2013 Arctic Cat Wildcat ROV Service & Repair Manual

FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2013 Arctic Cat Wildcat models (see cover). The complete manual is designed to aid service personnel in service-oriented applica- tions. 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 wor- thy 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.

1 TABLE OF CONTENTS General Information .............................................................. 2 General Specifications ............................................................... 2 Torque Specifications................................................................. 3 Torque Conversions (ft-lb/N-m) .................................................. 4 Break-In Procedure.................................................................... 4 Gasoline - Oil - Lubricant ........................................................... 4 Genuine Parts ............................................................................ 5 Preparation For Storage ............................................................ 5 Preparation After Storage .......................................................... 5 Periodic Maintenance/Tune-Up ............................................ 7 Periodic Maintenance Chart ...................................................... 7 Lubrication Points ...................................................................... 8 Air Filter ..................................................................................... 8 Valve/Tappet Clearance ............................................................. 8 Testing Engine Compression ..................................................... 9 Spark Plugs ............................................................................. 10 Muffler/Spark Arrester.............................................................. 10 Engine/Transmission Oil - Filter ............................................... 11 Front Differential - Rear Drive Lubricant .................................. 12 Driveshaft/Coupling ................................................................. 12 Nuts/Bolts/Cap Screws ............................................................ 12 Headlight/Taillight-Brakelight.................................................... 12 Shift Lever/Shift Cable ............................................................. 14 Hydraulic Brake System........................................................... 14 Burnishing Brake Pads ............................................................ 16 Replacing V-Belt (“Arctic Cat” Clutch) ...................................... 16 Replacing V-Belt (“Rapid Response” Clutch) ........................... 17 Engine/Transmission .......................................................... 19 Troubleshooting ....................................................................... 20 Removing Engine/Transmission............................................... 22 Installing Engine/Transmission ................................................ 26 Servicing “Arctic Cat Clutch” Engine........................................ 30 Servicing “Rapid Response Clutch” Engine............................. 73 Fuel/Lubrication/Cooling .................................................. 120 Electronic Fuel Injection......................................................... 120 Gas Tank................................................................................ 121 Gas/Vent Hoses ..................................................................... 122 Oil Filter/Oil Pump.................................................................. 122 Oil Cooler ............................................................................... 123 Liquid Cooling System ........................................................... 123 Radiator ................................................................................. 123 Thermostat............................................................................. 124 Fans ....................................................................................... 125 Water Pump ........................................................................... 125 Fuel Pump/Fuel Level Sensor................................................ 126 Troubleshooting ..................................................................... 128 Electrical System .............................................................. 129 Battery ................................................................................... 129 RPM Limiter ........................................................................... 130 Testing Electrical Components .............................................. 130 Accessory Receptacle/Connector ......................................... 130 Brakelight Switch ................................................................... 130 Engine Coolant Temperature (ECT) Sensor .......................... 131 Fan Motor............................................................................... 131 Power Distribution Module (PDM) .......................................... 131 Ignition Coil ............................................................................ 132 Manifold Absolute Pressure/Inlet Air Temperature (MAP/IAT) Sensor ................................................................................ 132 Speed Sensor ........................................................................ 133 Electronic Power Steering (EPS) ........................................... 133 Ignition Switch........................................................................ 134 Headlight Switch .................................................................... 135 Drive Select Switch ................................................................ 135 Reverse Override Switch ....................................................... 135 Front Drive Actuator ............................................................... 135 Stator Coil/Crankshaft Position (CKP) Sensor ....................... 136 Starter Motor.......................................................................... 137 Starter Relay .......................................................................... 137 Engine Control Module (ECM) ............................................... 138 Regulator/Rectifier ................................................................. 138 Headlights .............................................................................. 138 Taillight-Brakelight .................................................................. 138 Ignition Timing ....................................................................... 139 Tilt Sensor.............................................................................. 139 Throttle Position Sensor (TPS) .............................................. 140 EFI Diagnostic System .......................................................... 141 Troubleshooting ..................................................................... 146 Drive and Brake Systems................................................. 147 Front Drive Actuator ............................................................... 147 Front Differential .................................................................... 148 Drive Axles............................................................................. 160 Rear Gear Case..................................................................... 160 Hub ........................................................................................ 166 Hydraulic Brake Caliper ......................................................... 168 Troubleshooting ..................................................................... 171 Suspension ....................................................................... 172 Shock Absorbers ................................................................... 172 Front A-Arms ......................................................................... 172 Rear Trailing Arms ................................................................. 175 Wheels and Tires ................................................................... 176 Troubleshooting ..................................................................... 177 Steering/Frame/Controls .................................................. 178 Electronic Power Steering (EPS) ........................................... 178 Rack and Pinion Assembly .................................................... 180 Steering Wheel ...................................................................... 182 Steering Shaft ........................................................................ 182 Steering Knuckles .................................................................. 184 Checking/Adjusting Front Wheel Alignment........................... 186 Hood ...................................................................................... 187 Rear Body Panel .................................................................... 187 Accelerator Pedal................................................................... 188 Shift Lever .............................................................................. 188 Shift Cable ............................................................................. 189 LCD Gauge/Indicator Lights/Dash Switches.......................... 189 Exhaust System..................................................................... 190 Cargo Box .............................................................................. 190 Seats...................................................................................... 190 Troubleshooting ..................................................................... 191

