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2012 Arctic Cat Wildcat Service Manual – PDF DOWNLOAD
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2012 Arctic Cat Wildcat Service Manual – PDF DOWNLOAD
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Description
2012 Arctic Cat Wildcat Service Manual – PDF DOWNLOAD
DESCRIPTION:
2012 Arctic Cat Wildcat Service Manual – PDF DOWNLOAD
Break-In Procedure:
A new vehicle and an overhauled engine require a “breakin” period. The first 10 hours (or 200 miles) are most critical to the life of this vehicle. Proper operation during this break-in period will help assure maximum life and performance 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 breakin, 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 variations 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 adjustments and tightening of all fasteners (see Periodic Maintenance Chart in Periodic Maintenance/Tune-Up).
TABLE OF CONTENTS:
2012 Arctic Cat Wildcat Service Manual – PDF DOWNLOAD
Foreword ..................................................................................................................................... 1 TABLE OF CONTENTS............................................................................................................................. 2 General Information....................................................................................................................... 3 General Specifications.................................................................................................................... 3 Torque Specifications..................................................................................................................... 4 Torque Conversions (ft-lb/N-m)............................................................................................................ 5 Break-In Procedure........................................................................................................................ 5 Gasoline - Oil - Lubricant................................................................................................................ 5 RECOMMENDED GASOLINE.................................................................................................................. 5 RECOMMENDED ENGINE/ TRANSMISSION OIL.................................................................................................. 5 RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT................................................................................... 5 FILLING GAS TANK...................................................................................................................... 6 Genuine Parts............................................................................................................................. 6 Preparation For Storage................................................................................................................... 6 Preparation After Storage................................................................................................................. 6 Periodic Maintenance/ Tune-Up............................................................................................................. 8 SPECIAL TOOLS......................................................................................................................... 8 Periodic Maintenance Chart................................................................................................................ 8 Lubrication Points........................................................................................................................ 9 Air Filter................................................................................................................................ 9 CLEANING AND INSPECTING FILTER........................................................................................................ 9 CHECKING AND CLEANING DRAINS.......................................................................................................... 9 Valve/Tappet Clearance.................................................................................................................... 9 Feeler Gauge Procedure................................................................................................................ 10 Valve Adjuster Procedure.............................................................................................................. 10 Testing Engine Compression................................................................................................................ 10 Spark Plugs............................................................................................................................... 11 Muffler/Spark Arrester.................................................................................................................... 11 Engine/Transmission Oil - Filter.......................................................................................................... 12 OIL - FILTER.......................................................................................................................... 12 Front Differential - Rear Drive Lubricant................................................................................................. 13 Driveshaft/Coupling....................................................................................................................... 13 Nuts/Bolts/Cap Screws..................................................................................................................... 14 Headlight/Taillight- Brakelight........................................................................................................... 14 CHECKING/ADJUSTING HEADLIGHT AIM...................................................................................................... 14 Shift Lever/Shift Cable................................................................................................................... 15 ADJUSTING............................................................................................................................. 15 Hydraulic Brake System.................................................................................................................... 15 CHECKING/BLEEDING..................................................................................................................... 15 INSPECTING HOSES...................................................................................................................... 16 CHECKING/REPLACING PADS............................................................................................................... 16 BRAKE DISC............................................................................................................................ 17 Burnishing Brake Pads..................................................................................................................... 17 Checking/Replacing V- Belt................................................................................................................ 17 REMOVING.............................................................................................................................. 17 INSTALLING............................................................................................................................ 17 Troubleshooting Brake System.............................................................................................................. 18 Engine/Transmission....................................................................................................................... 19 SPECIAL TOOLS......................................................................................................................... 19 Troubleshooting........................................................................................................................... 20 Removing Engine/ Transmission............................................................................................................. 22 Top-Side Components....................................................................................................................... 26 Removing Top-Side Components.............................................................................................................. 27 A. Valve Cover/Rocker Arms B. Cylinder Head/Camshaft.................................................................................. 27 C. Cylinders D. Pistons............................................................................................................... 29 Servicing Top-Side Components............................................................................................................. 30 VALVE ASSEMBLY........................................................................................................................ 30 Cleaning/Inspecting Valve Cover....................................................................................................... 30 Removing Valves....................................................................................................................... 31 Measuring Valve Stem Runout........................................................................................................... 31 Measuring Valve Stem Outside Diameter................................................................................................. 31 Measuring Valve Face/Seat Width....................................................................................................... 31 Measuring Valve Face Radial Runout.................................................................................................... 31 Measuring Valve Guide/Valve Stem Deflection (Wobble Method)........................................................................... 32 Measuring Valve Guide (Inside Diameter)............................................................................................... 32 Servicing Valves/Valve Guides/Valve Seats............................................................................................. 