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General Information/Foreword
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2016 Arctic Cat Wildcat Trail. The complete manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections. Each section covers a specific vehicle component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The procedures found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special tools to be completed. The technician should use sound judgement when determining which procedures can be completed based on their skill level and access to appropriate special tools. NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is necessary.
When replacement of parts is necessary, use only genuine Arctic Cat parts. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illustrated Parts Manual for the correct part number, quantity, and description. 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 worthy 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.
Product Service and Warranty Department Arctic Cat Inc.
Specifications
CHASSIS
Dry Weight (approx) 449 kg (990 lb) ROPS Tested Curb Weight 817 kg (1802 lb) Length (overall) 280.6 cm (110.5 in.) Height (overall) 163.3 cm (64.3 in.) Width (overall) 127 cm (50 in.) Tire Size 25 x 8-12R (Front) 25 x 10-12R (Rear) Tire Inflation Pressure 0.98 kg/cm² (14 psi)
MISCELLANY
Spark Plug Type NGK CR8EB Spark Plug Gap 0.6-0.8 mm (0.023-0.031 in.) Gas Tank Capacity 28 L (7.4 U.S. gal.) Coolant Capacity (approx.) 3.1 L (3.2 U.S. qt) Front Differential Capacity 198 ml (6.7 fl oz)* Transaxle Capacity 1.2 L (1.2 U.S. qt)* Engine Oil Capacity 2.8 L (3.0 U.S. qt) - Change 3.34 L (3.4 U.S. qt) - Overhaul Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) Arctic Cat ACX All Weather Synthetic Front Differential Lubricant SAE Approved 80W-90 Hypoid Transaxle Lubricant Arctic Cat Synthetic Transaxle Fluid Drive Belt Width 33.0 mm (1.3”) Brake Fluid DOT 4 Taillight/Brakelight High Intensity LED Headlight 12V/60/55W
COOLING SYSTEM
Cooling Fan On 203° F (95° C) Cooling Fan Off 194° F (90° C)
ELECTRICAL SYSTEM
Spark Plug Cap 5000 ohms Ignition Coil Resistance (primary) Less than 1 ohm Ignition Coil Primary Voltage Battery Voltage Stator Coil (crankshaft position sensor) 100-150 ohms Resistance (AC generator) Less than 1 ohm Crankshaft Position Sensor 1.5 AC Volts or more AC Generator Output (no load) 65 AC volts @ 4000 RPM Ignition Timing 10° BTDC @ 1500 RPM
VALVES AND GUIDES
Valve Face Diameter (intake) (exhaust) 31.6 mm 27.9 mm
Valve/Tappet Clearance (intake) (cold engine) (max) (exhaust)
0.16 mm 0.22 mm Valve Guide/Stem (intake) 0.08 mm Clearance (max) (exhaust) 0.10 mm Valve Guide Inside Diameter (max) 4.532 mm Valve Head Thickness (min) 2.3 mm Valve Seat Angle 45° +15’/+30’ Valve Spring Free Length (min) 38.7 mm Valve Spring Tension @ 31.5mm 19.0 kg (42 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min) 36.5 mm Camshaft Journal Oil Clearance (max) 0.07 mm Camshaft Journal Holder (right & center) 21.94-22.04 mm Inside Diameter (left) 17.44-17.48 mm Camshaft Journal Outside(right & center) 21.96-21.98 mm Diameter (left) 17.48-17.53 mm Camshaft Runout (max) 0.05 mm Cylinder Head/Cover Distortion (max) 0.05 mm * Visible at plug threads.
Piston/Cylinder Clearance 0.14mm Cylinder Bore (max) 76.965 mm Piston Diameter 10 mm from Skirt End 76.825 mm Piston Ring Free End Gap (min) (1st/2nd) 12.5 mm Bore x Stroke 76.9 x 75.3 mm Cylinder Trueness (max) 0.05 mm Piston Ring End Gap (1st/2nd) 0.65 mm - Installed (max) (oil) 0.85 mm Piston Ring to Groove Clearance (max) 0.1 mm Piston Ring Groove Width (1st/2nd) 1.202-1.204 mm (oil) 2.501-2.503 mm Piston Ring Thickness (1st/2nd) 1.170-1.195 mm Piston Pin Bore (max) 18.018 mm Piston Pin Outside Diameter (min) 17.984 mm
CRANKSHAFT
Connecting Rod (small end bore) (max) 18.044 mm Crankshaft Runout (max) 0.03 mm
Specifications subject to change without notice.
