2015 Arctic Cat Wildcat Sport Service & Repair Manual

SERVICE MANUAL SERVICE MANUAL SERVICE MANUAL www.arcticcat.com WILDCAT SPORT

FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2015 Arctic Cat Wildcat Sport. 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. November 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 .................................................... 17 Front Bumper ........................................................................... 17 Hood/Grille/Storage Box .......................................................... 18 Body Panels ............................................................................. 19 Center Console ........................................................................ 24 Rack and Pinion Assembly ...................................................... 24 Steering Wheel ........................................................................ 26 Electronic Power Steering (EPS) ............................................. 27 Steering Shaft .......................................................................... 28 Steering Knuckles .................................................................... 30 Checking/Adjusting Front Wheel Alignment ............................. 32 Accelerator Pedal ..................................................................... 32 Shift Lever ................................................................................ 33 Shift Cable ............................................................................... 34 LCD Gauge .............................................................................. 35 Exhaust System....................................................................... 36 Cargo Box ................................................................................ 36 Seats........................................................................................ 37 Doors ....................................................................................... 37 Floor......................................................................................... 38 Troubleshooting ....................................................................... 39 Engine .................................................................................. 40 Troubleshooting ....................................................................... 41 Removing Engine .................................................................... 43 Top-Side Components ............................................................. 48 Removing Top-Side Components ............................................ 48 Servicing Top-Side Components ............................................. 51 Bottom-Side Components........................................................ 62 Removing Bottom-Side Components ...................................... 62 Servicing Bottom-Side Components ........................................ 66 Installing Bottom-Side Components ........................................ 68 Servicing Left-Side Components ............................................. 71 Installing Engine ...................................................................... 75 Fuel/Lubrication/Cooling ............................................................. 80 Throttle Body ........................................................................... 80 Gas Tank.................................................................................. 82 Gas/Vent Hoses ....................................................................... 83 Oil Filter/Oil Pump.................................................................... 83 Oil Cooler ................................................................................. 83 Oil Flow Chart .......................................................................... 84 Liquid Cooling System ............................................................. 85 Radiator ................................................................................... 85 Thermostat .............................................................................. 87 Fan........................................................................................... 88 Water Pump ............................................................................. 88 Troubleshooting ....................................................................... 90 Electrical System ................................................................ 91 Battery ..................................................................................... 91 Accessory Receptacle/Connector ........................................... 92 Brakelight Switch ..................................................................... 92 Engine Coolant Temperature (ECT) Sensor ............................ 93 Fan Motor................................................................................. 93 Power Distribution Module (PDM) ............................................ 94 Ignition Coils ............................................................................ 94 EFI Sensors/Components........................................................ 95 Speed Sensor .......................................................................... 96 RPM Limiter ............................................................................. 97 Electronic Power Steering (EPS) ............................................. 97 Ignition Switch.......................................................................... 98 Headlight Switch ...................................................................... 99 Drive Select Switch .................................................................. 99 Reverse Override Switch ......................................................... 99 Front Drive Actuator ............................................................... 100 Stator Coil .............................................................................. 100 Starter Motor.......................................................................... 100 Starter Relay .......................................................................... 101 Engine Control Module (ECM) ............................................... 101 Fuel Pump/Fuel Level Sensor................................................ 102 Regulator/Rectifier ................................................................. 103 Headlights .............................................................................. 103 Taillight-Brakelight .................................................................. 104 Tilt Sensor.............................................................................. 104 Throttle Position Sensor (TPS) .............................................. 105 EFI Diagnostic System .......................................................... 105 Troubleshooting ..................................................................... 110 Drive and Brake Systems................................................. 111 Front Drive Actuator ............................................................... 111 Front Differential .................................................................... 112 Drive Axles............................................................................. 125 Transaxle ............................................................................... 127 Driveshaft/Carrier Bearing ..................................................... 142 Hub ........................................................................................ 145 Hydraulic Brake Caliper (Front) ............................................. 147 Master Cylinder Assembly ..................................................... 153 Troubleshooting ..................................................................... 154 Suspension ....................................................................... 155 Shock Absorbers ................................................................... 155 Front A-Arms ......................................................................... 159 Rear A Arms .......................................................................... 162 Rear Sway Bar ....................................................................... 165 Wheels and Tires ................................................................... 165 Troubleshooting ..................................................................... 166

