Arctic Cat WILDCAT 4X, Service Manual

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

Page 2: ...Left Side Components 56 Servicing Left Side Components 58 Installing Left Side Components 60 Right Side Components 62 Removing Right Side Components 63 Servicing Right Side Components 64 Installing Right Side Components 70 Center Crankcase Components 71 Separating Crankcase Halves 71 Disassembling Crankcase Half 72 Servicing Center Crankcase Components 74 Assembling Crankcase Half 81 Joining Crank...

Page 3: ...efficiency and to improve clarity At the time of publication all information photographs and illustrations were technically correct Some photo graphs 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 sub...

Page 4: ... Bar Arm 35 48 Sway Bar Link Lower Trailing Arm 35 48 Trailing Arm Cross Mount min 60 81 Trailing Arm Cross Mounts Frame 60 81 Shock Absorber Lower Trailing Arm 35 48 Shock Absorber Upper Frame 40 54 Knuckle Lower Trailing Arm min 60 81 Knuckle Upper Trailing Arm 35 48 Upper Lower Lateral Link Knuckle 40 54 Upper Lower Lateral Link Frame 40 54 CHASSIS ROPS ASSEMBLY Shift Lever Shift Axle Bracket 2...

Page 5: ...tch 10 14 Magneto Cover Crankcase 10 14 Crankshaft Spacer Crankshaft 28 38 Oil Pump Drive Gear Crank Balancer Shaft 62 84 Rotor Flywheel Nut Crankshaft 107 145 Cam Sprocket Camshaft 10 14 V Belt Cover Inner Clutch Cover 9 5 13 Secondary Drive Gear Nut Secondary Drive Output Shaft 200 270 Oil Filter Engine 8 5 11 5 Shift Cam Stopper Support Crankcase 8 5 11 5 Shift Cam Stopper Spring Shift Cam Stop...

Page 6: ... 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 Tighten all nuts bolts cap screws and screws Care must be taken that all calibrated nuts cap screws and bolts are tightened to specifications 8 Fill the cooling system to the bottom of the stand pipe in the radiator neck with properly mixed coolant 9 Discon...

Page 7: ... 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 tightened to specifications 10 Make sure the steering moves freely and does not bind 11 Check the spark plugs Clean or replace as necessary 12 Check the air filter and the air filter housing Clean or re...

Page 8: ...f the filter frame WC024A 3 Fill 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 inne...

Page 9: ... nut and rotate the tappet adjuster screw until the clear ance is within specifications Tighten each jam nut securely after completing the adjustment CC007D ADJUSTING A Place the Valve Clearance Adjuster onto the jam nut securing the tappet adjuster screw then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw B While holding the valve adjuster dial in pl...

Page 10: ...ull open position crank the engine over with the electric starter until the gauge stops climbing five to 10 compression strokes Compression should be 190 220 psi NOTE If the throttle is not held in the full open position compression reading can be low 6 If compression is abnormally low verify the follow ing A Battery is fully charged and in good health B Starter cranks engine over normal speed C G...

Page 11: ...ain the oil into a drain pan Account for and discard the gasket PR078A 4 Using the Oil Filter Wrench and a ratchet handle or a socket or box end wrench remove the old oil fil ter Account for and discard the O ring 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 secure...

Page 12: ...d gear lube as necessary To change the lubricant use the following procedure 1 Place the vehicle on level ground 2 Remove each fill plug 3 Drain the lubricant into a drain pan by removing the drain plug from the gear case WC020B 4 After all the lubricant has been drained install the drain plugs and tighten to 45 in lb 5 Pour the appropriate amount of recommended lubri cant into the fill hole 6 Ins...

Page 13: ...e with new lock nuts Tighten securely then connect the electrical connector CHECKING ADJUSTING HEADLIGHT AIM The headlights can be adjusted vertically The geometric center of the HIGH beam light zone is to be used for ver tical aiming 1 Position the vehicle on a level floor so the headlights are approximately 6 1 m 20 ft from an aiming sur face wall or similar aiming surface 0748 171 NOTE The tire...

Page 14: ...rake System CHECKING BLEEDING The hydraulic brake system has been filled and bled at the factory To check and or bleed a hydraulic brake sys tem use the following procedure 1 With the master cylinder in a level position check the fluid level in the reservoir If the level in the res ervoir is not above the MIN add DOT 4 brake fluid PR095 2 Depress the brake pedal several times to check for a firm b...

Page 15: ...rake pads wear The only maintenance that is required is replacement of the brake pads when they show excessive wear Check the thick ness of each of the brake pads as follows 1 Remove a wheel 2 Measure the thickness of each brake pad PR242 3 If thickness of either brake pad is less than 1 0 mm 0 039 in the brake pads must be replaced NOTE The brake pads should be replaced as a set 4 To replace the ...

Page 16: ...ly burnished To properly burnish the brake pads use the following procedure 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 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 REMOVING 1 Raise the rear of the vehicle...

Page 17: ...t Side Components steps 10 13 1 Making sure the directional arrow on the belt is aligned with engine rotation place the new drive belt in place on the drive clutch then making sure the X marks are aligned install the movable sheave on the driven clutch WC667 WC810A 2 Secure the driven clutch with the cap screw A washer B and alignment shim s C then tighten to 60 ft lb WC741A 3 Place the alignment ...

Page 18: ...3 Reach up through the front fender wells and remove two fender screws D from the rear of the hood and remove the hood INSTALLING 1 Lay the hood in place on the frame then install the rear fender screws D 2 Install the two side fender screws C then place the grille on the vehicle and install the two machine screws B and fender screws A Tighten all fasten ers securely Front Bumper Assembly REMOVING...

Page 19: ...isassem 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 the steering wheel for cracks missing pad ding or broken spokes 2 Inspect the splines for wear 3 Check that the steering wheel is not bent INSTALLING 1 Inst...

Page 20: ...2 Remove two fender screws behind the headlights and two fender screws at the rear of the hood then remove the hood WC241A 3 Unplug the two connectors from the EPS unit then remove four cap screws and two lock nuts from the steering flex shaft clamp bracket and clamp WC242A 4 Remove the U clamp then remove the bracket 5 Loosen the Allen head cap screw securing the steer ing rack input coupler to t...

