PDF Service Manual 2016 Arctic Cat Wildcat Trail ATV - 7 MB
Keep your 2016 Arctic Cat Wildcat Trail in top shape with this factory service manual.
It covers everything from basic maintenance to complete engine overhauls.
This is the same manual used by dealership technicians, offering detailed diagrams and precise instructions.
Whether you're a seasoned mechanic or a dedicated owner, this guide is essential for any repair or service task.
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SERVICE MANUAL
®
www.arcticcat.com
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WT066A WT025A
2. If low, add Arctic Cat Transaxle Fluid as necessary.
CAUTION Tighten the fill/level plug to 16 ft-lb.
Do not over-fill the engine with oil. Always make sure
To change the lubricant, use the following procedure.
that the oil level is not above the upper mark.
12. Inspect the area around the drain plug and oil filter 1. Place the vehicle on level ground.
for leaks. 2. Remove each drain and fill plug.
3. Drain the lubricant into a drain pan.
Front Differential - 4. After all the lubricant has been drained, install the
Transaxle Lubricant drain plug and tighten to 18 ft-lb.
5. Pour the appropriate amount of recommended lubri-
To check front differential lubricant, use the following cant into the fill hole.
procedure. 6. Install the fill plug and tighten to 16 ft-lb.
1. Remove the level plug; lubricant should be level NOTE: If the lubricant is contaminated with water,
with the bottom threads. inspect the drain plug, fill plug, and/or bladder.
Headlight -
Taillight-Brakelight
HEADLIGHT BULB REPLACEMENT
1. Remove the wiring harness connector from the back
of the headlight.
2. Remove the rubber seal; then release the retaining
clip. Remove the bulb.
WT041A 3. Install the new bulb; then attach the retaining clip
2. If low, remove the fill plug and add lubricant until it and press on the rubber boot.
appears at the level plug threads. Tighten the fill plug 4. Connect the wiring harness.
to 16 ft-lb and the level plug to 45 in.-lb.
5. Adjust the headlight using the Checking/Adjusting
To check transaxle lubricant, use the following proce- Headlight Aim instructions in this sub-section.
dure.
REMOVING HEADLIGHT ASSEMBLY
1. Remove the fill/level plug; the lubricant level should
be level with the bottom of the plug threads. 1. Remove the grille.
NOTE: Removing the front fender will aid in
replacing the headlight assembly.
2. Remove the headlight adjustment cap screw.
10
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INSTALLING REAR BODY PANELS
1. If removed, install the clutch air intake tube through
the left rear body opening and secure it with the plate
and existing cap screws. Tighten securely.
WT028A
8. Loosen the clamp securing the clutch air intake tube
to engine; then pry the tube off of engine. Account
for the clamp.
WT484A
2. Install the tabs of the body panel into the slots in the
side panel; then route the air intake clutch tube to the
engine.
WT487A
9. Remove the fasteners securing the left rear body
panel.
WT490
WT250A
10. Remove the panel with the air/clutch intake tubes.
WT486
3. With the panel tabs in place, press the panel towards
the frame and maneuver the air intake tube inside the
boot.
WT486
20
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WT343
WT326
6. Install the dash; then install the steering wheel and
hood. 10. Using a suitable press, remove the bearing from the
knuckle.
Steering Knuckles
REMOVING AND DISASSEMBLING
1. Secure the vehicle on a support stand to elevate the
wheel; then remove the wheel.
2. Remove the nut securing the hub.
3. Remove the brake caliper.
4. Remove the hub assembly.
5. Remove the cotter pin from the tie rod end and WT327
remove the tie rod end from the knuckle.
CLEANING AND INSPECTING
6. Remove the upper cap screw securing the ball joint
in the knuckle. 1. Clean all knuckle components.
7. Tap the ball joint end out of the knuckle; then slide 2. Inspect the bearing for pits, scoring, rusting, or pre-
the axle out of the knuckle. mature wear.
8. Remove the cap screw securing the lower ball joint 3. Inspect the knuckle for cracks, breaks, or galling of
to the knuckle and remove the knuckle. the bearing surface.
ASSEMBLING AND INSTALLING
1. Using a suitable press and driver, press the bearing
into the knuckle until firmly seated; then install the
snap ring.
