2014 Arctic Cat Wildcat Trail ROV ATV Service Manual

Arctic Cat Wildcat Service Manual 2014 This manual is comprised of the 2014 Wildcat manual and the 2014 Wildcat Trail manual. Use the links below or the bookmarks to the left to get to the manual that covers your model. 2014 Arctic Cat Wildcat service manual 2014 Arctic Cat Wildcat Trail service manual

[ROV] SERVICE MANUAL 2014 WILDCAT/X - WILDCAT 4/4X

FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2014 Arctic Cat Wildcat models (see cover). The complete manual is designed to aid service personnel in service-oriented 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 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 Valve/Tappet Clearance ................................................................ 7 Testing Engine Compression ........................................................ 8 Spark Plugs................................................................................... 9 Muffler/Spark Arrester ................................................................... 9 Engine/Transmission Oil - Filter .................................................. 10 Front Differential - Rear Drive Lubricant ..................................... 11 Driveshaft/Coupling..................................................................... 11 Nuts/Bolts/Cap Screws ............................................................... 11 Headlight/Taillight-Brakelight ....................................................... 11 Shift Lever/Shift Cable ................................................................ 13 Hydraulic Brake System.............................................................. 13 Burnishing Brake Pads................................................................ 15 Replacing V-Belt ......................................................................... 16 Steering/Frame/Controls ............................................................. 18 Hood ........................................................................................... 18 Front Bumper Assembly (X/4X/Limited) ...................................... 18 Rear Body Panel ......................................................................... 18 Electronic Power Steering (EPS) ................................................ 19 Rack and Pinion Assembly ......................................................... 22 Steering Wheel ........................................................................... 23 Steering Shaft ............................................................................. 24 Steering Knuckles ....................................................................... 26 Checking/Adjusting Front Wheel Alignment ................................ 27 Accelerator Pedal ........................................................................ 28 Shift Lever ................................................................................... 28 Shift Cable .................................................................................. 29 LCD Gauge/Indicator Lights/Dash Switches ............................... 29 Exhaust System .......................................................................... 30 Cargo Box ................................................................................... 30 Seats ........................................................................................... 30 Doors .......................................................................................... 31 Roof (X Limited) .......................................................................... 32 Troubleshooting........................................................................... 33 Engine/Transmission ................................................................... 34 Troubleshooting........................................................................... 35 Removing Engine/Transmission (Wildcat/X) ............................... 37 Removing Engine/Transmission (Wildcat 4/4X) .......................... 41 Top-Side Components ................................................................ 46 Left-Side Components ................................................................ 63 Removing Left-Side Components ............................................... 63 Servicing Left-Side Components ................................................ 66 Installing Left-Side Components ................................................. 68 Right-Side Components .............................................................. 70 Removing Right-Side Components............................................. 70 Servicing Right-Side Components .............................................. 71 Installing Right-Side Components............................................... 77 Center Crankcase Components.................................................. 79 Separating Crankcase Halves..................................................... 79 Disassembling Crankcase Half ................................................... 80 Servicing Center Crankcase Components .................................. 82 Assembling Crankcase Half ........................................................ 89 Joining Crankcase Halves........................................................... 90 Installing Engine/Transmission (Wildcat/X) ................................. 92 Installing Engine/Transmission (Wildcat 4/4X) ............................ 95 Fuel/Lubrication/Cooling .............................................................99 Throttle Body ...............................................................................99 Gas Tank ...................................................................................100 Gas/Vent Hoses.........................................................................101 Oil Filter/Oil Pump .....................................................................101 Oil Cooler ..................................................................................102 Liquid Cooling System...............................................................102 Radiator .....................................................................................102 Thermostat ................................................................................103 Fans...........................................................................................104 Water Pump...............................................................................104 Fuel Pump/Fuel Level Sensor ...................................................105 Troubleshooting .........................................................................107 Electrical System........................................................................108 Battery .......................................................................................108 RPM Limiter ...............................................................................109 Accessory Receptacle/Connector .............................................109 Brakelight Switch .......................................................................109 Engine Coolant Temperature (ECT) Sensor ..............................110 Fan Motor ..................................................................................110 Power Distribution Module (PDM) .............................................110 Ignition Coil ................................................................................111 Manifold Absolute Pressure/Inlet Air Temperature (MAP/IAT) Sensor ....................................................................................111 Speed Sensor ............................................................................112 Electronic Power Steering (EPS) ...............................................112 Ignition Switch ...........................................................................114 Headlight Switch........................................................................114 Drive Select Switch ...................................................................114 Reverse Override Switch ...........................................................115 Front Drive Actuator ..................................................................115 Stator Coil/Crankshaft Position (CKP) Sensor ..........................115 Starter Motor .............................................................................116 Starter Relay .............................................................................117 Engine Control Module (ECM) ..................................................117 Regulator/Rectifier .....................................................................117 Headlights .................................................................................118 Taillight-Brakelight .....................................................................118 Ignition Timing ...........................................................................118 Tilt Sensor .................................................................................118 Throttle Position Sensor (TPS) ..................................................119 EFI Diagnostic System ..............................................................120 Troubleshooting .........................................................................125 Drive and Brake Systems ..........................................................126 Front Drive Actuator ..................................................................126 Front Differential ........................................................................127 Driveshaft (Wildcat 4/4X) ...........................................................139 Drive Axles ................................................................................142 Rear Gear Case ........................................................................145 Hub ............................................................................................151 Hydraulic Brake Caliper (Wildcat)..............................................153 Hydraulic Brake Caliper (X/Wildcat 4/4X) ..................................156 Master Cylinder Assembly .........................................................159 Troubleshooting Drive System...................................................161 Troubleshooting Brake System..................................................161 Suspension .................................................................................162 Shock Absorbers .......................................................................162 Shock Absorbers (Limited) .......................................................176 Front A-Arms .............................................................................178 Rear Trailing Arms .....................................................................181 Wheels and Tires ......................................................................183 Troubleshooting .........................................................................184

