2014 Arctic Cat Wildcat Wildcat X Wildcat 4 Wildcat 4x Rov Service Repair Workshop Manual Download
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2014 Arctic Cat Wildcat Wildcat X Wildcat 4 Wildcat 4x Rov Service Repair Workshop Manual Download
FOREWORD :
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2014 Arctic Cat Wildcat models (see cover). The complete manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections. Each section covers a specific vehicle component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions.
When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. The service technician should become familiar with the operation and construction of each component or system by carefully studying this manual.
- This manual will assist the service technician in becoming more aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of serious personal injury or even death.
- A CAUTION identifies unsafe practices which may result in vehicle-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the vehicle. The symbol NOTE: identifies supplementary information worthy of particular attention.
- The symbol AT THIS POINT directs the technician to certain and specific procedures to promote efficiency and to improve clarity. At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
- Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred. All materials and specifications are subject to change without notice. Keep this manual accessible in the shop area for reference. Product Service and Warranty Department Arctic Cat Inc.
TABLE OF CONTENTS:
2014 Arctic Cat Wildcat Wildcat X Wildcat 4 Wildcat 4x Rov Service Repair Workshop Manual Download
FRONT COVER ...................................................................................................................................... 1 FOREWORD ......................................................................................................................................... 2 TABLE OF CONTENTS................................................................................................................................. 3 General Information........................................................................................................................... 4 General Specifications.................................................................................................................... 4 Torque Specifications..................................................................................................................... 5 Torque Conversions (ft-lb/N-m)............................................................................................................ 6 Drive Belt Break-In Procedure............................................................................................................. 6 Gasoline - Oil - Lubricant................................................................................................................ 6 RECOMMENDED GASOLINE.................................................................................................................. 6 RECOMMENDED ENGINE/ TRANSMISSION OIL.................................................................................................. 6 RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT................................................................................... 6 FILLING GAS TANK...................................................................................................................... 7 Genuine Parts............................................................................................................................. 7 Preparation For Storage................................................................................................................... 7 Preparation After Storage................................................................................................................. 7 Periodic Maintenance/ Tune-Up................................................................................................................. 8 SPECIAL TOOLS............................................................................................................................. 8 Periodic Maintenance Chart................................................................................................................ 8 Lubrication Points........................................................................................................................ 9 Air Filter................................................................................................................................ 9 CLEANING AND INSPECTING FILTER........................................................................................................ 9 CHECKING AND CLEANING DRAINS.......................................................................................................... 9 Valve/Tappet Clearance.................................................................................................................... 9 Feeler Gauge Procedure................................................................................................................ 10 Valve Adjuster Procedure.............................................................................................................. 10 Testing Engine Compression................................................................................................................ 10 Spark Plugs............................................................................................................................... 11 Muffler/Spark Arrester.................................................................................................................... 11 Engine/Transmission Oil - Filter.......................................................................................................... 12 OIL - FILTER.......................................................................................................................... 12 Front Differential - Rear Drive Lubricant................................................................................................. 13 Driveshaft/Coupling....................................................................................................................... 13 Nuts/Bolts/Cap Screws..................................................................................................................... 13 Headlight/Taillight- Brakelight........................................................................................................... 13 CHECKING/ADJUSTING HEADLIGHT AIM...................................................................................................... 14 Shift Lever/Shift Cable................................................................................................................... 15 CHECKING.............................................................................................................................. 15 ADJUSTING............................................................................................................................. 15 Hydraulic Brake System.................................................................................................................... 15 CHECKING/BLEEDING..................................................................................................................... 15 INSPECTING HOSES...................................................................................................................... 16 CHECKING/REPLACING PADS (Wildcat)..................................................................................................... 16 CHECKING/REPLACING PADS (X/ Wildcat 4/4X)............................................................................................. 16 BRAKE DISC............................................................................................................................ 17 Burnishing Brake Pads..................................................................................................................... 17 Replacing V-Belt.......................................................................................................................... 18 REMOVING.............................................................................................................................. 18 INSTALLING............................................................................................................................ 18 Steering/Frame/Controls....................................................................................................................... 20 Hood...................................................................................................................................... 20 REMOVING.............................................................................................................................. 20 INSTALLING............................................................................................................................ 20 Front Bumper Assembly (X/4X/Limited)...................................................................................................... 20 REMOVING.............................................................................................................................. 20 CLEANING AND INSPECTING............................................................................................................... 20 INSTALLING............................................................................................................................ 20 Rear Body Panel........................................................................................................................... 