WT329A
9. Remove the snap ring securing the bearing in the
knuckle; then press the bearing out of the knuckle.
WT327
30
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Troubleshooting
Problem: Engine will not start or is hard to start (Compression too low)
Condition Remedy
1. Gasoline bad - contaminated 1. Drain gas - replace with clean gas
2. Valve clearance out of adjustment 2. Adjust clearance
3. Valve guides worn 3. Replace cylinder head
4. Valves mistimed 4. Retime engine
5. Piston rings worn - broken 5. Replace rings
6. Cylinder bore worn 6. Replace cylinder
7. Starter motor cranks too slowly - does not turn 7. See Electrical System
Problem: Engine will not start or is hard to start (No spark)
Condition Remedy
1. Spark plug(s) fouled 1. Clean - replace plug(s)
2. Spark plug(s) wet 2. Clean - dry plug(s)
3. Magneto defective 3. Replace stator coil
4. ECM defective 4. Replace ECM
5. Ignition coil defective 5. Replace ignition coil
6. High-tension lead open - shorted 6. Replace high tension lead
Problem: Engine will not start or is hard to start (No fuel reaching the fuel injector)
Condition Remedy
1. Gas tank vent hose obstructed 1. Clean vent hose
2. Fuel hose obstructed 2. Clean - replace hose
3. Fuel screens obstructed 3. Clean - replace inlet screen
4. Fuel pump defective 4. Replace fuel pump
Problem: Engine stalls easily
Condition Remedy
1. Gasoline bad - contaminated 1. Drain gas - replace with clean gas
2. Spark plug(s) fouled 2. Clean - replace plug(s)
3. Magneto defective 3. Replace stator coil
4. ECM defective 4. Replace ECM
5. Fuel injector obstructed 5. Replace fuel injector
6. Valve clearance out of adjustment 6. Adjust clearance
Problem: Engine noisy (Excessive valve chatter)
Condition Remedy
1. Valve clearance excessive 1. Adjust clearance
2. Valve spring(s) weak - broken 2. Replace spring(s)
3. Camshaft worn 3. Replace camshaft
Problem: Engine noisy (Noise seems to come from piston)
Condition Remedy
1. Piston - cylinder worn 1. Replace - service piston - cylinder
2. Combustion chamber carbon buildup 2. Clean cylinder head and piston
3. Piston pin - piston pin bore worn 3. Replace - service pin - replace connecting rod
4. Piston rings - ring groove(s) worn 4. Replace rings - piston
Problem: Engine noisy (Noise seems to come from timing chain)
Condition Remedy
1. Chain stretched 1. Replace chain
2. Sprockets worn 2. Replace sprockets
3. Tension adjuster malfunctioning 3. Repair - replace adjuster
Problem: Engine noisy (Noise seems to come from crankshaft)
Condition Remedy
1. Main bearing worn - burned 1. Replace bearing
2. Lower rod-end bearing worn - burned 2. Replace bearing
3. Rotor/flywheel loose 3. Tighten - replace flywheel - crankshaft
Problem: Engine noisy (Noise seems to come from crankcase)
Condition Remedy
1. Gears worn - chipped 1. Replace gears
2. Splines worn 2. Replace shaft(s)
3. Bearings worn 3. Replace bearings
4. Bushing worn 4. Replace bushing
40
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4. To select the correct replacement shim for an
out-of-specification clearance, note the three-digit
number on the surface of the existing shim; then
refer to the appropriate Tappet Shim Selection Table
(Exhaust or Intake) on the following pages and use
this procedure:
A. Find the Measured Tappet Clearance (from step 3) in
the left-side vertical column of the table.
B. Find the Present Shim Size (three-digit-number) at
the top-side horizontal column of the table.
C. Match the clearance in the vertical column with the
present shim size to obtain the recommended
ROV1-044
replacement shim.
17. Repeat step 16 for the other piston.
Cleaning/Inspecting Valve Cover
AT THIS POINT NOTE: If the valve cover cannot be trued, the cylin-
To service center crankcase components only, proceed der head assembly must be replaced.
to Removing Bottom-Side Components.
