling fins inside the radiator. Tighten the radiator cap.
9. Install the hood and tighten the two quarter-turn fasteners.

Thermostat

WT534A

INSPECTING
1. Inspect the thermostat for corrosion or spring damage.

REMOVING
NOTE: 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 water
pump
2. Clamp off the coolant hoses and place an absorbent
towel under the thermostat.

2. Using the following procedure, inspect the thermostat
for proper operation.
A. Suspend the thermostat in a container filled with
water.
B. Heat the water and monitor the temperature with a
thermometer.
C. The thermostat should start to open at 80.0-84.0° C
(176-183° F).
D. If the thermostat does not open, it must be
replaced.

3. Inspect all coolant hoses, connections, and clamps for
deterioration, cracks, and wear.

1. Using appropriate clamps, close-off the coolant hose
before and after the water pump.

NOTE: All coolant hoses and clamps should be
replaced every four years or 4000 miles.

INSTALLING
1. Install the thermostat into the thermostat housing so
the bleeder valve is facing up.

WT533

2. Drain the coolant from the pump and remove the
hoses from the water pump.

WT546A

2. Install the thermostat cover; then making sure the
thermostat is properly seated, tighten the cap screws to
5 ft-lb.
3. Install the hose on the bottom of thermostat housing
and secure with the hose clamp.
4. Remove the close-off clamps; then install the muffler
and secure with the springs.
5. Add the recommended anti-freeze as required; then
bleed the cooling system and check for leaks.

Fan

WT399A

3. Remove the cap screws securing the magneto cover to
the engine.
4. Remove the cap screws securing the impeller cover to
the magneto cover. Account for an O-ring and two
dowel pins.

REMOVING
1. Remove the radiator.
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 radiator.

Water Pump

WT578

5. Remove the E-clip and washer from the impeller shaft
and remove impeller from case half.

NOTE: The water pump is a non-serviceable component. It must be replaced as an assembly.

REMOVING
NOTE: If the engine is still in vehicle, drain the oil
and remover the muffler, exhaust pipe, and right-side
inner splash panel.
85

WT571

6. Using an appropriate press, remove the two bearings.

WT576A

CAUTION
Only apply pressure to the center race of the seal while
installing to avoid damaging the seal.

2. Using a section of 1” pipe, press in the mechanical
seal.

WT572

7. Using an appropriate press, remove the rubber seal
and mechanical seal as an assembly.

WT575

CAUTION
It is critical while pressing the seal into position to
press on the outer diameter of the seal to avoid damaging the mechanical seal.

3. Individually press in the bearings.

WT570

INSTALLING
1. Apply grease to the inside and outside of the seal; then
press in the rubber seal.

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. Install the impeller cover and secure with the cap
screws. Tighten the screws to 11 ft-lb.
86

NOTE: The two longer cap screws go in the dowel
pin locations.

7. Install the coolant hoses; then add the appropriate
mixture of coolant until the appropriate level is
reached (see Fuel/Cooling/Lubricant).
8. If removed, install the muffler, exhaust pipe, and
right-side inner splash panel.
9. If drained, add the appropriate engine oil until the correct level has been reached.

Fuel Pump/Fuel Level
Sensor
NOTE: Preliminary checks may be performed on
this component using the diagnostic mode on the
LCD gauge (see EFI Diagnostic System in the Electrical System section).

The fuel pump and fuel level sensor are not serviceable
components. If either component fails, it must be replaced.

TESTING

! WARNING
Whenever any maintenance or inspection is made on
the fuel system during which there may be fuel leakage,
there should be no welding, smoking, open flames, etc.,
in the area.

3. Turn the ignition switch to the ON position. The fuel
pressure should build until the pump shuts off. Pressure should read 3.0 kg-cm2 (43 psi).
4. Check for any flashing DTC (Diagnostic Trouble
Code) on the digital gauge. A disconnected or faulty
tilt sensor will cause the fuel pump not to run and a
code to flash.
5. If the pump is not running, check the 10 amp FUEL
fuse in the PDM under the passenger seat. Replace as
necessary and check for fuel pump operation.
6. If fuse is OK, check 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 REMOVING.

REMOVING
1. Remove the passenger seat.
NOTE: The power supply/wiring to the fuel pump
could be checked by 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.

2. Disconnect the fuel pump/fuel level sender connector;
then wrap a shop towel around the gasline connector
and disconnect the gasline from the fuel pump.
3. Mark the components for assembling purposes and
remove the screws securing the fuel pump to the gas
tank.

AT THIS POINT
Prior to removing the fuel pump, the following test
should be performed to determine that removal is
necessary.

1. Turn the ignition switch ON and listen for a momentary “whirring” sound of the pump building pressure.
If the sound is heard (10 seconds), no electrical checks
are necessary. Turn the ignition switch OFF.
2. Disconnect the gasline hose from the fuel rail; then
install a suitable pressure gauge.

! WARNING
Gasoline may be under pressure. Place an absorbent
towel under the connector to absorb any gasoline spray
when disconnecting.

WT552A

4. Carefully remove the fuel pump/fuel level sender
assembly from the gas tank; then tape over the opening.

INSPECTING

AT THIS POINT
If the pump has failed earlier test and must be
replaced, proceed to INSTALLING.

1. Move the float lever and check for free movement.
The float assembly should return to the lower position
without force. If not, replace the fuel level sensor
assembly.

FI092A

2. Test the fuel level sensor by connecting a multimeter
to the fuel level sensor leads (A); then select OHMS.
The multimeter should show 0-5 ohms at full fuel
position and 95-105 ohms at empty.
87

FULL

WT550B

EMPTY

WT552A

2. Secure the pump assembly with the mounting screws
and tighten securely in a crisscross pattern.

WT551B

NOTE: If readings are erratic, clean the resistor
wiper and resistor with clean alcohol and retest. If
still not correct, replace the fuel level sensor.

INSTALLING
1. Carefully place the fuel pump assembly into the gas
tank referencing orientation marks made during
removal.

WT552B

3. Connect the electrical connector and the gasline hose
connector to the fuel pump.
4. Install the passenger seat.

Troubleshooting
Problem: Starting impaired
Condition
1. Gas contaminated
2. Throttle cable too tight

Problem: Idling or low speed impaired
Condition
1. TPS out of adjustment
2. Throttle cable too tight
3. Throttle body dirty

Problem: Medium or high speed impaired
Condition
1. High RPM “cut out” against RPM limiter

Remedy
1. Drain gas tank and fill with clean gas
2. Adjust throttle cable and synchronize EFI system (see Section 5)

Remedy
1. Adjust TPS (out of warranty) or replace the throttle body
(under warranty)
2. Adjust throttle cable and synchronize EFI system (see Section 5)
3. Clean throttle body

Remedy
1. Decrease RPM speed

Electrical System
NOTE: Certain components and sensors can be
checked by using the EFI diagnostic system and digital gauge (see EFI Diagnostic System in this section
for more information).

The electrical connections should be checked periodically for
proper function. In case of an electrical failure, check fuses,
connections (for tightness, corrosion, damage), and/or bulbs.

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

Maintenance Charging
NOTE: Arctic Cat recommends 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.

SPECIAL TOOLS
A number of special tools must be available to the technician when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appropriate tool description.
Description

p/n

Fluke Model 77 Multimeter

0644-559

Timing Light

0644-296

MaxiClips

0744-041

NOTE: Special tools are available from the Arctic
Cat Service Department.

TESTING ELECTRICAL
COMPONENTS
All of the electrical tests should be made using the Fluke
Model 77 Multimeter. If any other type of meter is used,
readings may vary due to internal circuitry. When troubleshooting a specific component, always verify first the
fuse(s) are good, the LED(s) are good, the connections are
clean and tight, the battery is fully charged, and all appropriate switches are activated.

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 strip should NOT be removed
and NO fluid should be added.

NOTE: For absolute accuracy, all tests should be
made at room temperature of 68° F.

3. Be sure the charger and battery are in a well-ventilated area. Be sure the charger is unplugged from the
110-volt electrical outlet.

Battery

4. Connect the red terminal lead from the charger to the
positive terminal of the battery; then connect the
black terminal lead of the charger to the negative terminal of the battery.

NOTE: Preliminary checks may be performed on this
component using the diagnostic mode on the LCD
gauge (see EFI Diagnostic System in this section)

The battery is located under the passenger seat.

NOTE: Optional battery charging adapters are available from your authorized Arctic Cat dealer to connect
directly to your vehicle from the recommended chargers to simplify the maintenance charging process.
Check with your authorized Arctic Cat dealer for proper
installation of these charging adapter connectors.

NOTE: To access the battery box, the battery cover
must be removed.

5. Plug the battery charger into a 110-volt electrical
outlet.

After being in service, batteries require regular cleaning
and recharging in order to deliver peak performance and
maximum service life. The following procedures are recommended for cleaning and maintaining sealed batteries.
Always read and follow instructions provided with battery
chargers and battery products.

6. If using the CTEK Multi US 800, there are no further
buttons to push. If using the CTEK Multi US 3300,
press the Mode button (A) at the left of the charger
until the Maintenance Charge Icon (B) at the bottom
illuminates. The Normal Charge Indicator (C) should
illuminate on the upper portion of the battery charger.

NOTE: Refer to all warnings and cautions provided
with the battery or battery maintainer/charger.

NOTE: The maintainer/charger will charge the battery to 95% capacity at which time the Maintenance
Charge Indicator (D) will illuminate and the maintainer/charger will change to pulse/float maintenance. If the battery falls below 12.9 DC volts, the
charger will automatically start again at the first step
of the charge sequence.

Accessory Receptacle/
Connector
NOTE: This test procedure is for either the receptacles or the connectors.

VOLTAGE
1. Turn the ignition switch to the ON position; then set
the meter selector to the DC Voltage position.
2. Connect the red tester lead to the positive connector;
then connect the black tester lead to the negative connector.
3. The meter must show battery voltage.
NOTE: If the meter shows no battery voltage, troubleshoot the fuse, receptacle, connector, or the main
wiring harness.
3300A

NOTE: Not using a battery charger with the proper
float maintenance will damage the battery if connected over extended periods.

Charging
NOTE: Arctic Cat recommends the use of the CTEK
Multi US 800 or the CTEK Multi US 3300 for battery
maintenance charging.

1. Be sure the battery and terminals have been cleaned
with a baking soda and water solution.
NOTE: The sealing strip should NOT be removed
and NO fluid should be added.

2. Be sure the charger and battery are in a well-ventilated area. Be sure the charger is unplugged from the
110-volt electrical outlet.

Brakelight Switch
The switch connectors are spade-type connectors on the
side of the master cylinder.
NOTE: The ignition switch must be in the ON position.

VOLTAGE (Wiring Harness
Connector)
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the orange wire (B); then
connect the black tester lead to the red/blue wire (A).

3. Connect the red terminal lead from the charger to the
positive terminal of the battery; then connect the
black terminal lead of the charger to the negative terminal of the battery.
4. Plug the charger into a 110-volt electrical outlet.
5. By pushing the Mode button (A) on the left side of
the charger, select the Normal Charge Icon (E). The
Normal Charge Indicator (C) should illuminate on
the upper left portion of the charger.
6. The 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 minimum 1
hour after the Maintenance Charge Indicator (D) illuminates. If the battery becomes hot to the touch, stop
charging. Resume after it has cooled.

7. Once the battery has reached full charge, unplug the
charger from the 110-volt electrical outlet.

WT556A

3. The meter must show battery voltage.
NOTE: If the meter shows no battery voltage, troubleshoot the fuse, switch, or the main wiring harness.
NOTE: If the meter shows battery voltage, the main
wiring harness is good; proceed to test the switch/
component and the connector.

RESISTANCE (Switch Connector)
NOTE: The brake pedal must be depressed for this
test.

1. Set the meter selector to the OHMS position.
2. Connect the red tester lead to one terminal; then connect the black tester lead to the other terminal.
3. When the pedal is depressed, the meter must show less
than 1 ohm.
NOTE: If the meter shows more than 1 ohm of resistance, replace the switch.

Engine Coolant
Temperature (ECT)
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).

1. Connect the meter leads (selector in OHMS position)
to the sensor terminals.
2. Suspend the sensor and a thermometer in a container
of cooking oil; then heat the oil.
NOTE: Neither the sensor nor the thermometer
should be allowed to touch the bottom of the container or inaccurate readings will occur. Use wire
holders to suspend the sensor and thermometer.

! WARNING
Wear insulated gloves and safety glasses. Heated oil
can cause severe burns.

3. On the ECT sensor when the temperature reaches 60°
C (140° F), the meter should read approximately 703
ohms ± 5%.
4. On the ECT sensor when the temperature reaches 90°
C (194° F), the meter should read approximately 260
ohms ± 5%.
5. On the ECT sensor when temperature reaches 120° C
(248° F), the meter should read approximately 111
ohms ± 5%.
6. If the readings are not as indicated, the sensor must be
replaced.
7. Install the sensor and tighten securely.
8. Connect the leads.

Fan Motor
NOTE: To determine if the fan motor is good, connect the red wire from the fan connector to a 12 volt
battery; then connect the black wire from the fan connector to ground. The fan should operate.

! WARNING

WT558A

NOTE: Fan motor resistance checks are not recommended. Resistance values change with the motor
commutator position.

Power Distribution
Module (PDM)
FUSES/RELAYS
NOTE: To access fuses and relays, compress the
locking tabs on either side of the PDM cover and lift off.

The fuses are located in a power distribution module under
the driver’s seat. If there is any type of electrical system
failure, always check the fuses first.
The 4-pin relays are identical plug-in type located on the power
distribution module. Relay function can be checked by switching relay positions. The 4-pin relays are interchangeable.
NOTE: The PDM base and wiring harness are not a serviceable component and must be replaced as an assembly.