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) 478 kg (1054 lb) - Sport/XT 487 kg (1074 lb) - Limited ROPS Tested Curb Weight 845 kg (1864 lb) Length (overall) 280.6 cm (110.5 in.) Height (overall) 163.3 cm (64.3 in.) Width (overall) 152 cm (60 in.) Tire Size 26 x 9-12R (Front) 26 x 11-12R (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) - Change 3.34 L (3.4 U.S. qt) - Overhaul 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 8 10 Spark Arrester Muffler 6 8 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 8 11 Master Cylinder Frame 25 34 Rear Caliper Knuckle 20 27 Front Caliper**** Knuckle 35 47 SUSPENSION COMPONENTS (Front) A-Arm (Upper) Frame 42 57 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 35 48 A-Arm**** Knuckle 35 48 SUSPENSION COMPONENTS (Rear) Sway Bar Mount Frame 35 48 Sway Bar Sway Bar Link 20 27 Sway Bar Link A-Arm 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 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 EPS Mounting Bracket EPS Assembly 35 48 EPS Assembly Frame 20 27 CHASSIS/ROPS ASSEMBLY Door Latch Bracket Frame 8 11 Door Hinge Frame 20 27 Shift Lever Shift Mount Bracket 20 27 Shift Cable Shift Axle Arm 8 11 Front ROPS Tube Frame 40 54 Front ROPS Tube Rear ROPS Tube 40 54 Rear ROPS Tube Frame 40 54 Cargo Box Frame 5 7 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 8 11 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 6 8 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 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 wheel) Hub (20 ft-lb increments) 40 54 Wheel (aluminum wheel w/ black nuts) Hub (20 ft-lb increments) 60 81 Wheel (aluminum wheel w chrome nuts)) 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 7 9.5 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 7 9.5 Driven Clutch Input Shaft 35 48 Drive Clutch Crankshaft 60 81 Magneto Cover Crankcase 7 9.5 Tappet Cover Valve Cover 7 9.5 Oil Pump Crankcase 8 10 Rotor/Flywheel Crankshaft 60 81 Cam Sprocket** Camshaft 7 9.5 Inner Clutch Cover Engine 8 11 Camshaft Holder* Cylinder Head 7 9.5 Shifter Housing Crankcase 8 11 Starter Motor Crankcase 8 11 Outer Clutch Cover Inner Cover 5 5.5 Intake Boot Clamp Intake Boot 30 in.-lb 3.4 Starter One-Way Clutch** Rotor/Flywheel 20 27 Fuel Rail Engine 6 8 Air Filter Housing Frame 5 7 Ground Wire Engine 7 9.5 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 7 9.5 Oil Filter Union Crankcase 20 27 Phase Plate Sprocket 7 9.5 Timing Inspection Plug Magneto Cover 10 17 Magneto Plug Magneto Cover 8 11 Oil Hose Fitting Crankcase 25 34 PTO-Side Cover Crankcase 7 9.5 Tensioner Cap Tensioner 15 20 Upper Chain Guide Cylinder Head 7 9.5 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 1 1.4 26 35.4 51 69.4 76 103.4 2 2.7 27 36.7 52 70.7 77 104.7 3 4.1 28 38.1 53 72.1 78 106.1 4 5.4 29 39.4 54 73.4 79 107.4 5 6.8 30 40.8 55 74.8 80 108.8 6 8.2 31 42.2 56 76.2 81 110.2 7 9.5 32 43.5 57 77.5 82 111.5 8 10.9 33 44.9 58 78.9 83 112.9 9 12.2 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 I I C Fuses I R Air Filter I I* R Valve/Tappet Clearance I I A Engine Compression I Spark Plugs I I I R (4000 Mi or 18 Mo) Muffler/Spark Arrester C R Gas Hoses I I R (2 Yrs) Throttle Cable Ends/Accelerator Pedal Pivot I I C-L A-R Engine Oil/Filter R R*/R**/R*** A/R Front Differential Lubricant R I R Transaxle Lubricant R I R (2000Mi) Tires/Air Pressure I I R Steering Components I I I R V-Belt I l R Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows) I I R Nuts/Bolts/Cap Screws T T A Ignition Timing I Headlight/Taillight-Brakelight I I R Switches I I R Shift Lever I A-L Gauge/Indicators I I R Frame/Welds I I l Electrical Connections l C Complete Brake System I I Brake Pads I I* R Brake Fluid I I R (2 Yrs) Brake Hoses I I R (4 Yrs) Coolant/Cooling System I I R (2 Yrs) Wheel Lug Nuts T T

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. WS025A 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. WS035A ! 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.