Page 21: ...assembly INSTALLING EPS 1 Install the EPS mounting bracket onto the EPS unit and secure with the four cap screws Tighten to 35 ft lb 2 Mark the ends of the EPS input and output shafts to correspond with the flat splined segment then align the flat splined segment of the output shaft with the slot in the rack input coupler and install the EPS into the vehicle WC254A WC249A 3 Rock the EPS assembly t...

Page 22: ...eering flex shaft hold down strap and tighten the cap screw to 50 in lb WC247A 10 Connect the two electrical connectors and check EPS operation 11 Install the hood and grille REMOVING RACK AND PINION ASSEMBLY 1 Remove the hood and grille then remove the EPS assembly 2 Remove the front differential assembly see Drive and Brake Systems 3 Remove the cotter pins and nuts securing the tie rods to the s...

Page 23: ...e steering input shaft up through the shaft opening then rotate the assembly forward and into position on the front mounting bracket WC279A 2 Secure the assembly to the frame with four cap screws and tighten to 25 ft lb WC260A 3 Install the upper mounting bracket in the frame and secure with new patch lock cap screws Tighten to 20 ft lb WC278A 4 Connect the tie rods to the steering rack and secure...

Page 24: ...t of the upper steering support housing and remove from the vehicle Account for a flat washer and a wave washer WC326 WC337A INSPECTING 1 Check that the steering flex shaft rotates freely in the housing with no sticking or binding 2 Check the splines for wear or any signs of twisting 3 Check the housing for cuts cracks or kinks 4 If the assembly is serviceable remove the flex shaft and lubricate w...

Page 25: ...lar onto the tilt housing and tighten the nuts to 20 ft lb WC339A 5 Install the steering flex shaft coupler onto the EPS input shaft aligning the flat splined segment of the shaft to the slot in the coupler then install the U clamp on the lower sheering shaft housing and secure with two nuts Tighten to 7 ft lb WC251A WC252A WC242 6 Install the upper steering flex shaft hold down strap and secure w...

Page 26: ...ut 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 9 Remove the snap ring securing the bearing in the knuckle then press the bearing out of the knuckle CLEANING AND INSPECTING 1 Clean all knuckle components 2 Inspect the bearing for pits scoring rusting or pre mature wear 3 Inspect the knuckle for crac...

Page 27: ... hub WC317A NOTE If the hub plate cannot be fully installed due to misalignment of the hub nut tighten the nut until properly aligned and plate is fully installed 9 Install the wheels and 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 10 Remove the vehic...

Page 28: ...e the center console leaving the shift lever boot in the console 3 Remove the nut from the shift cable pivot bolt then remove the four machine screws from the shift lever axle mounting and remove the shift lever WC348A INSTALLING 1 Place the shift lever into position and secure with the four machine screws threads coated with blue Loc tite 243 Tighten to 20 ft lb 2 Connect the shift cable to the s...

Page 29: ...racket and finger tighten jam nut B then connect the cable to the shift arm pivot bolt and secure with the nut A Tighten the nut to 8 ft lb 4 Place the lower cable housing end into the mounting bracket on the engine and finger tighten jam nut D then connect cable E to the shift arm and install the E clip C 5 Install any necessary cable ties as marked during removal then check adjust the shift cabl...

Page 30: ...o box to the mounts and remove the cargo box WC346B INSTALLING 1 Set the cargo box into position on the cargo box mounts then secure with the six fender screws Tighten securely 2 Install the rear body panel Seats REMOVING INSTALLING X 1 To remove a seat pull the seat lock lever up Raise the rear of the seat and tilt it forward WC017A 2 To install a seat slide the front of the seat into the seat re...

Page 31: ...134A WC109A 2 To move latch forward or aft loosen the screws on the latch plate After adjustment tighten securely WC133A CHECKING ADJUSTING X Limited 1 Loosen the screws 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 Af...

Page 32: ... the roof over the top of the ROPS Install the P clamps in the proper locations onto the ROPS 3 Secure the roof to the P clamps using the cap screws washers and new lock nuts NOTE The lip of the roof faces the rear of the vehicle WC812 ...

Page 33: ...rings worn broken 4 Frame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Replace shock absorber Problem Steering impaired Condition Remedy 1 Tire pressure too high 2 Steering linkage connections worn 3 Cap screws suspension system loose 1 Adjust pressure 2 Replace connections 3 Tighten cap screws Problem Tire wear rapid or unev...

Page 34: ...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 35: ...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 Rocker arm rocker arm shaft worn 4 Camshaft worn 1 Adjust clearance 2 Replace spring s 3 Replace arm shaft 4 Replace camshaft Problem Engine noisy Noise seems to come from pisto...

Page 36: ...lled contaminated 3 Piston rings cylinder worn 4 Valve guides worn 5 Cylinder wall scored 6 Valve stems worn 7 Stem seals defective 1 Drain gas replace with clean gas 2 Drain excess oil change oil 3 Replace service rings cylinder 4 Replace guides 5 Replace cylinder 6 Replace valves 7 Replace seals Problem Engine lacks power Condition Remedy 1 Gasoline bad 2 Valve clearance incorrect 3 Valve spring...

Page 37: ...the front output drive flange then remove the starter cable WC187C 5 Remove all nuts and screws securing the rear body panel then loosen the gas tank fill hose clamp and remove the cover forward through the ROPS tubes Seal the fill hose to prevent contamination of gas or vapor escaping WC186 6 Remove the cargo box then disconnect the gasline hose connector from the fuel pump and separate the fuel ...

Page 38: ...ses yet WC350A WC192 WC193 12 Remove the radiator mounting screws then discon nect the coolant hoses from the engine and remove the radiator from the vehicle being careful not to release the clamps Coolant can remain in the radia tor WC197A 13 Remove the CVT cooling outlet duct then remove the screws securing the air filter mounting bracket to the CVT housing WC935 WC934A 14 Loosen the inlet boot ...

Page 39: ...ils and injectors WC203A 17 Remove the ECT connector A front coil primary connector B TPS connector C TMAP connector D and ISC connector E then tie the engine har ness out of the way WC204A WC206A 18 Remove the engine ground cable WC936A 19 Loosen the throttle body boot clamp then remove the throttle body leaving the throttle cable attached WC210A 20 With the heat shield removed remove the E clip ...

Page 40: ... be necessary to use a hoist to slightly raise the rear of the vehicle to free the link from the frame weldment 24 Remove two through bolts and one cap screw secur ing the rear drive gear case then reattach the lateral link and remove the hoist if used WC170A WC169A 25 Using a suitable engine lift and equalizer sling sup port the engine then remove the engine through bolts front first followed by ...