1. Remove a fuse from the power distribution module.
2. Set the meter selector to the DC Voltage position.
3. Connect the black tester lead to ground.
4. Using the red tester lead, contact each end of the fuse
holder connector terminals individually.
5. The meter must show battery voltage on one fuse terminal but not the other.
NOTE: Battery voltage will be indicated from only
one side of the fuse holder connector terminal; the
other side will show no voltage.
NOTE: When testing the HI-BEAM fuse holder, the
headlight switch must be in the HI position; when
testing the LO-BEAM fuse holder, the headlight dimmer switch must be in the LO position.
NOTE: If the meter shows no battery voltage, troubleshoot the battery, switches, power distribution
module, or the main wiring harness.

Care should be taken to keep clear of the fan blades.

1. Disconnect the coil connector. Connect the red tester
lead to one coil terminal; then connect the black tester
lead to the other coil terminal.
2. Resistance must be less than 1 ohm.
NOTE: If the meter does not show as specified,
replace ignition coil.
3411-964

This vehicle uses automotive-style (see-through) fuses. The
fuses can be visually inspected; replace fuse if link is open.

CAUTION
Always replace a blown fuse with a fuse of the same
type and rating.

NOTE: Secondary coil resistance checks are not
recommended. An internal diode in the coil prevents
accurate secondary resistance measurements.

Spark Plug Cap
1. Connect the red tester lead to one end of the cap; then
connect the black tester lead to the other end of the
cap.

NOTE: Make sure the fuses are returned to their
proper position according to amperage. Refer to the
amperage listed under each fuse on the power distribution module.

Ignition Coils
The ignition coils are mounted to the upper frame above
the engine.
WT553

2. The meter must show 5000 ohms.
NOTE: If the meter does not show as specified,
replace the spark plug cap.

EFI Sensors/Components

WT405

VOLTAGE (Primary Coil)
1. Set the meter selector to the DC Voltage position; then
disconnect the connector from the coil to be tested.
2. Using MaxiClips, connect the red tester lead to the
orange wire and the black tester lead to ground.

CRANKSHAFT POSITION (CKP)
SENSOR
NOTE: The cargo box must be removed for this procedure.

The three-pin CKP connector is located in front of the air
filter.

3. Turn the ignition switch to the ON position. The meter
must show battery voltage.
4. Repeat for the other coil.

RESISTANCE (Primary Winding)

CAUTION
Always disconnect the battery when performing resistance tests to avoid damaging the multimeter.

NOTE: For this test, the meter selector should be
set to the OHMS position.
WT562

1. Set the meter selector to the OHMS position.
92

2. Connect the red tester lead to the brown wire; then
connect the black tester lead to the white wire. The
meter reading must be 100-150 ohms.

1. Remove the cargo box.
2. Disconnect the sensor.

3. Set the meter selector to the AC Voltage position.
NOTE: The battery must be at full charge for these
tests.

4. Using MaxiClips, connect the red tester lead to the
brown/green wire; then connect the black tester lead
to the green/white wire.
5. Crank the engine over using the electric starter.
6. The meter should read approximately 1.0 volt.

OXYGEN (O2) SENSOR
The oxygen (O2) sensor is located in the exhaust pipe.

WT405D

NOTE: When testing the resistance of the sensor’s
heater, the engine/exhaust pipe must be at room temperature (65-75° F) or inaccurate readings will occur.

1. Remove the cargo box.
2. Disconnect the sensor.

NOTE: For this test, the meter must be in OHMS
position.

3. On the sensor side of connector, connect the black (negative) test lead to one black wire pin; then connect the red
(positive) test lead to the other black wire pin. The reading should be between 6.7k and 10.1k ohms.
NOTE: If the meter does not read as specified,
replace the sensor.

4. Select DC Voltage on the tester and turn the ignition
switch to the ON position.
5. Connect the black tester lead to the pink/black wire
and the red tester lead to the orange wire. The meter
should read battery voltage. If the meter does not read
as specified, check the wiring.

MANIFOLD ABSOLUTE PRESSURE/
INLET AIR TEMPERATURE (MAP/IAT)
SENSOR
WT405C

NOTE: For this test, the meter must be in OHMS
position.

NOTE: Preliminary checks may be performed on this
component using the diagnostic mode on the LCD
gauge (see EFI Diagnostic System in this section).

3. On the sensor side of connector, connect the black (negative) test lead to one white wire pin; then connect the red
(positive) test lead to the other white wire pin. The reading should be between 6.7 and 10.1 ohms.

1. Disconnect the MAP/IAT connector from the sensor
located on top of the throttle body.

NOTE: If the meter does not read as specified,
replace the sensor.

3. Connect the black tester lead to the pink/black wire and
the red tester lead to the green/black wire. The meter
should read 4.5-5.5 DC volts. If the meter does not read
as specified, check the ECM connector or wiring.

4. Select DC Voltage on the tester and turn the ignition
switch to the ON position.
5. Connect the black tester lead to the black/green wire
and the red tester lead to the orange wire. The meter
should read battery voltage. If the meter does not read
as specified, check the wiring.
NOTE: When testing the resistance of the sensor’s
heater, the engine/exhaust pipe must be at room temperature (65-75° F) or inaccurate readings will occur.

CAM POSITION SENSOR
The cam position sensor is located on the cylinder head.

2. Select DC Voltage on the tester and turn the ignition
switch to the ON position.

4. Connect the MAP/IAT to the harness; then using MaxiClips, connect the red tester lead to the brown/white
wire and the black tester lead to the pink/black wire.
With the engine running at idle speed, the meter should
read approximately 2.5 DC volts (MAP sensor signal).
5. Connect the red tester lead to the green/red wire. With
the engine at idle and at room temperature (approximately 68° F), the meter should read approximately
2.9 DC volts (IAT sensor signal).
NOTE: If the meter does not read as specified,
replace the sensor.
93

3. Meter must show battery voltage.

Speed Sensor

NOTE: If the meter shows no battery voltage, troubleshoot the main 30 amp fuse, the battery, or the
main wiring harness.

NOTE: Preliminary checks may be performed on this
component using the diagnostic mode on the LCD
gauge (see EFI Diagnostic System in this section).

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 meter must show battery voltage.

NOTE: Prior to testing the speed sensor, inspect the
three-wire connector on the speed sensor for contamination, broken pins, and/or corrosion.

1. Set the meter selector to the DC Voltage position.
2. Using MaxiClips, connect the red tester lead to the
orange wire; then connect the black tester lead to the
black wire.

5. Connect the red meter lead to the yellow/green wire;
then with the black lead grounded, turn the ignition
switch to the START position. The starter should
engage and the meter must show battery voltage.
NOTE: When the starter is engaged, battery voltage
will drop to approximately 10.5 DC volts.

Headlight Switch
VOLTAGE
1. Connect the red meter lead to the red/black wire; then connect the black meter lead to the black wire.
2. Turn the ignition switch to the ON position. The meter
must show battery voltage.

WT554

3. Turn the ignition switch to the ON position.
4. The meter must show approximately 6 DC volts.
5. Leave the black tester lead connected; then connect
the red tester lead to the pink/white wire.

NOTE: If the meter does not show battery voltage,
troubleshoot the LIGHTS fuse on the power distribution module, the ignition switch, or the main harness.

3. Using MaxiClips, connect the red meter lead to either of
the two yellow wires; then select the high beam position
on the headlight switch. The meter must show battery
voltage.

6. Slowly move the vehicle forward or backward; the meter
must show 0 and approximately 6 DC volts alternately.

4. Using MaxiClips, connect the red meter lead to either of
the two gray wires; then select the low beam position on
the headlight switch. The meter must show battery voltage.

NOTE: If the sensor tests are not within specifications, the sensor must be replaced.

NOTE: The battery voltage will show lower in steps
3 and 4 due to electrical loading of the headlights.

To replace a speed sensor, use the following procedure.
1. Disconnect the three-wire connector from the speed sensor;
then remove the cap screw securing the sensor to the transaxle.
2. Install the new speed sensor into the transaxle with new
O-ring lightly coated with multi-purpose grease; then
secure the sensor with the cap screw. Tighten to 10 ft-lb.

Ignition Switch
To access the ignition switch, the dash must be loosened
and slid to the rear.

VOLTAGE
1. Set the meter selector to the DC Voltage position.
2. Connect the red meter lead to the red wire; then connect the black meter lead to ground.
94

Drive Select Switch
RESISTANCE
1. Remove the switch assembly from the dash; then disconnect the harness from the switch.
NOTE: The switch can be removed from the dash
using a thin, flat pry bar or suitable putty knife. It is not
necessary to remove the dash to remove the switch.

2. Using an ohmmeter, the following readings must be
observed.
NOTE: Switch terminals A and D are connected with
a small metallic jumper.

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

VOLTAGE
PR566A

DIFFERENTIAL
LOCK
C to E 50 ohms ± 10% C to E 50 ohms ± 10% C to E 50 ohms ± 10%
A to B Open
A to B <1 ohm
A to B <1 ohm
A to C Open
A to C Open
A to C <1 ohm
A to E Open
A to B <1 ohm
A to C <1 ohm
2WD

4WD

1. Locate the 4-wire connector for the front drive actuator above the differential; then connect the red meter
lead to the orange wire using a MaxiClip.

VOLTAGE
NOTE: Voltage tests must be made with the switch
and the actuator connected. The meter can be connected at the actuator connector using a break-out
harness or MaxiClips.

1. Turn the ignition switch to the ON position.
2. Select the DC Volts position on the tester and observe
the meter readings for each of the three switch positions.
WIRE COLOR
2WD
4WD
DIFFERENTIAL LOCK
Black to Orange 12.0 DC Volts 12.0 DC Volts
12.0 DC Volts
Black to White/ 11.5 DC Volts 0 DC Volts
0 DC Volts
Green
Black to White/ 11.5 DC Volts 11.5 DC Volts
0 DC Volts
Orange

NOTE: If the meter does not show voltages according 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

WT561

2. Connect the black lead to the black wire using a MaxiClip;
then select 2WD on the drive select switch.
NOTE: The black tester lead can remain connected
to the black wire for the remaining tests.

3. Turn the ignition switch to the ON position. The meter
must show battery voltage.
NOTE: If battery voltage is not shown, troubleshoot the
10 amp ignition (IGN) fuse on the power distribution
module, the ignition switch, or the main wiring harness.

4. Connect the red meter lead to the white/green wire.
The meter must show battery voltage.
5. Select 4WD on the drive select switch. The meter
must show 0 DC volts.

VOLTAGE

6. Connect the red meter lead to the white/orange wire.
The meter must show battery voltage.

NOTE: To perform the following tests, the ignition
switch must be in the ON position and the transmission shifted into reverse gear.

7. Select LOCK on the drive select switch. The meter
must show 0 DC volts.

1. Connect the red meter lead to the red/green wire and
the black meter lead to a suitable ground; then select
2WD on the drive select switch. The meter must show
approximately 1.5 DC volts.

Stator Coil

2. Depress the reverse override switch. The meter showing should not change from step 1.

NOTE: The cargo box must be removed for this procedure.

3. Select 4WD on the drive select switch. The meter
must show approximately 5 DC volts.

VOLTAGE (AC Generator - Regulated
Output)

4. Depress the reverse override switch. The meter must
show approximately 1.5 DC volts.

NOTE: The battery must be at full charge for these
tests.
95

1. Set the meter selector to the DC Voltage position.

VOLTAGE

2. Connect the red tester lead to the positive battery post;
then connect the black tester lead to the negative battery post.

Perform this test on the starter motor positive terminal. To
access the terminal, slide the boot away.

3. With the engine running at a constant 4000 RPM (with the
headlights on), the meter must show 14-15.5 DC volts.

CAUTION
Do not run the engine at high RPM for more than 10 seconds.

NOTE: The ignition switch must be in the ON position, and the shift lever in the NEUTRAL position.

1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the starter terminal; then
connect the black tester lead to ground.

NOTE: If voltage is lower than specified, test AC
Generator - No Load.

VOLTAGE (AC Generator - No Load)
1. Set the meter selector to the AC Voltage position.
2. Test between the three black wires for a total of three
tests.
3. With the engine running at a constant 4000 RPM, all
wire tests must be approximately 65 volts.

CAUTION
Do not run the engine at high RPM for more than 10 seconds.

NOTE: If any stator coil test failed, replace the stator assembly.

RESISTANCE (AC Generator)
1. Set the meter selector to OHMS position.
2. Test between the three black wires for a total of three tests.
3. The meter reading must be less than 1 ohm.

WT555

3. With the ignition switch rotated, the meter must show
battery voltage and the starter motor should operate.
NOTE: If the meter showed battery voltage but the
starter motor did not operate or operated slowly,
inspect battery voltage (at the battery), starter motor
condition, and/or ground connections.
NOTE: If the meter showed no battery voltage,
inspect the main fuse, ground connections, starter
motor lead, battery voltage (at the battery), starter
relay, or the neutral start relay.

Starter Motor
Starter Relay
NOTE: The starter motor is not a serviceable component. If the motor is defective, it must be replaced.

REMOVING
1. Disconnect the battery.

CAUTION
Always disconnect the negative battery cable from the
battery first; then disconnect the positive cable.

1. Remove the driver’s seat; then using the multimeter set to
the DC Voltage position, check the relay as follows.
2. Connect the red tester lead to the positive battery
cable; then connect the black tester lead to the starter
cable connection on the starter relay. The meter must
show battery voltage.

2. Remove the nut securing the positive cable to the
starter motor; then remove the cable from the starter.
3. Remove the two cap screws securing the starter motor
with ground wires to the crankcase; then remove the
starter motor. Account for the wiring forms and an O-ring.

INSTALLING
1. Apply a small amount of grease to the O-ring seal on the
starter motor; then 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.
96

WT560

NOTE: Make sure the ignition switch is in the ON position and the transmission is in park.
NOTE: Verify there are no loose or corroded connections on the battery and/or starter relay.

3. Rotate the ignition switch while observing the multimeter. The multimeter should drop to 0 volts and the
starter should engage.
NOTE: If the starter engages but more than one volt
is indicated by the multimeter, replace the starter
relay. If no “click” is heard and the multimeter continues to indicate battery voltage, proceed to step 4.

4. Disconnect the two-wire plug from the starter relay;
then connect the red tester lead to the green wire and
the black tester lead to the yellow/green wire.
5. Depress the starter button and observe the multimeter.
NOTE: If battery voltage is indicated, replace the
starter relay. If no voltage is indicated, proceed to
Power Distribution Module (PDM) check.