20 REMOVING.............................................................................................................................. 20 INSTALLING............................................................................................................................ 21 Electronic Power Steering (EPS)........................................................................................................... 21 REMOVING.............................................................................................................................. 21 INSTALLING............................................................................................................................ 22 Rack and Pinion Assembly.................................................................................................................. 24 REMOVING.............................................................................................................................. 24 INSPECTING............................................................................................................................ 24 INSTALLING............................................................................................................................ 24 Steering Wheel............................................................................................................................ 25 REMOVING.............................................................................................................................. 25 INSPECTING............................................................................................................................ 25 INSTALLING............................................................................................................................ 25 Steering Shaft............................................................................................................................ 26 REMOVING.............................................................................................................................. 26 INSPECTING............................................................................................................................ 27 INSTALLING............................................................................................................................ 27 Steering Knuckles......................................................................................................................... 28 REMOVING AND DISASSEMBLING............................................................................................................ 28 CLEANING AND INSPECTING............................................................................................................... 28 ASSEMBLING AND INSTALLING............................................................................................................. 28 Checking/Adjusting Front Wheel Alignment.................................................................................................. 29 Accelerator Pedal......................................................................................................................... 30 REMOVING.............................................................................................................................. 30 INSTALLING............................................................................................................................ 30 Shift Lever............................................................................................................................... 30 REMOVING.............................................................................................................................. 30 INSTALLING............................................................................................................................ 31 Shift Cable............................................................................................................................... 31 REMOVING.............................................................................................................................. 31 INSTALLING............................................................................................................................ 31 LCD Gauge/Indicator Lights/Dash Switches.................................................................................................. 31 REPLACING............................................................................................................................. 31 Exhaust System............................................................................................................................ 32 REMOVING MUFFLER...................................................................................................................... 32 INSPECTING MUFFLER.................................................................................................................... 32 INSTALLING MUFFLER.................................................................................................................... 32 Cargo Box................................................................................................................................. 32 REMOVING.............................................................................................................................. 32 INSTALLING............................................................................................................................ 32 Seats..................................................................................................................................... 32 REMOVING/INSTALLING (Wildcat/X)....................................................................................................... 32 REMOVING/INSTALLING (Wildcat 4/ 4X)................................................................................................... 32 Doors..................................................................................................................................... 33 CHECKING/ADJUSTING (Wildcat/X)........................................................................................................ 33 CHECKING/ADJUSTING (Wildcat 4/4X)..................................................................................................... 33 CHECKING/ADJUSTING (X Limited)........................................................................................................ 34 Roof (X Limited).......................................................................................................................... 34 REMOVING/INSTALLING................................................................................................................... 34 Troubleshooting........................................................................................................................... 35 Engine/Transmission........................................................................................................................... 36 SPECIAL TOOLS............................................................................................................................. 36 Troubleshooting........................................................................................................................... 37 Removing Engine/ Transmission (Wildcat/X)................................................................................................. 39 Removing Engine/ Transmission (Wildcat 4/ 4X)............................................................................................. 43 Top-Side Components....................................................................................................................... 48 Removing Top-Side Components.............................................................................................................. 48 A. Valve Cover/Rocker Arms B. Cylinder Head/Camshaft.................................................................................. 48 C. Cylinders D. Pistons............................................................................................................... 50 Servicing Top-Side Components............................................................................................................. 52 VALVE ASSEMBLY........................................................................................................................ 52 Cleaning/Inspecting Valve Cover....................................................................................................... 52 Removing Valves....................................................................................................................... 52 Measuring Valve Stem Runout........................................................................................................... 52 Measuring Valve Stem Outside Diameter................................................................................................. 53 Measuring Valve Face/Seat Width....................................................................................................... 53 Measuring Valve Face Radial Runout.................................................................................................... 53 Measuring Valve Guide/Valve Stem Deflection (Wobble Method)........................................................................... 53 Measuring Valve Guide (Inside Diameter)............................................................................................... 53 Servicing Valves/Valve Guides/Valve Seats............................................................................................. 53 Measuring Rocker Arm (Inside Diameter)................................................................................................ 