Arctic Cat Wildcar Trail User manual

[ROV]
SERVICE MANUAL
2014
WILDCAT TRAIL

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2014 Arctic
Cat Wildcat Trail. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific vehicle component or system and, in addition to the
standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual
as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.
The service technician should become familiar with the operation and construction of each component or system by
carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient
with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.
All Arctic Cat publications and decals display the words Warning, Caution, Note, and At This Point to emphasize
important information. The symbol ! WARNING identifies personal safety-related information. Be sure to fol-
low the directive because it deals with the possibility of serious personal injury or even death. A CAUTION identi-
fies 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 wor-
thy of particular attention. The symbol AT THIS POINT directs the technician to certain and specific proce-
dures 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.
© 2014 Arctic Cat Inc. May 2014
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

1
TABLE OF CONTENTS
General Information ..............................................................2
General Specifications............................................................... 2
Torque Specifications................................................................. 3
Torque Conversions (ft-lb/N-m).................................................. 4
Drive Belt Break-In Procedure ................................................... 4
Gasoline - Oil - Lubricant ........................................................... 4
Genuine Parts............................................................................ 5
Preparation For Storage ............................................................ 5
Preparation After Storage .......................................................... 5
Periodic Maintenance/Tune-Up ............................................6
Periodic Maintenance Chart ...................................................... 6
Lubrication Points ...................................................................... 7
Air Filter ..................................................................................... 7
Testing Engine Compression ..................................................... 7
Spark Plugs ............................................................................... 8
Muffler/Spark Arrester................................................................ 8
Engine Oil - Filter ....................................................................... 9
Front Differential - Transaxle Lubricant ...................................... 9
Nuts/Bolts/Cap Screws ............................................................ 10
Headlight/Taillight-Brakelight.................................................... 10
Hydraulic Brake System........................................................... 13
Burnishing Brake Pads ............................................................ 14
Replacing V-Belt ...................................................................... 14
Steering/Frame/Controls ....................................................16
Front Bumper ........................................................................... 16
Hood and Grille........................................................................ 17
Body Panels............................................................................. 17
Center Console........................................................................ 22
Rack and Pinion Assembly ...................................................... 23
Steering Wheel ........................................................................ 25
Steering Shaft .......................................................................... 26
Steering Knuckles.................................................................... 27
Checking/Adjusting Front Wheel Alignment............................. 29
Accelerator Pedal..................................................................... 29
Shift Lever................................................................................ 30
Shift Cable ............................................................................... 31
LCD Gauge.............................................................................. 32
Exhaust System....................................................................... 33
Cargo Box ................................................................................ 33
Seats........................................................................................ 34
Doors ....................................................................................... 34
Floor......................................................................................... 35
Troubleshooting ....................................................................... 36
Engine ..................................................................................37
Troubleshooting ....................................................................... 38
Removing Engine .................................................................... 40
Top-Side Components ............................................................. 45
Removing Top-Side Components ............................................ 45
Servicing Top-Side Components ............................................. 48
Bottom-Side Components........................................................ 59
Removing Bottom-Side Components ...................................... 59
Servicing Bottom-Side Components........................................ 63
Installing Bottom-Side Components ........................................ 65
Servicing Left-Side Components ............................................. 68
Installing Engine ...................................................................... 72
Fuel/Lubrication/Cooling.............................................................77
Throttle Body ........................................................................... 77
Gas Tank.................................................................................. 79
Gas/Vent Hoses....................................................................... 80
Oil Filter/Oil Pump.................................................................... 80
Oil Cooler................................................................................. 80
Oil Flow Chart.......................................................................... 81
Liquid Cooling System ............................................................. 82
Radiator ................................................................................... 82
Thermostat .............................................................................. 84
Fan........................................................................................... 85
Water Pump............................................................................. 85
Fuel Pump/Fuel Level Sensor.................................................. 87
Troubleshooting ....................................................................... 88
Electrical System ................................................................ 89
Battery ..................................................................................... 89
Accessory Receptacle/Connector ........................................... 90
Brakelight Switch ..................................................................... 90
Engine Coolant Temperature (ECT) Sensor ............................ 91
Fan Motor................................................................................. 91
Power Distribution Module (PDM)............................................ 91
Ignition Coils ............................................................................ 92
EFI Sensors/Components........................................................ 92
Speed Sensor .......................................................................... 94
Ignition Switch.......................................................................... 94
Headlight Switch ...................................................................... 94
Drive Select Switch.................................................................. 94
Reverse Override Switch ......................................................... 95
Front Drive Actuator................................................................. 95
Stator Coil ................................................................................ 95
Starter Motor............................................................................ 96
Starter Relay............................................................................ 96
Engine Control Module (ECM)................................................. 97
Regulator/Rectifier ................................................................... 97
Headlights................................................................................ 97
Taillight-Brakelight.................................................................... 97
Tilt Sensor................................................................................ 98
Throttle Position Sensor (TPS) ................................................ 98
EFI Diagnostic System ............................................................ 99
RPM Limiter ........................................................................... 103
Troubleshooting ..................................................................... 104
Drive and Brake Systems................................................. 105
Front Drive Actuator............................................................... 105
Front Differential .................................................................... 106
Drive Axles............................................................................. 119
Transaxle ............................................................................... 121
Driveshaft/Carrier Bearing ..................................................... 136
Hub ........................................................................................ 139
Hydraulic Brake Caliper ......................................................... 141
Master Cylinder Assembly ..................................................... 144
Troubleshooting ..................................................................... 146
Suspension ....................................................................... 147
Shock Absorbers ................................................................... 147
Front A-Arms ......................................................................... 157
Rear A Arms .......................................................................... 161
Front Sway Bar ...................................................................... 164
Rear Sway Bar....................................................................... 164
Wheels and Tires................................................................... 165
Troubleshooting ..................................................................... 165