Engine Control Module
(ECM)

Regulator/Rectifier
The regulator/rectifier is secured to the coolant overflow
tank under the hood. Verify all other charging system components before the regulator/rectifier is replaced.

TESTING
1. Start engine and warm up to normal operating temperature; then connect a multimeter (set at the DC Voltage 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 voltage rises above 15.5 DC volts, the regulator is faulty or a battery connection is loose or
corroded. Clean and tighten battery connections or
replace the regulator/rectifier. If voltage does not rise,
see Stator Coil/Crankshaft Position (CKP) Sensor Voltage in this section. If charging coil voltage is normal, replace the regulator/rectifier.

Headlights
The ECM is located beneath the driver’s seat.
NOTE: The ECM is not a serviceable component. If
the unit is defective, it must be replaced.

The ECM is rarely the cause of electrical problems; however, if the ECM is suspected, substitute another modelcompatible ECM to verify the suspected one is defective.
This EFI system has a built-in feature that will only allow
an ECM of the same part number to be used in these models. Do not attempt to substitute an ECM from a different
model as the system will not allow it to start.
Error codes can be cleared by following the procedures
located in the EFI Diagnostic System sub-section in this
section.
NOTE: If the throttle body, ECM, TPS, or ISC are
replaced, the EFI system must be synchronized. Use
the following procedure.

1. With the key off, depress accelerator pedal to Wide
Open Throttle (WOT).
2. Place the ignition key in the ON position and wait for
10 seconds.

VOLTAGE
1. Set the meter selector to the DC Voltage position.
2. Set the light switch to the desired position; then connect the black tester lead to the black wire terminal.
3. Connect the red tester lead to the yellow/black wire
terminal (high beam) or white wire terminal (low
beam). The meter must show battery voltage.
NOTE: If battery voltage is not shown in any test,
inspect the fuses on the power distribution module,
headlight switch, ignition switch, or wiring harness.

Taillight-Brakelight
VOLTAGE (Taillight)
NOTE: The ignition switch must be in the ON position and either high beam or low beam selected on
the light switch.

3. Release the accelerator pedal, and wait an additional
10 seconds.

1. Set the meter selector to the DC Voltage position.

4. Turn the key to the OFF position and allow the gauge
to shut off.

2. Connect the black tester lead to the black wire; then
connect the red tester lead to the white/red wire. The
meter must show battery voltage.

VOLTAGE (Brakelight)
NOTE: The ignition switch must be in the ON position.

1. Set the meter selector to the DC Voltage position.

2. Select DC Voltage on the multimeter.

2. Connect the red tester lead to the red/blue wire; then
connect the black tester lead to the black wire.

3. Connect the red tester lead to the blue/brown wire and
the black tester lead to the pink/black wire; then turn
the ignition switch ON and observe the meter. The
meter should read 0.3-1.5 DC volts.

3. With the brake applied, the meter must show battery
voltage.
NOTE: If the meter shows no voltage, inspect the 10
amp ignition (IGN) fuse, brakelight switch, wiring harness, or connectors.

4. Tilt the sensor 60° or more to the left and right observing the meter. The meter should read 3.0-7.0 DC volts
after approximately one second in the tilted position.
If the meter readings are not as specified, the tilt sensor is defective.
NOTE: When replacing the sensor after testing
make sure the arrow is directed up.

Tilt Sensor
The tilt sensor is located beneath the driver’s seat.

WC159A

WT565A

! WARNING
Incorrect installation of the tilt sensor could cause sudden loss of engine power which could result in loss of
vehicle control resulting in injury or death.

CAUTION
Do not drop the tilt sensor as shock can damage the
internal mechanism.

SUPPLY VOLTAGE

Throttle Position Sensor
(TPS)
NOTE: Preliminary checks may be performed on this
component using the diagnostic mode on the LCD
gauge (see EFI Diagnostic System in this section).

TESTING
1. Remove the rear fenders and cargo box. Remove
the TPS connector plug from the TPS.

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 and the black tester lead to the pink/black wire.
2. Turn the ignition switch to the ON position. The multimeter should read battery voltage. If battery voltage
is not indicated, check the 30-amp fuse, wiring harness, or the ignition switch.
3. Remove the red tester lead and connect to the blue/
brown wire. The multimeter should read approximately 0.2 DC volts. If the specified voltage is not
indicated, check wire connections at the ECM or substitute another ECM to verify the test.

OUTPUT VOLTAGE
NOTE: MaxiClips will be required on the multimeter
leads as the following tests are made with the sensor
connected.

1. Connect the three-wire plug to the sensor; then
remove the right-side mounting screw securing the
sensor to the frame.
98

WT562A

NOTE: Prior to testing the TPS, inspect the threewire plug connector on the main harness and the
three-pin plug on the TPS for contamination, broken
pins, and/or corrosion.

NOTE: If the vehicle is in warranty, removing or
adjusting the TPS will void warranty. If the TPS is
tested out of specification, the throttle body must be
replaced. If the vehicle is out of warranty, the TPS can
be adjusted.

2. Connect the TPS Multi-Analyzer Harness connector #8 to the TPS; then connect the harness to the
TPS Analyzer Tool.
3. Using a multimeter, connect the black tester lead to
the center socket (GND) on the analyzer and the red
tester lead to the white socket (VAR); then select the
DC Voltage position. The gauge should read 0.45-0.55
and at Wide-Open Throttle it should read up to
approximately 3.6.

WT541

3. Press the center button (SELECT) to enter diagnostic
mode; cycle the display by pressing either the left or
right button to step to the desired function.
NOTE: The gauge can be utilized dynamically
(engine running/vehicle moving) or statically (engine/
vehicle stopped).

DIAGNOSTIC MODES
Battery (BATTERY)

WT563

NOTE: If the throttle body, ECM, TPS, or ISC are
replaced, the EFI system must be synchronized. Use
the following procedure.

EFI Diagnostic System
DIGITAL GAUGE
The digital gauge can be used as a diagnostic tool for many
of the DTC’s displayed. To place the gauge into the diagnostic mode, use the following procedure.

WT540

Display: System DC voltage.
DTC: P0562, P0563, P2531, P2532
Usage: Verify system voltage under following conditions.
1. Battery voltage with engine and accessories off (>12.2
VDC for fully charged).
2. Battery voltage with engine idling (charging = 13.8
VDC or greater).
3. Battery voltage with electrical accessories operating,
engine idling (13.5 VDC or greater).
4. Battery voltage starter cranking (10.5-11.5 VDC).

1. Turn the ignition switch ON.
2. Depress and hold both left and right buttons together
for approximately three seconds until “DIAGNOSTIC” appears on the LCD.

Coolant (COOLANT)

MAP (AIR PRESS)

WT591

Display: Engine coolant temperature as measured by the
ECT sensor.

WT602

Display: MAP in millibars and in./Hg.
DTC: P0107, P0108

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, indicated by a momentary drop or pause in the rising temperature reading.

Usage: Verify barometric pressure signal correct.
NOTE: Local barometric pressure is given in in./Hg
(inches of mercury) and millibars. The gauge should display approximately 965 millibars at 970 ft. above sea level.

Idle Step Control (ISC)

4. Fan ON @ 203° F, OFF @ 194° F:
A. fan motor
B. fan relay
C. fan fuse
D. wiring connections
5. High Temperature Rev Limiter 5000 RPM @ 230° F.

Inlet Air Temperature (INTAKE)
WT542

Display: ISC position
DTC: P0508, P0509
Usage: Verify correct ISC position.

TPS (TPS)

WT592

Display: Inlet air temperature in Fahrenheit 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 compartment heat as well as
intake manifold heating.

WT539

Display: TPS position (0% closed, 95-100% WOT).
DTC: P0121, P0122, P0123
Usage: Verify TPS signal and adjust throttle cable.

100

Fuel Sensor (FUEL)

Speedometer (SPEED)

WT545

Display: Fuel level signal from the fuel level sensor.
DTC: C1400, C1401, C1402

WT543

Display: Vehicle speed signal.
DTC: P0500

Usage: Check output of the fuel level sensor.*

Usage: Verify speedometer sensor signal from the following.

1. Full fuel is indicated by a reading of 0-5 ohms.
2. Empty is indicated by a reading of 95-105 ohms.
* 110-500 ohms, suspect the fuel level sensor or wiring. 0-100 ohms but
no gauge indication, suspect the gauge.

1. Speed sensor to ECM.
2. ECM (CAN) signal to gauge (speedometer/odometer).

DIAGNOSTIC TROUBLE CODES
(DTC)

Tachometer (RPM)

If an EFI or related chassis component fails or an out-oftolerance signal is detected by the ECM, a diagnostic trouble code (DTC) will be generated in the ECM and displayed on the LCD. The DTC will be displayed alternately
with a wrench icon or malfunction indicator light (MIL).
The DTC will continue to flash until the malfunction is
corrected and the code cleared.

Code List

WT544

Display: Engine RPM
DTC: P0336, P0337, P0339
Usage: Verify engine speed signal from the following.
1. CKP (crankshaft position) sensor to ECM

NOTE: Each of the following numerical codes will
have a one-letter prefix of C, P, or U. A “C” prefix
denotes a chassis malfunction, a “P” prefix denotes a
power train malfunction, and a “U” prefix denotes a
loss of communication with the gauge.
NOTE: Normal malfunction codes are cleared from
the LCD when the component is replaced or the malfunction is corrected; however, intermittent codes
must be cleared as noted in the code chart.

2. ECM (CAN) signal to gauge (tachometer)
Code
C0063
C0064
C1263
C1264

Fault Description
Tilt Sensor Circuit High
Tilt Sensor Circuit Low/SG/Open
Backup/Reverse-Light Circuit Open
Backup/Reverse-Light Circuit High

C1265 Backup/Reverse-Light Circuit Low/SG
P0030
P0031
P0032
P0107
P0108
P0112
P0113
P0114
P0116

O2 Heater Intermittent/Open
O2 Heater Low/SG
O2 Heater High/SP
MAP Sensor Circuit Low/SG/Open
MAP Sensor Circuit High/SP
Intake Air Temp Sensor Circuit Low/SG
Intake Air Temp Sensor Circuit High/Open
Intake Air Temp Sensor Circuit Intermittent
ECT Sensor Circuit Range/Performance

Possible Cause
Sensor or interconnect harness shorted to battery power
Sensor or interconnect harness open or shorted to chassis ground
Bulb has failed or is disconnected or interconnect harness is open
Bulb has failed or is disconnected or interconnect harness shorted to
battery power
Bulb has failed or is disconnected or interconnect harness shorted to
chassis ground
Heater or interconnect harness is intermittent or open
Heater or interconnect harness shorted to chassis ground
Heater or interconnect harness shorted to battery power
Sensor or interconnect harness shorted to chassis ground
Sensor or interconnect harness shorted to battery power
Sensor or interconnect harness shorted to chassis ground
Sensor or interconnect harness open or shorted to battery power
Sensor or interconnect harness intermittent
Sensor producing an out-of-range voltage

Fault Recovery
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*
Correct condition*

101

Code
P0117
P0118
P0119
P0121
P0122
P0123
P0130
P0131
P0132
P0171
P0172
P0219
P0231
P0232
P0233
P0261
P0262
P0263
P0264
P0265
P0266
P0336
P0337
P0339
P0340
P0341
P0342
P0480
P0484
P0485
P0500
P0508
P0509
P0520
P0562
P0563
P0601
P0615
P0616
P0617
P0630
P0642
P0643
P2300