1. Wash the camshaft holder in parts-cleaning solvent.
2. Place the camshaft holder on the Surface Plate cov-
Servicing Top-Side ered with #400 grit wet-or-dry sandpaper. Using light
pressure, move the camshaft holder in a figure eight
Components motion. Inspect the sealing surface for any indication
of high spots. A high spot can be noted by a bright
metallic finish. Correct any high spots before assem-
MEASURING VALVE/TAPPET bly by continuing to move the camshaft holder in a
CLEARANCE figure eight motion until a uniform bright metallic
1. Rotate the engine two full revolutions. finish is attained.
NOTE: Rotating the engine two full revolutions will CAUTION
ensure that any oil trapped in the tappet/shim is
Do not remove an excessive amount of the sealing sur-
purged to maintain an accurate clearance reading.
face or damage to the camshaft will result. Always
2. Rotate the engine until the camshaft lobe of the valve check camshaft clearance when resurfacing the valve
being measured is directly away from the tappet. cover.
3. Using an appropriate thickness gauge, measure and
record the intake and exhaust valve clearance of the
cylinder that is on the compression stroke; then
rotate the engine 360° and measure and record the
valve clearance of the other cylinder. Valve clearance
must be within specifications.
Valve Clearance (Cold)
15°-25° C Intake: 0.16 mm (0.006 in.)
(59°-77° F)
Exhaust: 0.22 mm (0.009 in.)
WT581
CAUTION
Water or parts-cleaning solvent must be used in con-
junction with the wet-or-dry sandpaper or damage to
the sealing surface may result.
VALVE ASSEMBLY
When servicing valve assembly, inspect valve seats,
valve stems, valve faces, and valve stem ends for pits,
burn marks, or other signs of abnormal wear.
KC534A
NOTE: Whenever a valve is out of tolerance, it must
be replaced.
50
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NOTE: Applying a small bead of silicone between
the head cover and rubber gasket will aid in assem-
bling.
24. Tighten the head cover fasteners in the order shown
to 7 ft-lb with the rubber washers and steel cups.
ROV1-116A
28. Install the thermostat housing.
NOTE: Apply a small amount of grease to the
O-ring before installing.
WT163A
25. Install the cam timing sensor with O-ring (lightly
coated with grease).
WT168
Bottom-Side Components
WT165
26. Install the timing inspection and magneto plugs. NOTE: For efficiency, it is preferable to remove and
Tighten the timing inspection plug to 10 ft-lb and the disassemble only those components which need to be
magneto plug to 8 ft-lb. addressed and to service only those components. The
technician should use discretion and sound judgment.
AT THIS POINT
To service any one specific component, only limited dis-
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.
NOTE: The engine must be removed from the frame
for this procedure.
Removing Bottom-Side
Components
WT166A
27. Install the starter motor and secure with the two cap
1. Remove the cap screws securing the PTO-side cover
screws. to crankcase.
60
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ROV1-105 ROV1-107
17. If the flywheel and starter gear were removed, install 21. With two dowel pins and the gasket in place, install
the starter gear onto the crankshaft; then install the the PTO-side cover onto the crankcase and tighten to
flywheel key. 7 ft-lb.
KC543 ROV1-045A
NOTE: Be sure to wipe any grease or oil from the
end of the crankshaft.
Servicing Left-Side
18. Install the flywheel onto the crankshaft and secure Components
with the cap screw. Tighten to 60 ft-lb.
NOTE: The engine does not need to be removed
from the frame for this procedure.
NOTE: To remove left-side components, see Engine
- Removing Engine.
DRIVE CLUTCH
Disassembling
NOTE: Note the timing marks (X) on the cover, spi-
der, and movable sheave. These must be aligned when
assembling the drive clutch for balance purposes.
1. Loosen the machine screws securing the cover.
KC545 Remove every other cap screw from the cover; then
19. Using a gasket scraper, clean off the existing gasket while firmly holding the cover, remove the three
and case from the MAG-side cover. Using a new remaining screws equally.
gasket and dowel pins, install the cover making sure
the coolant pump shaft is aligned with the oil pump
shaft. Tighten to 7 ft-lb.