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. General Specifications * Visible at plug threads. Specifications subject to change without notice. CHASSIS Dry Weight (approx) 592 kg (1305 lb) ROPS Tested Curb Weight 986 kg (2174 lb) - Wildcat 975 kg (2150 lb) - Wildcat X Length (overall) 304.8 cm (120 in.) - Wildcat 314.9 cm (124 in.) - Wildcat X Height (overall) 167.0 cm (65.8 in.) Width (overall) 162.6 cm (64 in.) Suspension Travel 43.2 cm (17 in.) (Front) 45.4 cm (18 in.) (Rear) Brake Type Hydraulic Disc (Four-Wheel) Tire Size (Wildcat) 26 x 9R14 (Front) 26 x 11R14 (Rear) Tire Size (Wildcat X) 27 x 9R14 (Front 27 x 11R14 (Rear) Tire Inflation Pressure 0.84 kg/cm² (12 psi) MISCELLANY Spark Plug Type NGK CPR8E Spark Plug Gap 0.5-0.6 mm (0.019-0.024 in.) Gas Tank Capacity 33.3 L (8.8 U.S. gal.) Coolant Capacity 3.3 L (3.5 U.S. qt) Front Differential Capacity 200 ml (6.7 fl oz)* Rear Drive Capacity 175 ml (5.9 fl oz)* Engine Oil Capacity 2.8 L (3.0 U.S. qt) - Overhaul 2.3 L (2.4 U.S. qt) - Change Gasoline (recommended) 87 Octane Regular Unleaded - Wildcat 91 Octane Regular Unleaded - Wildcat X Engine Oil (recommended) Arctic Cat ACX All Weather Synthetic Front Differential/Rear Drive Lubricant SAE Approved 80W-90 Hyp- oid Belt Width 32 mm (1.25”) - Rapid Response Clutch 35 mm (1.38”) - Arctic Cat Clutch Brake Fluid DOT 4 Taillight/Brakelight High Intensity LED Headlight High Intensity LED ELECTRICAL SYSTEM Spark Plug Cap 5000 ohms Ignition Coil (primary) Resistance (secondary) Less than 1 ohm (terminal (+) to ground (-)) 1.8M ohms (high tension - plug cap removed to either primary terminal (+)) Ignition Coil Primary Voltage Battery Voltage (orange (+) to ground) ELECTRICAL SYSTEM (cont.) Stator Coil (crankshaft position sensor) Resistance (AC generator) 150-250 ohms (brown/white to green/white) Less than 1 ohm (brown/ white to green/white) Crankshaft Position Sensor AC Voltage 2.0 or more (brown/white to green/white) AC Generator Output (no load) 75 AC volts @ 5000 RPM (black to black) 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) 0.1016 mm 0.1524 mm Valve Guide/Stem Clearance (max) 0.013 mm Valve Guide/Valve Stem Deflection (max) (wobble method) 0.35 mm Valve Guide Inside Diameter 5.000-5.012 mm Valve Stem Outside Diameter 4.972-4.987 mm Valve Stem Runout (max) 0.1 mm Valve Head Thickness (min) 2.3 mm Valve Face/Seat Width (intake) (exhaust) 2.25 mm 2.60 mm Valve Seat Angle 45° +15’/+30’ Valve Face Radial Runout (max) 0.2 mm 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) 34.18 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 Rocker Arm Inside Diameter (max) 12.018 mm Rocker Arm Shaft Outside Diameter (min) 11.97 mm Cylinder Head/Cover Distortion (max) 0.05 mm CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance 0.05 mm Cylinder Bore 91.992-92.008 mm Piston Diameter 15 mm from Skirt End 91.949-91.959 mm Piston Ring Free End Gap (min) (1st/2nd) 12.5 mm Bore x Stroke 92 x 71.6 mm Cylinder Trueness (max) 0.075 mm Piston Ring End Gap - Installed 0.38 mm Piston Ring to Groove Clearance 1st (max) (2nd) 0.034 mm 0.033 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) 20.012 mm Piston Pin Outside Diameter (min) 19.995 mm CRANKSHAFT Connecting Rod (max) (small end inside diameter) 20.021 mm Connecting Rod (big end side-to-side) 0.95 mm Connecting Rod (max) (small end deflection) 0.3 mm Crankshaft (web-to-web) 98 mm Crankshaft Runout (max) 0.03 mm Oil Pump Gerotor Clearance (max) 0.15 mm