32 Measuring Rocker Arm (Inside Diameter)................................................................................................ 32 Measuring Rocker Arm Shaft (Outside Diameter)......................................................................................... 32 Installing Valves..................................................................................................................... 32 PISTON ASSEMBLY....................................................................................................................... 33 Removing Piston Rings................................................................................................................. 33 Cleaning/Inspecting Piston............................................................................................................ 33 Measuring Piston-Ring End Gap (Installed)............................................................................................. 33 Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore........................................................................... 33 Measuring Piston Skirt/Cylinder Clearance............................................................................................. 34 Installing Piston Rings............................................................................................................... 34 CYLINDER/CYLINDER HEAD ASSEMBLY....................................................................................................... 34 Cleaning/Inspecting Cylinder Head..................................................................................................... 35 Measuring Cylinder Head Distortion.................................................................................................... 35 Cleaning/Inspecting Cylinder.......................................................................................................... 35 Inspecting Cam Chain Guide............................................................................................................ 35 Inspecting Cylinder................................................................................................................... 35 Measuring Camshaft Runout............................................................................................................. 36 Measuring Camshaft Lobe Height........................................................................................................ 36 Inspecting Camshaft Bearing Journal................................................................................................... 36 Measuring Camshaft to Cylinder Head Clearance......................................................................................... 36 Inspecting Camshaft Spring/Drive Pin (Front Camshaft Only)............................................................................ 37 Installing Top-Side Components............................................................................................................ 37 A. Pistons B. Cylinders............................................................................................................... 37 C. Cylinder Head D. Valve Cover....................................................................................................... 38 Left-Side Components...................................................................................................................... 44 Removing Left-Side Components............................................................................................................. 44 A. Magneto Cover/Stator Coils B. Water Pump C. Shifter Assembly D. Rotor/Flywheel/Starter Clutch E. Speed Sensor/ Trigger Assembly.... 44 Servicing Left-Side Components............................................................................................................ 46 INSPECTING STARTER CLUTCH/ GEAR....................................................................................................... 46 REPLACING STARTER CLUTCH ASSEMBLY..................................................................................................... 47 REPLACING STARTER GEAR BEARING........................................................................................................ 47 INSPECTING STATOR COIL/ MAGNETO COVER ASSEMBLY........................................................................................ 48 REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR..................................................................................... 48 Installing Left-Side Components........................................................................................................... 48 Right-Side Components..................................................................................................................... 51 Removing Right-Side Components............................................................................................................ 51 A. CVT Cover B. Driven Pulley C. Clutch Cover D. Centrifugal Clutch................................................................... 51 Servicing Right-Side Components........................................................................................................... 53 INSPECTING CENTRIFUGAL CLUTCH SHOE.................................................................................................... 53 INSPECTING CLUTCH HOUSING............................................................................................................. 53 DRIVEN PULLEY ASSEMBLY................................................................................................................ 53 WATER PUMP DRIVE ASSEMBLY............................................................................................................. 53 Disassembling......................................................................................................................... 53 Inspecting............................................................................................................................ 54 Assembling............................................................................................................................ 54 Installing Right-Side Components.......................................................................................................... 54 Center Crankcase Components............................................................................................................... 56 Separating Crankcase Halves............................................................................................................... 56 Disassembling Crankcase Half.............................................................................................................. 57 Servicing Center Crankcase Components..................................................................................................... 59 SECONDARY OUTPUT DRIVE GEARS.......................................................................................................... 59 Initial Set-Up........................................................................................................................ 59 Checking Backlash..................................................................................................................... 60 Correcting Backlash................................................................................................................... 60 OIL PUMP ASSEMBLY..................................................................................................................... 61 Disassembling and Inspecting.......................................................................................................... 61 Assembling............................................................................................................................ 62 CRANKSHAFT ASSEMBLY................................................................................................................... 62 Measuring Connecting Rod (Small End Inside Diameter).................................................................................. 62 Measuring Connecting Rod (Small End Deflection)....................................................................................... 63 Measuring Connecting Rod (Big End Side-to-Side)....................................................................................... 63 Measuring Crankshaft (Runout)......................................................................................................... 63 Measuring Crankshaft (Web-to- Web).................................................................................................... 63 COUNTERSHAFT.......................................................................................................................... 63 Disassembling......................................................................................................................... 63 Assembling............................................................................................................................ 64 Assembling Crankcase Half................................................................................................................. 66 Joining Crankcase Halves.................................................................................................................. 68 Installing Engine/ Transmission........................................................................................................... 70 Fuel/Lubrication/Cooling.................................................................................................................. 74 SPECIAL TOOLS......................................................................................................................... 74 Electronic Fuel Injection................................................................................................................. 74 TROUBLESHOOTING....................................................................................................................... 