Page 41: ...ose components The technician should use discretion and sound judgment NOTE The engine transmission does not need to be removed for this procedure Removing Top Side Components A Valve Cover Rocker Arms B Cylinder Head Camshaft 1 Remove the timing inspection plug spark plugs and magneto housing cover then install the 10 mm cap screw left hand threads in the crankshaft and rotate the desired cylinde...

Page 42: ...n place Note the two rubber washers on the remaining cap screws 5 Remove the valve cover Account for and note the orientation of the cylinder head plug Note the loca tion of the two alignment pins GZ162 GZ132A 6 Remove the cap screw on the end of the tensioner then using a flat blade screwdriver turn the tensioner clockwise to remove the tension Remove the two cap screws securing the tensioner adj...

Page 43: ...the cylinder head CC266D NOTE Loop the chain over the cylinder head and secure it to keep it from falling into the crankcase GZ408 10 Remove the five nuts securing the cylinder head to the cylinder then remove the four cylinder head cap screws and washers NOTE Removing the starter will simplify removal of the front cylinder base nuts GZ209A 11 Remove the cylinder head from the cylinder remove the ...

Page 44: ...the cylinder then remove the union from the cylinder Account for an O ring GZ140A 14 Remove the two nuts securing the cylinder to the crankcase GZ141A GZ160A 15 Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase Account for the gasket and two alignment pins GZ142 GZ144 AT THIS POINT To service valves and cylinder head see Servicing Top Side Compon...

Page 45: ...right metallic finish Correct any high spots before assem bly by continuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained CC130D 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 ...

Page 46: ...e a lower spring seat and valve guide seal over each valve guide CC144D 2 Insert each valve into its original location 3 Install the valve springs with the painted end of the spring facing away from the cylinder head NOTE If the paint is not visible install the ends of the springs with the closest wound coils toward the head ATV 1011A 4 Place a spring retainer over the valve springs then using the...

Page 47: ...ide diameter at each end and in the center If measurement exceeds specifica tions the piston pin must be replaced ATV 1070 2 Insert an inside dial indicator into the piston pin bore The diameter must not exceed specifications Take two measurements to ensure accuracy ATV 1069 Measuring Piston Skirt Cylinder Clearance 1 Measure the cylinder front to back in six places CC127D 2 Measure the correspond...

Page 48: ...l a uniform bright metallic finish is attained 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 specifications CC141D Cleaning Inspecting Cylinder 1 Wash the cylinder in parts cleaning solvent...

Page 49: ... 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 CC390D 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...

Page 50: ... in the piston NOTE The piston should be installed so the arrow points toward the exhaust of the respective cylinder GZ166 2 Place the two alignment pins into position Place the cylinder gasket into position with a drop of silicone sealant at the front and rear crankcase junction then place a piston holder or suitable substitute beneath the piston skirt and square the piston in respect to the cran...

Page 51: ...tion on the cylinder while guiding the cam chain through the cylinder head GZ151 8 Install the cylinder head cap screws Tighten only until snug GZ132B 9 Loosely install the five cylinder head nuts 10 In a crisscross pattern tighten the four cylinder head cap screws from step 8 initially to 20 ft lb then increase to 30 ft lb and finally to 37 ft lb Tighten the 8 mm nut from step 9 to 21 ft lb then ...

Page 52: ...mshaft They must be parallel to the valve cover mating surface If rotating the camshaft is necessary for alignment rotate the sprocket inside the chain until the alignment pin can be engaged in the sprocket with the camshaft properly aligned to the head GZ519 14 Seat the cam sprocket onto the camshaft making sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket then ...

Page 53: ... the engine forward 270 until rear piston is at TDC indi cated by timing mark R GZ059 20 With the alignment pin installed in the rear camshaft loosely place the cam sprocket with the recessed side facing the cam shaft lobes onto the camshaft At this point do not seat the sprocket onto the shaft 732 307B GZ130 NOTE At this point oil the camshaft bearings cam lobes and the three seating journals on ...

Page 54: ...obes directed down toward the piston C Camshaft alignment marks parallel to the valve cover mating surface D Recessed side of the sprocket directed toward the cam lobes E Camshaft alignment pin and sprocket alignment hole smallest are aligned 23 Place tab washer onto the sprocket making sure it covers the pin in the alignment hole ATV 1027 24 Install the first cap screw threads coated with red Loc...

Page 55: ...ensioner clockwise until the screw bottoms and the adjuster shaft is held in place CD501 NOTE The adjuster shaft will be drawn into the tensioner as the adjuster screw is rotated clockwise The adjuster shaft tension will be released in step 31 30 Place the chain tensioner adjuster assembly and gas ket into position on the cylinder and secure with the two cap screws CD469 31 Using a flat blade scre...

Page 56: ...ssure on them 35 Install the valve cover cap screws with rubber wash ers then install the remaining cap screws Tighten only until snug CC003D 36 In a crisscross pattern starting from the center and working outward tighten the cap screws on both valve covers to 8 5 ft lb 37 Adjust valve tappet clearance see Periodic Mainte nance Tune Up 38 Place the tappet covers into position on the valve cover ma...

Page 57: ...e starter motor starter driven gear A starter countershaft bushing B and starter counter shaft gear C then remove the starter gear shafts D noting the longer shaft is nearest the starter WC917A NOTE The starter is not serviceable and must be replaced as a complete assembly 3 Remove the rotor flywheel nut then install the appropriate crankshaft protector into the crankshaft H2 018 4 Install Magneto...

Page 58: ... 9 Make match marks on the shift arm and shift shaft for installing purposes then remove the cap screw shift select arm and gear position switch from the shift shaft GZ416 10 With the heat shield removed remove the cap screws securing the gear shift cover to the crankcase then remove the gear shift cover Account for a gasket and dowel pins H2 013A 11 Remove the nut A from the shift cam stopper sup...

Page 59: ...e replaced 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 it must be replaced FI569 3 Inspect the one way bearing for chipped surfaces missing rollers or discoloration If any of the above conditions exist replace the starter clutch assembly FI572 REPLACING S...

