Arctic Cat 2016 Wildcat Sport, Service Manual

Page 1: ...www arcticcat com SERVICE MANUAL www arcticcat com ...

Page 2: ...talling Top Side Components 57 Bottom Side Components 60 Removing Bottom Side Components 60 Servicing Bottom Side Components 64 Installing Bottom Side Components 66 Servicing Left Side Components 70 Installing Engine 74 Fuel Lubrication Cooling 79 Throttle Body 79 Gas Tank 81 Oil Pump 82 Oil Cooler 82 Oil Flow Chart 83 Liquid Cooling System 84 Radiator 84 Thermostat 86 Fan 87 Water Pump 87 Trouble...

Page 3: ...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 with out notice Product Service and Warranty Department Arctic Cat Inc Specifications NOTE Specifications subject to change without notice Visible at plug threads CHASSIS Dry Weight approx 478 k...

Page 4: ...le 30 41 Jam Nut Tie Rod 8 11 Tilt Steering Link Frame 10 14 Tilt Steering Frame 20 27 Intermediate Shaft Rack and Pinion 25 34 Intermediate Shaft Shaft Adjuster 25 34 EPS Mounting Bracket EPS Assembly 35 48 EPS Assembly Frame 20 27 Upper Steering Shaft Assembly EPS Assembly 25 34 CHASSIS ROPS ASSEMBLY Door Latch Bracket Frame 8 11 Door Hinge Frame 20 27 Shift Lever Shift Mount Bracket 20 27 Shift...

Page 5: ...r Filter Housing Frame 5 7 Ground Wire Engine 8 11 Stator Coil Magneto Cover 11 15 Oil Drain Plug Engine 20 27 Drain Plug Clutch Cover 50 in lb 5 5 Cam Chain Tensioner Cylinder Head 15 20 Connecting Rod Connecting Rod step 1 step 2 final 22 36 45 29 49 60 Oil Crossover Tube Crankcase 13 5 18 Cylinder Head Side Crankcase 7 9 5 Oil Filter Union Crankcase 20 27 Phase Plate Sprocket 7 9 5 Timing Inspe...

Page 6: ...rom the entire vehi cle Allow the vehicle to dry thoroughly DO NOT get water into any part of the engine or air intake 3 Either drain the gas tank or add a fuel stabilizer to the gas in the gas tank 4 Clean the interior of the air filter housing 5 Plug the hole in the exhaust system with a clean cloth 6 Apply light oil to the upper steering shaft bushing and plungers of the shock absorbers 7 Tight...

Page 7: ...Connect the battery cables making sure to connect the positive cable first 7 Check the entire brake systems fluid level pads etc all controls headlights taillight brakelight and headlight aim adjust or replace if necessary 8 Check the tire pressure Inflate to recommended pressure as necessary 9 Tighten all nuts bolts cap screws and screws mak ing sure all calibrated nuts cap screws and bolts are t...

Page 8: ... a wash pan larger than the filter with a non flam mable cleaning solvent then dip the inner filter and outer foam medium in the solvent and wash them NOTE Foam Filter Cleaner and Foam Filter Oil are available from Arctic Cat 4 Dry both filter components 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 ...

Page 9: ... 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 cyl inder see Engine Servicing Top Side Components Spark Plugs A light brown insulator indicates the plug and fuel air ra...

Page 10: ...e 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 11 Remove the oil level stick the oil level must be within ...

Page 11: ...th water inspect the drain plug fill plug and or bladder Headlight Taillight Brakelight 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 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 th...

Page 12: ...rior stud in place in the grommet work the exterior stud into position NOTE It may be necessary to lightly pull on the exterior bracket to insert the exterior mounting stud WT270 5 Secure the headlight with the existing screws 6 Connect the wiring harness and install the front fender then install the grille 7 Check and adjust headlight aim see Periodic Main tenance Tune Up section REMOVING TAILLIG...

Page 13: ...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 7 Install the front grille Ti...

Page 14: ...caps are installed and no leakage is present INSPECTING HOSES Carefully inspect the hydraulic brake hoses for cracks or other damage If found the brake hoses must be replaced CHECKING REPLACING PADS 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 wea...

Page 15: ...ph then release the accelerator pedal and depress the brake pedal to decelerate to 0 5 mph 3 Repeat procedure 20 times until brake pads are bur nished 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 se...

Page 16: ...ned 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 WT517A 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 wash...

Page 17: ...uld be checked periodically for damage bends cracks deterioration broken compo nents and missing components Front Bumper REMOVING 1 Remove the hood and grille see Hood Grille Stor age Box 2 Disconnect the headlights WS033 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 WS040A 4 Remove the cap screws from b...

Page 18: ...LING HOOD 1 Turn the two quarter turn fasteners counterclockwise and remove hood WS033A 2 Insert the hood tabs into the grille and lay the hood down flat Turn both of the fasteners clockwise securing the hood WT251 REMOVING UNDER HOOD STORAGE BOX 1 Remove the hood 2 Remove the cap screws securing the under hood stor age box to the frame WS018A INSTALLING UNDER HOOD STORAGE BOX 1 Install the storag...

Page 19: ...taillight brake light assembly to the frame and disconnect the har ness WS036A WT222 4 Remove the fasteners securing the right rear body panel WT241A WS050A 5 Loosen the gas tank filler hose clamp and slide it down towards the tank WT244 6 Remove the panel from the frame while also pulling on the filler hose Seal off the hose to prevent objects from entering the hose WT246 WARNING The heat deflect...

Page 20: ...left rear body panel WS053A 10 Remove the panel with the air clutch intake tubes WS048 INSTALLING REAR BODY PANELS 1 If removed install the clutch air intake tube through the left rear body opening and secure it with the plate and existing cap screws Tighten securely WT484A 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 WT4...