2
General Information
NOTE: Some photographs and illustrations used in
this manual are used for clarity purposes only and are
not designed to depict actual conditions.
NOTE: Whenever a part is worn excessively, cracked,
or damaged in any way, replacement is necessary.
NOTE: Never reuse a lock nut. Once a lock nut has
been removed, it must be replaced with a new lock nut.
General Specifications
* Visible at plug threads.
Specifications subject to change without notice.
CHASSIS
Dry Weight (approx) 449 kg (990 lb)
ROPS Tested Curb Weight 817 kg (1802 lb)
Length (overall) 280.6 cm (110.5 in.)
Height (overall) 163.3 cm (64.3 in.)
Width (overall) 127 cm (50 in.)
Tire Size 25 x 8-12R (Front)
25 x 10-12R (Rear)
Tire Inflation Pressure 0.98 kg/cm² (14 psi)
MISCELLANY
Spark Plug Type NGK CR8EB
Spark Plug Gap 0.6-0.8 mm (0.023-0.031 in.)
Gas Tank Capacity 28 L (7.4 U.S. gal.)
Coolant Capacity 3.1 L (3.2 U.S. qt)
Front Differential Capacity 200 ml (6.8 fl oz)*
Transaxle Capacity 1.2 L (1.2 U.S. qt)*
Engine Oil Capacity 2.8 L (3.0 U.S. qt) - Overhaul
3.34 L (3.4 U.S. qt) - Change
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather
Synthetic
Front Differential Lubricant SAE Approved 80W-90 Hyp-
oid
Transaxle Lubricant Arctic Cat Synthetic Transaxle
Fluid
Belt Width 31.3 mm (1.23”)
Brake Fluid DOT 4
Taillight/Brakelight High Intensity LED
Headlight Halogen
COOLING SYSTEM
Cooling Fan On 203° F (95° C)
Cooling Fan Off 194° F (90° C)
ELECTRICAL SYSTEM
Spark Plug Cap 5000 ohms
Ignition Coil Resistance(primary) Less than 1 ohm
Ignition Coil Primary Voltage Battery Voltage
Stator Coil (crankshaft position sensor)
Resistance(AC generator)
100-150 ohms
Less than 1 ohm
Crankshaft Position Sensor 1.5 AC Volts or more
AC Generator Output (no load) 65 AC volts @ 4000 RPM
Ignition Timing 10° BTDC @ 1500 RPM
VALVES AND GUIDES
Valve Face Diameter (intake)
(exhaust)
31.6 mm
27.9 mm
Valve/Tappet Clearance (intake)
(cold engine) (max) (exhaust)
0.16 mm
0.22 mm
Valve Guide/Stem (intake)
Clearance (max) (exhaust)
0.08 mm
0.10 mm
Valve Guide Inside Diameter (max) 4.532 mm
Valve Head Thickness (min) 2.3 mm
Valve Seat Angle 45° +15’/+30’
Valve Spring Free Length (min) 38.7 mm
Valve Spring Tension @ 31.5 mm 19.0 kg (42 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min) 36.5 mm
Camshaft Journal Oil Clearance (max) 0.07 mm
Camshaft Journal Holder(right & center)
Inside Diameter (left)
21.94-22.04 mm
17.44-17.48 mm
Camshaft Journal Outside(right & center)
Diameter (left)
21.96-21.98 mm
17.48-17.53 mm
Camshaft Runout (max) 0.05 mm
Cylinder Head/Cover Distortion (max) 0.05 mm
CYLINDER, PISTON, AND RINGS
Piston/Cylinder Clearance 0.14mm
Cylinder Bore (max) 76.965 mm
Piston Diameter 10 mm from Skirt End 76.825 mm
Piston Ring Free End Gap (min) (1st/2nd) 12.5 mm
Bore x Stroke 76.9 x 75.3 mm
Cylinder Trueness (max) 0.05 mm
Piston Ring End Gap (1st/2nd)
- Installed (max) (oil)
0.65 mm
0.85 mm
Piston Ring to Groove Clearance (max) 0.1 mm
Piston Ring Groove Width (1st/2nd)
(oil)
1.202-1.204 mm
2.501-2.503 mm
Piston Ring Thickness (1st/2nd) 1.170-1.195 mm
Piston Pin Bore (max) 18.018 mm
Piston Pin Outside Diameter (min) 17.984 mm
CRANKSHAFT
Connecting Rod (small end bore) (max) 18.044 mm
Crankshaft Runout (max) 0.03 mm