53 Measuring Rocker Arm Shaft (Outside Diameter)......................................................................................... 53 Installing Valves..................................................................................................................... 54 PISTON ASSEMBLY....................................................................................................................... 54 Removing Piston Rings................................................................................................................. 54 Cleaning/Inspecting Piston............................................................................................................ 54 Measuring Piston-Ring End Gap (Installed)............................................................................................. 54 Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore........................................................................... 54 Measuring Piston Skirt/Cylinder Clearance............................................................................................. 55 Installing Piston Rings............................................................................................................... 55 CYLINDER/CYLINDER HEAD ASSEMBLY....................................................................................................... 56 Cleaning/Inspecting Cylinder Head..................................................................................................... 56 Measuring Cylinder Head Distortion.................................................................................................... 56 Cleaning/Inspecting Cylinder.......................................................................................................... 56 Inspecting Cam Chain Guide............................................................................................................ 57 Measuring Camshaft Runout............................................................................................................. 57 Measuring Camshaft Lobe Height........................................................................................................ 57 Inspecting Camshaft Bearing Journal................................................................................................... 57 Measuring Camshaft to Cylinder Head Clearance......................................................................................... 57 Inspecting Camshaft Spring/Drive Pin (Front Camshaft Only)............................................................................ 58 Installing Top-Side Components............................................................................................................ 58 A. Pistons B. Cylinders............................................................................................................... 58 C. Cylinder Head D. Valve Cover....................................................................................................... 59 Left-Side Components...................................................................................................................... 65 Removing Left-Side Components............................................................................................................. 65 A. Magneto Cover/Stator Coils B. Water Pump C. Shifter Assembly D. Rotor/Flywheel/Starter Clutch E. Speed Sensor/ Trigger Assembly.... 65 Servicing Left-Side Components............................................................................................................ 68 INSPECTING STARTER CLUTCH/ GEAR....................................................................................................... 68 REPLACING STARTER CLUTCH ASSEMBLY..................................................................................................... 68 REPLACING STARTER GEAR BEARING........................................................................................................ 69 INSPECTING STATOR COIL/ MAGNETO COVER ASSEMBLY........................................................................................ 69 REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR..................................................................................... 69 Installing Left-Side Components........................................................................................................... 70 Right-Side Components..................................................................................................................... 72 Removing Right-Side Components............................................................................................................ 72 A. CVT Cover B. Drive Clutch C. Driven Clutch D. Inner Clutch Cover................................................................... 72 Servicing Right-Side Components........................................................................................................... 73 DRIVE CLUTCH.......................................................................................................................... 73 Disassembling......................................................................................................................... 73 Cleaning and Inspecting............................................................................................................... 75 Assembling............................................................................................................................ 75 DRIVEN CLUTCH......................................................................................................................... 76 Disassembling......................................................................................................................... 76 WATER PUMP DRIVE ASSEMBLY............................................................................................................. 78 Disassembling......................................................................................................................... 78 Inspecting............................................................................................................................ 79 Assembling............................................................................................................................ 79 Installing Right-Side Components.......................................................................................................... 79 Center Crankcase Components............................................................................................................... 81 Separating Crankcase Halves............................................................................................................... 81 Disassembling Crankcase Half.............................................................................................................. 82 Servicing Center Crankcase Components..................................................................................................... 84 SECONDARY OUTPUT DRIVE GEARS.......................................................................................................... 84 Initial Set-Up........................................................................................................................ 84 Checking Backlash..................................................................................................................... 85 Correcting Backlash................................................................................................................... 85 OIL PUMP ASSEMBLY..................................................................................................................... 86 Disassembling and Inspecting.......................................................................................................... 86 Assembling............................................................................................................................ 86 CRANKSHAFT ASSEMBLY................................................................................................................... 87 Measuring Connecting Rod (Small End Inside Diameter).................................................................................. 87 Measuring Connecting Rod (Small End Deflection)....................................................................................... 87 Measuring Connecting Rod (Big End Side-to-Side)....................................................................................... 87 Measuring Crankshaft (Runout)......................................................................................................... 87 Measuring Crankshaft (Web-to- Web).................................................................................................... 88 COUNTERSHAFT.......................................................................................................................... 88 Disassembling......................................................................................................................... 88 Assembling............................................................................................................................ 89 Assembling Crankcase Half................................................................................................................. 91 Joining Crankcase Halves.................................................................................................................. 92 Installing Engine/ Transmission (Wildcat/X)............................................................................................... 94 Installing Engine/ Transmission (Wildcat 4/ 4X)........................................................................................... 