Page 21: ...and secure it with the clamp Tighten securely WT487A 6 Install the left rear fender and secure it with the exist ing hardware 7 Install the tabs of the body panel into the slots in side panel then insert the plastic insert into the gas tank filler hose Tighten the clamp and install the gas cap WT245 8 Secure the panel to the frame with the existing cap screws and push pins WS050A WT489A 9 Install ...

Page 22: ...e the bottom of the side panel is on the outside of the inner splash panel WT212 2 Secure the side panel using the existing cap screws and push pins Tighten all hardware to 60 in lb Dash Switches REMOVING 1 Remove the hood then remove the steering wheel see Steering Wheel in this section 2 Remove the top steering tilt assembly cap screw and discard the nut WT338A 3 Remove the door latches and disc...

Page 23: ... until they snap into place WT341 2 Connect the 12 volt accessory plug ignition switch and LCD gauge 3 With the steering shaft slid through the dash install the dash and secure it with the 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...

Page 24: ... 1 Remove the steering wheel cover then mark the steering shaft and steering wheel for installing pur poses WT298A NOTE Any time steering components are disassem bled all connecting components should be marked for proper alignment during assembling 2 Remove the hairpin clip from the steering shaft then remove the nut securing the steering wheel and remove the steering wheel INSPECTING 1 Inspect th...

Page 25: ...ring wheel hood and dash 2 Remove the cap screws and discard the lock nuts securing the upper steering shaft to the frame WT607A 3 Unplug the electrical connections A then remove the cap screw and discard the lock nut B WT608A 4 Remove upper steering shaft then remove the cap screws securing the EPS assembly to the frame and steering shaft Discard lock nut WT604A WT604B 5 Remove the EPS assembly f...

Page 26: ...to the EPS assembly WT604B NOTE Loosening but not removing the cap screw connecting the steering shaft to the rack and pinion will aid in installing the lower cap screw connecting the lower steering shaft to the EPS assembly If this step was done the lower lock nut must be replaced and tightened to 25 ft lb WT610A 5 Tighten the cap screws securing the EPS assembly to the frame to 35 ft lb 6 Instal...

Page 27: ...G SHAFT 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 STEERING SHAFT 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 steer...

Page 28: ... 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 WS055A 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 WT369A 5 Support the steering rack assembly in a suitable bench vise then remove th...

Page 29: ...ring assembly rack and pinion is not repairable and must be replaced as an assembly however the tie rods and boots are replaceable INSTALLING RACK AND PINION 1 With the threads coated with red Loctite 271 thread the inner tie rod end onto the rack and tighten with a crow foot to 37 ft lb WT370A NOTE Always attach the crow foot to the torque wrench with the open end 90 to the torque wrench handle t...

Page 30: ...Front Wheel Alignment 10 Remove the vehicle from the support stand 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 3 Remove the brake caliper 4 Remove the hub assembly 5 Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle 6 Remove the upper cap screw ...

Page 31: ... 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 WT451 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 WT275 NOTE During assembly new cot...

Page 32: ...he front and rear The front measurement should be 3 6 mm 1 8 1 4 in greater than the rear measurement toe out WT292A To adjust the wheel alignment use the following proce dure 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 WS009A 2 Turn the left side and right side tie rods B in equal increments to achieve the proper to...

Page 33: ...able end There should not be any free play and the tension sleeve should not be com pressed WT099B 3 To adjust the throttle cable locate the in line cable adjuster beneath the clutch cover then slide the pro tective sleeve upward from the adjuster WT081A 4 Loosen the jam nut A and turn the adjuster B clockwise to increase free play or counterclockwise to decrease WT082A 5 Tighten the jam nut secur...

Page 34: ... cap screw and lock nut securing the shift cable to the shift arm Discard the nut WT296B 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 1 Install the new shift cable in place noting the routing fr...

Page 35: ... to 20 ft lb 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 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 dis connect the multi pin co...

Page 36: ...uffler back and forth and listening for rattles or loose debris inside the muffler INSTALLING MUFFLER AND HEAT SHIELD 1 Slide the heat shield over the muffler and secure with six cap screws 2 With the gasket in place place the muffler onto the holder pins and slide into position WT293A NOTE Starting with the upper rear pin will aid in installing 3 Secure the muffler to the exhaust pipe with the fo...

Page 37: ...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 WT003A 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 loc...

Page 38: ...ews on the hinge plate to raise or lower the door to latch contact or to move the door forward or backward After adjustment tighten securely WC801A WC798A 2 Loosen the screws on the latch plate to move the latch forward or backward After adjustment tighten securely Floor REMOVING 1 Remove the seats engine access panel and center console 2 Remove the fasteners securing the floor to the frame WT344A...

Page 39: ...b bearings worn broken 4 Frame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Replace shock absorber Problem Steering impaired Condition Remedy 1 Tire pressure too high 2 Steering linkage connections worn 3 Cap screws suspension system loose 1 Adjust pressure 2 Replace connections 3 Tighten cap screws Problem Tire wear rapid or...

Page 40: ...ion 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 SPECIAL TOOLS A number of special tools must be available to the techni cian when performing service procedures in this section Refer to the current Special Tools Catalog for the appro priate tool description N...

Page 41: ...efective 4 ECM defective 5 Fuel injector obstructed 6 Valve clearance out of adjustment 1 Drain gas replace with clean gas 2 Clean replace plug s 3 Replace stator coil 4 Replace ECM 5 Replace fuel injector 6 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance excessive 2 Valve spring s weak broken 3 Camshaft worn 1 Adjust clearance 2 Replace spring s 3 ...

Page 42: ...eplace with clean gas 2 Drain excess oil change oil 3 Replace service rings cylinder 4 Replace cylinder head 5 Replace cylinder 6 Replace valves 7 Replace seals Problem Engine lacks power Condition Remedy 1 Gasoline bad contaminated 2 Valve clearance incorrect 3 Valve springs weak 4 Valve timing incorrect 5 Piston ring s cylinder worn 6 Valve seating poor 7 Spark plug fouled 8 Spark plug gap incor...