3
Torque Specifications
*w/Oil **w/Red Loctite #271 ***w/Green Loctite #270
****w/“Patch-Lock” *****w/Anti-Seize
Torque (ft-lb) Tolerance
0-15 ±20%
16-39 ±15%
40+ ±10%
EXHAUST COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Exhaust Pipe Flange Engine 810
Spark Arrester Muffler 68
Heat Shield Frame 48 in.-lb 6
Heat Shield Manifold 10 14
O2 Sensor Manifold 20 27
BRAKE COMPONENTS
Brake Disc Hub 15 20
Brake Hose Caliper 20 27
Brake Hose Master Cylinder 20 27
Brake Hose Frame 811
Master Cylinder Frame 25 34
Caliper Knuckle 20 27
SUSPENSION COMPONENTS (Front)
A-Arm (Upper) Frame 35 48
A-Arm (Lower) Frame 40 54
Knuckle Ball Joint 35 48
Knuckle Tie Rod End 30 40
Shock Absorber Frame 35 48
Shock Absorber A-Arm 25 34
Sway Bar Mount Frame 35 48
Sway Bar Sway Bar Link 20 27
Sway Bar Link A-Arm 20 27
SUSPENSION COMPONENTS (Rear)
Sway Bar Mount Frame 35 48
Sway Bar Sway Bar Link 20 27
A-Arm Frame 35 48
Shock Absorber (Lower) A-Arm 35 48
Shock Absorber (Upper) Frame 35 48
Knuckle A-Arm 35 48
Sway Bar Link A-Arm 20 27
STEERING COMPONENTS
Steering Wheel Steering Shaft 25 34
Rack and Pinion Assembly Frame 25 34
Rack and Pinion Bracket Frame 25 34
Tie Rod* Rack and Pinion Assembly 37 50
Jam Nut Tie Rod 25 34
Tilt Steering Link Frame 10 14
Tilt Steering Frame 20 27
Intermediate Shaft Rack and Pinion 25 34
Intermediate Shaft Shaft Adjuster 25 34
CHASSIS/ROPS ASSEMBLY
Door Latch Bracket Frame 811
Door Hinge Frame 20 27
Shift Lever Shift Mount Bracket 20 27
Shift Cable Shift Axle Arm 811
Front ROPS Tube Frame 40 54
Front ROPS Tube Rear ROPS Tube 40 54
Rear ROPS Tube Frame 40 54
Cargo Box Frame 57
Seat Belt Retractor Frame 60 81
Seat Belt Shoulder ROPS Hoop 35 48
Seat Belt Buckle Frame 60 81
Seat Belt Anchor Frame 60 81
Accelerator Pedal Bracket Splash Panel 10 14
Accelerator Pedal Accelerator Pedal Bracket 20 27
Throttle Cable Throttle Body 811
Brake Pedal Frame 20 27
Front Bumper Frame 20 27
DRIVE TRAIN COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Engine/Transaxle Mounting
Bracket*****
Transaxle 75 102
Front Differential Differential Bracket 38 52
Carrier Bearing Bearing Bracket 35 48
Carrier Bearing Bracket Frame 20 27
Carrier Bearing Set Screw** Front Shaft 68
Pinion Housing Differential Housing 23 31
Differential Housing Cover*** Differential Housing 23 31
Hub Axle/Knuckle 200 270
Detent Plug Transaxle 20 27
Speed Sensor Rear Transaxle 10 14
Oil Drain Plug Front Differential 45 in.-lb 5
Oil Fill Plug Front Differential 16 22
Drain Plug Transaxle 18 24
Fill Plug Transaxle 18 24
Wheel (steel) Hub (20 ft-lb increments) 40 54
Wheel (aluminum) Hub (20 ft-lb increments) 80 108
ENGINE
Front Rubber Mount Engine Mounting Bracket 20 27
Front Rubber Mount Frame 25 34
Transaxle Rubber Mount Frame 20 27
Front Engine Mount Engine 35 48
Rear Engine Mount Frame 40 54
Adjuster Nut Engine/Transaxle Mounting Bracket 15 20
Transaxle Mounting Bracket Transaxle 37 50
Transaxle Mounting Bracket Rubber Mount 25 34
Crankcase Half (6 mm) Crankcase Half 79.5
Crankcase Half (8 mm) Crankcase Half 21 28
Cylinder Head (Cap Screw)* Crankcase(step 1)
(step 2)
(final)
22
29
36
29
39
49
Cylinder Head Cover Cylinder Head 79.5
Driven Clutch Input Shaft 35 48
Drive Clutch Crankshaft 60 81
Magneto Cover Crankcase 79.5
Tappet Cover Valve Cover 79.5
Oil Pump Crankcase 810
Rotor/Flywheel Crankshaft 60 81
Cam Sprocket** Camshaft 79.5
Inner Clutch Cover Engine 811
Camshaft Holder* Cylinder Head 79.5
Shifter Housing Crankcase 811
Starter Motor Crankcase 811
Outer Clutch Cover Inner Cover 55.5
Intake Boot Clamp Intake Boot 30 in.-lb 3.4
Starter One-Way Clutch** Rotor/Flywheel 20 27
Fuel Rail Engine 68
Air Filter Housing Frame 57
Ground Wire Engine 79.5
Stator Coil Magneto Cover 11 15
Oil Drain Plug Engine 20 27
Drain Plug Clutch Cover 50 in.-lb 5.5
Cam Chain Tensioner Cylinder Head 15 20
Connecting Rod Connecting Rod(step 1)
(step 2)
(final)
22
36
45
29
49
60
Oil Crossover Tube Crankcase 13.5 18
Cylinder Head (Side) Crankcase 79.5
Oil Filter Union Crankcase 20 27
Phase Plate Sprocket 79.5
Timing Inspection Plug Magneto Cover 10 17
Magneto Plug Magneto Cover 811
Oil Hose Fitting Crankcase 25 34
PTO-Side Cover Crankcase 79.5
Tensioner Cap Tensioner 15 20
Upper Chain Guide Cylinder Head 79.5
Oil Cooler Hose Oil Cooler/Engine 35 in.-lb 4
Coolant Hose Coolant Pipe 40 in.-lb 4.5
Coolant Hose Water Pump/Cylinder 35 in.-lb 4
Bypass Hose Thermostat Coolant Pipe 15 in.-lb 1.7