Page 60: ...1 Inspect the stator coil for burned or discolored wir ing broken or missing hold down clips or loose cap screws 2 Inspect the bearings in the magneto housing for dis coloration roughness when rotated and secure fit in bearing bores REPLACING STATOR COIL CRANKSHAFT POSITION SENSOR 1 Remove the three cap screws securing the stator coil two cap screws securing the crankshaft position sen sor and two...

Page 61: ...nd sealant from mating surfaces 2 Install a new O ring on the oil filler cover and coat it with clean engine oil then install the oil filler cover into the crankcase and secure with the cap screws Tighten to 8 ft lb GZ250 3 Clean the countershaft and trigger splines thoroughly and install the inner snap ring onto the shaft then apply green Loctite 620 to the trigger and counter shaft splines and i...

Page 62: ... housing and secure with the cap screws Tighten in a crisscross pattern to 8 ft lb H2 020 9 Install the gear position switch then align and install the shift select arm to the shift shaft using the match marks as a guide GZ416 10 Install the heat shield tighten the fasteners to 20 ft lb 11 With the O ring lightly coated with grease and prop erly positioned install the water pump Secure using the t...

Page 63: ...unting cap screws to 8 ft lb GZ251 17 Using Seal Protector Tool install the outer magneto cover using a new gasket and secure with the cap screws Using the pattern shown tighten to 8 ft lb GZ212B Right Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discret...

Page 64: ... an appropriate clutch puller remove the drive clutch WC666A 4 Remove the drive belt 5 Remove the fixed driven sheave 6 Remove and discard the cap screws securing the V belt housing to the crankcase then remove the V belt housing Account for two alignment pins WC664A 7 Remove the cap screws securing the clutch cover then using a rubber mallet carefully remove the cover Account for two alignment pi...

Page 65: ... holding the cover remove the three remaining screws equally WC659 WC658 2 Remove the cover spring and nylon shift stop WC657 WC656A NOTE Some models were produced without a shift stop and instead feature a threaded nut At this point on these models no further disassembling should be performed For models with a shift stop proceed to step 3 GZ529 3 Remove the windage plate then position the drive c...

Page 66: ...aded area will aid in clutch disassembly The heat will loosen the Loctite used during assembly 7 Remove the drive clutch from the clutch holder 8 Remove the spider idler sleeve needle bearing and thrust washers from the fixed drive sheave hub WC647A NOTE The spider is a non serviceable component If damaged or worn parts are found the clutch assembly must be replaced MS405 Cleaning and Inspecting N...

Page 67: ...timing marks then making sure the cam arms are properly posi tioned drop the spider into position in the moveable sheave 3 Place the movable sheave spacer washers and spi der into position on the stationary sheave hub Make sure all threads are clean and free of oily residue Apply Loctite Primer 7649 and allow to dry per instructions then apply red Loctite 277 to the threads of the stationary sheav...

Page 68: ... the wing nut to tighten WC638 2 Remove the driven cam then remove the spider assembly WC636 WC635 3 Remove the E clips securing the cam rollers to the spider then remove the thrust washer and roller WC628 NOTE The relief in the roller is directed towards the spider 4 Remove the spring and movable sheave 5 Using a suitable punch remove the roller pin secur ing the roller axle in movable sheave the...

Page 69: ... the sheaves together lining up the X marks WC811 4 Place the roller onto the spider beveled side of roller facing in then install the thrust washer and E Ring WC677A 5 Place the insert and spider onto the bearing assembly WC670 6 Insert the bearing assembly with spider insert into the spider making sure to line up the X marks WC672 7 Place the spring and spider into the movable sheave making sure...

Page 70: ...ver GZ441 Inspecting 1 Inspect the water pump drive housing A for scoring or discoloration GZ440A 2 Inspect the bearing B for smooth rotation and no discoloration or scoring 3 Inspect the gear C for chipped or missing teeth excessive hub wear or excessive wear in the drive pin slot 4 Inspect the drive pin D and driveshaft E for excessive wear or looseness Assembling 1 Install the bearing in the wa...

Page 71: ...isting bearing retainers and machine screws threads coated with blue Loctite 242 Tighten to 8 ft lb GZ508 4 With the gasket and alignment pins in position install the clutch cover and secure with the existing cap screws Tighten to 8 ft lb GZ528A 5 Making sure the alignment pins are correctly installed place a bead of silicone sealant on the mat ing surfaces of the V belt housing and install the ho...

Page 72: ...If belt clearance is too small add additional shims to gain the desired clearance If belt clearance is too large remove shims to gain the desired clearance 11 Install the cap screw A washer B and shim s C Tighten the screw to 60 ft lb 12 Repeat steps 8 11 until proper clearance is achieved 13 Place the CVT cover gasket into position then with the two alignment pins in position install the cover an...

Page 73: ...is required If disassembled secondary gear sets will have to be reset for backlash and gear contact see Servicing Center Crankcase Components sub section 4 Remove one cap screw from the right side crankcase and eight cap screws from the left side crankcase then using a rubber mallet separate the crankcase halves leaving all components in the right side case Account for a thrust washer on the crank...

Page 74: ...then remove the drive idler GZ299A 3 Rotate and align the water pump idler shaft flat sur face towards the open end of the snap ring then remove the snap ring securing the water pump idler shaft C in the crankcase Remove the shaft and bearings GZ463A 4 Remove the snap ring securing the oil pump driven gear D to the oil pump driveshaft then remove the gear Account for a drive pin and washer GZ463B ...

Page 75: ...isassembled the initial set up must be performed to establish correct gear tooth contact If only the secondary output driveshaft or secondary output driven gear are replaced proceed to Correct ing Backlash in this sub section 1 Install a new bearing A onto the secondary driven shaft B making sure the bearing locating groove is directed away from the driven gear splines MT011A 2 Using a suitable pr...

Page 76: ...rectly shim the driven shaft 7 After correct tooth contact is established proceed to Checking Backlash in this sub section Checking Backlash 1 Install the drive bevel gear assembly and driven bevel gear output shaft assembly into the crankcase bottom cover 2 Mount the dial indicator so the tip is contacting a tooth on the secondary drive bevel gear FW 008 3 Firmly hold the bearing down and while r...

Page 77: ...ten to 200 ft lb The output drive assembly is now ready for installation FW 006 OIL PUMP ASSEMBLY Disassembling and Inspecting 1 Remove the oil pump cover then remove the gerotor set shaft and pin see Disassembling Crankcase Halfin this sub section 2 Inspect the crankcase for scoring discoloration or cracks in the gerotor bore If scored crankcase assembly must be replaced GZ357 3 Inspect the gerot...