97 Fuel/Lubrication/Cooling......................................................................................................................101 SPECIAL TOOLS.............................................................................................................................101 TROUBLESHOOTING...........................................................................................................................101 Throttle Body.............................................................................................................................101 REMOVING..............................................................................................................................101 INSTALLING............................................................................................................................102 Gas Tank..................................................................................................................................102 REMOVING..............................................................................................................................102 INSTALLING............................................................................................................................103 Gas/Vent Hoses............................................................................................................................103 Oil Filter/Oil Pump.......................................................................................................................103 TESTING OIL PUMP PRESSURE.............................................................................................................103 REMOVING/DISASSEMBLING................................................................................................................103 CLEANING AND INSPECTING...............................................................................................................103 ASSEMBLING/INSTALLING.................................................................................................................103 Oil Cooler................................................................................................................................104 REMOVING..............................................................................................................................104 CLEANING AND INSPECTING...............................................................................................................104 INSTALLING............................................................................................................................104 Liquid Cooling System.....................................................................................................................104 Radiator..................................................................................................................................104 REMOVING..............................................................................................................................104 INSTALLING............................................................................................................................105 Thermostat................................................................................................................................105 REMOVING..............................................................................................................................105 INSPECTING............................................................................................................................105 INSTALLING............................................................................................................................106 Fans......................................................................................................................................106 REMOVING..............................................................................................................................106 INSTALLING............................................................................................................................106 Water Pump................................................................................................................................106 REMOVING..............................................................................................................................106 INSTALLING............................................................................................................................106 Fuel Pump/Fuel Level Sensor...............................................................................................................107 TESTING...............................................................................................................................107 REMOVING..............................................................................................................................107 INSPECTING............................................................................................................................107 INSTALLING............................................................................................................................108 Troubleshooting...........................................................................................................................109 Electrical System.............................................................................................................................110 SPECIAL TOOLS.............................................................................................................................110 TESTING ELECTRICAL COMPONENTS.............................................................................................................110 Battery...................................................................................................................................110 Maintenance Charging..................................................................................................................110 Charging..............................................................................................................................111 RPM Limiter...............................................................................................................................111 Accessory Receptacle/ Connector...........................................................................................................111 VOLTAGE...............................................................................................................................111 Brakelight Switch.........................................................................................................................111 VOLTAGE (Wiring Harness Connector)....................................................................................................111 RESISTANCE (Switch Connector).........................................................................................................112 Engine Coolant Temperature (ECT) Sensor...................................................................................................112 Fan Motor.................................................................................................................................112 RESISTANCE (Fan Motor Connector)......................................................................................................112 Power Distribution Module (PDM)...........................................................................................................112 FUSES/RELAYS..........................................................................................................................112 Ignition Coil.............................................................................................................................113 VOLTAGE (Primary Coil)................................................................................................................113 RESISTANCE............................................................................................................................113 Primary Winding.......................................................................................................................113 Secondary Winding.....................................................................................................................113 Spark Plug Cap........................................................................................................................113 Manifold Absolute Pressure/Inlet Air Temperature (MAP/IAT) Sensor.........................................................................113 Speed Sensor..............................................................................................................................114 Electronic Power Steering (EPS)...........................................................................................................114 Ignition Switch...........................................................................................................................116 VOLTAGE...............................................................................................................................116 Headlight Switch..........................................................................................................................116 VOLTAGE...............................................................................................................................116 Drive Select Switch.......................................................................................................................116 RESISTANCE............................................................................................................................116 