P2301
P2303
P2304
P2531
P2532
U0155
U1000
U1001
FUEL
OFF

Fault Description

Fault Recovery

Sensor or interconnect harness shorted to chassis ground
Correct condition*
Sensor or interconnect harness open or shorted to battery power
Correct condition*
Sensor or interconnect harness intermittent
Correct condition*
Sensor producing an out-of-range voltage
Correct condition*
Sensor or interconnect harness shorted to chassis ground
Correct condition*
Sensor or interconnect harness open or shorted to battery power
Correct condition*
Sensor or interconnect harness intermittent or open
Correct condition*
Sensor or interconnect harness shorted to chassis ground or an air- Correct condition*
leak exists
O2 Sensor High/SP
Sensor or interconnect harness shorted to battery power
Correct condition*
O2 Feedback Below Minimum Correction
Low fuel rail pressure, dirty fuel filter, or dirty injectors
Correct condition*
O2 Feedback Exceeds Maximum Correction Excessive fuel rail pressure, MAP or temp sensors out-of-spec
Correct condition*
Engine Over-Speed Condition
Engine speed (RPM) has exceeded the ECM over-speed setpoint/limit Reduce engine speed
Fuel Pump Relay Circuit Low/SG/Open
Relay removed or interconnect harness shorted to chassis ground
Correct condition*
Fuel Pump Relay Circuit High
Relay or interconnect harness shorted to battery power
Correct condition*
Fuel Pump Relay Circuit
Relay circuit erratic or intermittent
Correct condition*
Correct condition**
Cylinder #1 Fuel injector Circuit Low/SG
Injector #1 or interconnect harness shorted to chassis ground
Correct condition**
Cylinder #1 Fuel injector Circuit High
Injector #1 or interconnect harness shorted to battery power
Correct condition**
Cylinder #1 Fuel injector Balance/Open
Injector #1 disconnected or interconnect harness is open
Correct condition**
Cylinder #2 Fuel injector Circuit Low/SG
Injector #2 or interconnect harness shorted to chassis ground
Correct condition**
Cylinder #2 Fuel injector Circuit High
Injector #2 or interconnect harness shorted to battery power
Correct condition**
Cylinder #2 Fuel injector Balance/Open
Injector #2 disconnected or interconnect harness is open
Crankshaft Angle Sensor Synchronization
Sensor or interconnect harness intermittent
Correct condition**
Crankshaft Angle Sensor Circuit/SG
Sensor or interconnect harness shorted to chassis ground
Correct condition**
Crankshaft Angle Sensor Intermittent/Erratic Sensor or interconnect harness intermittent
Correct condition**
Camshaft Angle Sensor Synchronization
Sensor or interconnect harness intermittent
Correct condition**
Camshaft Angle Sensor Circuit/SG
Sensor or interconnect harness shorted to chassis ground
Correct condition**
Camshaft Angle Sensor Intermittent/Erratic
Sensor or interconnect harness intermittent
Correct condition**
Fan Relay Control Circuit
Relay erratic or intermittent
Correct condition*
Fan Relay Control Circuit High
Relay or interconnect harness shorted to battery power
Correct condition*
Fan Relay Control Circuit Low/SG/Open
Fan fuse has blown, fan relay removed, or interconnect harness
Correct condition*
shorted to chassis ground
Vehicle Speed-Sensor
Sensor circuit signal intermittent or missing
Correct condition*, start
and drive the vehicle*
Idle Air Control System Circuit Low/SG
IAC interconnect harness shorted to chassis ground
Correct condition*
Idle Air Control System Circuit High/Open
IAC disconnected or the interconnect harness shorted to battery power Correct condition*
Engine Oil Sensor/Switch
Sensor or interconnect harness erratic or intermittent
Correct condition*
System Voltage Low
Battery charge condition low or the regulator/rectifier output low
Correct condition*
System Voltage High
Battery cable connections are loose or regulator/rectifier output high Correct condition*
Correct CAN communiECM CAN Communication Shutdown
Intermittent CAN connections or unstable CAN conditions have
cation issue*
caused the ECM to temporarily shutdown CAN communication
Starter Relay Circuit
Start switch/button, starter relay, gearswitch or interconnect harness Correct condition*
erratic or intermittent
Starter Relay Circuit Low
Start switch/button, starter relay or interconnect harness intermittent or Correct condition*
shorted to chassis ground
Starter Relay Circuit High
Start switch/button, starter relay or interconnect harness intermittent or Correct condition*
shorted to battery power
VIN Not Programmed or Incompatible
Verify the LCD gauge and ECM part numbers are correct for the vehi- Correct gauge and ECM
cle model number and VIN
VIN compatibility issue*
Sensor Power Circuit Low
One or more of the sensors defective or shorted to chassis ground
Correct condition*
Sensor Power Circuit High
One or more of the sensors defective or shorted to battery power
Correct condition*
Ignition Coil #1 Primary Circuit Low/SG/Open Ignition coil #1 or interconnect harness open or shorted to chassis Correct condition**
ground
Correct condition**
Ignition Coil #1 Primary Circuit High
Ignition coil #1 or interconnect harness shorted to battery power
Ignition Coil #2 Primary Circuit Low/Open
Ignition coil #2 or interconnect harness open or shorted to chassis Correct condition**
ground
Correct condition**
Ignition Coil #2 Primary Circuit High
Ignition coil #2 or interconnect harness shorted to battery power
Ignition Switch Circuit Low
Battery charge condition low or the regulator/rectifier output low
Correct condition*
Ignition Switch Circuit High
Battery cable connections are loose or regulator/rectifier output high Correct condition*
LCD Gauge to EFI ECM CAN Communication Gauge CAN circuit or interconnect harness intermittent or has failed Correct condition*
Lost
Vehicle Not Registered or Invalid PIN Entered An invalid registration PIN has been entered
Enter the correct registration PIN*
Vehicle Not Registered and Vehicle Limits
An invalid registration PIN has been entered
Enter the correct regisEnabled
tration PIN*
Tilt Sensor Activation Code
Sensor activated
Restore the vehicle chassis to an upright position*

High: A high voltage condition has been detected
Low: A low voltage condition has been detected
Intermittent: An intermittent circuit condition has been
detected

102

Possible Cause

ECT Sensor Circuit Low/SG
ECT Sensor Circuit High/Open/SP
ECT Sensor Circuit Intermittent
TPS Range/Performance
TPS Circuit Low/SG
TPS Circuit High
O2 Sensor Intermittent/Open
O2 Sensor Low/SG or Air-Leak

Open: An open circuit condition has been detected
* After correcting the condition, cycle the key switch On-Off-On
**After correcting the condition, cycle the key switch On-OffOn, start the engine, then cycle the key switch Off-On.

RPM Limiter
NOTE: This vehicle is equipped with an ECM that
interrupts the ignition when maximum RPM is
approached (see table). When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire.
Gear
2WD
4WD
4WD Lock
2WD Override
4WD Override
Differential-Lock
Override

Reverse

Park/
Incorrect
High/ Fail-Safe ECU/
Warranty
Neutral/ Mode
Gauge Registration
Low
(P0630)

5000
6000

7750

5000

6750

4500

7750

103

Troubleshooting
Problem: Spark absent or weak
Condition
1.
2.
3.
4.

Ignition coil defective
Spark plug(s) defective
CKP sensor defective
ECM defective

Problem: Spark plug fouled with carbon
Condition
1.
2.
3.
4.
5.

Gasoline incorrect
Air cleaner element dirty
Spark plug(s) incorrect (too cold)
Valve seals cracked - missing
Oil rings worn - broken

Problem: Spark plug electrodes overheat or burn
Condition
1. Spark plug(s) incorrect (too hot)
2. Engine overheats
3. Spark plug(s) loose

Problem: Battery does not charge
Condition
1. Lead wires/connections shorted - loose - open
2. Stator coils shorted - grounded - open
3. Regulator/rectifier shorted

Remedy
1.
2.
3.
4.

Replace ignition coil
Replace plug(s)
Replace CKP sensor
Replace ECM

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

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

Remedy
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
1.
2.
3.
4.

Lead wires shorted - open - loose (at terminals)
Stator coils grounded - open
Regulator/rectifier defective
Cell plates (battery) defective

Problem: Magneto overcharges
Condition
1. Battery short circuited
2. Regulator/rectifier defective
3. Regulator/rectifier poorly grounded

Problem: Charging unstable
Condition
1. Lead wire intermittently shorting
2. Magneto internally shorted
3. Regulator/rectifier defective

Problem: Starter does not engage
Condition
1.
2.
3.
4.
5.
6.

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.
2.
3.
4.

Repair - tighten lead wires
Replace stator coils
Replace regulator/rectifier
Replace battery

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

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

Remedy
1.
2.
3.
4.
5.
6.

Recharge - replace battery
Replace switch
Replace starter
Replace relay
Connect - tighten - repair connections
Replace relay

Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates)
Condition
Remedy
1. Charging rate too low - too high
2. Battery discharged

Problem: Battery discharges too rapidly
Condition
1.
2.
3.
4.

Charging system (charging operation) not set properly
Cell plates overcharged - damaged
Battery short-circuited
Electrical load too high

Problem: Battery polarity reversed
Condition
1. Battery incorrectly connected

104

1. Replace battery
2. Charge battery

Remedy
1.
2.
3.
4.

Check AC generator - regulator/rectifier - circuit connections
Replace battery - correct charging system
Replace battery
Reduce load

Remedy
1. Reverse connections - replace battery

Drive and Brake Systems
The following drive system components should be
inspected periodically to ensure proper operation.
A. Spline lateral movement (slop).
B. Coupling cracked, damaged, or worn.
C.Carrier bearing smooth rotation and bearing support
tight.
WT504A

GENERAL INFORMATION
The die-cast aluminum housings have been assembled
with thread-rolling screws (trilobular). When assembling
with these screws, start the screws carefully into the housing; then use the following torque values.
Size

2. Remove the floor; then using a T-30 torx wrench,
remove the mounting cap screw from the driveshaft
side of the actuator.

New Housing Reassembled Housing

M6 (Torx T-30 Recess) 9 ft-lb

8 ft-lb

M8 (Torx T-40 Recess) 28 ft-lb

23 ft-lb

p/n

Backlash Measuring Tool

0544-010

WT529A

CV Boot Clamp Tool

0444-120

Hose Clamp Pliers

0644-545

3. Remove the mounting cap screw from above the actuator on the suspension side.

Internal Hex Socket

0444-104

Pinion Gear/Shaft Removal Tool

0444-127

Gear Case Seal Installer Tool

0444-224

Transaxle Tool Kit

0544-030

NOTE: Special tools are available from the Arctic
Cat Service Department.

Front Drive Actuator
NOTE: The actuator is not a serviceable component. If it is defective, it must be replaced.
NOTE: The actuator will operate only when the ignition switch is in the ON position.

The front drive actuator is located on the left side of the
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 heard, see Electrical System. If the actuator runs constantly or makes squealing or
grinding sounds, the actuator must be replaced.

WT530A

4. Loosen but do not remove the mounting cap screw at
the front of the actuator; then slide the actuator to the
rear enough to clear the slotted mounting tab and the
selector shaft. Remove from the left side.

REMOVING
1. Select LOCK on the drive select switch; then disconnect the connector on the actuator harness.

105

WT531A

INSTALLING
1. Lubricate the O-rings on the actuator; then ensure all
mounting surfaces are clean and free of debris.
2. Align the actuator with the selector shaft and slide it
forward onto the shaft taking care to engage the cap
screw in the slot of the front mounting tab.
NOTE: Make sure to properly align the differential
lock actuator lever with the hole in the differential
lock plunger.

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 remaining cap screws to 36 in.-lb; then
connect the electrical plug to the main harness.
6. Turn the ignition switch to the ON position and check
the operation by shifting the drive select switch several times.
7. Secure the wiring harness to the frame with a nylon
cable tie; then install the floor.

Front Differential
REMOVING
1. Lift and support the vehicle with a stand that allows
access to the front suspension with the vehicle off the
floor.
2. Remove the front skid plate.
GC002A

3. While holding the actuator firmly forward, tighten the
front cap screw to hold the actuator in place; then
install but do not tighten the two remaining cap
screws.

WT499A

3. Remove the front differential drain plug and drain the
gear case lubricant into a suitable pan. Account for a
rubber O-ring.
GC001

4. Loosen the front cap screw; then tighten the cap screw
on the driveshaft side to 36 in.-lb.

106

WT500A

WT498A

NOTE: After all lubricant is drained, install the drain
plug and tighten to 45 in.-lb.

9. Remove and discard the upper ball joint cap screw and
rotate the knuckle downward and away from the drive
axle.

4. Remove the steering wheel and dash; then remove the
steering post (see Steering/Frame/Controls).
5. Remove the rack and pinion assembly; then remove
the front wheels.
6. Remove and discard the “patch-lock” cap screws
securing the brake calipers.

WT329A

WT287A

7. Remove the hub nut and discard the cotter key.

WT332

10. Using a suitable strap, swing the upper A-arm and
shock absorber upward; then secure them to the frame.
11. Remove the axles and front differential vent hose.

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 absorber from
the upper A-arm.

WT503A

107

12. Cut the cable tie securing the actuator plug to the
frame; then disconnect the actuator.

WT502

WT504A

NOTE: Note the position of the cable ties for assembly purposes.

13. Remove the cap screws and spacers securing the front
differential to the frame. Discard the nuts.

16. Remove the differential from the vehicle from the left
side.

Disassembling Input Shaft
1. Using a T-40 torx wrench, remove the cap screws
securing the pinion housing.

GC004A

14. Remove the clamp securing the boot on the output
shaft of the front differential.

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 purposes.

WT422A

GC015

WT423A

15. Pull the front differential forward until the driveshaft
splines are free from the differential.

108

CD106

GC011

3. Remove the snap rings from the input shaft; then
remove the input shaft from the pinion housing.

AF984

GC009A

4. Using a seal removal tool, remove the input shaft seal.
Account for a spacer.

KX219

Assembling Input Shaft

GC010

5. Remove the snap ring securing the input shaft bearing;
then place the pinion housing in a press and remove
the bearing.

1. Place the pinion housing in a press and install the
input shaft bearing. Secure the bearing with the existing snap ring making sure the sharp edge of the snap
ring faces to the outside.

GC012

109

GC011

KX209

2. Install the input shaft seal making sure it is fully
seated in the edge of the housing.

GC004A

Disassembling Differential Assembly
GC014

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 present during assembly. Secure with new clamps.
NOTE: Any time drive splines are separated, clean
all splines with parts-cleaning solvent and dry with
compressed air; then lubricate with recommended
grease.

NOTE: This procedure can be performed on a rear
gear case.

1. Using a T-40 torx wrench, remove the cap screws
securing the pinion housing. Account for the coupler,
fork, and spring (differential only).

4. Install the input shaft into the pinion housing; then
secure in the bearing with a circlip.

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 the differential cover. Account for an O-ring.
GC009A

5. Place the pinion housing with new gasket onto the differential housing; then secure with existing cap
screws. Tighten to 23 ft-lb.
NOTE: If a new differential housing is being
installed, tighten the cap screws to 28 ft-lb.
110

KX174

KX178

NOTE: If the cover is difficult to remove, pry on the
cover in more than one recessed location.

6. Place the differential with the open side down; then
lift the housing off the spider assembly. Account for
shim(s) and mark as right-side.

4. Remove the splined coupler, shifter fork, pin, and
spring of the differential lock assembly and set aside.
Note position of parts for assembling purposes.

KX179

KX175

5. Remove the left differential bearing flange assembly
and account for a shim. Mark the shim as left-side.

KX181

Disassembling Pinion Gear
1. Remove the internal snap ring securing the pinion
bearing in the housing.
KX177

111

WC430

CC882

2. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing.

CC883

2. Place the pinion assembly in a bearing puller; then
install the bearing using a press.
CC878

3. Secure the pinion gear in a bearing puller; then
remove the pinion bearing using a press. Account for a
collar and a bearing.

CC884

3. Using a propane torch, heat the gear case housing to
approximately 200° F; then install the pinion assembly.
CC879

4. Remove any reusable parts from the gear case housing; then discard the housing and lock collar.

Assembling Pinion Gear
1. Install the bearing onto the pinion shaft. Install the
pinion shaft collar.

112

4. Install the internal snap ring with the sharp side
directed away from the bearing.

2. Install the ring gear with shim in the gear case; then
while holding the pinion stationary, rock the ring gear
forward and back to determine if any backlash exists.
If no backlash exists, install a thicker shim and
recheck.

WC429

Shimming Procedure/Shim Selection

p/n

Case-Side Shims (Backlash)
mm

in.