74 REMOVING THROTTLE BODY................................................................................................................ 74 INSTALLING THROTTLE BODY.............................................................................................................. 75 Gas Tank.................................................................................................................................. 75 REMOVING.............................................................................................................................. 75 INSTALLING............................................................................................................................ 76 Gas/Vent Hoses............................................................................................................................ 76 Oil Filter/Oil Pump....................................................................................................................... 76 TESTING OIL PUMP PRESSURE............................................................................................................. 76 REMOVING/DISASSEMBLING................................................................................................................ 76 CLEANING AND INSPECTING............................................................................................................... 76 ASSEMBLING/INSTALLING................................................................................................................. 76 Oil Cooler................................................................................................................................ 77 REMOVING.............................................................................................................................. 77 CLEANING AND INSPECTING............................................................................................................... 77 INSTALLING............................................................................................................................ 77 Liquid Cooling System..................................................................................................................... 77 Radiator.................................................................................................................................. 77 REMOVING.............................................................................................................................. 77 INSTALLING............................................................................................................................ 78 Thermostat................................................................................................................................ 79 REMOVING.............................................................................................................................. 79 INSPECTING............................................................................................................................ 79 INSTALLING............................................................................................................................ 79 Fans...................................................................................................................................... 79 REMOVING.............................................................................................................................. 79 INSTALLING............................................................................................................................ 79 Water Pump................................................................................................................................ 79 REMOVING.............................................................................................................................. 79 INSTALLING............................................................................................................................ 79 Fuel Pump/Fuel Level Sensor............................................................................................................... 80 TESTING............................................................................................................................... 80 REMOVING.............................................................................................................................. 80 INSPECTING............................................................................................................................ 81 INSTALLING............................................................................................................................ 81 Troubleshooting........................................................................................................................... 82 Electrical System......................................................................................................................... 83 SPECIAL TOOLS......................................................................................................................... 83 Battery................................................................................................................................... 83 Maintenance Charging.................................................................................................................. 83 Charging.............................................................................................................................. 84 RPM Limiter............................................................................................................................... 84 Testing Electrical Components............................................................................................................. 84 Accessory Receptacle/ Connector........................................................................................................... 84 VOLTAGE............................................................................................................................... 84 Brakelight Switch......................................................................................................................... 84 VOLTAGE (Wiring Harness Connector).................................................................................................... 84 RESISTANCE (Switch Connector)......................................................................................................... 85 Engine Coolant Temperature (ECT) Sensor................................................................................................... 85 Fan Motor................................................................................................................................. 85 RESISTANCE (Fan Motor Connector)...................................................................................................... 85 Power Distribution Module (PDM)........................................................................................................... 85 FUSES/RELAYS.......................................................................................................................... 85 Ignition Coil............................................................................................................................. 86 VOLTAGE (Primary Coil)................................................................................................................ 86 RESISTANCE............................................................................................................................ 86 Primary Winding....................................................................................................................... 86 Secondary Winding..................................................................................................................... 86 Spark Plug Cap........................................................................................................................ 86 EFI Sensors/Components.................................................................................................................... 86 CRANKSHAFT POSITION (CKP) SENSOR...................................................................................................... 86 MANIFOLD ABSOLUTE PRESSURE/ INLET AIR TEMPERATURE (MAP/IAT) SENSOR.................................................................... 86 Speed Sensor.............................................................................................................................. 87 Electronic Power Steering (EPS)........................................................................................................... 87 Ignition Switch........................................................................................................................... 88 VOLTAGE............................................................................................................................... 88 Headlight Switch.......................................................................................................................... 89 VOLTAGE............................................................................................................................... 89 Drive Select Switch....................................................................................................................... 89 RESISTANCE............................................................................................................................ 89 VOLTAGE............................................................................................................................... 89 Reverse Override Switch................................................................................................................... 89 VOLTAGE............................................................................................................................... 89 Front Drive Actuator...................................................................................................................... 89 VOLTAGE............................................................................................................................... 90 Stator Coil/Crankshaft Position (CKP) Sensor.............................................................................................. 