VOLTAGE...............................................................................................................................117 Reverse Override Switch...................................................................................................................117 VOLTAGE...............................................................................................................................117 Front Drive Actuator......................................................................................................................117 VOLTAGE...............................................................................................................................117 Stator Coil/Crankshaft Position (CKP) Sensor..............................................................................................117 VOLTAGE (AC Generator - Regulated Output).............................................................................................118 VOLTAGE (AC Generator - No Load)......................................................................................................118 RESISTANCE (AC Generator).............................................................................................................118 RESISTANCE (Crankshaft Position Sensor)...............................................................................................118 AC VOLTAGE............................................................................................................................118 Crankshaft Position Sensor............................................................................................................118 Starter Motor.............................................................................................................................118 REMOVING..............................................................................................................................118 INSTALLING............................................................................................................................118 TESTING VOLTAGE.......................................................................................................................118 Starter Relay.............................................................................................................................119 Engine Control Module (ECM)...............................................................................................................119 Regulator/Rectifier.......................................................................................................................119 TESTING...............................................................................................................................119 Headlights................................................................................................................................120 VOLTAGE...............................................................................................................................120 Taillight-Brakelight......................................................................................................................120 VOLTAGE (Taillight)...................................................................................................................120 VOLTAGE (Brakelight)..................................................................................................................120 Ignition Timing...........................................................................................................................120 Tilt Sensor...............................................................................................................................120 SUPPLY VOLTAGE........................................................................................................................120 OUTPUT VOLTAGE........................................................................................................................121 Throttle Position Sensor (TPS)............................................................................................................121 TESTING...............................................................................................................................121 EFI Diagnostic System.....................................................................................................................122 DIGITAL GAUGE.........................................................................................................................122 Coolant (COOL) Diagnostic Mode........................................................................................................123 Fuel Sensor (FUEL) Diagnostic Mode....................................................................................................123 Tachometer (tACH) Diagnostic Mode.....................................................................................................123 Speed (SPd) Diagnostic Mode...........................................................................................................124 TPS (tPS) Diagnostic Mode.............................................................................................................124 MAP (bArO) Diagnostic Mode............................................................................................................124 Inlet Air Temperature (AIr) Diagnostic Mode...........................................................................................124 Battery (bAtt) Diagnostic Mode........................................................................................................124 DIAGNOSTIC TROUBLE CODES (DTC)........................................................................................................125 Code List.............................................................................................................................125 Troubleshooting...........................................................................................................................127 Drive and Brake Systems.......................................................................................................................128 GENERAL INFORMATION.......................................................................................................................128 SPECIAL TOOLS.............................................................................................................................128 Front Drive Actuator......................................................................................................................128 REMOVING..............................................................................................................................128 INSTALLING............................................................................................................................128 Front Differential........................................................................................................................129 REMOVING..............................................................................................................................129 Disassembling Input Shaft.............................................................................................................131 Assembling Input Shaft................................................................................................................132 Disassembling Differential Assembly...................................................................................................133 Disassembling Pinion Gear.............................................................................................................134 Assembling Pinion Gear................................................................................................................134 Shimming Procedure/Shim Selection.....................................................................................................135 Backlash..............................................................................................................................135 Ring Gear End-Play....................................................................................................................137 Assembling Differential Assembly......................................................................................................137 Removing/Installing Axle Seal.........................................................................................................139 INSTALLING............................................................................................................................139 Driveshaft (Wildcat 4/4X).................................................................................................................141 REMOVING/DISASSEMBLING................................................................................................................141 ASSEMBLING/INSTALLING.................................................................................................................143 Drive Axles...............................................................................................................................144 REMOVING REAR DRIVE AXLE..............................................................................................................144 REMOVING FRONT DRIVE AXLE.............................................................................................................145 CLEANING AND INSPECTING AXLES.........................................................................................................145 DISASSEMBLING AXLES...................................................................................................................145 ASSEMBLING