Page 43: ...the cap screws securing the rear splash pan els to the frame WS053A WT489A WT362A 2 Remove the left rear wheel then remove the outer clutch cover Retain the cap screws WS034A 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 4 Remove the cap screw securing the drive clutc...

Page 44: ...r tube and loosen the air intake clamp WT405A WT311A NOTE Removing the intake boot with air box will aid in installation 7 Loosen the throttle body clamp WT316A 8 Remove and discard the top patch lock fasteners securing the air box then remove and retain the lower air box cap screws and grommets WT313A AT THIS POINT If the technician s objective is to service the left side com ponents no further d...

Page 45: ...ensor con nector 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 WT397A 12 Remove the springs securing the exhaust pipe to the muffler then remove muffler WS111 13 Remove the cap screws securing the heat shield to the exhaust pipe then carefully remove the heat shiel...

Page 46: ...ten securely 16 Remove the spark plug caps A Disconnect the cam position sensor B and coil connectors C WT405F 17 Remove the water pump drain plug and drain the coolant into a suitable pan WT399A NOTE Opening the radiator cap will aid in drain ing the coolant 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 ...

Page 47: ...transaxle mounting plate WT225A 22 Loosen the jam nut A then loosen the adjuster nut B but do not remove it from plate WT412A 23 Remove the cap screws securing the transaxle to the engine plate then remove the lock nuts securing the front engine mounts to the frame WT 412B WT407 24 Using a proper lifting device remove the engine from the vehicle WT413 ...

Page 48: ...WT168 2 Remove the four cap screws securing the cylinder head cover Account for rubber washers and sili cone held gaskets ROV1 005A ROV1 001A 3 Remove the two fasteners securing the starter motor ROV1 116A 4 Remove the magneto and timing inspection plugs then turn the crankshaft to the TDC position ROV1 012 ROV1 013 5 Remove the cam chain tensioner Account for a gas ket and the fasteners AT THIS P...

Page 49: ...procket will aid in removing the camshaft holder ROV1 010 NOTE The camshaft holder and cylinder head have matching code numbers and must remain a set KC548A KC549A 8 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 ROV1 019 9 On the left side of the head remove the three cap screws ROV1 021A 10 Loosen th...

Page 50: ...king care not to let the pistons fall against the cyl inder remove the cylinder and account for two dowel pins Remove and discard the base gasket 16 Using a suitable pick remove the circlip from the piston then push the piston pin out from the other side ROV1 043 NOTE Only one piston circlip needs to be removed CAUTION Do not use an impact tool to remove the head bolts or damage to the cam shaft j...

Page 51: ... with the present shim size to obtain the recommended replacement shim Cleaning Inspecting Valve Cover NOTE If the valve cover cannot be trued the cylin der head assembly must be replaced 1 Wash the camshaft holder in parts cleaning solvent 2 Place the camshaft holder on the Surface Plate cov ered with 400 grit wet or dry sandpaper Using light pressure move the camshaft holder in a figure eight mo...

Page 52: ...51 KCINTAKE TAPPET CLEARANCE TABLE INTAKE ...

Page 53: ...52 KCEXHAUST TAPPET CLEARANCE TABLE EXHAUST ...

Page 54: ...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 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 KC522 4 Place a spring retainer over the valve springs then using the valve spring compressor compress the val...

Page 55: ... or 0 85 mm oil WT586 Measuring Piston Pin Outside Diameter and Piston Pin Bore 1 Measure the piston pin outside diameter at each end and in the center If measurement is less than 17 894 mm the piston pin must be replaced ATV 1070 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 ATV 1069 Measuring Connecting ...

Page 56: ...andpaper 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 assem bly by continuing to move the cylinder head in a fig ure eight motion until a uniform bright metallic finish is attained Measuring Cylinder Head Distortion 1 Remove any car...

Page 57: ...g a 320 grit ball hone NOTE To produce the proper 60 cross hatch pat tern use a low RPM drill 600 RPM at the rate of 30 strokes per minute If honing oil is not available use a lightweight petroleum 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 cy...

Page 58: ...g the intake side of the engine and slide the piston pin through the piston then install the other piston circlip 3 Repeat steps 1 and 2 for the other piston 4 Install a new base gasket and the two 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 ...

Page 59: ...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 WT471A 14 Install the two left side fasteners and tighten to 7 ft lb WT143A 15 Making sure the chain stays on the crankshaft sprocket rotate the engine to TDC WT145 WT144 16 Install the exhaust cam shaft then i...

Page 60: ...NOTE Each holder has an In and Ex WT156A 20 To ensure the holders are evenly seated to the cylin der head tighten the fasteners in 24 in lb increments to a final value of 84 in lb using the pattern shown WT156B 21 Install the upper chain guide and tighten the fasteners to 7 ft lb WT159 22 Install the head wall fastener with the rubber washer and steel cup WT160 23 Install the rubber gasket onto th...

Page 61: ...wo cap screws ROV1 116A 28 Install the thermostat housing NOTE Apply a small amount of grease to the O ring before installing WT168 Bottom Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine must be removed from the...

Page 62: ...o the crankcase Account for two dowel pins and an O ring 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 108A NOTE Account for the different lengthed fasteners for assembling purposes NOTE If the technician s objective is to service or replace the flywheel or starter gear proceed to the step 7 if not continue to ...

Page 63: ...he crankcase ROV1 063 12 Remove the oil pump leaving the chain on the top sprocket Account for two dowel pins and two O rings ROV1 066 ROV1 064 13 Remove the fasteners connecting the top case half to the bottom case half ROV1 077A NOTE The fastener just above the oil filter is lon ger than the others 14 Rotate the engine and remove the cap screws secur ing the oil pan to the crankcase ...