4
Torque Conversions
(ft-lb/N-m)
Drive Belt Break-In
Procedure
New drive belts require a break-in period of approximately
25 miles. During this period, drive the vehicle for 25 miles
at 3/4 throttle or less while varying throttle position (but
not exceeding 40 mph). By varying throttle position, the
exposed cord on the side of a new belt will be conditioned
allowing the drive belt to gain its optimum flexibility and
will extend drive belt life.
Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum octane
regular unleaded. In many areas, oxygenates are added to
the gasoline. Oxygenated gasolines containing up to 10%
ethanol or 5% methane are acceptable gasolines.
When using ethanol blended gasoline, it is not necessary to
add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.
RECOMMENDED ENGINE OIL
The recommended oil to use is Arctic Cat ACX All
Weather synthetic engine oil, which has been specifically
formulated for use in this Arctic Cat engine. Although
Arctic Cat ACX All Weather synthetic engine oil is the
only oil recommended for use in this engine, use of any
API certified SM 0W-40 oil is acceptable.
OILCHARTJ
RECOMMENDED FRONT
DIFFERENTIAL LUBRICANT
The recommended lubricant is Arctic Cat Gear Lube or an
equivalent gear lube which is SAE approved 80W-90 hypoid.
This lubricant meets all of the lubrication requirements of the
Arctic Cat vehicle front differential and rear drive.
RECOMMENDED TRANSAXLE
LUBRICANT
The recommended transaxle lubricant is Arctic Cat Syn-
thetic Transaxle Fluid. This lubricant meets all of the lubri-
cation requirements of this vehicle.
FILLING GAS TANK
Since gasoline expands as its temperature rises, the gas
tank must be filled to its specified capacity only. Expan-
sion room must be maintained in the tank particularly if
the tank is filled with cold gasoline and then moved to a
warm area.
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
11.4 26 35.4 51 69.4 76 103.4
22.7 27 36.7 52 70.7 77 104.7
34.1 28 38.1 53 72.1 78 106.1
45.4 29 39.4 54 73.4 79 107.4
56.8 30 40.8 55 74.8 80 108.8
68.2 31 42.2 56 76.2 81 110.2
79.5 32 43.5 57 77.5 82 111.5
810.9 33 44.9 58 78.9 83 112.9
912.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
CAUTION
Do not use white gas. Only Arctic Cat approved gaso-
line additives should be used.
CAUTION
Any lubricant used in place of the recommended lubri-
cant could cause serious front differential damage.
CAUTION
Any lubricant used in place of the recommended lubri-
cant could cause serious transaxle damage.
! WARNING
Always fill the gas tank in a well-ventilated area. Never
add fuel to the gas tank near any open flames or with
the engine running. DO NOT SMOKE while filling the
gas tank.
! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the engine to
cool before filling the gas tank.

5
Tighten the gas tank cap securely after filling the tank.
Genuine Parts
When replacement of parts is necessary, use only genuine Arc-
tic Cat parts. They are precision-made to ensure high quality
and correct fit. Refer to the appropriate Illustrated Parts Man-
ual for the correct part number, quantity, and description.
Preparation For Storage
1. Clean the seat cushion (cover and base) with a damp
cloth and allow it to dry.
2. Clean the vehicle thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire vehicle.
Allow it to dry thoroughly. DO NOT get water into
any part of the engine or air intake.
3. Either drain the gas tank or add Fuel Stabilizer to the
gas in the gas tank. Remove the air filter housing
cover and air filter. Start the engine and allow it to
idle. Using Arctic Cat Engine Storage Preserver, rap-
idly inject the preserver into the air filter opening for a
period of 10 to 20 seconds; then stop the engine.
Install the air filter and housing cover.
4. Plug the exhaust hole in the exhaust system with a
clean cloth.
5. Apply light oil to the plungers of the shock absorbers.
6. Tighten all nuts, bolts, cap screws, and screws. Make
sure rivets holding components together are tight.
Replace all loose rivets. Care must be taken that all
calibrated nuts, cap screws, and bolts are tightened to
specifications.
7. Fill the cooling system to the bottom of the stand pipe
in the radiator neck with properly mixed coolant.
8. Disconnect the battery cables; then remove the bat-
tery, clean the battery posts and cables, and store in a
clean, dry area.
9. Store the vehicle indoors in a level position.
Preparation After
Storage
Taking the vehicle out of storage and correctly preparing it
will assure many miles and hours of trouble-free riding.
1. Clean the vehicle thoroughly.
2. Clean the engine. Remove the cloth from the exhaust
system.
3. Check all control wires and cables for signs of wear or
fraying. Replace if necessary.
4. Change the engine oil and filter.
5. Check the coolant level and add properly mixed cool-
ant as necessary.
6. Charge the battery; then install. Connect the battery
cables.
7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight, and
headlight aim; adjust or replace as necessary.
8. Tighten all nuts, bolts, cap screws, and screws making
sure all calibrated nuts, cap screws, and bolts are tight-
ened to specifications.
9. Check tire pressure. Inflate to recommended pressure
as necessary.
10. Make sure the steering moves freely and does not
bind.
11. Check the spark plugs. Clean or replace as necessary.
! WARNING
Do not over-fill the gas tank.
CAUTION
Prior to storing the vehicle, it must be properly serviced
to prevent rusting and component deterioration.
CAUTION
If the interior of the air filter housing is dirty, clean the
area before starting the engine.
CAUTION
Avoid storing outside in direct sunlight and avoid using
a plastic cover as moisture will collect on the vehicle
causing rusting.
CAUTION
The ignition switch must be in the OFF position prior to
installing the battery or damage may occur to the igni-
tion system.
CAUTION
Connect the positive battery cable first; then the nega-
tive.