0402-405
0402-406
0402-407
0402-408
0402-409

1.3
1.4
1.5
1.6
1.7

0.051
0.055
0.059
0.063
0.067

GC036A

3. Install the 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.

Cover-Side Shims (Ring Gear End-Play)
p/n
mm
in.
1402-074
1402-075
1402-076
1402-077
1402-078

1.3
1.4
1.5
1.6
1.7

0.051
0.055
0.059
0.063
0.067

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 differential or rear drive gear case.

GC032A

NOTE: All bearings must be installed in the gear case
and the pinion properly installed before proceeding.

Backlash
NOTE: Always set backlash prior to any other shimming.

1. Install the existing shim or a 0.051-0.055-in. shim on
the gear case side of the ring gear assembly.

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 crisscross pattern.

GC031A

113

GC036B

5. Place the Backlash Measuring Tool into the splines of
the ring gear and install a dial indicator making sure it
contacts the gauge at a 90° angle and on the index
mark.

GC037A

Ring Gear End-Play
After correcting backlash, ring gear end-play can be
adjusted. To adjust end-play, use the following procedure.
1. Secure the gear case in a holding fixture with the
cover side up; then install a dial indicator contacting
the ring gear axle flange.

GC040

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.

GC039A

6. Zero the dial indicator; then while holding the pinion
stationary, rock the ring gear assembly forward and
back and record the backlash. Backlash must be
0.011-0.015 in. If backlash is within specifications,
proceed to Ring Gear End-Play. If backlash is not
within specifications, increase shim thickness to
increase backlash or decrease shim thickness to
decrease backlash.

NOTE: Once proper backlash and end play are
established, the gear case can be assembled (see
Assembling Differential Assembly in this sub-section).

NOTE: Higher backlash settings usually result in
quieter gear operation.

CC888

114

Assembling Differential Assembly
1. With the pinion gear and new bearings installed, place
the selected (backlash) shim on the gear case side of
the ring gear with the chamfered side toward the ring
gear; then install into gear case/differential housing.

CF266A

GC031A

CF267A

4. Apply a light coat of Gear Case Sealant to the cover
face and O-ring.

GC020

2. Place the selected (end-play) shim, chamfered side
toward the gear, onto the cover side of the ring gear.

CF275A

5. Install the cover with existing cap screws (coated with
green Loctite #270). Tighten the cap screws evenly to
23 ft-lb.
GC036B

NOTE: Grease can be applied to the O-ring for ease
of assembling.

NOTE: The spider and ring gear assembly must be
replaced as a complete unit.

NOTE: If a new housing is being installed, tighten
the cap screws to 28 ft-lb.

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.

6. Install the shift fork shaft w/spring into the housing
making sure the shaft O-ring is positioned to the
inside.

115

CD110

CC892

7. Install the shift fork assembly making sure the fork leg
is facing upward. Apply a small amount of oil to the
gasket; then install the gasket.

Removing/Installing Axle Seal
NOTE: This procedure can be performed on a rear
gear case.

1. Remove the seal using a seal removal tool.

CC893

8. Place the input shaft assembly onto the gear case
housing; then secure with the existing cap screws.
Tighten to 23 ft-lb.
NOTE: If a new housing is being installed, tighten
the cap screws to 28 ft-lb.

CC899

NOTE: Prior to installing the seal, apply High-Performance #2 Molybdenum Disulphide grease to the
seal outside diameter.

2. Using Gear Case Seal Installer Tool, evenly press the
seal into the cover bore until properly seated.

CD103

CF278

CAUTION
Make sure the tool is free of nicks or sharp edges or
damage to the seal may occur.

3. Repeat steps 1-2 for the opposite side.

116

INSTALLING
1. From the right side of vehicle, place the differential
into the vehicle (actuator side down); then maneuver it
into the mounting brackets.

WT503A

6. Install the rack and pinion assembly. Using new lock
nuts, secure it to the frame and tighten to 25 ft-lb.
WT501

2. Slide the differential towards the front of the vehicle
to align the driveshaft; then apply molybdenum grease
and slide the differential rearward onto the driveshaft.

WT369A

7. Install the steering shaft, dash, and steering wheel.
8. Install the drive axles.

WT502

9. Connect the actuator harness and secure it with cable
ties.

3. Install the existing cap screws and spacers securing
the front differential to the frame. Using new cap lock
nuts, tighten to 38 ft-lb.
NOTE: The spacers 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.

WT504A

10. Install the axle into the knuckles; then swing the
knuckles upward and engage the ball joint of the
upper A-arm into the knuckle. Using a new “patchlock” cap screw, tighten to 35 ft-lb.

WT422A

5. Install the differential vent hose.

117

WT333

WT328A

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

13. Using a new “patch-lock” cap screw and the existing
washer, secure the shock absorber to the upper A-arm
and tighten to 25 ft-lb.

WT329

11. Install the tie rod end and secure it with the castle nut
(coated with red Loctite #271). Tighten to 55 ft-lb;
then install a new cotter pin and spread the pin to
secure the nut.

WT498A

14. Using new “patch-lock” cap screws, secure the brake
caliper to the brake disc. Tighten to 20 ft-lb.

WT330A

12. Install the hub assembly and secure with the hub nut.
Tighten to 200 ft-lb. Install a new cotter pin and
spread the pin to secure the nut.

WT287A

15. Add SAE approved 80W-90 hypoid differential lubricant until it is visible at the level plug.

118

WT041A

WT328A

16. Install the plugs (with O-rings); then tighten the fill
plug to 16 ft-lb and the level plug to 45 in.-lb.

5. Remove and discard the upper ball joint cap screw and
rotate the knuckle downward away from the drive
axle.

17. Install the front skid plate; then install the wheels and
tighten to 40 ft-lb (steel wheel) or 80 ft-lb (aluminum
wheel).

6. Place a drain pan under the vehicle to contain any oil
leakage; then pushing the axle shaft in, pull the axle
assembly from the transaxle.

Drive Axles
REMOVING REAR DRIVE AXLE
1. Secure the vehicle on a support stand to elevate the
wheels.

! WARNING
Make sure the vehicle is solidly supported on the support stand to avoid injury.

2. With the vehicle in park, remove the wheels.

PR729C

3. Remove and discard the “patch lock” cap screws
securing the brake calipers.

7. Account for the rubber O-ring.

WT509A
WT287A

4. Remove hub nut and discard the cotter key.

REMOVING FRONT DRIVE AXLE
NOTE: For removing a front drive axle, see Front
Differential in this section.

CLEANING AND INSPECTING
AXLES
NOTE: Always clean and inspect the drive axle components to determine if any service or replacement is
necessary.

119

1. Using a clean towel, wipe away any oil or grease
from the axle components.

CF334

CD019

2. Inspect boots for any tears, cracks, or deterioration.
NOTE: If a boot is damaged in any way, it must be
replaced with a boot kit.

DISASSEMBLING AXLES
NOTE: Only the boots are serviceable on the axles;
if any other component is worn or damaged, the axle
must be replaced.

1. Using CV Boot Clamp Tool, remove and retain both
clamps for assembly purposes.

NOTE: Steps 1-3 can be used to replace the outboard 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 positioned correctly when the
small end of the boot seats down into the recessed
groove.

2. Using the boot clamp tool, secure the small clamp of
the inner boot.

ATV-1048
CF337

2. Place the end of the CV joint into a vise.

3. Apply 80 grams (2/3 of contents) of grease from the
pack into the bearing housing.
NOTE: Steps 1-3 can be used to replace the outboard boot.
NOTE: In the outboard boot, use the final 40 grams
(1/3 of contents) of grease from the pack in the bearing housing.

INSTALLING REAR DRIVE AXLE
1. Push the axle shaft into the CV coupler to release the
lock ring while pulling back on the CV coupler and
slide drive axle into place in the transaxle.

CF335

3. To disengage the axle from the CV joint, sharply pull
back on the axle; then slide the boot off of the axle.

120

5. Set the parking brake; then turn the ignition switch to
the ON position, select LOCK on the drive select
switch. Turn the ignition switch to the OFF position.
6. Tighten the axle nut (from step 3) to 200 ft-lb; then
install and spread a new cotter pin making sure each
side of the pin is flush to the hub nut.

PR729C

NOTE: To ensure proper axle seating, give the axle
a light pull; the axle should remain “clipped” in place.

2. Install the axle into the knuckle; then swing the
knuckle upward and engage the ball joint of the upper
A-arm into the knuckle; using a new “patch lock” cap
screw secure and tighten to 35 ft-lb.
3. Install the hub assembly and secure with the hub nut.
Tighten the nut to 200 ft-lb and install a new cotter
pin. Spread the pin to secure the nut.

WT328A

7. Install the wheel and tighten in a crisscross pattern in
20 ft-lb increments to 80 ft-lb (aluminum wheel) or
to 40 ft-lb (steel wheel).
8. Remove the vehicle from the support stand.
9. Check the front differential lubricant level and add
lubricant as necessary (see Periodic Maintenance/
Tune-Up).

Transaxle
REPLACING SEALS
Output (Axle) Seals
WT328A

4. Using new “patch lock” cap screws, secure the brake
caliper to the brake disc. Tighten to 20 ft-lb.
5. Install the wheels and tighten in 20 ft-lb increments to
40 ft-lb (steel wheel) or 80 ft-lb (aluminum wheel).
6. Remove the vehicle from the stand.

NOTE: The transaxle does not need to be removed
for this procedure.

1. Support the vehicle on an appropriate stand; then
remove a rear wheel and axle.
2. Using an awl and a mallet, pry the seal from the case
taking care not to damage the seal bore.

INSTALLING FRONT DRIVE AXLE
1. Push the axle shaft into the CV coupler to release the
lock ring; then position the drive axle in the gear case
and steering knuckle; then insert the ball joints into
the steering knuckles. Secure with cap screws tightened to 35 ft-lb.
2. Secure the lower shock eyelet to the upper A-arm
with a new “patch-lock” cap screw and existing
washer. Tighten to 35 ft-lb.
3. Slide the hub w/brake disc into position in the steering 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 ft-lb.

TA118

3. Wipe any oil or dirt from the seal area of the transaxle.
4. Using an appropriate seal installer and protector,
install a new seal so it seats fully past the chamfer of
the case (approximately 1.5-2.0 mm deep).
121

TA113

TA110

Front Output Seal
NOTE: The transaxle must be removed for this procedure.

1. Using an awl and a mallet, pry the seal from the case
taking care not to damage the seal bore.

TA115

Input (Driven Clutch) Seal
NOTE: The transaxle does not need to be removed
for this procedure.

1. Support the vehicle on an appropriate stand; then
remove the left rear wheel, the outer clutch cover, the
clutches, and the inner clutch cover.
2. Using an awl and a mallet, pry the seal from the case
taking care not to damage the seal bore.

TA117

CAUTION
Do not drive the awl too far or bearing damage will occur.

2. Wipe any oil or dirt from the seal area of the transaxle.
3. Tape the splined portion of the pinion shaft to protect
the seal; then using an appropriate seal installer, install
the front output seal (approximately 0.5-1.0 mm
deep).

TA109

3. Wipe any oil or dirt from the seal area of the transaxle.
4. Using an appropriate seal installer and protector,
install a new seal so it seats flush with the case (0.5
mm deep).
TA129

122

2. Remove the hood, wheels, seats, center console, floor,
and driveshaft.
3. Remove the E-clip connecting the shift cable to the
transaxle. Remove the shift cable bracket; then disconnect the speed sensor and the gear position switch.

TA130

Pinion Plug
NOTE: The transaxle does not need to be removed
for this procedure.

1. Support the vehicle on an appropriate stand; then
remove the right rear wheel and axle.
2. Using an awl and a mallet, pry the pinion plug from
the case taking care not to damage the seal bore.

WT439A

4. Remove and discard the two lock nuts securing the
transaxle to the frame.

WT440A
TA084

CAUTION
Do not drive the awl too far or bearing damage will occur.

5. Lift the transaxle off the mounting studs and remove
out the left side of the vehicle.
6. Remove the bracket securing the transaxle to the rear
mounts. Discard the lock nuts.

3. Wipe any oil or dirt from the plug area of the transaxle.
4. Using an appropriate tool, lightly tap the plug so it
seats fully past the chamfer of the case (approximately
1.0-1.5 mm deep).

WT435A

SEPARATING HALVES
1. With the transaxle on a bench, drain the fluid into a
suitable pan.
TA132

REMOVING
1. Place the vehicle securely on a support stand.
123

TA004

TA027

NOTE: Tip the transaxle towards the drain to get
any remaining fluid.

4. Remove the clip securing the gear position switch.
Gently pry the switch off the shift rail and account for
the wave washer.

NOTE: Install the drain plug and tighten to 18 ft-lb.

5. Remove the screws securing the case halves together.

2. Lay the transaxle flat on the bench; then remove the
19 mm detent (gold plug) near the gear position
switch. Account for the spring and O-ring.

6. While prying the two halves apart with an assistant,
use a rubber mallet to gently tap the shift shaft (A),
shift drum (B), and output shaft (C) into the lower
half.

TA012A

3. Remove and discard the lock nut securing the bell
crank; then using two screwdrivers, pry the bell crank
off the shift shaft.

TA131A

NOTE: Use a suitable bearing seal protection tool
and when driving the bearing and gears into the
lower half of the transaxle.

7. Clean any silicone residue from the case halves.

DISASSEMBLING HALVES
1. Remove the shift shaft assembly and the detent.

TA012B

TA006A

2. Remove the park pawl with dowel pin and account for
the spring.

124

TA028A

3. Remove the output gear assembly with bearings.

TA059

6. Place the transaxle upright on the bench and dump any
remaining fluid into the pan.

AT THIS POINT
If the pinion shaft and gear are not being serviced or
replaced, no further disassembling is required.

7. With the transaxle flat on the bench, remove the four
screws securing the pinion gear assembly.

TA026

4. Lift on the shift rail assembly to disengage the rail assembly from the case and rotate the rail away from the shift
drum; then remove the shift drum assembly.
NOTE: Spread the shift forks while removing.