90 VOLTAGE (AC Generator - Regulated Output)............................................................................................. 90 VOLTAGE (AC Generator - No Load)...................................................................................................... 90 RESISTANCE (AC Generator)............................................................................................................. 90 RESISTANCE (Crankshaft Position Sensor)............................................................................................... 91 AC VOLTAGE............................................................................................................................ 91 Crankshaft Position Sensor............................................................................................................ 91 Starter Motor............................................................................................................................. 91 REMOVING.............................................................................................................................. 91 INSTALLING............................................................................................................................ 91 TESTING VOLTAGE....................................................................................................................... 91 Starter Relay............................................................................................................................. 91 Engine Control Module (ECM)............................................................................................................... 92 Regulator/Rectifier....................................................................................................................... 92 TESTING............................................................................................................................... 92 Headlights................................................................................................................................ 92 VOLTAGE............................................................................................................................... 92 Taillight-Brakelight...................................................................................................................... 92 VOLTAGE (Taillight)................................................................................................................... 92 VOLTAGE (Brakelight).................................................................................................................. 92 Ignition Timing........................................................................................................................... 93 Tilt Sensor............................................................................................................................... 93 SUPPLY VOLTAGE........................................................................................................................ 93 OUTPUT VOLTAGE........................................................................................................................ 93 Throttle Position Sensor (TPS)............................................................................................................ 94 INSPECTING............................................................................................................................ 94 REMOVING.............................................................................................................................. 95 INSTALLING/ADJUSTING.................................................................................................................. 95 Diagnostic Trouble Codes (DTC)............................................................................................................ 95 Code List............................................................................................................................. 95 Troubleshooting........................................................................................................................... 97 Drive System.............................................................................................................................. 98 GENERAL INFORMATION................................................................................................................... 98 SPECIAL TOOLS......................................................................................................................... 98 Front Drive Actuator...................................................................................................................... 98 REMOVING.............................................................................................................................. 98 INSTALLING............................................................................................................................ 98 Front Differential........................................................................................................................ 99 REMOVING.............................................................................................................................. 99 Disassembling Input Shaft.............................................................................................................101 Assembling Input Shaft................................................................................................................102 Disassembling Differential Assembly...................................................................................................103 Disassembling Pinion Gear.............................................................................................................104 Assembling Pinion Gear................................................................................................................105 Shimming Procedure/Shim Selection.....................................................................................................106 Backlash..............................................................................................................................106 Ring Gear End-Play....................................................................................................................107 Assembling Differential Assembly......................................................................................................108 Removing/Installing Axle Seal.........................................................................................................109 INSTALLING DIFFERENTIAL...............................................................................................................110 Drive Axles...............................................................................................................................112 REMOVING/INSTALLING DRIVE AXLES.......................................................................................................112 CLEANING AND INSPECTING AXLES.........................................................................................................112 DISASSEMBLING/ASSEMBLING AXLES........................................................................................................112 Rear Gear Case............................................................................................................................112 REMOVING..............................................................................................................................112 RING GEAR/THRUST BUTTON...............................................................................................................114 Removing..............................................................................................................................114 Inspecting............................................................................................................................114 Installing/Shimming...................................................................................................................114 REAR DRIVE INPUT SHAFT/ HOUSING.......................................................................................................114 Removing/Disassembling................................................................................................................114 Cleaning and Inspecting...............................................................................................................115 Assembling/Installing.................................................................................................................116 INSTALLING............................................................................................................................116 Hub.......................................................................................................................................118 REMOVING..............................................................................................................................118 CLEANING AND INSPECTING...............................................................................................................119 REPLACING WHEEL STUDS.................................................................................................................119 INSTALLING............................................................................................................................119 Hydraulic Brake Caliper...................................................................................................................120 REMOVING/DISASSEMBLING................................................................................................................120 CLEANING AND INSPECTING...............................................................................................................121 ASSEMBLING/INSTALLING.................................................................................................................121 MASTER CYLINDER ASSEMBLY..............................................................................................................122 