6
Periodic Maintenance/
Tune-Up
This section has been organized into sub-sections showing
common maintenance procedures.
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 appropri-
ate tool description.
NOTE: Special tools are available from the Arctic
Cat Service Department.
Periodic Maintenance
Chart
A = Adjust I = Inspect C = Clean L = Lubricate R = Replace T = Tighten
* Service/Inspect more frequently when operating in adverse conditions.
** When using an API certified SM 0W-40 oil.
*** When using Arctic Cat ACX All Weather synthetic oil, oil change and strainer inspection interval can be increased to every
1,000 miles or every year.
Description p/n
Compression Tester Kit 0444-213
Oil Filter Wrench 0644-389
Timing Light 0644-296
Item Initial Service After Break-In (First
Month or 100 Miles) Daily Monthly
(100 Miles)
Every 3
Months (300
Miles)
Every 6
Months (500
Miles)
Annually
(1500 Miles) As Needed
Battery II C
Fuses IR
Air Filter II* R
Valve/Tappet Clearance IIA
Engine Compression I
Spark Plugs I I I R (4000 Mi
or 18 Mo)
Muffler/Spark Arrester CR
Gas Hoses II R(2Yrs)
Throttle Cable Ends/Accelerator Pedal Pivot II C-L A-R
Engine Oil/Filter R R*/R**/R*** A/R
Front Differential Lubricant RI R
Transaxle Lubricant RI R
(2000Mi)
Tires/Air Pressure II R
Steering Components II I R
V-Belt IlR
Suspension (Ball joint boots, drive axle boots
front and rear, tie rods, differential and rear
drive bellows)
II R
Nuts/Bolts/Cap Screws TT A
Ignition Timing I
Headlight/Taillight-Brakelight II R
Switches II R
Shift Lever IA-L
Gauge/Indicators II R
Frame/Welds II l
Electrical Connections lC
Complete Brake System II
Brake Pads II* R
Brake Fluid II R(2Yrs)
Brake Hoses II R(4Yrs)
Coolant/Cooling System II R(2Yrs)
Wheel Lug Nuts TT

7
Lubrication Points
It is advisable to lubricate certain components periodically
to ensure free movement. Apply light oil to the compo-
nents using the following list as reference.
A. Accelerator Pedal Pivot/Cable Ends
B. Brake Pedal Pivot
C. Shift Cable
Air Filter
CLEANING AND INSPECTING FILTER
1. Unsnap the five fasteners securing the air filter hous-
ing cover and remove the cover.
WT006A
2. Remove the air filter knob; then remove the air filter.
WT176A
NOTE: Do not attempt to remove the inner foam
from the wire mesh. It is part of the filter frame.
3. Fill a wash pan larger than the filter with a non-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 fil-
ter oil and work the filter.
NOTE: Apply oil to the inner filter; then carefully
squeeze excessive oil from the filter element. Do not
twist foam to remove oil.
6. Attach the foam filter to the inner filter screen.
WT179
7. Clean any dirt or debris from inside the air cleaner. Be
sure no dirt enters the throttle body.
8. Place the foam filter onto the filter frame; then install
the air filter on the filter rod and install the filter knob.
Tighten securely.
9. Install the air filter housing cover and secure with the
retaining clips.
CHECKING AND CLEANING DRAINS
1. Inspect the drain beneath the main housing for debris
or liquid. Remove and clean the drain bulb if contami-
nated.
2. Wipe any accumulation of oil or gas from the filter
housing and drain.
Testing Engine
Compression
 NOTE: The engine should be warm (operating tem-
perature) and the battery fully charged for an accurate
compression test.
NOTE: The access panel must be removed for this
procedure.
CAUTION
Failure to inspect the air filter frequently if the vehicle is
used in dusty, wet, or muddy conditions can damage
the engine.
CAUTION
A torn air filter can cause damage to the vehicle engine. Dirt
and dust may get inside the engine if the element is torn.
Carefully examine the element for tears before and after
cleaning it. Replace the element with a new one if it is torn.