TA025A

8. Pry the pinion gear assembly to remove it from the
case. Account for the shim.

TA022A

5. Using an assistant, lift and remove all remaining shafts
simultaneously.

TA029

9. If the pinion shaft or bearing are being removed, use
an awl and mallet to pry the front output seal off the
case.

125

TA127

TA009

SERVICING COMPONENTS

CAUTION
There is a ball bearing below the pinion seal. Use caution not to damage the bearing while removing the seal.

NOTE: If any bearing is removed, install a new bearing using a suitable press.

NOTE: The pinion seal must be replaced if removed.

NOTE: Keep all components in order for assembling
purposes.

10. Remove the inner snap ring on the front output shaft;
then using a mallet, tap the front output shaft down
into the case half. Account for the shim.

A. Output Gear
1. Inspect the bearings for free and smooth turning. If
either bearing does not turn freely, it must be replaced.

TA073A

CAUTION

TA016

When tapping the output shaft, make sure not to drop
the shaft when it releases from the bearing to avoid gear
damage.

2. Inspect the gear teeth for nicks, cracks, chips, or signs
of wear. If any are present, the gear must be replaced.

B. Intermediate Shaft

11. Remove the outer snap ring and shim securing the ball
bearing; then using an appropriate tool, remove the
bearing.

1. Inspect the bearing for free and smooth turning. If the
bearing does not turn freely, it must be replaced.

TA013

2. Inspect the gear teeth for nicks, cracks, chips, or signs
of wear. If any are present, the gear must be replaced.

TA035

126

TA036

TA034

3. Inspect the shaft gear teeth for nicks, cracks, chips, or
signs of wear. If any are present, the shaft must be
replaced.

C. Shift Shaft Rail

F. Shift Drum

1. Inspect the shift forks for nicks, cracks, chips, or signs
of wear. If any are present, the forks must be replaced.

1. Remove the snap ring and washer; then pull the cam
off the shift drum.

TA041

TA038A

2. Inspect the rail for nicks, cracks, chips, or signs of
wear. If any are present, the rail must be replaced.

2. Inspect the cam groove for signs of wear. If present,
replace the cam.

D. Shift Shaft
Inspect the gear for nicks, cracks, chips, or signs of wear.
If any are present, the gear 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.

TA133A

3. Check the shaft splines for nicks, cracks, chips, or
signs of wear. If any are present, the shift drum must
be replaced.

TA033

2. Inspect the gear teeth for nicks, cracks, chips, or signs
of wear. If any are present, the gear must be replaced.

127

7. While holding pressure on the washer, rotate the cam
counterclockwise to lock the cam onto the shift drum.

TA039

4. Check the detent star (A) and shift drum gear (B) for
nicks, cracks, chips, or signs of wear. If any are present, the detent star must be replaced.

TA040

8. Install the snap ring.

G. Reverse Shaft
1. Inspect the bearings for free and smooth turning. If
either bearing does not turn freely, it must be replaced.

TA057A

5. Install the spring into the shift drum.

TA048

TA121

6. Rotate the cam clockwise so the tab of the spring installs into
the shift drum groove. Install the washer to retain the spring.
TA055

2. Inspect the gear teeth for nicks, cracks, chips, or signs
of wear. If any are present, the gear must be replaced.

TA122A

128

TA049

TA053

4. Inspect the dogs for nicks, cracks, chips, or signs of
wear. If any are present, the dog must be replaced.

TA050

TA054

H. Input Shaft
1. Inspect the bearings for free and smooth turning. If
either bearing does not turn freely, it must be replaced.

TA051

3. Inspect the shaft gear teeth for nicks, cracks, chips, or
signs of wear. If any are present, the shaft must be
replaced.

TA042

TA052

TA044

129

2. Inspect the sprocket teeth for nicks, cracks, chips, or
signs of wear. If any are present, the sprocket must be
replaced.

2. Remove the small inner snap ring and account for the
shim.

TA043

3. With the aid of an assistant and using an appropriate
driver, remove the gear.

TA082A

3. Inspect the shaft gear teeth for nicks, cracks, chips, or
signs of wear. If any are present, the shaft must be
replaced.

TA031
TA045

4. Remove the large outer snap ring and account for the
shim.

K. Pinion Assembly
Inspect the teeth of the pinion gear and front output shaft.
If any chipping, nicks, wear, or damage are observed, the
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 case. Discard the
plug.

TA086

5. Using an appropriate bearing driver, press the bearing
from the housing.

TA084

CAUTION
Do not drive the awl too far or bearing damage will
occur.

130

BACKLASH

AT THIS POINT
If the pinion shaft or gear were replaced or serviced,
backlash must be checked. If not, proceed to ASSEMBLING HALVES.

1. Install the pinion shaft into the case. With the appropriate shim in place, secure with the snap ring.

TA081

6. Using an appropriate bearing installer, install a new
bearing into the housing.

TA073

NOTE: To determine the appropriate shim, start with
the thickest 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.
TA132

7. Install the large outer snap ring with the shim.

2. With the appropriate shim in place and the O-ring
coated with molybdenum grease, install the pinion
gear assembly into the case half and secure with the
four screws. Tighten to 20 ft-lb.

TA086

8. Install the gear into the housing.

TA025A

NOTE: To determine the appropriate shim, proceed to
step 3.

3. Using an appropriate tool, lock the pinion gear in place.

TA077

9. Install the small inner snap ring with shim.
131

6. Acceptable backlash range is 0.076-0.241 mm (0.0030.0095 in.).
NOTE: If backlash measurement is within the
acceptable range, no correction is necessary.

7. If backlash measurement is less than specified,
remove the existing shim and install a new thicker
shim (from shim kit).

TA124A

4. Mount a dial indicator so the tip is contacting a tooth
on the pinion shaft.

TA102

8. If backlash measurement is more than specified,
remove the existing shim and install a thinner shim.
NOTE: Continue to remove, measure, and install
until backlash measurement is within tolerance. Note
the following chart.
TA096

Backlash Measurement
Under 0.076 mm (0.003 in.)

Shim Correction
Increase Shim Thickness

At 0.076-0.241 mm (0.003-0.0095 in.)

No Correction Required

Over 0.241 mm (0.0095 in.)

Decrease Shim Thickness

9. Tape the splined portion of the pinion shaft to protect
the seal; then using an appropriate seal installer, install
the front output seal so it seats fully past the chamfer
of the case.

TA095

5. While pushing in on the front output shaft, and while
rocking the shaft back and forth and note the maximum backlash reading on the gauge.

TA129

TA125

132

TA130

ASSEMBLING HALVES

TA059

NOTE: Make sure the shift fork pins face the installer.

1. Install the intermediate shaft and idler shaft into the
case only partially. Do not seat the shafts completely
into the case at this time.

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 should remain un-seated at
this point.

3. Install the shift drum into the case; then engage the
fork tabs into the grooves in the shift drum.

TA056

2. With the aid of an assistant and with the gear forks in
position, install the input shaft and reverse shaft with
chain as an assembly.

TA062

4. Pinch the forks together and slide the rail into position
in the case.

TA058

TA063

5. Install the output gear. Use slight force to seat it and
ensure the gear teeth engage with the intermediate
shaft.

133

NOTE: Rotate the shift drum and the shift shaft to
ensure the timing marks are correctly aligned.

9. Install the star detent over the shift drum aligning the
appropriate splines of the detent with the shaft splines
and the dot facing up.

TA064

6. Install the park pawl with dowel and spring.

TA134A

10. Install an appropriate bearing seal protector tool onto
the bearing of the output shaft.

TA074

TA067

11. Apply a coat of Loctite #5699 to the case; then ensuring the shift shaft (O-ring lightly coated with grease)
and shift rail are correctly seated, install the cover.

TA065A

7. Install the shift drum gear onto the shift drum aligning
the appropriate splines of the drum with the gear.
8. Install the shift shaft gear onto the shift shaft with the
timing marks facing up; then install into the case with
the gear aligning with the shift drum gear.

TA068

NOTE: It will be necessary to tap the cover onto the
case using a rubber mallet. Ensure the alignment
pins are properly oriented.

12. Secure the cover with the cap screws and tighten to 20
ft-lb.
13. Install the detent (gold plug) with spring and O-ring.
Tighten to 20 ft-lb.
TA066A

134

INCORRECT

TA137A

TA012A

14. Install the gear position switch. Secure with the wave
washer and snap ring.
15. Install the bell crank being sure to correctly align the
splines of the bell crank and shift shaft and secure
with a new lock nut. Tighten to 15 ft-lb.
NOTE: Ensure the transaxle is in neutral by turning
the input shaft (A). It should turn freely and the front
output shaft (B) should not turn. If the front output
shaft turns with the input shaft, turn the bell crank to
the correct position.

TA012B

16. Using an appropriate seal installer, gently install a new
plug over the pinion gear assembly so it fully seats
past the chamfer (approximately 1.0-1.5 mm deep).

TA012C

CORRECT

TA135A

17. Add the appropriate amount of Arctic Cat Synthetic
Transaxle Fluid to the transaxle; then install the fill
plug and tighten to 18 ft-lb.

INSTALLING
1. Using new lock nuts, secure the bracket to the rear of
the transaxle. Tighten to 38 ft-lb.
TA138A

2. Place the transaxle into position on the rear mounting
studs and secure using new lock nuts. Tighten to 25 ft-lb.

135

WT430

3. Install the shift cable bracket and tighten to 7 ft-lb.
4. Connect the shift cable to the transaxle and secure with the
E-clip. Connect the speed sensor and gear position switch.

WT323A

4. Rotate the steering rack all the way to the right; then
remove the upper cap screw securing the upper A-arm
to the frame and remove it from the mounting brackets. Account for the washer and bushing. Discard the
lock nut.

WT439A

5. Install the hood, wheels, seats, center console, floor,
and driveshaft.
6. Remove from the vehicle from the support stand.

Driveshaft/Carrier
Bearing

WT334

NOTE: Removing the inner upper A-arm from the
frame will aid in removing the upper front differential
cap screw.

5. Remove the cap screws securing the front differential to
the frame. Account for washers and discard the lock nuts.

REMOVING
1. Remove the hood, seats, center console, floor, and engine.
2. Secure the vehicle on a support stand to elevate the
wheels; then remove the front wheels.
3. Remove the 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.

WT423A

6. Remove the cap screws and lock nuts securing the carrier
bearing housing to the frame. Discard the lock nuts.

136

WT421A

WT426

7. Remove the front boot clamp securing the driveshaft
to the transaxle.

9. Remove the clamp behind the carrier bearing and slide the
rear driveshaft rearward. Remove the rear driveshaft.

WT424A

NOTE: Having the transmission in neutral will aid in
rotating the driveshaft for ease of removing the clamps.

WT421B

10. Remove the front boot clamp securing the front differential to the driveshaft. Slide the front driveshaft rearward and remove it from the vehicle.

NOTE: Using a suitable tool to break the seal of the
boot from the driveshaft will aid in removing the
driveshaft.

WT422A

WT437A

8. From the front of the vehicle, hold both of the axles
and pull forward until the front differential is against
the frame. Slide the driveshaft off of the transaxle.

NOTE: At this point, no further disassembling is
required to replace the driveshaft. If the technician’s
objective is to replace the carrier bearing, proceed to
step 11.
NOTE: The carrier bearing is a non serviceable
item. It must be replaced as an assembly.

11. Loosen the set screws on the bearing but do not
remove them.

137

WT431A

12. Remove the snap ring.

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 the snap ring groove.
Do not tighten the set screws at this time.

WT434

13. Slide the carrier bearing assembly off of the shaft.
NOTE: It may be necessary to lightly tap the carrier
bearing with a mallet to aid in removing it.

WT432

2. Slide the snap ring over the shaft and snap them into
position.

WT436

INSTALLING
NOTE: If the carrier bearing was not removed, proceed to step 5.
NOTE: The carrier bearing is intended to be a “slip
fit” assembly. It is very important that the surface is
free of nicks and rust. It may be necessary to lightly
scrub unpainted surfaces with emery cloth to ensure
a smooth surface.

138

WT431

3. Remove each set screw and place one drop of red Loctite #271 on each; then tighten to 75 in.-lb.
4. With the front differential slid forward against the
frame, apply a small amount of molybdenum grease to
the splines and install the front driveshaft into the
front differential. Tighten the clamp securely.

WT422A

WT425

5. Apply molybdenum grease to the splines on both ends of
the rear driveshaft and insert the rear driveshaft into the
mating end of front driveshaft. Tighten the clamp securely.

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 to 35 ft-lb.

WT427

WT334

6. Mate the rear driveshaft with the output shaft of the transaxle so they are meshed together by pushing on the front
axles rearward until the front differential mounting holes
are aligned. Tighten the clamp securely.

10. Install the front left shock onto the upper A-arm. With
the existing washer and new patch lock cap screw,
tighten to 25 ft-lb.
11. Install the front wheels. Tighten in 20 ft-lb increments
to 40 ft-lb (steel wheel) or 80 ft-lb (aluminum wheel).
12. Install the hood, seats, center console, floor, and
engine.
13. Remove the vehicle from the stand.

Hub
REMOVING
WT429

1. Secure the vehicle on a support stand to elevate the
wheel; then remove the wheel.

7. Using new lock nuts, secure the carrier bearing housing to the frame. Tighten to 35 ft-lb.

2. Remove the hub nut securing the hub and discard the
cotter pin.

8. Install the front differential cap screws, washers, and
new lock nuts. Tighten to 38 ft-lb.

3. Remove the brake caliper.

139

4. Inspect the hub for pits, cracks, loose studs, or spline wear.

REPLACING WHEEL STUDS
1. Secure the hub in a suitable holding fixture and
remove the brake disc (if applicable).
2. Drive the damaged stud out of the hub; then place the
new stud into the hub and thread on an appropriate
flange nut.

WT287A

4. Remove the hub assembly.
5. Remove the four cap screws securing the brake disc.

PR250

3. Using a socket and ratchet handle, tighten the nut until
the stud is fully drawn into the hub.

WT325A

NOTE: It may be necessary to heat the cap screws
to loosen the Loctite.