Removing..............................................................................................................................122 Inspecting............................................................................................................................123 Installing............................................................................................................................123 Troubleshooting...........................................................................................................................123 Suspension................................................................................................................................124 Shock Absorbers...........................................................................................................................124 REMOVING..............................................................................................................................124 CLEANING AND INSPECTING...............................................................................................................124 INSTALLING............................................................................................................................124 Front A-Arms..............................................................................................................................125 REMOVING..............................................................................................................................125 CLEANING AND INSPECTING...............................................................................................................125 INSTALLING............................................................................................................................125 Rear Trailing Arms........................................................................................................................127 REMOVING..............................................................................................................................127 INSPECTING............................................................................................................................127 INSTALLING............................................................................................................................127 Wheels and Tires..........................................................................................................................129 TIRE SIZE.............................................................................................................................129 TIRE INFLATION PRESSURE...............................................................................................................129 REMOVING..............................................................................................................................129 CLEANING AND INSPECTING...............................................................................................................129 INSTALLING............................................................................................................................129 CHECKING/INFLATING....................................................................................................................129 Troubleshooting...........................................................................................................................129 Steering/Frame/Controls...................................................................................................................130 Electronic Power Steering (EPS)...........................................................................................................130 REMOVING..............................................................................................................................130 INSTALLING............................................................................................................................131 Rack and Pinion Assembly..................................................................................................................132 REMOVING..............................................................................................................................132 INSPECTING............................................................................................................................133 INSTALLING............................................................................................................................133 Steering Wheel............................................................................................................................134 REMOVING..............................................................................................................................134 INSPECTING............................................................................................................................134 INSTALLING............................................................................................................................134 Steering Shaft............................................................................................................................134 REMOVING..............................................................................................................................134 INSPECTING............................................................................................................................136 INSTALLING............................................................................................................................136 Steering Knuckles.........................................................................................................................137 REMOVING AND DISASSEMBLING............................................................................................................137 CLEANING AND INSPECTING...............................................................................................................138 ASSEMBLING AND INSTALLING.............................................................................................................138 Checking/Adjusting Front Wheel Alignment..................................................................................................139 Hood......................................................................................................................................140 REMOVING..............................................................................................................................140 INSTALLING............................................................................................................................140 Rear Body Panel...........................................................................................................................140 REMOVING..............................................................................................................................140 INSTALLING............................................................................................................................141 Accelerator Pedal.........................................................................................................................141 REMOVING..............................................................................................................................141 INSTALLING............................................................................................................................141 Shift Lever...............................................................................................................................141 REMOVING..............................................................................................................................141 INSTALLING............................................................................................................................141 Shift Cable...............................................................................................................................142 REMOVING..............................................................................................................................142 INSTALLING............................................................................................................................142 LCD Gauge/Indicator Lights/Dash Switches..................................................................................................142 REPLACING.............................................................................................................................142 Exhaust System............................................................................................................................143 REMOVING MUFFLER......................................................................................................................143 INSPECTING MUFFLER....................................................................................................................143 INSTALLING MUFFLER....................................................................................................................143 Cargo Box.................................................................................................................................143 REMOVING..............................................................................................................................143 INSTALLING............................................................................................................................143 Seats.....................................................................................................................................143 REMOVING/INSTALLING...................................................................................................................143 Troubleshooting...........................................................................................................................144
2012 ARCTIC CAT WILDCAT SERVICE MANUAL – PDF DOWNLOAD:
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