Torque Specifications
Torque (ft-lb) Tolerance
0-15 ±20% 16-39 ±15% 40+ ±10%
Part EXHAUST COMPONENTS
Part Bolted To Torque ft-lb N-m
Exhaust Pipe Flange Engine 8 11 Spark Arrester Muffler 72 in.-lb 8 Heat Shield Frame 48 in.-lb 6 Heat Shield Manifold 10 14 O2 Sensor Manifold 20 27 BRAKE COMPONENTS
Brake Disc Hub 15 20 Brake Hose Caliper 20 27 Brake Hose Master Cylinder 20 27 Brake Hose Frame 8 11 Master Cylinder Frame 25 34 Caliper Knuckle 20 27 SUSPENSION COMPONENTS (Front)
A-Arm (Upper) Frame 35 48 A-Arm (Lower) Frame 40 54 Knuckle Ball Joint 35 48 Knuckle Tie Rod End 30 40 Shock Absorber Frame 35 48 Shock Absorber A-Arm 25 34 Sway Bar Mount Frame 35 48 Sway Bar Sway Bar Link 20 27 Sway Bar Link A-Arm 20 27 SUSPENSION COMPONENTS (Rear)
Sway Bar Mount Frame 35 48 Sway Bar Sway Bar Link 20 27 A-Arm Frame 35 48 Shock Absorber (Lower) A-Arm 35 48 Shock Absorber (Upper) Frame 35 48 Knuckle A-Arm 35 48 Sway Bar Link A-Arm 20 27
Part Part Bolted To Torque ft-lb N-m
Steering Wheel Steering Shaft 25 34 Rack and Pinion Assembly Frame 25 34 Rack and Pinion Bracket Frame 25 34 Tie Rod* Rack and Pinion Assembly 37 50 Jam Nut Tie Rod 25 34 Tilt Steering Link Frame 10 14 Tilt Steering Frame 20 27 Intermediate Shaft Rack and Pinion 25 34 Intermediate Shaft Shaft Adjuster 25 34 EPS Mounting Bracket EPS Assembly 35 48 EPS Assembly Frame 20 27
CHASSIS/ROPS ASSEMBLY
Door Latch Bracket Frame 8 11 Door Hinge Frame 20 27 Shift Lever Shift Mount Bracket 20 27 Shift Cable Shift Axle Arm 8 11 Front ROPS Tube Frame 40 54 Front ROPS Tube Rear ROPS Tube 40 54 Rear ROPS Tube Frame 40 54 Cargo Box Frame 5 7 Seat Belt Retractor Frame 60 81 Seat Belt Shoulder ROPS Hoop 35 48 Seat Belt Buckle Frame 60 81 Seat Belt Anchor Frame 60 81 Accelerator Pedal Bracket Splash Panel 10 14 Accelerator Pedal Accelerator Pedal Bracket 20 27 Throttle Cable Throttle Body 8 11 Brake Pedal Frame 20 27 Front Bumper Frame 20 27 DRIVE TRAIN COMPONENTS
Engine/Transaxle Mounting Bracket***** Transaxle 75 102
Transaxle Rubber Mount Frame 20 27 Jam Nut Engine/Transaxle Mounting 15 20 Bracket Adjuster Nut Engine/Transaxle Mounting 10 14 Bracket Transaxle Mounting Bracket Transaxle 37 50 Transaxle Mounting Bracket Rubber Mount 25 34 Front Differential Differential Bracket 38 52 Carrier Bearing Bearing Bracket 35 48 Carrier Bearing Bracket Frame 20 27 Carrier Bearing Set Screw** Front Shaft 6 8 Pinion Housing Differential Housing 23 31 Differential Housing Cover*** Differential Housing 23 31 Hub Axle/Knuckle 200 270 Detent Plug Transaxle 20 27 Speed Sensor Transaxle 10 14 Level/Drain Plug Front Differential 45 in.-lb 5 Oil Fill Plug Front Differential 16 22 Drain Plug Transaxle 16 22 Fill Plug Transaxle 16 22 Wheel (steel) Hub (20 ft-lb increments) 40 54 Wheel (aluminum wheel w/black Hub (20 ft-lb increments) 60 81 nuts) Wheel (aluminum wheel w/ Hub (20 ft-lb increments) 80 108 chrome nuts) Pinion Gear Assembly Transaxle 20 28
ENGINE
Front Rubber Mount Engine Mounting Bracket 20 27 Front Rubber Mount Frame 25 34 Front Engine Mount Engine 35 48 Rear Engine Mount Frame 38 51
Crankcase Half (6 mm) Crankcase Half 7 9.5 Crankcase Half (8 mm) Crankcase Half 21 28 Cylinder Head (Cap Screw)* Crankcase (step 1) 22 29 (step 2) 29 39 (final) 36 49 Cylinder Head Cover Cylinder Head 7 9.5 Driven Clutch Input Shaft 35 48 Drive Clutch Crankshaft 60 81 Drive Clutch Cover Drive Clutch 10 14 Mag-Side Cover Crankcase 7 9.5 Magneto Cover Engine 11 15 Tappet Cover Valve Cover 7 9.5 Oil Pump Crankcase 8 11 Rotor/Flywheel Crankshaft 60 81 Cam Sprocket** Camshaft 7 9.5 Inner Clutch Cover Engine 8 11 Camshaft Holder* Cylinder Head (in steps) 84 in.-lb 9.5 Shifter Housing Crankcase 8 11 Starter Motor Crankcase 8 11 Outer Clutch Cover Inner Cover 5 5.5 Intake Boot Clamp Intake Boot 30 in.-lb 3.4 Starter One-Way Clutch** Rotor/Flywheel 20 27 Fuel Rail Engine 6 8 Air Filter Housing Frame 5 7 Ground Wire Engine 8 11 Stator Coil Magneto Cover 11 15 Oil Drain Plug Engine 20 27 Drain Plug Clutch Cover 50 in.-lb 5.5 Cam Chain Tensioner Cylinder Head 15 20 Connecting Rod Connecting Rod (step 1) 22 29 (step 2) 36 49 (final) 45 60 Oil Crossover Tube Crankcase 13.5 18 Cylinder Head (Side) Crankcase 7 9.5 Oil Filter Union Crankcase 20 27 Phase Plate Sprocket 7 9.5 Timing Inspection Plug Magneto Cover 10 17 Magneto Plug Magneto Cover 8 11 Oil Hose Fitting Crankcase 25 34 PTO-Side Cover Crankcase 7 9.5 Tensioner Cap Tensioner 15 20 Upper Chain Guide Cylinder Head 7 9.5 Oil Cooler Hose Oil Cooler/Engine 35 in.-lb 4 Coolant Hose Coolant Pipe 40 in.-lb 4.5 Coolant Hose Water Pump/Cylinder 35 in.-lb 4 Impeller Cover Magneto Cover 11 15 Bypass Hose Thermostat Coolant Pipe 15 in.-lb 1.7 Radiator Frame 8 11 Oil Pan Crankcase 8 11 Spring Retaining Plate Driven Clutch 11 15 *w/Oil **w/Red Loctite #271 ***w/Green Loctite #270 ****w/“Patch-Lock” *****w/Anti-Seize