20. Install the chain guide and secure with the fastener.
70
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WT315A WT566A
7. Remove the air filter housing. 3. Connect the ISC connector (A), MAP/IAT connector
(B), and the TPS connector (C).
8. Remove the ISC connector (A), MAP/IAT connector
(B), and TPS connector (C).
WT397A
4. Install the air filter housing in place and install the
WT397A
outlet boot of the housing over the throttle body.
9. Remove the throttle arm cover; then disconnect the Secure with the clamp.
throttle cable.
5. With the existing cap screws, grommets, and spacers,
10. Loosen the clamp securing the throttle body to the secure the lower portion of air filter housing to the
intake manifold; then remove the throttle body. frame. Tighten to 5 ft-lb.
INSTALLING
1. Connect the throttle cable to the throttle arm; then
install the throttle cable housing cover to the throttle
body. Tighten to 8 ft-lb.
2. Make sure the alignment tab on the throttle body
aligns with the slot in the intake boot and install the
throttle body fully into the boot. Secure with worm
clamps and tighten securely.
WT315A
6. Using new “patch lock” cap screws, secure the air
filter housing mount to the intake manifold (A).
Tighten to 5 ft-lb; then secure the mount to the air fil-
ter housing (B). Tighten to 36 in.-lb.
7. Install the engine intake tube and air intake to the air
filter housing and secure with the clamps.
WT567A
80
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NOTE: The two longer cap screws go in the dowel 8. If removed, install the muffler, exhaust pipe, and
pin locations. right-side inner splash panel.
7. Install the coolant hoses; then add the appropriate 9. If drained, add the appropriate engine oil until the
mixture of coolant until the appropriate level is correct level has been reached.
reached (seeFuel/Lubrication/Cooling).
Troubleshooting
Problem: Starting impaired
Condition Remedy
1. Gas contaminated 1. Drain gas tank and fill with clean gas
2. Throttle cable too tight 2. Adjust throttle cable and synchronize EFI system (see Elec-
trical System)
Problem: Idling or low speed impaired
Condition Remedy
1. TPS out of adjustment 1. Adjust TPS (out of warranty) or replace the throttle body
(under warranty)
2. Throttle cable too tight 2. Adjust throttle cable and synchronize EFI system (see Elec-
trical System)
3. Throttle body dirty 3. Clean throttle body
Problem: Medium or high speed impaired
Condition Remedy
1. High RPM “cut out” against RPM limiter 1. Decrease RPM speed
90
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6. If the readings are not as indicated, the sensor must FUEL PUMP/FUEL LEVEL SENSOR
be replaced.
7. Install the sensor and tighten securely.
8. Connect the leads.
Component data can be retrieved using the CATT II. Uti-
SPEED SENSOR lize the Sensor Data screen.
NOTE: Preliminary checks may be performed on NOTE: Preliminary checks may be performed on
this component using the diagnostic mode on the LCD this component using the diagnostic mode on the LCD
gauge (see EFI Diagnostic System in this section). gauge (see EFI Diagnostic System in the Electrical
System section).
NOTE: Prior to testing the speed sensor, inspect the
three-wire connector on the speed sensor for contami- The fuel pump and fuel level sensor are not serviceable
nation, broken pins, and/or corrosion. components. If either component fails, it must be
replaced.
1. Set the meter selector to the DC Voltage position.
Testing
2. Using MaxiClips, connect the red tester lead to the
orange wire; then connect the black tester lead to the ! WARNING
black wire. Whenever any maintenance or inspection is made on
the fuel system during which there may be fuel leakage,
there should be no welding, smoking, open flames, etc.,
in the area.
AT THIS POINT
Prior to removing the fuel pump, the following test
should be performed to determine that removal is nec-
essary.
1. Turn the ignition switch ON and listen for a momen-
tary “whirring” sound of the pump building pressure.
If the sound is heard (10 seconds), no electrical
checks are necessary. Turn the ignition switch OFF.
2. Disconnect the gasline hose from the fuel rail; then
WT554
install a suitable pressure gauge.
3. Turn the ignition switch to the ON position.
4. The meter must show battery voltage. ! WARNING
Gasoline may be under pressure. Place an absorbent
5. Leave the black tester lead connected; then connect towel under the connector to absorb any gasoline spray
the red tester lead to the pink/white wire. when disconnecting.