AXLES......................................................................................................................146 INSTALLING REAR DRIVE AXLE............................................................................................................146 INSTALLING FRONT DRIVE AXLE...........................................................................................................147 Rear Gear Case............................................................................................................................147 REMOVING..............................................................................................................................147 RING GEAR/THRUST BUTTON...............................................................................................................149 Removing..............................................................................................................................149 Inspecting............................................................................................................................149 Installing/Shimming...................................................................................................................149 REAR DRIVE INPUT SHAFT/ HOUSING.......................................................................................................150 Removing/Disassembling................................................................................................................150 Cleaning and Inspecting...............................................................................................................151 Assembling/Installing.................................................................................................................151 INSTALLING............................................................................................................................152 Hub.......................................................................................................................................153 REMOVING..............................................................................................................................153 CLEANING AND INSPECTING...............................................................................................................154 REPLACING WHEEL STUDS.................................................................................................................154 INSTALLING............................................................................................................................155 Hydraulic Brake Caliper (Wildcat).........................................................................................................155 REMOVING/DISASSEMBLING................................................................................................................155 CLEANING AND INSPECTING...............................................................................................................156 ASSEMBLING/INSTALLING.................................................................................................................156 Hydraulic Brake Caliper (X/Wildcat 4/4X)..................................................................................................158 REMOVING/DISASSEMBLING................................................................................................................158 CLEANING AND INSPECTING...............................................................................................................159 ASSEMBLING/INSTALLING (Rear Brake)....................................................................................................159 ASSEMBLING/INSTALLING (Front Brake)...................................................................................................160 Master Cylinder Assembly..................................................................................................................161 Removing..............................................................................................................................161 Inspecting............................................................................................................................162 Installing............................................................................................................................162 Troubleshooting Drive System..............................................................................................................163 Troubleshooting Brake System..............................................................................................................163 Suspension....................................................................................................................................164 SPECIAL TOOLS.............................................................................................................................164 Shock Absorbers...........................................................................................................................164 REMOVING..............................................................................................................................164 CLEANING AND INSPECTING...............................................................................................................164 INSTALLING............................................................................................................................164 REBUILDING............................................................................................................................164 Inspection............................................................................................................................164 Preliminary Set-Up....................................................................................................................164 Disassembling Shock Absorber..........................................................................................................165 RESERVOIR - LCS REPLACEMENT...........................................................................................................167 Disassembling Shaft Assembly..........................................................................................................168 Assembling............................................................................................................................170 Assembling Shock Absorber.............................................................................................................173 Shock Absorbers (Limited).................................................................................................................178 REMOVING..............................................................................................................................178 CLEANING AND INSPECTING...............................................................................................................178 INSTALLING............................................................................................................................180 Front.................................................................................................................................180 Rear..................................................................................................................................180 Front A-Arms..............................................................................................................................180 REMOVING..............................................................................................................................180 CLEANING AND INSPECTING...............................................................................................................182 INSTALLING............................................................................................................................182 Rear Trailing Arms........................................................................................................................183 REMOVING..............................................................................................................................183 INSPECTING............................................................................................................................184 INSTALLING............................................................................................................................184 Wheels and Tires..........................................................................................................................185 TIRE SIZE.............................................................................................................................185 TIRE INFLATION PRESSURE...............................................................................................................185 REMOVING..............................................................................................................................185 CLEANING AND INSPECTING...............................................................................................................185 INSTALLING............................................................................................................................185 CHECKING/INFLATING....................................................................................................................185 Troubleshooting...........................................................................................................................186 BACK COVER .......................................................................................................................................187
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]