Page 78: ...set separate the inner rotor from the outer rotor and with the ref erence dot directed toward the oil pump cover place the rotor on the shaft then install the drive pin and push the shaft into the rotor GZ356 GZ363 3 With the outer rotor reference dot directed toward the oil pump cover install the rotor onto the inner rotor GZ360 4 Place a new O ring seal on the outside of the oil pump cover The o...

Page 79: ...ting Rod Big End Side to Side 1 Push the lower end of the connecting rod to one side of the crankshaft journal 2 Using a feeler gauge measure the gap between the connecting rod and crankshaft journal 3 Acceptable gap range must be within specifications Measuring Crankshaft Runout 1 Place the crankshaft on a set of V blocks 2 Mount a dial indicator and base on the surface plate Position the indicat...

Page 80: ...2 3 Remove the reverse driven gear dog GZ313A 4 Remove the snap ring securing the reverse driven gear and washer then remove the washer and gear GZ314 5 Remove the reverse driven washer then remove the low driven gear locking washer GZ320 GZ319 CAUTION When disassembling the countershaft care must be taken to note the direction each major component dog gear faces If a major component is installed ...

Page 81: ...ing then install the low driven gear and washer GZ317A GZ318 2 Install the low driven gear locking washer then install the inner reverse driven gear washer GZ319B GZ320B 3 Install the reverse driven bushing and bearing then install the reverse driven gear GZ286A GZ287 4 Install the outer reverse driven washer then secure the reverse driven gear assembly with a snap ring ...

Page 82: ...allation Assembling Crankcase Half 1 Install the oil pump gerotor assembly and oil pump cover in the crankcase and secure with two cap screws Coat the threads with red Loctite 271 and tighten securely to 8 ft lb GZ305 2 Install a flat washer drive pin and drive gear onto the oil pump shaft then secure with a snap ring flat side away from the gear GZ347 3 Install the countershaft into the crankcase...

Page 83: ...mp and countershaft gears 6 Install the driveshaft then with a flat washer on each end of the reverse idler assembly install into the crankcase GZ332 GZ333 7 Install the gear shift shaft into the crankcase making sure the flat washer is in place on the right case end and the spacer on the gear shift stop end DE677A GZ335 8 Place the larger flat washer on the drive gear end of the countershaft and ...

Page 84: ...ed toward the crankshaft GZ341 3 Install the two alignment pins then apply a thin bead of silicone sealant to the crankcase mating surface NOTE When applying silicone make sure to keep clear of all oil galleys and ports Do not over apply sil icone GZ345C 4 Carefully join the crankcase halves by placing the left side crankcase onto the assembled right side Secure with the cap screws eight left side...

Page 85: ...OTE If the secondary drive driven assemblies have been disassembled refer to Servicing Center Crankcase Components sub section for proper gear tooth contact and backlash 6 Install the locating ring in the crankcase assembly then install the secondary driven shaft assembly and secondary drive assembly making sure the locating ring and bearing engage correctly GZ269A GZ448A 7 Make sure the locating ...

Page 86: ...front drive shaft and loosely install at least one cap screw then work the engine down into the mounting brackets 4 Install the engine mounting through bolts with flat washer rear first then front Tighten new lock nuts to 40 ft lb 5 Support the rear of the vehicle then remove the lat eral link pivot bolt drop the lateral link down and install the upper through bolt on the rear drive gear case Rein...

Page 87: ...A WC925A WC362A 10 Install the heat shield tighten the fasteners to 20 ft lb 11 Making sure the tab on the throttle body aligns and fully engages the alignment slot on the intake boot install the throttle body and tighten the clamp nut to 30 in lb then install the engine ground cable and tighten to 8 ft lb WC164A WC210A 12 Connect the ECT connector A front coil primary connector B TPS connector C ...

Page 88: ...ing screws then connect and secure the cool ant hoses with the clamps Tighten securely 19 Connect the fan connectors rear spark plug cap and rear coil primary connector 20 Install the gas tank cradle and gas tank and secure with the hold down bracket then connect the fuel hose and fuel pump fuel level sensor connector 21 Install the heat shield and secure with the appropriate fasteners then instal...

Page 89: ...e rear body panel with the appropriate fas teners then pour in the prescribed engine oil and connect the negative battery cable Install the battery cover and seats 27 Start the engine allowing it to warm up for a few minutes then shut the engine off and check for leaks Check all fluid levels and correct as necessary 28 On the 4X install the rear center console then install the seat belt anchors an...

Page 90: ... panel then remove the cargo box 4 Remove the two screws securing the heat shield to the radiator cooling fan assembly WC351B 5 Remove the two upper radiator support mounting screws then while holding the heat shield away from the radiator tip the radiator back and secure with an appropriate holding strap such as a tarp strap WC212 6 Remove the air filter housing strap Loosen the air filter to thr...

Page 91: ...tall the battery cover and seats 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 the 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 a...

Page 92: ...ing for this test 1 Remove the oil hose from the fitting nearest the oil filter base WC222A 2 Using a suitable T fitting connect Oil Pressure Test Kit to the oil fitting and hose Tighten all clamps securely NOTE Some oil seepage may occur when installing the oil pressure gauge Wipe up oil residue with a cloth 3 Place the transmission in park and start the engine Allow the engine to warm up to oper...

Page 93: ...stem 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 upper coolant pipe or the water pump 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...

Page 94: ... when removing and secure with the appropriate hose clamps Tighten the mounting cap screws securely 2 Connect the spark plug wire and primary coil con nector then secure the heat shield to the radiator frame 3 Connect the cooling fan connectors then press the wiring harness anchors into the appropriate loca tions WC919B 4 Install the cargo box see Steering Body Controls 5 Pour the proper mixture a...

Page 95: ...g system with the recommended amount of antifreeze Check for leakage Fans 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 NOTE The water pump is a non serviceable com ponent It must be replaced as an ass...

Page 96: ...for the initial 5 10 minutes stop the engine allow the engine to cool down and check the coolant level Add coolant as necessary Problem Starting impaired Condition Remedy 1 Gas contaminated 1 Drain gas tank and fill with clean gas Problem Idling or low speed impaired Condition Remedy 1 TPS out of adjustment 1 Adjust TPS Problem Medium or high speed impaired Condition Remedy 1 High RPM cut out agai...