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 Curb Weight (approx) 649.5 kg (1432 lb) - Wildcat 658.6 kg (1452 lb) - X 681.3 kg (1502 lb) - X Limited 738.9 kg (1629 lb) - Wildcat 4 ROPS Tested Curb Weight 981 kg (2162 lb) - Wildcat/X 1265 kg (2789 lb) - Wildcat 4/4X Length (overall) 304.8 cm (120 in.) - Wildcat 314.9 cm (124 in.) - X 378.5 cm (149 in.) - Wildcat4/4X Height (overall) 167.0 cm (65.8 in.) Width (overall) 162.6 cm (64 in.) Tire Size (Wildcat/Wildcat 4/4X) 26 x 9R14 (Front) 26 x 11R14 (Rear) Tire Size (X) 27 x 9R14 (Front 27 x 11R14 (Rear) Tire Inflation Pressure 0.84 kg/cm² (12 psi) - Wildcat/X 1.12 kg/cm² (16 psi) - Wildcat 4/ 4X/Limited 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/Wildcat 4 91 Octane Regular Unleaded - X/ 4X Engine Oil (recommended) Arctic Cat ACX All Weather Syn- thetic Front Differential/Rear Drive Lubri- cant SAE Approved 80W-90 Hypoid Belt Width 32 mm (1.25”) Brake Fluid DOT 4 Taillight/Brakelight High Intensity LED Headlight High Intensity LED ELECTRICAL SYSTEM Spark Plug Cap 5000 ohms Ignition Coil Resistance (primary) (secondary) Less than 1 ohm 1.8M ohms Ignition Coil Primary Voltage Battery Voltage Stator Coil (crankshaft position sensor) Resistance (AC generator) 150-250 ohms Less than 1 ohm Crankshaft Position Sensor AC Voltage 2.0 or more AC Generator Output (no load) 75 AC volts @ 5000 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) 0.1016 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 (small end inside diameter) (max) 20.021 mm Connecting Rod (big end side-to-side) 0.95 mm Connecting Rod (small end deflection) (max) 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 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 6 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 Front Brake Caliper (Wildcat 4/ 4X) Knuckle 35 48 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 Sway Bar Link Lower Trailing Arm 35 48 Trailing Arm Cross Mount (min) 60 81 Lower Trailing Arm Cross- Mount 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 CHASSIS/ROPS ASSEMBLY Shift Lever Shift Axle Bracket 20 27 Shift Cable Shift Arm 8 11 Front ROPS Tube Frame 35 48 Top ROPS Support Front/Rear ROPS Tubes 35 48 Rear ROPS Tube Lower ROPS Support 35 48 Cargo Box Cargo Box Support 6 8 Seat Belt Retractor Frame 60 81 Seat Belt Flange Frame 60 81 Seat Belt Buckle Frame 60 81 Shoulder Anchor ROPS Hoop 35 48 Front Bumper Frame 20 27 Upper Bumper Support Front Bumper 20 27 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 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 Part Part Bolted To Torque ft-lb N-m Rear Drive/Gear Case Frame 38 52 Drive Coupler (Front) Drive Flange 40 54 Drive Coupler (Rear) Drive Flange 40 54 Front Differential Frame/Differential Bracket 38 52 Set Screw** (Wildcat 4/4X) Carrier Bearing 75 in.-lb 8.5 Center Front Driveshaft (Wildcat 4/4X) Front Driveshaft 40 54 Center Rear Driveshaft (Wildcat 4/4X) Rear Driveshaft 40 54 Carrier Bearing Bracket 35 52 Carrier Bearing Support Bracket Frame 20 27 Input Shaft Assembly Gear Case Housing 23 31 Secondary Drive Gear Nut Secondary Drive Gear 48 in.-lb 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 Wheel Hub (20 ft-lb increments) 80 108 Bead Lock (Limited) Wheel 11 15 ENGINE/TRANSMISSION Oil Drain Plug Engine 20 27 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 10 14 Lower Crankcase Cover (8 mm) Crankcase 21 28 Crankcase Half Crankcase Half 21 28 Cylinder Head (Cap Screw) Crankcase (step 1) (step 2) (final) 20 30 37 27 41 50 Cylinder Head Nut (6 mm) Cylinder 8.5 11.5 Cylinder Head Nut (8 mm) Cylinder 21 28 Valve Cover Cylinder Head 8.5 11.5 Driven Clutch Bolt** Input Shaft 60 81 Drive Clutch Bolt Crankshaft 60 81 Drive Clutch Spider***** Fixed Driven Hub 265 359 Magneto Cover Crankcase 8.5 11.5 Tappet Cover Valve Cover 8.5 11.5 Crankshaft Spacer Crankshaft 28 38 Oil Pump Drive Gear** Crank Balancer Shaft 62 84 Output Pinion Nut* Output Shaft 150 204 Outer Magneto Cover Magneto Cover 8 11 Rotor/Flywheel Nut** Crankshaft 107 145 Cam Sprocket** Camshaft 10 14 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