Torque Conversions (ft-lb/N-m)
Drive Belt Break-In Procedure
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
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
FILLING GAS TANK ! 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.
Since gasoline expands as its temperature rises, the gas tank must be filled to its specified capacity only. Expansion 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.
! 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.
RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, oxygenates are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol or 5% methane are acceptable gasolines. When using ethanol blended gasoline, it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system.
CAUTION
Do not use white gas. Only Arctic Cat approved gasoline additives should be used.
RECOMMENDED ENGINE OIL The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil, which has been specifically formulated for use in this Arctic Cat engine. Although Arctic Cat ACX All Weather synthetic engine oil is the only oil recommended for use in this engine, use of any API certified SM 0W-40 oil is acceptable.
OILCHARTJ
RECOMMENDED FRONT DIFFERENTIAL LUBRICANT The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of the Arctic Cat vehicle front differential and rear drive.
CAUTION
Any lubricant used in place of the recommended lubricant could cause serious front differential damage.
RECOMMENDED TRANSAXLE LUBRICANT The recommended transaxle lubricant is Arctic Cat Synthetic Transaxle Fluid. This lubricant meets all of the lubrication requirements of this vehicle.
CAUTION
Any lubricant used in place of the recommended lubricant could cause serious transaxle damage.
Preparation For Storage
Arctic Cat recommends the following procedure to prepare the vehicle for storage.
1.Clean the seat cushions with a damp cloth and allow to dry. 2.Clean the vehicle thoroughly by washing dirt, oil, grass, and other foreign matter from the entire vehicle. Allow the vehicle to dry thoroughly. DO NOT get water into any part of the engine or air intake. 3.Either drain the gas tank or add a fuel stabilizer to the gas in the gas tank. 4.Clean the interior of the air filter housing. 5.Plug the hole in the exhaust system with a clean cloth.
6.Apply light oil to the upper steering shaft bushing and plungers of the shock absorbers. 7.Tighten all nuts, bolts, cap screws, and screws. Care must be taken that all calibrated nuts, cap screws, and bolts are tightened to specifications. 8.Fill the cooling system to the bottom of the stand pipe in the radiator neck with properly mixed coolant.
9.Disconnect the battery cables (negative cable first); then remove the battery, clean the battery posts and cables, and store in a clean, dry area.
CAUTION
Prior to storing this vehicle, it must be properly serviced to prevent rusting and component deterioration.
NOTE: For storage, use a battery maintainer or
make sure the battery is fully charged (see Battery section in this manual).
10.Store the vehicle indoors in a level position.
CAUTION
Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the vehicle causing rusting.
Preparation After Storage
Taking this vehicle out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. Arctic Cat recommends the following procedure. 1.Clean the vehicle thoroughly. 2.Clean the engine. Remove the cloth from the exhaust system. 3.Check all control wires and cables for signs of wear or fraying. Replace if necessary. 4.Change the engine oil and filter. 5.Check the coolant level and add properly mixed coolant as necessary. 6.Charge the battery; then install. Connect the battery cables making sure to connect the positive cable first. 7.Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, and headlight aim; adjust or replace if necessary. 8.Check the tire pressure. Inflate to recommended pressure as necessary. 9.Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap screws, and bolts are tightened to specifications. 10.Make sure the steering moves freely and does not bind.
11.Check the spark plugs. Clean or replace as necessary. 12.Check the air filter and the air filter housing. Clean or replace as necessary.