Page 97: ...ing and 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 ...

Page 98: ...wing is a list of DTCs possible conditions and causes NOTE If no active codes are present on the LCD or verified through CATT II and the vehicle is experi encing steering related issues there may be a mechanical steering related issue In this case the EPS is not be the cause of the issue Components that may contribute to this type of issue could be abnormal tire wear bad wheel bearings ball joints...

Page 99: ...cation 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 programming EPS must be reprogrammed C1319 Boot Counter Exceeded EPS internal application code co...

Page 100: ...ts Ignition Coil The ignition coils are mounted to the lower radiator frame rear cylinder and the forward heat shield front cylinder Remove the rear body panel and cargo box to access the coils Primary Voltage 1 Set the meter selector to the DC Voltage position then disconnect the connector from the coil to be tested 2 Connect the red tester lead to the orange wire and the black tester lead to gro...

Page 101: ... EFI fuse EFI relay 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 Brakelight 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 con nect the black tester lead to the other ter...

Page 102: ... The meter must show less than 1 DC volt Fan Motor NOTE To determine if the fan motor is good con nect the red wire from the fan connector to a 12 volt battery then connect the black wire from the fan con nector to ground The fan should operate WT558A NOTE Fan motor resistance checks are not recom mended Resistance values change with the motor commutator position Lights VOLTAGE Headlights The conn...

Page 103: ...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 from one side of the connector terminal ends...

Page 104: ... turn the ignition switch to the ON position 3 Connect the black tester lead to the pink black wire and the red tester lead to the orange blue 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 ...

Page 105: ...ose grease then secure the sensor with the Allen head cap screw threads coated with blue Loctite 242 Tighten securely CD071 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 ...

Page 106: ... fuel pump 4 Mark the components for assembling purposes and remove the screws securing the fuel pump to the gas tank WC226 5 Carefully remove the fuel pump fuel level sender assembly from the gas tank then tape over the open ing Inspecting 1 Inspect the fuel screen and blow clean with low pres sure compressed air 2 Move the float lever and check for free movement The float assembly should return ...

Page 107: ...tester lead to the pink black wire then turn the ignition switch ON and observe the meter The meter should read 0 3 2 9 DC volts 4 Tilt the sensor 60 or more to the left and right observing the meter The meter should read 3 0 8 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 afte...

Page 108: ...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 With the vehicle off the gauge should read 0 48 0 52 and at Wide Open Throttle it should read up to approximately 3 69 WC772 Adjusting 1 Loosen the screw securing the TPS to the throttle body 2 Adjust the TPS until the correct reading is obtained then tight...

Page 109: ...ier The regulator rectifier is located under the hood above the differential Verify all other charging system compo nents before the regulator rectifier is replaced TESTING 1 Start engine and warm up to normal operating tem perature 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...

Page 110: ...ections starter motor lead battery voltage at the battery or starter solenoid Starter Relay 1 Remove the battery cover then using the multimeter set to the DC Voltage position check the relay as fol lows 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 WC937A NOTE ...

Page 111: ... a diagnostic tool for many of the DTC s displayed To place the gauge into the diagnostic mode use the following procedure 1 Turn the ignition switch ON 2 Depress and hold both Mode and Set buttons together for approximately 10 seconds after which the letters dIAg will appear on the LCD momen tarily followed by COOL EFI033A NOTE The display on the gauge will display in SAE speedometer in MPH mode ...

Page 112: ...nal from the fuel level sensor measured in ohms DTC C1400 C1401 C1402 Usage Check output of the fuel level sensor 1 Full fuel is indicated by a reading of 86 100 ohms 2 Empty is indicated by a reading of 0 5 ohms 110 500 ohms suspect the fuel level sensor or wiring 0 100 ohms but no fuel gauge indication suspect the fuel gauge Tachometer tACH Diagnostic Mode EFI030 Display Engine RPM DTC P0336 P03...

Page 113: ...t Diagnostic Mode EFI025 Display System DC voltage DTC P0562 P0563 P2531 P2532 Usage Verify system voltage under following condi tions 1 Battery voltage with engine and accessories off 12 2 VDC for fully charged 2 Battery voltage with engine running charging 13 8 VDC or greater 3 Battery voltage with electrical accessories operating engine idling 13 5 VDC or greater 4 Battery voltage starter crank...

Page 114: ...ceeds Maximum Correction Excessive fuel rail pressure MAP or temp sensors out of spec Correct condition P0219 Engine Over Speed Condition Engine speed RPM has exceeded the ECM over speed set point limit Reduce engine speed P0231 Fuel Pump Relay Circuit Low SG Open Relay removed or interconnect harness shorted to chassis ground Correct condition P0232 Fuel Pump Relay Circuit High Relay or interconn...

Page 115: ...t condition P0643 Sensor Power Circuit High One or more of the sensors defective or shorted to battery power Correct condition P2300 Ignition Coil 1 Primary Circuit Low SG Open Ignition coil 1 or interconnect harness open or shorted to chassis ground Correct condition P2301 Ignition Coil 1 Primary Circuit High Ignition coil 1 or interconnect harness shorted to battery power Correct condition P2303...

Page 116: ...tor rectifier 4 Replace battery Problem Battery overcharges Condition Remedy 1 Internal battery short circuited 2 Regulator rectifier resistor damaged defective 3 Regulator rectifier poorly grounded 1 Replace battery 2 Replace resistor 3 Clean tighten ground connection Problem Charging unstable Condition Remedy 1 Lead wire intermittently shorting 2 Magneto internally shorted 3 Regulator rectifier ...

Page 117: ...or makes squealing or grinding sounds the actuator must be replaced REMOVING 1 Select LOCK on the drive select switch then discon nect the connector on the actuator harness 2 Using a T 30 torx wrench remove the mounting cap screw from the driveshaft side of the actuator WC938A 3 Remove the mounting cap screw from below the actuator on the suspension side WC940A 4 Loosen but do not remove the mount...

Page 118: ... 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 inner fender panel Front Differential REMOVING 1 Remove the forward belly panel X or seats and center console 4X then drain the lubricant from the differential 2 Using an appropriate jack or lift raise the vehicle so t...