Page 64: ...Remove the oil passage tube and oil level stick ROV1 092A 18 Remove the fasteners and washers securing the bot tom case half to the top case half ROV1 078A NOTE Bolts 1 6 are longer than the other fasteners 19 Pull the case halves apart and note the six plain bear ings in each case half NOTE Using a rubber mallet will aid in separating the case halves ROV1 088A NOTE Note the color coding on the be...

Page 65: ...nsor in place then remove the stator ROV1 059A 24 Remove the retaining ring and washer securing the water pump to the case ROV1 115A 25 Remove the impeller 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 th...

Page 66: ...he stator coil crankshaft position sensor Account for and note the position of the harness hold down under the crankshaft position sensor 3 Install the new stator coil assembly and secure with three cap screws Tighten the cap screws to 11 ft lb 4 Place the stator wire harness hold down into posi tion then install the crankshaft position sensor and secure with two cap screws Tighten securely CRANKS...

Page 67: ...d on the side surface of the case as shown Determine the replacement bearing color by following the table KC538A The crank balancer utilizes a grade letter mark The mark will be A or B located on the balancer shaft as shown Determine the replacement bearing color by fol lowing the table KC531A Installing Bottom Side Components NOTE Verify all four alignment pins are installed and all four of the a...

Page 68: ...s between the two connecting rod halves match in a straight line 3 In the top crankcase apply a suitable assembly lubri cant to the six plain bearing tops and bottoms then carefully place the crankshaft into the crank case ROV1 088A 4 Place the counterbalance shaft into the case making sure the alignment marks on the counterbalance gear and crankshaft are aligned ROV1 089A 5 Wipe off the sides of ...

Page 69: ...2 ft lb then to 36 ft lb and finally to 45 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 092A NOTE Verify the correct positioning of the wash ers 10 Place the rubber O ring into the oil pressure relief valve bore then push the oil pressure relief valve until the O ring on the valve is past the chamfer RO...

Page 70: ... O rings and dowel pins in the proper loca tions install and secure the oil pump with the appro priate fasteners Tighten to 8 ft lb ROV1 101A ROV1 063 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 ROV1 103A 15 Install the starter idler gear and pin with the smaller gear facing outward ROV1 065A 1...

Page 71: ... Tighten to 7 ft lb 20 Install the chain guide and secure with the fastener 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 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 Disa...

Page 72: ...e 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 Assembling 1 Place the cam arms thrust washers and cam arm pivot pins pivot pin heads with the direction of rota tion into the moveable drive sheave and secure with new lock nuts Tighten to 48 in lb NOTE The drive clutch rota...

Page 73: ...E The roller pins are not a serviceable item If they are damaged in any way the stationary sheave must be replaced WT193A 3 Place the moveable sheave in an appropriate driven clutch compression tool Finger tighten the wing nut and remove the spring retaining plate WT189 4 Remove the spring retaining plate cup and spring WT523 Assembling 1 Install the roller A and flat washer B then secure with the...

Page 74: ...wards the movable sheave WT191A 5 Place the stationary sheave in the movable sheave making sure the X timing marks are aligned WT526 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 With the drive clutch and driven clutch installed position ...

Page 75: ...ber engine mounts to the front engine brackets Secure the front engine brackets to the front of the crankcase assembly 1 Using a proper lifting device install the front engine mount studs into the frame In the chassis install the new lock nuts but do not tighten at this time WT515A 2 Align and install the cap screws securing the engine to the transaxle Account for a spacing washer A Apply anti sei...

Page 76: ...m clamps WT394 8 Install the coolant hose as noted when removing connecting the cylinder and the water pump WT410A WT399B 9 Connect the coolant return hose A the coolant out put hose B and the thermostat bypass hose C Secure them with the hose clamps and connect the ECT sensor D WT411A 10 Install the coil bracket to the frame and tighten securely Install the spark plug caps A then con nect the coi...

Page 77: ...tall the heat shield onto the exhaust pipe and tighten to 10 ft lb Connect the oxygen O2 sensor WT403A 14 Install the muffler and account for the gasket Secure using the exhaust springs WS111 15 Install the throttle body into the intake manifold and tighten the clamp securely Connect the ISC connec tor A TMAP sensor connector B TPS connector C and stator wires D Secure the air filter housing E wit...

Page 78: ...2 Install the drive clutch then install the driven clutch moveable sheave Tighten the cap screws to 60 ft lb 23 Using the existing flat washer install the belt and the stationary sheave of the driven clutch Tighten the cap screw to 35 ft lb 24 Install the outer clutch cover to the inner clutch cover Tighten to 5 ft lb 25 Install the left rear wheel then using a crisscross pat tern tighten the whee...

Page 79: ...harness to the left side splash panel WT364A 28 Install the rear fenders see Steering Body Controls 29 Install the vent hose gasline hose fuel pump con nector and gasline hose loom NOTE Be sure to route the gasline hose and vent hose through the hole on the right side splash panel WS106 30 Install the cargo box Tighten to 5 ft lb ...

Page 80: ...EMOVING 1 Turn the ignition switch to the OFF position then remove the ignition key 2 Remove the rear body panels and the cargo box 3 Remove the clamp on the engine intake tube and loosen the air intake clamp WT314A NOTE Removing the intake boot with the air filter housing will aid in installation 4 Loosen the throttle body clamp WT316A 5 Remove and discard the patch lock cap screws securing the a...

Page 81: ...all the throttle body fully into the boot Secure with worm clamps and tighten securely WT567A WT566A 3 Connect the ISC connector A TMAP sensor con nector B and the TPS connector C WT397A 4 Install the air filter housing in place and install the outlet boot of the housing over the throttle body Secure with the clamp 5 With the existing cap screws grommets and spacers secure the lower portion of air...