8
WT021
1. Remove the spark plug wires from the spark plugs.
2. Using compressed air, blow any debris from around
the spark plugs.
3. Remove the spark plugs; then attach the spark plug wires
to the plugs and ground the plugs on the cylinder heads
well away from the spark plug holes.
4. Attach the Compression Tester Kit.
5. While holding the throttle in the full-open position, crank
the engine over with the electric starter until the gauge
stops climbing (five to 10 compression strokes). Compres-
sion should be as shown in the chart.
6. If compression is abnormally low, verify the following:
A. Starter cranks engine over (normal speed).
B. Gauge is functioning properly.
C. Throttle in the full-open position.
D. Valve/tappet clearance correct.
E. Engine warmed up.
7. If compression is still low, check for blown cylinder head
gasket, valve leakage, or worn piston rings or cylinder
(see Engine – Servicing Top-Side Components).
Spark Plugs
A light brown insulator indicates the plug is correct. A white or
dark insulator indicates that the engine may need to be ser-
viced. To maintain a hot, strong spark, keep the plug free of
carbon. Adjust the gap to 0.6-0.8 mm (0.023-0.031 in.).
ATV-0051
ATV-0052
When installing a spark plug, be sure to tighten it securely. A
new spark plug should be tightened 1/2 turn once the washer
contacts the cylinder head. A used spark plug should be tight-
ened 1/8-1/4 turn once the washer contacts the cylinder head.
Muffler/Spark Arrester
Clean the spark arrester using the following procedure.
1. Remove the spark arrester screen; then using a suit-
able brush, clean the carbon deposits from the screen
taking care not to damage the screen.
WT005A
! WARNING
Always wear safety glasses when using compressed air.
PSI (WOT)
Cylinder #1/Cylinder #2 185
CAUTION
Before removing a spark plug, be sure to clean the area
around the spark plug. Dirt could enter engine when
removing or installing the spark plug.
! WARNING
Wait until the muffler cools to avoid burns.

9
NOTE: If the screen or gasket is damaged in any
way, it must be replaced.
2. Install the spark arrester assembly and gasket and
secure with the cap screws. Tighten the cap screws to
72 in.-lb.
Engine Oil - Filter
OIL - FILTER
Change the engine oil and oil filter at the scheduled inter-
vals. The engine should always be warm when the oil is
changed so the oil will drain easily and completely.
1. Park the vehicle on level ground; then remove the
access panel.
WT037A
2. Remove the oil level stick/filler plug.
WT035A
3. Remove the drain plug from the bottom of the engine
and drain the oil into a drain pan.
WT294A
4. Using the Oil Filter Wrench and a ratchet handle (or a
socket or box-end wrench), remove the old oil filter.
 NOTE: Clean up any excess oil after removing the filter.
5. Apply oil to a new filter O-ring and check to make
sure it is positioned correctly; then install the new oil
filter. Tighten securely.
6. Install the engine drain plug and tighten to 16 ft-lb.
Pour the specified amount of the recommended oil in
the filler hole. Install the oil level stick/filler plug.
7. Start the engine (while the vehicle is outside on level
ground) and allow it to idle for a few minutes.
8. Turn the engine off and wait approximately one minute.
9. Unscrew the oil level stick and wipe it with a clean
cloth.
10. Install the oil level stick and thread into the engine
case.
NOTE: The oil level stick should be threaded into
the case for checking the oil level.
11. Remove the oil level stick; the oil level must be within
the operating range but not exceeding the upper mark.
WT066A
12. Inspect the area around the drain plug and oil filter for
leaks.
Front Differential -
Transaxle Lubricant
To check front differential lubricant, use the following pro-
cedure.
1. Remove the level plug; lubricant should be level with
the bottom threads.
CAUTION
Any oil used in place of the recommended oil could cause
serious engine damage. Do not use oils which contain
graphite or molybdenum additives. These oils can
adversely affect clutch operation. Also, not recommended
are racing, vegetable, non-detergent, and castor-based oils.
CAUTION
Do not over-fill the engine with oil. Always make sure
that the oil level is not above the upper mark.

10
WT041A
2. If low, remove the fill plug and add lubricant until it
appears at the level plug threads. Tighten the fill plug
to 16 ft-lb and the level plug to 45 in.-lb.
To check transaxle lubricant, use the following procedure.
1. Remove the fill/level plug; the lubricant level should
be level with the bottom of the plug threads.
WT025A
2. If low, add Arctic Cat Transaxle Fluid as necessary.
Tighten the fill/level plug to 16 ft-lb.
To change the lubricant, use the following procedure.
1. Place the vehicle on level ground.
2. Remove each drain and fill plug.
3. Drain the lubricant into a drain pan.
4. After all the lubricant has been drained, install the
drain plug and tighten to 16 ft-lb.
5. Pour the appropriate amount of recommended lubri-
cant into the fill hole.
6. Install the fill plug and tighten to 16 ft-lb.
NOTE: If the lubricant is contaminated with water,
inspect the drain plug, fill plug, and/or bladder.
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure rivets
holding components together are tight. Replace all loose
rivets. Care must be taken that all calibrated nuts, bolts,
and cap screws are tightened to specifications.
Headlight/Taillight-
Brakelight
HEADLIGHT BULB REPLACEMENT
1. Remove the wiring harness connector from the back
of the headlight.
2. Remove the rubber seal; then release the retaining
clip. Remove the bulb.
3. Install the new bulb; then attach the retaining clip and
press on the rubber boot.
4. Connect the wiring harness.
5. Adjust the headlight using the Checking/Adjusting
Headlight Aim instructions in this sub-section.
REMOVING HEADLIGHT ASSEMBLY
1. Remove the grille.
NOTE: Removing the front fender will aid in replac-
ing the headlight assembly.
2. Remove the headlight adjustment cap screw.
WT065A
3. Remove the inner cap screw securing the rear of the
headlight assembly.
WT272
4. Push the headlight assembly inward towards the radia-
tor and lift slightly on the exterior bracket until the
mounting stud is free; then remove the headlight
assembly.
5. Remove the rubber seal at the rear of the headlight
assembly.