3 Torque Specifications NOTE: Torque specifications have the following tolerances: *w/Red Loctite #263 ***w/Green Loctite #270 **w/Red Loctite #271 ****w/“Patch-Lock” *****w/Primer #7649 and Loctite #277 †Arctic Cat Clutch ††Rapid Response Clutch 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 Cylinder Head 20 27 Spark Arrester Muffler 72 in.-lb 8 BRAKE COMPONENTS Brake Disc** Hub 15 20 Brake Hose Caliper 20 27 Brake Hose Master Cylinder 20 27 Master Cylinder Frame 25 34 Caliper Holder**** Knuckle 20 27 SUSPENSION COMPONENTS (Front) A-Arm Frame 40 54 Knuckle**** Ball Joint 35 48 Shock Absorber Frame/Lower A-Arm 40 54 SUSPENSION COMPONENTS (Rear) Sway Bar Bracket Frame 40 54 Sway Bar Link Sway Bar Arm 35 48 Lower Trailing Arm Cross-Mount Frame 60 81 Upper Trailing Arm Frame 60 81 Shock Absorber (Lower) Trailing Arm 35 48 Shock Absorber (Upper) Frame 40 54 Knuckle Lower Trailing Arm 60 81 Knuckle Upper Trailing Arm 35 48 Upper/Lower Lateral Link Knuckle 40 54 Upper/Lower Lateral Link Frame 40 54 Cargo Box Cargo Box Support 72 in.-lb 8 CHASSIS/ROPS ASSEMBLY Shift Lever Shift Axle Bracket 20 27 Shift Cable Shift Arm 8 11 Front ROPS Tube Frame 25 34 Top ROPS Support Front/Rear ROPS Tubes 25 34 Rear ROPS Tube Lower ROPS Support 25 34 STEERING COMPONENTS Steering Wheel** Steering Wheel Shaft 25 34 Rack and Pinion Bracket Frame 20 27 Rack and Pinion Assembly Frame 25 34 Tie Rod** Rack 55 75 Tie Rod End** Knuckle 55 74 Jam Nut Tie Rod End 10 14 Steering Flex-Shaft Hold-Down Strap Housing 50 in.-lb 5.5 Tilt-Steering Link Frame 10 14 EPS Mounting Bracket EPS 35 48 EPS Assembly Frame 20 27 Steering Shaft Upper Collar Tilt Assembly 20 27 Steering Shaft Lower U-Clamp Frame 7 9 DRIVE TRAIN COMPONENTS Rear Drive/Gear Case Frame 38 52 Drive Coupler (Front) Drive Flange (Front) 40 54 Driveline Coupler Rear Drive Input Flange 20 27 Front Differential Frame/Differential Bracket 38 52 Carrier Bearing Bracket 38 52 Carrier Bearing Support Bracket Frame 20 27 Input Shaft Assembly Gear Case Housing 23 31 DRIVE TRAIN COMPONENTS (cont.) Part Part Bolted To Torque ft-lb N-m Secondary Drive Gear Nut Secondary Drive Gear 4 6 Pinion Housing Differential Housing 23 31 Thrust Button** Gear Case Cover 8 11 Differential Housing Cover*** Differential Housing 23 31 Lock Collar Differential Housing 125 170 Hub***** Axle (min) 250 340 Oil Drain Plug Front Differential - Rear Drive 45 in.-lb 5 Oil Fill/Level Plug Front Differential - Rear Drive 16 22 Oil Drain Plug Engine 16 22 Wheel Hub (20 ft-lb increments) 80 108 ENGINE/TRANSMISSION Front Engine Through-Bolt Frame 40 54 Rear Engine Through-Bolt Frame 40 54 Clutch Shoe** Crankshaft 221 300 Clutch Cover/Housing Assembly Crankcase 8 11 Lower Crankcase Cover (6 mm) Crankcase 8 11 Lower Crankcase Cover (8 mm) Crankcase 20 27 Crankcase Half Crankcase Half 8 11 Cylinder Head (Cap Screw) Crankcase (step 1) (step 2) (final) 20 30 37 27 40 50 Cylinder Head Nut (6 mm) Cylinder 8 11 Cylinder Head Nut (8 mm) Cylinder 18 24 Valve Cover Cylinder Head 8.5 11.5 Driven Clutch Nut** † Driveshaft 165 224 Movable Drive Face Nut** † Driveshaft 165 224 Driven Clutch Bolt** †† Input Shaft 60 81 Drive Clutch Bolt †† Crankshaft 60 81 Drive Clutch Spider***** †† Fixed Driven Hub 265 359 Ground Wire Engine 8 11 Magneto Cover Crankcase 112 in.-lb 12.5 Tappet Cover Valve Cover 9 12 Crankshaft Spacer Crankshaft 28 38 Oil Pump Drive Gear** Crank Balancer Shaft 62 84 Output Flange Nut** † Output Shaft 150 204 Output Pinion Nut* †† Output Shaft 150 204 Outer Magneto Cover Magneto Cover 8 11 Rotor/Flywheel Nut** Crankshaft 105 143 Cam Sprocket** Camshaft 11 15 CVT Cover Crankcase 8 11 Secondary Drive Gear Nut* Secondary Drive Output Shaft 200 270 Oil Filter Cover Crankcase 8 11 Shift Cam Stopper Crankcase 8 11 Shift Cam Stopper Spring Shift Cam Stopper 8 11 Shift Cam Plate Shift Cam Shaft 8 11 Shifter Housing Crankcase 8 11 Starter Motor Crankcase 8 11 V-Belt Cover Crankcase 8 11 Oil Pump Cover Crankcase 8 11 Oil Strainer Cap Crankcase 8 11 Intake Boot Clamp Intake Boot 30 in.-lb 3.4 Starter One-Way Clutch** Rotor/Flywheel 26 35 Fuel Rail Engine 6 8 Air Filter Housing Engine 6 8 Ground Wire Engine 8 11