Page 82: ... discard the lock nuts securing the right side frame tube WT365A 6 Remove the four cap screws securing the seat base to the frame WT359A 7 Remove the remaining cap screws securing the frame tubes to the frame Remove both frame tubes WT360 8 Slide the gas tank slightly forward and disconnect the gasline hose vent hose and fuel pump then remove the gas tank WS106A INSTALLING 1 Place the gas tank int...

Page 83: ...cling 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 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 Informa tion Foreword clogged oil passage ...

Page 84: ...kets 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 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 ...

Page 85: ...MOVING 1 Remove the hood and grille 2 Using appropriate clamps close off the coolant hoses to the radiator and the oil hoses to the oil cooler WT455 WT459 3 Using an appropriate Allen wrench remove the 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 WT452 NOTE Opening the radiator cap will aid in drain ing the radiator 4 ...

Page 86: ...ing coolant into a suitable container WT458 NOTE If the radiator will be replaced transfer the cooling fan and oil cooler to the new radiator INSTALLING 1 Place the assembled radiator studs into the 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 WT464 2 Connect the fan motor connector and connect...

Page 87: ... 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 WT535 3 Remove the hose from the bottom of the thermostat housing and push out of the way WT547 4 Remove the t...

Page 88: ... 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 NOTE The water pump is a non serviceable com ponent It must be replaced as an assembly REMOVING NOTE If the engine is still in the vehicle drain the oil and remove the muffler exhaust pip...

Page 89: ... to 11 ft lb 6 Install the impeller cover and secure with the cap screws Tighten the screws to 11 ft lb 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 Lubrication Cooling 8 If removed install the muffler exhaust pipe and right side inner splash panel 9 If drained ad...

Page 90: ...peed impaired Condition Remedy 1 Gas contaminated 2 TPS out of adjustment 3 Throttle cable too tight 4 Throttle body dirty 1 Drain gas tank and fill with clean gas 2 Adjust TPS out of warranty or replace the throttle body under warranty 3 Adjust throttle cable and synchronize EFI system see Elec trical System 4 Clean throttle body Problem Medium or high speed impaired Condition Remedy 1 High RPM c...

Page 91: ...nd maintaining sealed batteries Always read and follow instructions provided with bat tery chargers and battery products NOTE Refer to all warnings and cautions provided with the battery or battery maintainer charger Loss of battery charge may be caused by ambient tem perature ignition OFF current draw corroded terminals self discharge frequent start stops and short engine run times Frequent winch...

Page 92: ... electrical outlet Electronic Power Steering EPS The EPS system is an electro mechanical device that uti lizes 12 volt DC power to drive a motor linked to the steering shaft to assist the driver when rotating the steer ing wheel Driver steering inputs are detected by a torque sensing transducer assembly within the EPS hous ing These inputs are converted to electronic signals by the transducer and ...

Page 93: ...ed Internal EPS condition Correct EPS condition C1317 CAN Bus Error The EPS has lost CAN communication with the EFI ECM Broken CAN wires in the main harness EFI ECM connector has been disconnected Correct EPS condition C1318 Internal CRC Error EPS internal CRC calculation condition has been detected EPS reflash has failed Battery power was lost or the key switch was turned off during EPS reflash p...

Page 94: ...e black lead grounded turn the ignition switch to the ON position The meter must show bat tery voltage 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 Igniti...

Page 95: ...nnector or the main wiring harness Switches The switch connectors are spade type connectors on the side of the master cylinder NOTE The ignition switch must be in the ON posi tion VOLTAGE Brakelight 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 WT556A 3 The meter must show battery vol...

Page 96: ...e actuator is plugged in then troubleshoot the switch ignition fuses battery connections or wiring harness VOLTAGE Reverse Override NOTE To perform the following tests the ignition switch must be in the ON position and the transmis sion shifted into reverse gear 1 Connect the red meter lead to the red green wire and the black meter lead to a suitable ground then select 2WD on the drive select swit...

Page 97: ...ution module headlight switch ignition switch or wiring harness VOLTAGE Taillight NOTE The ignition switch must be in the ON posi tion and either high beam or low beam selected on the light switch 1 Set the meter selector to the DC Voltage position 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 Br...

Page 98: ...ON 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 WT562 1 Set the meter selector to the OHMS position 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 3 Set the meter selector to the AC Voltage position NOTE The battery must ...

Page 99: ...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 Connect the sensor to the harness then using Maxi Clips 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 appr...

Page 100: ... pump building pressure If the sound is heard several 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 FI092A 3 Turn the ignition switch to the ON position The fuel pressure should build until the pump shuts off Pres sure should read 3 0 kg cm2 43 psi 4 Check for any flashing DTC Diagnost...

Page 101: ...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 WT552A 2 Secure the pump assembly with the mounting screws and tighten securely in a crisscross pattern WT552B 3 Connect the electrical connector and the gasline hose connector to the fuel pump 4 Install the passenger seat TILT SENSOR The...

Page 102: ...iagnostic mode on the LCD gauge see EFI Diagnostic System in this section Verifying TPS Adjustment Tool Before using the TPS adjustment tool verify its battery condition The battery used in the tool is a 9 volt battery To check battery condition use a digital volt ohmmeter set on DC volt scale Test between the adjustment tool black and red jacks Insert the red lead of the digital volt meter into t...

Page 103: ... 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 NOTE If any stator coil test failed replace the sta tor 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 ...

Page 104: ...he ON posi tion 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 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 oper...

Page 105: ... 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 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 EFI Diagnostic...

Page 106: ...eit or Celsius DTC P0112 P0113 P0114 Usage Verify correct output of IAT sensor NOTE After engine has been running IAT read ings will be higher than outside air temperature due to engine and engine compartment heat as well as intake manifold heating MAP AIR PRESS WT602 Display MAP in millibars and in Hg DTC P0107 P0108 Usage Verify barometric pressure signal correct NOTE Local barometric pressure i...