11
WT263
6. Release the spring clip securing the headlight bulb;
then remove the bulb.
WT264
INSTALLING HEADLIGHT ASSEMBLY
1. Install the headlight bulb making sure each tab is posi-
tioned correctly and that it cannot rotate clockwise.
Secure the bulb with the spring.
WT264A
2. Install the rubber seal so that it is fully seated.
WT262
3. Starting with the interior mounting stud, install the
headlight assembly into position.
WT269A
NOTE: Applying lubricant to the studs will aid in
assembly.
4. With the interior stud in place in the grommet, work
the exterior stud into position.
NOTE: It may be necessary to lightly pull on the
exterior bracket to insert the exterior mounting stud.
WT270
5. Secure the headlight with the existing screws.
6. Connect the wiring harness and install the front
fender; then install the grille.
7. Check and adjust headlight aim (see Periodic Mainte-
nance section).
REMOVING TAILLIGHT/BRAKELIGHT
NOTE: The LED taillights are not replaceable. The
entire assembly must be replaced as a component.

12
1. Remove the fasteners securing the facia to the storage box.
WT101A
2. Disconnect the wiring harness.
WT222
3. Remove the lock nuts securing the taillight to the facia.
WT259A
INSTALLING TAILLIGHT/
BRAKELIGHT
1. Install the new taillight into the facia using new lock
nuts. Tighten to 36 in.-lb.
WT260
2. Connect the wiring harness and secure the facia using
the existing fasteners. Tighten securely.
CHECKING/ADJUSTING HEADLIGHT
AIM
The headlights can be adjusted vertically. The geometric
center of the HIGH beam light zone is to be used for verti-
cal 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).
0748-285
NOTE: There should be an average operating load
on the vehicle when adjusting the headlight aim.
2. Measure the distance from the floor to the mid-point
of each headlight.
3. Using the measurements obtained in step 2, make hor-
izontal marks on the aiming surface.
4. Switch on the lights. Make sure the HIGH beam is on.
DO NOT USE LOW BEAM.
5. Observe each headlight beam aim. Proper aim is when
the most intense beam is 5 cm (2 in.) below the hori-
zontal mark on the aiming surface.
6. Remove the front grille; then loosen the cap screw and
move the headlight assembly up or down as required.
Tighten to 60 in.-lb.

13
WT065A
Hydraulic Brake System
CHECKING/BLEEDING
The hydraulic brake system has been filled and bled at the
factory. To check and/or bleed a hydraulic brake system,
use the following procedure.
1. With the vehicle in a level position and the tires prop-
erly inflated, check the fluid level in the reservoir. If
the level in the reservoir is not above the MIN, add
DOT 4 brake fluid.
WT012A
2. Depress the brake pedal several times to check for a firm
brake. If the brake is not firm, the system must be bled.
3. To bleed the brake system, use the following procedure:
A. Remove the cover and fill the reservoir with DOT
4 brake fluid.
B. Install and secure the cover; then slowly press the
brake pedal several times.
C. Install one end of a clear hose onto the bleed screw
farthest from the cylinder (right rear) and direct the
other end into a container; then while holding
slight pressure on the brake pedal, open the bleed
screw and watch for air bubbles. Close the bleed
screw before releasing the brake pedal. Repeat this
procedure until no air bubbles are present.
WT045A
NOTE: During the bleeding procedure, watch the
reservoir very closely to make sure there is always a
sufficient amount of brake fluid. If the fluid level gets
low in the reservoir, refill the reservoir before the
bleeding procedure is continued.
D. Repeat step C until the brake pedal is firm.
E. At this point, perform step B, C, and D on the left
rear bleed screw; then move to the right front bleed
screw and follow the same procedure. Finish with
the left front bleed screw.
4. Carefully check the entire hydraulic brake system
that all hose connections are tight, the bleed screws
are tight, the protective caps are installed, and no
leakage is present.
INSPECTING HOSES
Carefully inspect the hydraulic brake hoses for cracks or
other damage. If found, the brake hoses must be replaced.
CHECKING/REPLACING PADS
The clearance between the brake pads and brake discs is
adjusted automatically as the brake pads wear. The only
maintenance that is required is replacement of the brake
pads when they show excessive wear. Check the thickness
of each of the brake pads as follows.
1. Remove a front wheel.
2. Measure the thickness of each brake pad.
WT220
CAUTION
This hydraulic brake system is designed to use DOT 4
brake fluid only. If brake fluid must be added, care must be
taken as brake fluid is very corrosive to painted surfaces.