4 *w/Red Loctite #263***w/Green Loctite #270 **w/Red Loctite #271 ****w/“Patch-Lock” *****w/Primer #7649 and Loctite #277 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 (Wildcat/Wildcat 4) or 91 (X/4X) minimum octane regular unleaded. In many areas, oxygenates are added to the gasoline. Oxy- genated 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 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. ENGINE/TRANSMISSION (cont) Air Filter Housing Engine 6 8 Ground Wire Engine 8 11 Stator Coil Magneto Cover (New) 15 20 Stator Coil Magneto Cover (Original) 13 18 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/Wildcat 4, 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 Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive damage.

5 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. 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. 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. ! 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. 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.

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 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

7 Lubrication Points It is advisable to lubricate certain components periodically to ensure free movement. Apply light oil to the components 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 cleaner housing cover and remove the cover. WC023A 2. Remove the air filter from the housing; then remove the foam filter medium. NOTE: Do not attempt to remove the inner foam from the wire mesh. It is part of the filter frame. WC024A 3. Fill a wash pan larger than the filter with a non-flam- mable cleaning solvent; then dip the inner filter and outer foam medium in the solvent and wash them. NOTE: Foam Filter Cleaner and Foam Filter Oil are available from Arctic Cat. 4. Dry both filter components. 5. Put the foam filter in a plastic bag; then pour in air filter oil and work the filter. NOTE: Apply oil to the 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. WC140 7. Clean any dirt or debris from inside the air cleaner. Be sure no dirt enters the throttle body. 8. Install the filter in the air filter housing. Position the filter frame on top. 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. Valve/Tappet Clearance To check and adjust valve/tappet clearance, use the following procedure. NOTE: The engine must be cold for this procedure. NOTE: On the Wildcat/X, the seats, left-side seat belt and anchor, left-side heat shroud and shield, cargo box, and rear body panel must be removed for this procedure. NOTE: On the Wildcat 4/4X, the rear seats, left-rear seat belt retractor, left-side heat shroud and shield, cargo box, and rear body 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.

2014 Arctic Cat Wildcat Trail ROV ATV Service Manual

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