Page 107: ...peed sensor to ECM 2 ECM CAN signal to gauge speedometer odometer 3 ECM CAN signal to EPS DIAGNOSTIC TROUBLE CODES DTC If an EFI or related chassis component fails or an out of tolerance signal is detected by the ECM a diag nostic 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 DT...

Page 108: ... or Air Leak Sensor or interconnect harness shorted to chassis ground or an air leak exists Correct condition P0132 O2 Sensor High SP Sensor or interconnect harness shorted to battery power Correct condition P0171 O2 Feedback Below Minimum Correction Low fuel rail pressure dirty fuel filter or dirty injectors Correct condition P0172 O2 Feedback Exceeds Maximum Correction Excessive fuel rail pressu...

Page 109: ...or interconnect harness intermittent or shorted to battery power Correct condition P0630 VIN Not Programmed or Incompatible Verify the LCD gauge and ECM part numbers are correct for the vehicle model number and VIN Correct gauge and ECM VIN compatibility issue P0642 Sensor Power Circuit Low One or more of the sensors defective or shorted to chassis ground Correct condition P0643 Sensor Power Circu...

Page 110: ...eplace battery Problem Magneto overcharges Condition Remedy 1 Battery short circuited 2 Regulator rectifier defective 3 Regulator rectifier poorly grounded 1 Replace battery 2 Replace regulator rectifier 3 Clean tighten ground connection Problem Charging unstable Condition Remedy 1 Lead wire intermittently shorting 2 Magneto internally shorted 3 Regulator rectifier defective 1 Replace lead wire 2 ...

Page 111: ... 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 Sys tem If the actuator runs constantly or makes squealing or grinding sounds the actuator must be replaced REMOVING 1...

Page 112: ...ew then tighten the cap screw on the driveshaft side to 36 in lb WT532A NOTE It is important to tighten this cap screw while the others are loose to ensure proper seating of the actuator 5 Tighten the 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...

Page 113: ...b nut and discard the cotter key WT328A 8 Remove the cap screw securing the shock absorber to the upper A arm and discard the lock nut Remove the shock absorber from the upper A arm WS061A 9 Remove and discard the upper ball joint cap screw and rotate the knuckle downward and away from the drive axle WS058 10 Using a suitable strap swing the upper A arm and shock absorber upward then secure them t...

Page 114: ...ng the boot on the output shaft of the front differential WT422A 16 Pull the front differential forward until the driveshaft splines are free from the differential WT502 17 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 2 Using a rubber mallet remove the housing Account for a ...

Page 115: ...ccount for a spacer GC010 5 Remove the snap ring securing the input shaft bear ing then place the pinion housing in a press and remove the bearing GC011 AF984 KX219 Assembling Input Shaft 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 ...

Page 116: ...ommended grease 4 Install the input shaft into the pinion housing then secure in the bearing with a circlip GC009A 5 Place the pinion housing with new gasket onto the differential housing then secure with existing cap screws Tighten to 22 ft lb NOTE If a new differential housing is being installed tighten the cap screws to 28 ft lb KX209 GC004A Disassembling Differential Assembly 1 Using a T 40 to...

Page 117: ...ition of parts for assembling purposes KX175 5 Remove the left differential bearing flange assembly and account for a shim Mark the shim as left side KX177 KX178 6 Place the differential with the open side down then lift the housing off the spider assembly Account for shim s and mark as right side KX179 KX181 Disassembling Pinion Gear 1 Remove the internal snap ring securing the pinion bearing in ...

Page 118: ...ts from the gear case hous ing then discard the housing and lock collar Assembling Pinion Gear 1 Install the bearing onto the pinion shaft Install the pinion shaft collar CC882 CC883 2 Place the pinion assembly in a bearing puller then install the bearing using a press CC884 3 Using a propane torch heat the gear case housing to approximately 200 F then install the pinion assem bly 4 Install the in...

Page 119: ...se then while holding the pinion stationary rock the ring gear forward and back to determine if any backlash exists If no backlash exists install a thicker shim and recheck GC036A 3 Install the bearing flange onto the gear case cover making sure the alignment locating pin engages the locating hole in the cover then make sure the bear ing flange is completely seated in the cover GC032A GC033A 4 Ins...

Page 120: ... Play After correcting backlash ring gear end play can be adjusted To adjust end play use the following proce dure 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 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 ...

Page 121: ...ange bearing assembly and seat firmly into the cover CF266A CF267A 4 Apply a light coat of Loctite 598 to the cover face CF275A 5 Install the cover with existing cap screws coated with green Loctite 270 Tighten the cap screws evenly to 22 ft lb NOTE Grease can be applied to the O ring for ease of assembling NOTE If a new housing is being installed tighten the cap screws to 28 ft lb 6 Install the s...

Page 122: ...his procedure can be performed on a rear gear case 1 Remove the seal using a seal removal tool GC066 NOTE Prior to installing the seal apply High Per formance 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 CF278 3 Repeat steps 1 2 for the opposite side INSTALLING 1 From the right side...

Page 123: ...side of the differential 4 Install the boot clamp securing the boot to the output shaft of the front differential WT422A 5 Install the differential vent hose WT503A 6 Install the rack and pinion assembly Using new lock nuts secure it to the frame and tighten to 25 ft lb WT369A 7 Install the steering shaft dash and steering wheel 8 Install the drive axles 9 Connect the actuator harness and secure i...

Page 124: ...e slots in the nut always tighten the nut until it is properly aligned 13 Using a new lock nut secure the shock absorber to the upper A arm and tighten to 35 ft lb WS061A 14 Using new patch lock cap screws secure the brake caliper to the brake disc Tighten to 35 ft lb WS041A 15 Add SAE approved 80W 90 hypoid differential lubricant until it is visible at the level plug WS001A 16 Install the plugs w...