4 Torque Conversions (ft-lb/N-m) Break-In Procedure ENGINE A new vehicle and an overhauled engine require a “break- in” period. The first 10 hours (or 200 miles) are most criti- cal to the life of this vehicle. Proper operation during this break-in period will help assure maximum life and perfor- mance from the vehicle. During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle. Varying the engine RPM during the break-in period allows the components to “load” (aiding the mating process) and then “unload” (allowing components to cool). Although it is essential to place some stress on the engine components during break- in, care should be taken not to overload the engine too often. Do not pull a trailer or carry heavy loads during the 10-hour break-in period. When the engine starts, allow it to warm up properly. Idle the engine several minutes until the engine has reached normal operating temperature. Do not idle the engine for excessively long periods of time. During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and vari- ations in driving speeds contribute to good engine break-in. After the completion of the break-in period, the engine oil and oil filter should be changed. Other maintenance after break-in should include checking of all prescribed adjust- ments and tightening of all fasteners (see Periodic Mainte- nance Chart in Periodic Maintenance/Tune-Up). DRIVE BELT 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 (Wildcat) or 91 (Wildcat X) 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/ TRANSMISSION 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 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 gasoline additives should be used. CAUTION On the Wildcat, 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.

5 RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE 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. FILLING GAS TANK ATV0049B 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. 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 battery, 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. CAUTION Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive 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. ! 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.

6 4. Change the engine/transmission oil and filter. 5. Check the coolant level and add properly mixed coolant 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 tightened 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. CAUTION The ignition switch must be in the OFF position prior to installing the battery or damage may occur to the ignition system. CAUTION Connect the positive battery cable first; then the nega- tive.

7 Periodic Maintenance/ Tune-Up This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat Wildcat. SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section. Refer to the current Special Tools Catalog for the appropriate 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 Valve Clearance Adjuster 0444-255 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-Transmission Oil/Filter R R*/R**/R*** A/R Front Differential - Rear Drive Lubricant I I R 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

2013 Arctic Cat Wildcat ROV Service & Repair Manual

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