Page 119: ...in on the axle shaft while pulling outward on the axle coupler and remove the axle assembly from the differential PR729C 8 On the X from underneath the vehicle remove the carrier bearing support bracket then remove the bolts and nuts securing the carrier bearing to the bracket and remove the bracket WC265A WC266A 9 Disconnect the drive line coupler by removing three nuts from the Allen head bolts ...

Page 120: ...d lower through bolts then slide the differential rearward and lay it on the right side Remove from the vehicle from either left or right side WC277 Disassembling Input Shaft 1 Using a T 40 torx wrench remove the cap screws securing the pinion housing GC004A 2 Using a rubber mallet remove the housing Account for a gasket Remove the fork collar and spring Note the location of all the components for...

Page 121: ... to the outside GC012 GC011 2 Install the input shaft seal making sure it is fully seated in the edge of the housing GC014 3 Lubricate the input shaft with High Performance 2 Molybdenum Disulphide Grease packing the boot ribs and splines then assemble allowing excess grease to freely escape Slight pressure on the boot will be present during assembly Secure with new clamps NOTE Any time drive splin...

Page 122: ...housing Account for the coupler fork and spring differential only GC015 2 Using a T 40 torx wrench remove the cap screws securing the differential cover 3 Using a plastic mallet tap lightly to remove the dif ferential cover Account for an O ring KX174 NOTE If the cover is difficult to remove pry on the cover in more than one recessed location 4 Remove the splined coupler shifter fork pin and sprin...

Page 123: ...the housing WC430 2 Using the Pinion Gear Shaft Removal Tool and a hammer remove the pinion gear from the gear case housing 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 CC879 4 Remove any reusable parts from the gear case hous ing then discard the housing and lock collar Assembling Pinion Gear 1 Install the beari...

Page 124: ...th front differ ential or rear drive gear case NOTE All bearings must be installed in the gear case and the pinion properly installed before proceed ing 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 GC031A 2 Install the ring gear with shim in the gear case then while holding the pin...

Page 125: ...n GC036B 5 Place the appropriate 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 GC040 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 specifi...

Page 126: ...backlash and end play are established the gear case can be assembled see Assembling Differential Assembly in this sub section 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 GC031A GC020 2 Place the ...

Page 127: ...evenly to 23 ft lb NOTE Grease can be applied to the O ring for ease of assembling NOTE If a new housing is being installed tighten the cap screws to 28 ft lb 6 Install the shift fork shaft w spring into the housing making sure the shaft O ring is positioned to the inside CC892 7 Install the shift fork assembly making sure the fork leg is facing upward Apply a small amount of oil to the gasket the...

Page 128: ...n its right side and place in the frame of the vehicle then turn it upright and maneuver into the mounting brackets WC277 2 Apply molybdenum grease to the splines and install the forward driveshaft into the differential splined coupler then install the three Allen head bolts in the driveshaft coupler and tighten to 50 ft lb WC267A 3 Install the two through bolts and secure the differen tial with n...

Page 129: ...the splines then install the front axles into the differential pushing in on the axle shafts to seat the splines into the differen tial PR729C 9 Install the axles into the knuckles then swing the knuckles vertical and engage the ball joint shanks into the knuckles While holding the ball joint securely in the knuckle secure with a new patch lock cap screw Tighten to 35 ft lb WC272 WC271 10 Install ...

Page 130: ...til the lubricant shows on the threads of the level hole then install the fill level plug and tighten to 16 ft lb 16 Install the hub caps then install the forward belly panel Remove the jack stands and lower the vehi cle Driveshaft 4X REMOVING DISASSEMBLING 1 Remove the front and rear seats WC722A 2 Remove the battery access panel shift knob front and rear console and front seat belts Make sure to...

Page 131: ...ar bearing assembly Accounting for an O ring on the splined end of the shaft 9 Remove the shaft then remove the remaining Allen head screws and nuts NOTE Inspect the rubber coupler for deteriorating rubber or augured holes WC697A 10 Slide the bearing housing off of the shaft NOTE The set screws face the splined end of the shaft WC689 11 Check the bearing housing for any cracks Check the bearing to...

Page 132: ...en the set screw at this time 3 Using the existing hardware connect the bearing housing to the bracket Tighten to 35 ft lb Do not tighten set screws at this time WC697A 4 Place the rear driveshaft in position then using new Allen head screws connect the front and rear cou plers Starting with rear coupler tighten to 50 ft lb 5 Remove the set screws on the front and rear bearing housing and apply on...

Page 133: ...the brake caliper WC268A 4 Remove the hub assembly 5 Leaving the lower trailing arm connected to the knuckle remove the upper trailing arm and lateral links from the knuckle then move the top of the knuckle outward and rotate forward to disengage the axle from the axle bearing WC282B WC286A 6 Remove the rear axles from the rear drive gear case by pushing the axle shaft toward the gear case and pul...

Page 134: ...re 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 CF337 2 Place the end of the CV joint into a vise as shown CF335 3 To disengage the axle from the CV joint sharply pull back on the axle then slide the boot off of the axle CF334 NOTE Steps 1 3 can be used to replace the out ...

Page 135: ...e but do not tighten then connect the lower lateral link and upper lateral links to the knuckle Tighten the upper trailing arm cap screw and the lateral link bolts to 40 ft lb WC282B 4 Install the hub brake disc assemblies onto the axles and apply Loctite primer and red Loctite 277 to the axle threads 5 Engage the hub nut into the Belleville washer on the convex side then with the concave side of ...

Page 136: ...tion select LOCK on the drive select switch Turn the ignition switch to the OFF position 6 Tighten the axle nut from step 3 to 250 ft lb then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut WC281 7 Install the wheels and 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 w...

Page 137: ... gear 2 Remove the thrust button from the gear case cover left hand threads Account for a shim Inspecting 1 Inspect the ring gear for excessive wear missing or chipped teeth or discoloration 2 Inspect the thrust button for excessive wear or dis coloration 3 Inspect the bearings for discoloration roughness or excessive wear NOTE For servicing bearings or seals see Front Differential in this section...

Page 138: ...specified repeat steps 1 and 2 using thicker clearance too great or thinner clear ance too small until correct specification is reached REAR DRIVE INPUT SHAFT HOUSING Removing Disassembling 1 Remove the cap screws securing the rear drive input shaft housing to the rear gear case then remove the input housing assembly GZ183 2 Remove the clutch pack from the clutch basket then remove the snap ring s...