Page 125: ... the transaxle CF633A 7 Account for the rubber O ring WT509B 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 replace ment is necessary 1 Using a clean towel wipe away any oil or grease from the axle components CD019 2 Inspect boo...

Page 126: ... 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 out board boot NOTE In the outboard boot use the final 40 grams 1 3 of contents of grease from the pack in the bear ing 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 int...

Page 127: ...hen 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 WT328A 7 Install the wheel and tighten the wheel nuts in a crisscross pattern in 20 ft lb increments to a final torque of ...

Page 128: ...ut Seal NOTE The transaxle must be removed for this pro cedure 1 Using an awl and a mallet pry the seal from the case taking care not to damage the seal bore TA117 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 TA129 TA1...

Page 129: ...r position switch WT439A 4 Remove and discard the two lock nuts securing the transaxle to the frame WT440A 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 WT435A SEPARATING HALVES 1 With the transaxle on a bench drain the fluid into a suitable pan TA004 NOTE Tip the transaxl...

Page 130: ...hile 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 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 ...

Page 131: ...inion gear assembly TA025A 8 Pry the pinion gear assembly to remove it from the case Account for the shim 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 TA009 NOTE The pinion seal must be replaced if removed 10 Remove the inner snap ring on the front output shaft then using a mallet tap the front output shaft down into the c...

Page 132: ...gns of wear If any are present the gear must be replaced B Intermediate Shaft 1 Inspect the bearing for free and smooth turning If the bearing does not turn freely it must be replaced TA035 2 Inspect the gear teeth for nicks cracks chips or signs of wear If any are present the gear must be replaced TA036 3 Inspect the shaft gear teeth for nicks cracks chips or signs of wear If any are present the ...

Page 133: ...signs of wear If any are present the gear must be replaced TA034 3 Inspect the shaft gear teeth for nicks cracks chips or signs of wear If any are present the shaft must be replaced F Shift Drum 1 Remove the snap ring and washer then pull the cam off the shift drum TA038A 2 Inspect the cam groove for signs of wear If present replace the cam TA133A 3 Check the shaft splines for nicks cracks chips o...

Page 134: ...A 7 While holding pressure on the washer rotate the cam counterclockwise to lock the cam onto the shift drum 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 TA048 TA055 2 Inspect the gear teeth for nicks cracks chips or signs of wear If any are present the gear must be replaced TA049 ...

Page 135: ...he dogs for nicks cracks chips or signs of wear If any are present the dog must be replaced TA054 H Input Shaft 1 Inspect the bearings for free and smooth turning If either bearing does not turn freely it must be replaced TA042 TA044 2 Inspect the sprocket teeth for nicks cracks chips or signs of wear If any are present the sprocket must be replaced TA043 ...

Page 136: ...e bearing must be replaced Use the follow ing procedure 1 Using an awl pry the plug from the case Discard the plug TA084 2 Remove the small inner snap ring and account for the shim TA082A 3 With the aid of an assistant and using an appropriate driver remove the gear TA031 4 Remove the large outer snap ring and account for the shim TA086 5 Using an appropriate bearing driver press the bear ing from...

Page 137: ... the shim and install the next size smaller shim Continue until the snap ring can be installed 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 TA025A NOTE To determine the appropriate shim proceed to step 3 3 Using an appropriate tool lock the pinion gear in pla...

Page 138: ...xisting shim and install a thinner shim NOTE Continue to remove measure and install until backlash measurement is within tolerance Note the following chart 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 TA129 TA130 ASSEMBLING HALVES 1 Install the intermediate sh...

Page 139: ...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 TA062 4 Pinch the forks together and slide the rail into posi tion in the case TA063 5 Install the output gear Use slight force to seat it and ensure the gear teeth engage w...

Page 140: ...priate bearing seal protector tool onto the bearing of the output shaft 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 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 th...

Page 141: ... 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 2 Place the transaxle into position on the rear mounting studs and secure using new lock nuts Tighten to 25 ft lb WT430 3 Install the shift cable bracket and tighten to 7 ft lb 4 Connect the shift cab...

Page 142: ...ount for the washer and bushing Dis card the lock nut 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 differen tial to the frame Account for washers and discard the lock nuts WT423A 6 Remove the cap screws and lock nuts securing the carrier bearing housing to the frame Discard the lock n...

Page 143: ...aft Slide the front driveshaft rearward and remove it from the vehicle WT422A 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 WT431A 1...

Page 144: ...er the shaft and snap them into position 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 5 Apply molybdenum grease to the splines on b...

Page 145: ... ft lb steel wheel 60 ft lb aluminum wheel w black nuts or 80 ft lb aluminum wheel w chrome nuts 12 Install the hood seats center console floor and engine 13 Remove the vehicle from the stand Hub REMOVING 1 Secure the vehicle on a support stand to elevate the wheel then remove the wheel 2 Remove the hub nut securing the hub and discard the cotter pin 3 Remove the brake caliper WS041A 4 Remove the ...

Page 146: ... an appropriate flange nut PR250 3 Using a socket and ratchet handle tighten the nut until the stud is fully drawn into the hub PR252A INSTALLING 1 Using a suitable press press in the new bushing WT598 2 Place the hub in a bench vise and using a 16 mm reamer ream out the bushings WT595 3 Insert the sleeve into the hub and apply molybdenum grease to the inside of the seals Install the seals on the ...

Page 147: ...sed 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 sig nificantly lowering the boiling point This increases the chance of vapor lock reducing braking power and increasing stopping distance 3 Remove the brake hose from the caliper and close the bleed screw then remove the caliper 4 Compress the caliper holde...

Page 148: ...the seals from the brake caliper housing then remove the four O rings from the brake caliper housing noting the location of the different sized O ring 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 b...