6. Remove the seals and sleeve and inspect for cracks,
nicks, or tears.
NOTE: Only remove the bushings if they must be
serviced.

7. Place the hub in a bench vise and using an appropriate
tool, drive out and discard the bushings.

PR252A

INSTALLING
1. Using a suitable press, press in the new bushing.

WT598
WT597

CLEANING AND INSPECTING
1. Clean all hub components.
2. Inspect all threads for stripping or damage.
3. Inspect the brake disc (if applicable) for cracks or warping.

140

2. Place the hub in a bench vise and using a 16 mm
reamer, ream out the bushings.

WT328A
WT595

3. Insert the sleeve into the hub and apply molybdenum
grease to the inside of the seals. Install the seals on the
hub.
4. Secure the brake disc to the hub with four new “patch
lock” cap screws. Tighten to 15 ft-lb.

7. Install the wheel and using a crisscross pattern, tighten the
wheel nuts in 20 ft-lb increments to a final torque factor of
40 ft-lb (aluminum wheel) or 80 ft-lb (steel wheel).
8. Remove the vehicle from the support stand.

Hydraulic Brake Caliper
! WARNING
WT325A

5. Install the hub assembly onto the axle. Install the
brake caliper and secure with new “patch-lock” cap
screws. Tighten to 20 ft-lb.

Arctic Cat recommends only authorized Arctic Cat Wildcat dealers perform hydraulic brake service. Failure to
properly repair brake systems can result in loss of control causing severe injury or death.

REMOVING/DISASSEMBLING
1. Secure the vehicle on a support stand to elevate the
wheel; then remove the wheel.

! WARNING
Never let brake fluid contact the eyes. Damage to the eyes
will occur. Always wear appropriate protective safety goggles and latex gloves when handling brake fluid.

2. Drain the brake fluid from the caliper, hose, and master cylinder through the bleed screw by pumping the
brake pedal.

CAUTION
WC281

6. Install the hub nut and tighten to 200 ft-lb. Install a
new cotter pin and spread the pin to secure.

Brake fluid is highly corrosive. Do not spill brake fluid on
any surface of the vehicle and do not reuse brake fluid.

NOTE: Whenever brake components are removed,
disassembled, or repaired where brake fluid is
exposed to air, drain all fluid and replace with new
DOT 4 brake fluid from an unopened container. Brake
fluid readily absorbs moisture from the air significantly lowering the boiling point. This increases the
chance of vapor lock reducing braking power and
increasing stopping distance.

141

3. Remove the brake hose from the caliper and close the
bleed screw; then remove the caliper.
4. Compress the caliper holder against the caliper (opposite the O-ring side) and remove the outer brake pad;
then remove the inner brake pad.

PR713A

PR237A

NOTE: If brake pads are to be returned to service,
do not allow brake fluid to contaminate them.

PR715

! WARNING
Make sure to hold the towel firmly in place or the piston
could be ejected from the housing causing injury.

PR238

5. Remove the caliper holder from the caliper and discard the O-ring.

7. Using an appropriate seal removal tool, carefully
remove the seals from the brake caliper housing; then
remove four O-rings from the brake caliper housing
noting the location of the different sized O-rings. Discard all seals, O-rings, and crush washers.

CLEANING AND INSPECTING
1. Clean all caliper components (except the brake pads)
with DOT 4 brake fluid. Do not wipe dry.
2. Inspect the brake pads for damage and excessive wear.
NOTE: For measuring brake pads, see Periodic
Maintenance/Tune-Up.

3. Inspect 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 binding or galling.
5. Inspect the caliper holder for wear or bending.
PR239B

NOTE: The O-ring is used for shipping purposes
and provides no function in operation.

6. Cover the piston end of the housing with a shop towel;
then keeping fingers clear of piston travel, apply compressed air to the fluid port to blow the piston free of
the housing. Account for two seal rings in the housing.

142

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.

CAUTION
Make sure the seals are properly in place and did not
twist or roll during installation.

PR715

PR719C

4. Install the caliper onto the caliper holder making sure
the caliper and holder are correctly oriented.
NOTE: It is very important to apply silicone grease
to the O-rings and caliper bores prior to assembly.

PR717A

2. Press the piston into the caliper housing using hand
pressure only. Completely seat the piston; then wipe
off any excessive brake fluid.
PR239C

5. Making sure brake fluid does not contact the brake pads,
compress the caliper holder toward the caliper and
install the inner brake pad; then install the outer pad.

CAUTION
If brake pads become contaminated with brake fluid, they
must be thoroughly cleaned with brake cleaning solvent
or replaced with new pads. Failure to do so will result in
reduced braking and premature brake pad failure.

PR711A

PR238

PR712

3. Apply high-temperature silicone grease (supplied with
the O-ring kit) to the inside of the caliper holder bores
and O-rings; then install the four O-rings into the caliper.

143

WT514A

PR239

6. Place the brake caliper assembly into position and
secure with new “patch-lock” cap screws. Tighten the
caliper to 20 ft-lb.
7. Place a new crush washer on each side of the brake hose
fitting and install it on the caliper. Tighten to 20 ft-lb.
8. Fill the reservoir; then bleed the brake system (see
Periodic Maintenance/Tune-Up).

! WARNING
Never use brake fluid from an open container or reuse
brake fluid. Moisture-contaminated brake fluid could cause
vapor build-up (expansion) during hard braking resulting in
greatly increased stopping distance or loss of control leading to injury or death.

WT512

3. Remove the two banjo bolts securing the banjo fittings
to the master cylinder. Discard the four crush washers.

9. Install the wheel; then using a crisscross pattern,
tighten the wheel nuts in 20 ft-lb increments to a final
torque factor of 80 ft-lb.
10. 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 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 reservoir is empty.

WT511A

CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the vehicle.

4. Remove the two cap screws securing the master cylinder to the frame.

2. Remove the cotter pin and pivot pin from the yoke; then
disconnect the two spade connectors from the switch.

WT513A

144

INSPECTING
1. Inspect the master cylinder push rod and clevis for
wear, bending, or elongation of clevis holes.
2. Inspect the push rod boot for tears or deterioration.

2. Install the pivot pin and secure with a new cotter pin;
then connect the switch.
3. Using four new crush washers installed on both sides
of the banjo fitting, secure the banjo bolts into the
master cylinder. Tighten to 20 ft-lb.

3. Inspect the reservoir for cracks and leakage.
4. Inspect the brake hose for cracks and deterioration and
the condition of the banjo-fittings.

INSTALLING
1. Place the master cylinder into position and secure with
cap screws. Tighten to 25 ft-lb.

WT511A

4. Fill the master cylinder and bleed the brake system (see
Hydraulic Brake system in Periodic Maintenance/Tune-Up).

WT513A

145

Troubleshooting
Problem: Power not transmitted from engine to wheels
Condition
1. Rear axle shaft serration worn - broken

Remedy
1. Replace shaft

Problem: Power not transmitted from engine to either front wheel
Condition
Remedy
1. Gear teeth broken
2. Front differential gears/pinions broken - damaged
3. Front drive actuator not operating

1. Replace gear(s)
2. Replace gears - pinions
3. Replace fuse - drive select switch - front drive actuator

Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)
Condition
Remedy
1.
2.
3.
4.
5.

Backlash excessive
Tooth contact improper
Bearing damaged
Gears worn - chipped
Splines worn

Problem: Braking poor
Condition
1. Pad worn
2. Brake fluid leaking
3. Master cylinder/brake cylinder seal worn

Problem: Brake pedal travel excessive
Condition
1. Brake fluid low
2. Piston seal - cup worn

Problem: Brake fluid leaking
Condition
1. Fittings loose
2. Hose cracked
3. Piston seal worn

Problem: Brake pedal spongy
Condition
1. Air trapped in hydraulic system
2. Brake fluid low

146

1.
2.
3.
4.
5.

Adjust backlash
Adjust contact
Replace bearing
Replace gears
Replace shaft(s)

Remedy
1. Replace pads
2. Repair leak(s)
3. Replace seal(s)

Remedy
1. Add fluid to proper level
2. Replace seal - cup

Remedy
1. Tighten fittings
2. Replace hose
3. Replace seal

Remedy
1. Bleed hydraulic system
2. Add brake fluid and bleed hydraulic brake system

INSTALLING

Suspension

1. Place the shock absorber spring over the shock
absorber, compress the spring, and install the retainer.

The following suspension system components should be
inspected periodically to ensure proper operation.

2. Place bushings and sleeves (where appropriate) into
shock eyelet; then install shocks with two cap screws
and nuts.

A. Shock absorber rods bent, pitted, or damaged.
B. Reservoirs damp or leaking.
C. Shock absorber body damaged, punctured, or leaking.
D. Shock absorber eyelets broken, bent, or cracked.
E. Shock absorber eyelet bushings worn, deteriorated,
cracked, or missing.
F. Shock absorber spring broken or sagging.
G. Sway bar mountings tight and bushings secure.
H. Proper pre-load and damping for conditions.

3. Tighten the front shock absorber cap screws to 40 ft-lb
(head side). Tighten the upper rear shock absorber cap
screws to 40 ft-lb and the lower rear shock absorber
cap screws to 35 ft-lb.
4. Remove the vehicle from the support stand.

CHECKING/ADJUSTING RIDE
HEIGHT
NOTE: Ensure the vehicle is on level ground, the
tires are properly inflated to 14 psi, and there is an
average operating load in the vehicle.

1. Measure from the ground to the bottom of the skid
plate along the front sway bar. Measurement should be
10.5 inches.

p/n

Shaft Bullet Tool

0644-404

Inflation Needle

0744-020

Piston Location (IFP) Tool

0644-575

Gas Shock Rod/Body Clamping Tool

0644-425

NOTE: Special tools are available from the Arctic
Cat Service Department.

Shock Absorbers

WT492A

2. If measurement is not as specified, use an appropriate
spanner wrench to adjust the left and right spring as
required.

REMOVING
1. Secure the vehicle on a support stand to elevate the
wheels and to release load on the suspension.
2. Remove the two cap screws and nuts securing each
front shock absorber to the frame and lower A-arm.
Account for bushings and sleeves from each.
3. Remove the two cap screws and nuts securing each
rear shock absorber to the frame and lower trailing
arm. Account for bushings and sleeves from each.

CLEANING AND INSPECTING
1. Completely remove pre-load by turning the adjusters
to the end of the threads and removing the retainer;
then remove the spring.
2. Clean all shock absorber components in parts-cleaning solvent.

WT077B

3. Measure from the ground to the bottom of the skid
plate along the receiver hitch. Measurement should be
10 inches.

3. Inspect each shock rod for nicks, pits, rust, bends, and
oily residue.
4. Inspect all springs, spring retainers, shock rods,
sleeves, bushings, shock bodies, and eyelets for
cracks, leaks, and bends.
147

WT590A

FX068

4. If measurement is not as specified, use an appropriate
spanner wrench to adjust the left and right spring as
required.

1. Loosen the spring preload adjuster rings with spanner
wrenches.

FX067
WT078B

2. Remove the spring retainer and spring.

REBUILDING
Inspection
Inspect all components for any signs of wear or damage
and replace parts as necessary.

Preliminary Set-Up
1. Clean and dry the shock before beginning disassembly.
2. Stroke the shock to assess its condition and function.
Compress and rebound adjustment positions should be
noted.
NOTE: This is done by turning 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 noting positions, open all
adjustment knobs by turning them counter-clockwise
fully open.

FX066

3. Press the rubber-bonded bushing out from the body
end cap and eyelet bushings.

NOTE: Throughout all procedures as a general rule,
replace all volatile parts (seals, O-rings, bearings,
etc.).

DISASSEMBLING
NOTE: Measure spring preload before removing the
spring.
FX065

148

FX064

FX061

4. Secure the shock eyelet in the vise and insert the nitrogen needle. Fully depress the needle to release nitrogen pressure from the shock. After installing the
appropriate body cap removal tool, insert the retaining
wire into the groove between the cap and body.

FX060

6. Using a valve shim, remove the retaining wire and
pull the shaft assembly out of the body.

FX063

FX059

FX062

5. Tap upward on body cap removal tool to release cap;
then depress the bearing assembly to full expose
retaining wire.

FX058

7. Dispose of used oil in an environmentally-acceptable
manner; then use a body clamp block to secure the
body in the vise.

149

FX057

FX053

FX056

FX052

8. Apply sufficient heat to the body cap to break down
the thread lock bond between the body cap and body.
Remove any thread lock residue from the body and
body cap using a wire brush and small pick.

10. Remove the lock nut.

FX049

11. Remove the rebound valve stack and cable tie the
valves together.
FX055

FX054

9. Remove the O-ring from the body cap; then push the
IFP out of body.

150

FX048

FX047

FX042

12. Remove the piston assembly; then remove the compression valve stack and cable tie it together.
13. Remove the rubber washer, bearing assembly, bearing
cap, bumper, and washer.

FX041

15. Using a small pick, remove all seals and O-rings from
the bearing cap and bearing assembly. If a bearing is
required in the bearing assembly, replace the bearing
assembly.
FX044

FX040
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 eyelet.

FX039

151

ASSEMBLING
1. Apply Loctite Primer #7649 to the shaft. Allow proper
curing time before applying green Loctite #638 to the
shaft.

FX035

FX038

FX034

4. Replace the wiper seal in the bearing cap.

FX037

2. Tighten to 50 ft-lb.

FX033

5. Replace the U-cup seal and O-ring.

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 installing.

FX032

152

FX031

FX027

6. Using Shaft Bullet Tool, install the bearing cap assembly and bearing assembly.

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.

FX030
FX026

FX029

7. Install the bumper and compression valve stack.

FX025

9. Install the rebound valve stack; then replace the valve
stack. Replace the lock nut and tighten to 18 ft-lb. Set
aside for later assembly.

FX028

FX024

153

FX023

10. Replace the O-ring on the IFP. Apply a thin layer of
molybdenum grease to the body before installing the
IFP into the body with the IFP relief contour facing
towards the top of the body.

FX019

NOTE: When setting IFP depth, note the shock
absorber IFP shuttles 0.480” during installation.