6. Slowly move the vehicle forward or backward; the
meter must show 0 and battery voltage alternately.
NOTE: If the sensor tests are not within specifica-
tions, the sensor must be replaced.
To replace a speed sensor, use the following procedure.
1. Disconnect the three-wire connector from the speed
sensor; then remove the cap screw securing the sen-
sor to the transaxle.
2. Install the new speed sensor into the transaxle with
new O-ring lightly coated with multi-purpose grease;
then secure the sensor with the cap screw. Tighten to
10 ft-lb. FI092A
3. Turn the ignition switch to the ON position. The fuel
pressure should build until the pump shuts off. Pres-
sure should read 3.0 kg-cm2 (43 psi).
4. Check for any flashing DTC (Diagnostic Trouble
Code) on the digital gauge. A disconnected or faulty
tilt sensor will cause the fuel pump not to run and a
code to flash.
5. If the pump is not running, check the 10 amp FUEL
fuse in the PDM under the passenger seat. Replace as
necessary and check for fuel pump operation.
100
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Troubleshooting
Problem: Spark absent or weak
Condition Remedy
1. Ignition coil defective 1. Replace ignition coil
2. Spark plug(s) defective 2. Replace plug(s)
3. CKP sensor defective 3. Replace CKP sensor
4. ECM defective 4. Replace ECM
Problem: Spark plug fouled with carbon
Condition Remedy
1. Gasoline incorrect 1. Change to correct gasoline
2. Air cleaner element dirty 2. Clean element
3. Spark plug(s) incorrect (too cold) 3. Replace plug(s)
4. Valve seals cracked - missing 4. Replace seals
5. Oil rings worn - broken 5. Replace rings
Problem: Spark plug electrodes overheat or burn
Condition Remedy
1. Spark plug(s) incorrect (too hot) 1. Replace plug(s)
2. Engine overheats 2. Service cooling system
3. Spark plug(s) loose 3. Tighten plug(s)
Problem: Battery does not charge
Condition Remedy
1. Lead wires/connections shorted - loose - open 1. Repair - replace - tighten lead wires
2. Stator coils shorted - grounded - open 2. Replace stator coils
3. Regulator/rectifier shorted 3. Replace regulator/rectifier
Problem: Battery charges, but charging rate is below the specification
Condition Remedy
1. Lead wires shorted - open - loose (at terminals) 1. Repair - tighten lead wires
2. Stator coils grounded - open 2. Replace stator coils
3. Regulator/rectifier defective 3. Replace regulator/rectifier
4. Cell plates (battery) defective 4. Replace battery
Problem: Magneto overcharges
Condition Remedy
1. Battery short circuited 1. Replace battery
2. Regulator/rectifier defective 2. Replace regulator/rectifier
3. Regulator/rectifier poorly grounded 3. Clean - tighten ground connection
Problem: Charging unstable
Condition Remedy
1. Lead wire intermittently shorting 1. Replace lead wire
2. Magneto internally shorted 2. Replace stator coil
3. Regulator/rectifier defective 3. Replace regulator/rectifier
Problem: Starter does not engage
Condition Remedy
1. Battery charge low 1. Recharge - replace battery
2. Switch contacts defective 2. Replace switch
3. Starter motor brushes not seating 3. Replace starter
4. Starter relay defective 4. Replace relay
5. Wiring connections loose - disconnected 5. Connect - tighten - repair connections
6. Start-in-gear/neutral relay defective 6. Replace relay
Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates)
Condition Remedy
1. Charging rate too low - too high 1. Replace battery
2. Battery discharged 2. Charge battery
Problem: Battery discharges too rapidly
Condition Remedy
1. Charging system (charging operation) not set properly 1. Check AC generator - regulator/rectifier - circuit connections
2. Cell plates overcharged - damaged 2. Replace battery - correct charging system
3. Battery short-circuited 3. Replace battery
4. Electrical load too high 4. Reduce load
Problem: Battery polarity reversed
Condition Remedy
1. Battery incorrectly connected 1. Reverse connections - replace battery
110
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