14
3. If thickness of either brake pad is less than 1.0 mm
(0.039 in.), the brake pads must be replaced.
NOTE: The brake pads should be replaced as a set.
4. To replace the brake pads, use the following procedure.
A. Remove the cap screws securing the caliper holder to
the knuckle; then remove the pads from the caliper.
WT221
B. Install the new brake pads.
C. Secure the caliper holder to the knuckle with new
“patch-lock”cap screws. Tighten to 20 ft-lb.
WT287A
5. Install the wheel; then using a crisscross pattern, tighten
the wheel nuts in 20 ft-lb increments to a final torque of 40
ft-lb (steel wheel) or 80 ft-lb (aluminium wheel).
6. Burnish the brake pads (see Burnishing Brake Pads in this
section).
BRAKE DISC
Using a micrometer, measure the thickness of the brake disc in
the contact surface. If thickness is 0.125-in. or less, the disc must
be replaced. To replace the brake disc, see Drive System – Hub.
Burnishing Brake Pads
Brake pads must be burnished to achieve full braking effective-
ness. Braking distance will be extended until brake pads are
properly burnished. To properly burnish the brake pads, use the
following procedure.
1. Choose an area large enough to safely accelerate the vehi-
cle to 30 mph and to brake to a stop.
2. Accelerate to 30 mph; then depress the brake pedal to
decelerate to 0-5 mph.
3. Repeat procedure 20 times until brake pads are burnished.
Replacing V-Belt
NOTE: If a clutch or any clutch component has been
replaced or the technician is unsure of shim quantity/
placement, clutch offset must be verified (see Engine
- Servicing Left-Side Components).
 NOTE: Drive belts require a break-in period (see Break-in
Procedure - Drive Belt in the General Information Section).
REMOVING
1. Raise the rear of the vehicle just enough to unload the rear
suspension (weight off the shock absorbers).
2. Remove the left rear tire.
3. Remove the cap screws securing the outer clutch cover;
then remove the outer clutch cover.
WT182A
4. Remove the cap screw securing the driven clutch to
the output shaft. Account for the washer.
! WARNING
Failure to properly burnish the brake pads could lead to
premature brake pad wear or brake loss. Brake loss can
result in severe injury.
CAUTION
Failure to properly break-in a new drive belt will result in
premature belt failure.

15
WT183A
5. Remove the stationary sheave and V-belt and any belt
threads or debris in the clutch housing or sheaves.
NOTE: If removing the stationary sheave, account
for the alignment shims in the moveable sheave (see
Servicing Left-Side Components in the Engine sec-
tion for proper shimming).
WT186A
INSTALLING
1. Making sure the directional arrows on the belt are aligned
with engine rotation, place the drive belt on the drive
clutch; then making sure the “X” marks are aligned, install
the alignment shims (if applicable) and stationary sheave
on the driven clutch.
WT517A
WT200A
2. Using an appropriate strap or oil filter wrench (3 5/8”)
to hold the driven clutch and ensuring the splines of the
sheave and input shaft are engaged, secure the clutch
with the cap screw and washer. Tighten to 35 ft-lb.
WT202
3. Install the clutch cover and secure with the cap screws.
Tighten to 50 in.-lb.
WT182A
4. Install the left rear tire. Tighten in a crisscross pattern
in 20 ft-lb increments to 40 ft-lb (steel wheel) or 80 ft-
lb (aluminum wheel).

16
Steering/Frame/Controls
The following steering components should be inspected
periodically to ensure safe and proper operation.
A. Steering wheel secure.
B. Steering has equal and complete full-left and full-
right capability.
C. Steering sector mounting bolts tight.
D. Ball joints not worn, cracked, or damaged.
E. Tie rods not bent or cracked.
F. Knuckles not worn, cracked, or damaged.
G. Cotter pins not damaged or missing.
H. Steering wheel tilt locks securely.
The frame and welds should be checked periodically for
damage, bends, cracks, deterioration, broken components,
and missing components.
Front Bumper
REMOVING
1. Remove the hood and grille (see Hood and Grille). \
2. Disconnect the headlights.
WT463
3. Using a suitable prying tool, pry the clips out from
between the wiring harness and the frame. Press the
clips downward to remove from frame.
WT454
4. Remove the cap screws from both sides securing the
front fenders to the frame.
WT453A
5. Remove the cap screws (A, B, and C) and discard the
lock nuts from (A). Remove the bumper.
WT548A
INSTALLING
1. Place the bumper frame into position place and with
the existing cap screws and new lock nuts (A), finger-
tighten at this point.

17
WT548A
2. Install the lower bumper cap screws (C); then tighten
the upper and lower bumper cap screws to 20 ft-lb.
3. Install the cap screws and nuts securing the radiator to
the frame (B). Tighten to 8 ft-lb.
4. Install the cap screws securing the front fenders to the
frame; then tighten securely.
5. Connect the headlights.
6. Using the existing cap screws, secure the grille and
tighten securely.
7. Install the hood and secure with the quarter-turn fas-
teners
Hood and Grille
REMOVING/INSTALLING HOOD
1. Turn the two quarter-turn fasteners counterclockwise
and remove hood.
WT226A
2. Insert the hood tabs into the grille and lay the hood
down flat. Turn both of the fasteners clockwise secur-
ing the hood.
WT251
REMOVING GRILLE
Remove the fasteners securing the grille; then remove the
grille.
WT256A
CLEANING AND INSPECTION GRILLE
Clean any dirt or debris from the grille webbing. This
helps air flow to the radiator and oil cooler.
INSTALLING GRILLE
Place the grille into position and secure it using the exist-
ing cap screws. Tighten all hardware to 60 in.-lb.
Body Panels
REMOVING REAR BODY PANELS
1. Remove the seats.
2. Remove the push pins and cap screws securing the
rear fenders.

18
WT209A
3. Remove the cap screws securing the taillight/brake-
light assembly to the frame and disconnect the har-
ness.
WT101A
WT222
4. Remove the fasteners securing the right rear body
panel.
WT241A
WT227A
5. Loosen the gas tank filler hose clamp and slide it
down towards the tank.
WT244
6. Remove the panel from the frame while also pulling
on the filler hose. Seal off the hose to prevent objects
from entering the hose.
WT246
7. Remove the air pre-filter cover.
! WARNING
The heat deflector under the right-rear fender has sharp
edges and can cause serious injury if care is not taken.