A. The designed depth of 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 once the IFP is
set.

12. Replace the O-ring in the body cap. If the shock has
been rebuilt several times, the body cap assembly may
need to be replaced.

FX022

FX018

FX021

11. Apply Loctite Primer #7649 to the body and set the
IFP depth.

FX1020

154

13. Apply green Loctite #638 two threads wide for 360°
two threads up from the start of threads. Ensure the
Loctite does not make contact with the O-ring. Secure
the body in Gas Shock Rod/Body Clamping Tool and
tighten the body cap to 75 ft-lb.

FX017

FX018

FX012

14. Verify the IFP depth is correct. Fill the body with
specified oil 3/8” from top of body. Pass a propane
torch quickly over the body to eliminate any air bubbles in oil.

16. Push the bearing assembly just past the retainer
groove in the body; then install the wire retainer.

FX011
FX015

FX010
FX014

15. Slide the bearing assembly to the bottom of shaft
before inserting. Insert the shaft assembly into the oil
slowly allowing air bubbles to escape.

17. Once the wire retainer is fully installed, slowly push
the shaft assembly down. DO NOT pull the shaft out.
Clean any excess oil off the body.
NOTE: If the shaft rebounds upward, it has hit the
IFP meaning the IFP will need to be reset.

FX013

155

FX007

FX005

FX008

FX004

18. Secure the body with body clamps and ensure the
shaft has room to fully extend when charged. Charge
with nitrogen using Inflation Needle to the specified
pressure for about 10 seconds; the shaft should fully
extend.

20. Install the body cap and eyelet bushings.

FX003

FX007

FX002

21. Clean the assembly and install the spring to the
desired preload setting.
FX006

19. Inspect both ends of shocks for leaks. Use rubber mallet to secure bearing cap assembly.
156

FX001

WT330A

6. Remove and discard the cap screws securing the ball
joints to the knuckle.

Front A-Arms
REMOVING UPPER
1. Lift and support the vehicle with a support stand to
allow access to the front suspension.
2. Remove the front wheels.
3. Remove the cotter pin and hub nut securing the hub.

WT329A

CAUTION
Support the knuckle when removing the cap screws or
damage to the threads will occur.

7. Tap the ball joints out of the knuckle; then remove the
knuckle.

WT328A

8. Remove and discard the cap screw securing the lower
shock eyelet to the upper A-arm. Remove the shock
from the A-arm.

4. Remove and discard the “patch-lock” cap screws
securing the brake caliper to the hub.

WT498A
WT287A

5. Remove the cotter pin and nut securing the tie rod end
to the knuckle; then remove the tie rod end from the
knuckle.

9. Remove the brakeline hose routing clip from the
upper A-arm; then remove the cap screw securing the
A-arm to the frame. Remove the A-arm.
NOTE: Having the steering rack turned completely
to the left and the clamp orientated as shown will aid
in removing the cap screw.

157

WT334

10. Remove the snap ring securing the ball joint in the Aarm. Remove ball joint.

WT600

REMOVING LOWER
NOTE: Having the steering rack turned completely
to the left and the clamp orientated as shown will aid
in removing the cap screw.

WT496

NOTE: Only remove the ball joint if replacement is
necessary.
WT333

11. Remove and discard the cap screw and lock nut securing the sway bar link to the lower A-arm.

1. Remove and discard the cap screw and lock nut securing the sway bar link to the lower A-arm.

WT494A

12. Remove the seals and sleeve and inspect for cracks,
nicks, or tears.
NOTE: Only remove the bushings if they must be
serviced.

13. Place the A-arm in a bench vise and using an appropriate tool, drive out and discard the bushings.

158

WT494A

2. Remove the front bumper.
NOTE: The front bumper will need to be removed to
remove lower A-arm cap screw from frame.

3. Remove the cap screw and discard the lock nut securing the lower A-arm to the frame. Remove the A-arm.

INSTALLING
1. Using a suitable press, press in the new bushing.

WT492A

WT599

2. Place the A-arm in a bench vise and using a 16 mm
reamer, ream out the bushings.

WT493A

4. Remove the seals and sleeve and inspect for cracks,
nicks, or tears.
NOTE: Only remove the bushings if they must be
serviced.

5. Place the A-arm in a bench vise and using an appropriate tool, drive out and discard the bushings.

WT596

3. Insert the sleeve into the A-arm and apply molybdenum grease to the inside of the seals. Install the seals
on the A-arm.
4. Apply Loctite Primer “T” to the A-arm socket; then
apply Green Loctite #609 to the entire outside diameter of the ball joint. Install the ball joint into the A-arm
and secure it with the snap ring.

WT600

CLEANING AND INSPECTING
1. Clean all of the A-arm components in a parts-cleaning
solvent.
2. Clean the ball joint opening of all residual Loctite,
grease, oil, or dirt.

WC237

3. Inspect the A-arms for bends, cracks, and worn bushings.
4. Inspect the ball joint mounting holes for cracks or
damage.
5. Inspect the frame mounts for signs of damage, wear,
or weldment damage.
159

WT497

WT332

5. Install the lower A-arm into the frame mounts and
secure it with the cap screw and new lock nut. Fingertighten only at this time.

11. Install the tie rod end and secure it with the castle nut
(coated with red Loctite #271). Tighten to 55 ft-lb;
then install a new cotter pin and spread the pin to
secure the nut.

6. With a new “patch-lock” cap screw and new lock nut,
secure the sway bar link to the lower A-arm. Tighten
to 20 ft-lb.

WT330A

WT494A

7. Tighten the lower A-arm cap screw to 40 ft-lb.

12. Install the hub assembly and secure it with the hub
nut. Tighten to 200 ft-lb and install the new cotter pin.
Spread the pin to secure the nut.

8. Install the upper A-arm to the frame with the cap
screw and new lock nut. Finger-tighten only at this
point.

WT328A

NOTE: During assembly, new cotter pins should
always be used.
WT334

9. Route the brakeline hose underneath the upper A-arm
and secure it with the clip. Tighten to 30 in.-lb.
10. Install the knuckle on the lower ball joint using a new
“patch-lock” cap screw. Finger-tighten only at this
time. With 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.

160

NOTE: If the cotter pin cannot be inserted due to
misalignment of the hole and the slots in the nut,
always tighten the nut until it is properly aligned.

13. Using a new “patch-lock” cap screw and existing
washer, secure the shock to the upper A-arm. Tighten
to 25 ft-lb.

WT498A

WT418A

14. Tighten the cap screw securing the upper A-arm to the
frame to 35 ft-lb.

3. Remove and discard the cotter pin from the hub nut;
then remove nut and hub.

15. Using new “patch-lock” cap screws, secure the brake
caliper to the brake disc. Tighten to 20 ft-lb.

WT418B

WT287A

4. Remove the lower shock cap screw and discard the
nut.

16. Install the wheels and tighten to 40 ft-lb (steel wheel)
or 80 ft-lb (aluminum wheel).
17. Install the front bumper; then remove the vehicle from
the support stand.

Rear A Arms
REMOVING
1. Lift and support the vehicle on a support 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 technician’s objective to only remove the upper A-arm, proceed to step 5.

WT417A

5. Remove the cap screws securing the upper A-arm to
the frame and knuckle. Discard the nuts.

2. Remove and discard the “patch-lock” cap screws
securing the brake caliper to the hub.

WT447A

161

6. Remove the cap screw securing the lower A-arm to
the hub. Discard the nut.

WT444

W446A

NOTE: The drive axle does not have to be removed
for this procedure.

NOTE: Only remove the bushings if they must be
serviced.

10. Place the A-arm in a bench vise and using an appropriate tool, drive out and discard the bushings.

7. Remove and discard the cap screw and lock nut securing the sway bar link to the lower A-arm (A). Remove
the cap screw and clip securing the brake line to the
lower A-arm (B); then remove the cap screw and nut
securing the shock to the lower A-arm (C).

WT600

CLEANING AND INSPECTING
1. Clean all A-arm components in parts-cleaning solvent.
WT448A

8. Remove the cap screws and nuts securing the lower
A-arm to the frame. Discard the nuts.

2. Inspect the A-arm for bends, cracks, and worn bushings.
3. Inspect the frame mounts for signs of damage, wear,
or weldment damage.

INSTALLING
NOTE: If only the upper A-arm was removed, skip to
step 6.

1. Using a suitable press, press in the new bushing.

WT445A

9. Remove the seals and sleeve.

WT599

162

2. Place the A-arm in a bench vise and using a 16 mm
reamer, ream out the bushings.

6. Using the existing cap screws and new lock nuts,
secure the knuckle to the upper and lower A-arms.
Tighten to 35 ft-lb.
NOTE: It is important that the hub is installed in a
manner that allows you to read the text.

WT596

3. Insert the sleeve into the A-arm; then apply grease to
the seal and insert it into the end of the A-arm along
with the end caps.
WT450A

7. If the upper A-arm was removed, insert the sleeve into
the end of the upper A-arm. Apply grease to the seals
and install into the A-arm.

WT449

4. Install the lower A-arm into the frame mount and
secure with cap screws and new lock nuts (A). Only
finger tighten at this point. Install the shock into the
lower A-arm and secure it with the cap screw and new
lock nut (B). Only finger tighten at this point. Install
the sway bar link into the lower A-arm and secure it
with the new “patch-lock” cap screw and lock nut (C).
Only finger tighten at this point. Install the cap screw
and clip securing the brake line to the lower A-arm
(D).

9. Install the hub assembly and using an appropriate
spanner wrench, secure the hub to the axle with the
castle nut. Tighten to 200 ft-lb.

WT448B

WT451

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.

10. Install a new cotter pin and spread the pin to secure
the nut.

WT449

8. Install the upper A-arm into the frame. Mount and secure
the hub with the cap screws and new locking nuts.

NOTE: If the pin does not line up with the castle nut,
always tighten the nut to the next opening and install
the pin.
163

11. Using new “patch-lock” cap screws, install the brake
caliper and tighten to 20 ft-lb.
12. Install the wheel and tighten the lug nuts to 40 ft-lb
(steel wheels) or 80 ft-lb (aluminum wheels).
13. Remove the vehicle from the stand.

2. Tighten the A-arm links to 20 ft-lb; then tighten the
sway bar link to 35 ft-lb.

Rear Sway Bar
REMOVING

Front Sway Bar

1. Remove and discard the cap screws and lock nuts
securing the sway bar link to the lower A-arms on
both sides.

REMOVING
1. Remove the front wheels (see Wheels and Tires in this
section).
2. Remove and discard the cap screws and lock nuts
securing the sway bar to the A-arm links.

WT320A

2. Remove the cap screws securing the sway bar to the
frame and remove the sway bar. Account for the bushing retainers and bushings.
WT323A

3. Remove the sway bar bushing retainers and bushings
and slide the sway bar out of the vehicle.

INSPECTING
1. Inspect the sway bar for any signs of twisting or
cracking.
2. Inspect the bushing retainers and bushings for any
signs of wear or damage.

INSTALLING
1. Using new “patch-lock” cap screws and new lock
nuts, install the sway bar into position and secure it to
the lower A-arm links.
2. Install the bushing retainers and bushings. Fingertighten the cap screws only at this point.

WT315B

INSPECTING
1. Inspect the sway bar for any signs of twisting or
cracking.
2. Inspect the bushing retainers and bushings for any
signs of wear or damage.

INSTALLING
1. Using new “patch-lock” cap screws and new lock
nuts, secure the sway bar to the lower A-arm link. Finger-tighten only at this point.
2. Install the bushings and bushing retainers. Fingertighten only at this point.
3. Tighten the lower A-arm links to 20 ft-lb; then tighten
the sway bar link to 35 ft-lb.
WT324

164

Wheels and Tires

2. Remove the nuts securing the wheels; then remove the
wheels.

CLEANING AND INSPECTING
1. Clean the wheels and hubs with parts-cleaning solvent.

TIRE SIZE

2. Clean the tires with soap and water.

! WARNING
Use only Arctic Cat approved tires when replacing tires.
Failure to do so could result in unstable vehicle operation.

The Wildcat Trail is equipped with low-pressure tubeless
tires of the size and type listed in General Information. Do
not under any circumstances substitute tires of a different
type or size.

! WARNING
Always use the size and type of tires specified. Always
maintain proper tire inflation pressure.

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

TIRE INFLATION PRESSURE
Front and rear tire inflation pressure should be as specified in
the General Information section.

3. Inspect each wheel for cracks, dents, or bends.
4. Inspect each tire for cuts, wear, missing lugs, and leaks.

INSTALLING
Install the wheel; then using a crisscross pattern, tighten the
wheel nuts in 20 ft-lb increments to 40 ft-lb (steel wheel) 80 ftlb (aluminum wheel).

CHECKING/INFLATING
1. Using an air pressure gauge, measure the air pressure in
each tire. Adjust the air pressure as necessary to meet the
recommended inflation pressure.
2. Inspect the tires for damage, wear, or punctures.

! WARNING
Do not operate the vehicle if tire damage exists.

NOTE: If repair is needed, follow the instructions found
on the tire repair kit or replace the tire.

REMOVING
1. Secure the vehicle on a support stand to elevate the
wheels.

Troubleshooting
Problem: Suspension too soft
Condition
1. Spring preload incorrect
2. Spring(s) weak
3. Shock absorber damaged

Problem: Suspension too stiff
Condition
1. Spring preload incorrect
2. A-arm-related bushings worn

Problem: Suspension noisy
Condition
1. Cap screws (suspension system) loose
2. A-arm-related bushings worn

Problem: Vehicle pulling or steering erratic
Condition
1. Vehicle steering is erratic on dry, level surface
2. Vehicle pulls left or right on dry, level surface

Remedy
1. Adjust preload
2. Replace spring(s)
3. Replace shock absorber

Remedy
1. Adjust preload
2. Replace bushing

Remedy
1. Tighten cap screws
2. Replace bushings

Remedy
1. Check front wheel alignment and adjust if necessary (see
Steering/Frame/Controls)
2. Check air pressure in tires and adjust to specifications

165

Printed in U.S.A.

Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-145

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2014 Wildcat Trail Service

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