Page 139: ...he clutch pack is not a serviceable compo nent If worn discolored or damaged in any way it must be replaced Assembling Installing 1 Install a new bearing into the input housing and secure with the snap ring flat side directed away from bearing GZ184 2 Using a suitable seal driver install a new oil seal into the front of the input housing until the seal is flush with the housing GZ182A 3 Apply grea...

Page 140: ...e splined shaft then install the lower front and upper rear through bolts Do not tighten at this time NOTE Make sure all spacers are correctly located at the gear case mounting points 4 Install the boot clamp on the drive coupler then install the lower frame gear case bracket and mount ing cap screw Do not tighten at this time WC295A 5 Install the lower lateral links and secure with the bolts and ...

Page 141: ...her and hub nut securing the hub WC304 3 Remove the brake caliper WC268 WC606 4 Remove the hub assembly 5 Remove the four cap screws securing the brake disc PR254A NOTE It may be necessary to heat the cap screws to loosen the Loctite 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 4 Inspec...

Page 142: ... side then with the concave side of the washer directed toward the hub install the nut and washer Keeping the nut and washer engaged tighten the hub nut to 250 ft lb WC303A WC769A 4 Install the hub plate making sure it fits completely over the nut and lies flat against the hub WC317A NOTE If the hub plate cannot be fully installed due to misalignment of the nut tighten the nut until prop erly alig...

Page 143: ...ads from the caliper WC694 5 Cover the piston end of the housing with cardboard or 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 four seal rings in the housing WC941 6 Using an appropriate seal removal tool carefully remove the seals from the brake caliper housing then remove four O rings from the ...

Page 144: ... the caliper holder against the caliper oppo site 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 function in operation 6 Co...

Page 145: ...lling 5 Inspect the caliper holder or anchor bolts for wear or bending ASSEMBLING INSTALLING Rear Brake 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 seat the piston then wipe off any excessive b...

Page 146: ...rque of 40 ft lb steel wheel 60 ft lb aluminum wheel w black nuts or 80 ft lb aluminum wheel w chrome nuts 10 Remove the vehicle from the support stand and ver ify brake operation ASSEMBLING INSTALLING Front Brake 1 Install new seals and O rings into the brake caliper housing and apply DOT 4 brake fluid to the cylinder bores and pistons WC723A WC725A 2 Install the pistons into the caliper seating ...

Page 147: ...riodic Maintenance Tune Up 7 Install the wheels and 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 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 tu...

Page 148: ...ose for cracks and deterioration and the condition of the banjo fittings Installing 1 Place the master cylinder into position then using new crush washers secure the banjo fitting and brakelight switch to the master cylinder Tighten to 20 ft lb 2 Secure the master cylinder assembly to the frame with two cap screws Tighten to 25 ft lb 3 Install the pivot pin and secure with a new cotter pin 4 Fill ...

Page 149: ...Replace shaft 3 Replace coupling 4 Replace joint 5 Replace gear s 6 Replace gears pinions 7 Replace fuse drive select switch front drive actuator Problem Braking poor Condition Remedy 1 Pad worn 2 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 cup wo...

Page 150: ...towards the position for more compres sion stiffer or the position for less compression softer WC910 REMOVING 1 Secure the vehicle on a support stand to elevate the wheels and release the load on the suspension 2 Remove the two cap screws and nuts securing each front shock absorber to the frame and the lower A arm 3 Remove the two cap screws and nuts securing each rear shock absorber to the frame ...

Page 151: ...ring screw securely NOTE When tightening the lock ring the spring retainer must be past the snap ring retainer WC909 CHECKING ADJUSTING RIDE HEIGHT X Limited 4X Limited NOTE Ensure the vehicle is on level ground the tires are properly inflated and there is an average operating load in the vehicle Front 1 Measure from the ground to the bottom of the outer frame tube WC911A 2 If measurement is not a...

Page 152: ...order to return the spring to the proper preload setting WC786A WC789C NOTE Only the external parts are serviceable If the shock absorber is damaged it must be replaced 1 Loosen but do not remove the lock ring screw WC778A WC789A 2 Loosen the lock ring towards the top of the shock until there is no pressure on the springs WC778B Model Front Rear Wildcat X EPS 13 75 13 5 Wildcat 4X 13 75 13 5 Wildc...

Page 153: ...ll of the spring retainers shock rods spring couplers shock bodies and eyelets for cracks leaks or bends ASSEMBLING X Limited 4X Limited Front 1 With the proper orientation slide the top spring spring coupler and spring support plate up to the lock ring WC786B 2 Install the main spring up to the spring support plate 3 With the lower support plate in position install the spring retainer WC795 4 Ins...

Page 154: ...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 Remove the vehicle from the stand Front A Arms REMOVING 1 Secure the vehicle on a support stand to elevate the front wheels then remove the wheels and account for the hub plate NOTE The upper A arms can be removed without remo...

Page 155: ...ings 4 Inspect the ball joint mounting holes for cracks or damage 5 Inspect the frame mounts for signs of damage wear or weldment damage INSTALLING 1 Apply Loctite Primer T to the A arm socket then apply green Loctite 609 to the entire outside diame ter of the ball joint Install the ball joint into the A arm and secure with the snap ring WC237 WC359 2 Install the A arm assemblies into the frame mo...

Page 156: ...aking sure it fits completely over the nut and lies flat against the hub WC317A NOTE If the hub plate cannot be fully installed due to misalignment of the hub nut tighten the nut until properly aligned and plate is fully installed 12 Install the wheels and 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 bl...

Page 157: ...ot then remove the for ward cross mount bolt and remove the lower trailing arm WC305A INSPECTING 1 Inspect the arm for any signs of metal fatigue cracked or broken welds or severe dents or gouges 2 Check the pivot seals and bushings for signs of dirt or water contamination and corrosion 3 Check the knuckle pivot bushing for excessive wear 4 Check the shock mount for wear or fatigue cracks where we...

Page 158: ...king sure it fits completely over the nut and lies flat against the hub WC317A NOTE If the hub plate cannot be fully installed due to misalignment of the hub nut tighten the nut until properly aligned and plate is fully installed 9 Install the wheels and 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 blac...

Page 159: ...ts Install the hub cap 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 NOTE If repair is needed follow the instructions found on the tire repair kit or replace the tire Troubleshooting WARNING Do not operate the vehicle if tire dama...

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