Page 149: ...on the side of the jam screw 5 Install the caliper onto the caliper holder WS090 6 Making sure the brake fluid does not contact the brake pads compress the caliper holder towards the caliper and install the inner brake pad then the outer pad WS098 7 Install jam screw and tighten to 9 ft lb 8 Place the brake caliper assembly into position and secure with new patch lock cap screws Tighten the calipe...

Page 150: ...e 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 PR237A NOTE If brake pads are to be returned to service do not allow brake fluid to contaminate them PR238 5 Remove the caliper holder from the caliper and dis card the O ring PR239B NOTE The O ring is used for shipping purposes and provides no fun...

Page 151: ...the piston surface for scoring discoloration or evidence of binding or galling 5 Inspect the caliper holder for wear or bending ASSEMBLING INSTALLING 1 Install new seals into the brake caliper housing and apply a liberal amount of DOT 4 brake fluid to the cylinder bore of the housing seals and brake piston PR715 PR717A 2 Press the piston into the caliper housing using hand pressure only Completely...

Page 152: ...black nuts or 80 ft lb aluminum wheel w chrome nuts 10 Remove the vehicle from the support stand and ver ify 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 cylinde...

Page 153: ...t 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 WT513A 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 Ti...

Page 154: ...ct improper 3 Bearing damaged 4 Gears worn chipped 5 Splines worn 1 Adjust backlash 2 Adjust contact 3 Replace bearing 4 Replace gears 5 Replace shaft s Problem Braking poor Condition Remedy 1 Pad worn 2 Brake fluid leaking 3 Master cylinder brake cylinder seal worn 1 Replace pads 2 Repair leak s 3 Replace seal s Problem Brake pedal travel excessive Condition Remedy 1 Brake fluid low 2 Piston seal...

Page 155: ...pecial tools are available from the Arctic Cat Service Department Shock Absorbers 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 NOTE When ride height adjustment is required raise the vehicle to release all load from the shock absorbers 1 Measure from the ground to the bottom ...

Page 156: ... Remove the two cap screws and nuts securing each shock absorber to the frame and A arms Account for the spacers and O rings from each DISASSEMBLING Sport XT NOTE It is very important to measure the preload with a tape measure before disassembling in order to return the spring to the proper preload setting WC901A NOTE Only the external parts are serviceable If the shock absorber is damaged it must...

Page 157: ...nd secure the snap ring WC904 3 Tighten the lock ring until preload is at the measure ment noted during cleaning and inspecting then tighten the lock ring set screw securely NOTE When tightening the lock ring the spring retainer must be past the snap ring retainer WC909 INSTALLING 1 Place the spacers and O rings where appropriate into shock eyelet then install shocks with two cap screws and nuts 2...

Page 158: ...e top spring WS107 NOTE Note the orientation of the spring retainer for installing purposes 5 Clean all of the shock absorber components in a parts cleaning solvent 6 Inspect each shock rod for nicks pits rust bends and oil residue 7 Inspect all of the spring retainers shock rods spring couplers shock bodies and eyelets for cracks leaks or bends ASSEMBLING Limited Rear 1 With the proper orientatio...

Page 159: ...scross pattern tighten the wheel nuts in 20 ft lb increments to a final torque of 40 ft lb steel wheel 60 ft lb aluminum wheel w black nuts or 80 ft lb aluminum wheel w chrome nuts and remove the vehicle from the stand 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...

Page 160: ...ll joint WS062 NOTE Remove the ball joint only if replacement is necessary REMOVING LOWER 1 Remove the front bumper NOTE The front bumper will need to be removed to remove the lower A arm cap screw from the frame 2 Remove the cap screw and discard the lock nut securing the lower A arm to the frame Remove the A arm WS067A WS068A 3 Remove the seals and inspect for cracks nicks or tears 4 Place the A...

Page 161: ...t Tighten to 40 ft lb 4 Install the upper A arm to the frame with the cap screw and new lock nut Finger tighten only at this point WS066 5 Route the brakeline hose above the upper A arm and secure it with the clips Tighten to 30 in lb 6 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...

Page 162: ...nal torque of 40 ft lb steel wheel 60 ft lb alumi num wheel w black nuts or 80 ft lb aluminum wheel w chrome nuts 13 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...

Page 163: ... securing the sway bar link to the lower A arm WS080A 9 Remove the cap screws securing the lower A arm to the hub and frame Discard the nuts Remove the A arm WS086A NOTE The drive axle does not need to be removed for this procedure CLEANING AND INSPECTING 1 Clean all A arm components in parts cleaning sol vent 2 Inspect the A arm for bends cracks and worn bush ings 3 Inspect the frame mounts for s...

Page 164: ...iper to the hub using new patch lock cap screws Tighten to 20 ft lb 6 Install the shift cable onto the transaxle secure with the E clip A and tighten the jam nut B to 8 ft lb WS081C 7 Install the shock and secure with the cap screws and new lock nuts Tighten to 35 ft lb WS075A 8 Install the wheel and tighten the wheel nuts in 20 ft lb increments to a final torque of 40 ft lb steel wheel 60 ft lb a...

Page 165: ...h soap and water 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 a final torque of 40 ft lb steel wheel 60 ft lb aluminum wheel w black nuts or 80 ft lb aluminum wheel w chrome nuts CHECKING INFLATING 1 Using an air pressure gauge mea...

Page 166: ... worn 1 Adjust preload 2 Replace bushing Problem Suspension noisy Condition Remedy 1 Cap screws suspension system loose 2 A arm related bushings worn 1 Tighten cap screws 2 Replace bushings Problem Vehicle pulling or steering erratic Condition Remedy 1 Vehicle steering is erratic on dry level surface 2 Vehicle pulls left or right on dry level surface 1 Check front wheel alignment and adjust if nec...

Page 167: ...166 NOTES ...

Page 168: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2260 646 2015 Arctic Cat Inc Effective November 2015 ...