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General Information/Foreword
This Service Manual contains service, maintenance, and troubleshooting information for the 2019 Wildcat X. 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 a 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 judgment 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 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 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 the manufacturer 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 Textron Off Road
Specifications
NOTE: Specifications subject to change without notice.
CHASSIS
Curb Weight (approx) 658.6 kg (1452 lb) — X 681.3 kg (1502 lb) — X Limited ROPS Tested Curb Weight 981 kg (2162 lb) Length (overall) 314.9 cm (124 in.) Height (overall) 167.0 cm (65.8 in.) Width (overall) 162.6 cm (64 in.) Tire Size 27 x 9R14 (Front) 27 x 11R14 (Rear) Tire Inflation Pressure 16 psi (110 kPa)
MISCELLANEOUS
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) 91 Octane Regular Unleaded Engine Oil (recommended) ACX All Weather (Synthetic) Front Differential/Rear Drive SAE-Approved 80W-90 Hypoid Lubricant Belt Width (standard) 33.4 mm (1.31 in.) Brake Fluid DOT 4 Taillight/Brake Light High Intensity LED Headlight High Intensity LED
ELECTRICAL SYSTEM
Spark Plug Cap 5000 ohms Ignition Coil (primary) Less than 1 ohm Resistance (secondary) N/A Ignition Coil Primary Voltage Battery Voltage Stator Coil (CKP sensor) 104-156 ohms Resistance (AC generator) Less than 1 ohm CKP 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) 31.6mm (exhaust) 27.9mm Valve/Tappet (intake) 0.1016 mm Clearance (exhaust) 0.1524 mm (cold engine) (max) Valve Guide/Stem (max) 0.013mm Clearance Valve Guide Inside Diameter 5.000-5.012mm Valve Head Thickness (min) 2.3mm Valve Seat Angle 45° +15’/+30’ Valve Spring Free Length(min)38.7mm Valve Spring Tension @ 31.5mm 19.0 kg (42 lb)
* Visible at plug threads.
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min) 34.18 mm Camshaft Journal Oil Clearance (max) 0.07mm Camshaft Journal Holder(right & center) 21.94-22.04 mm Inside Diameter (left) 17.44-17.48 mm Camshaft Journal (right & center) 21.96-21.98 mm Outside Diameter (left) 17.48-17.53 mm Camshaft Runout (max) 0.05 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 15mm 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) 0.034 mm (max) (2nd) 0.033 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) 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) 0.3 mm (max) Crankshaft (web-to-web) 97.4-97.5 mm Crankshaft Runout (max) 0.20 mm (0.008 in.) PTO 0.25 mm (0.010 in.) MAG Oil Pump Gerotor Clearance (max) 0.15 mm
Torque Specifications
Torque (ft-lb) Tolerance
0-15 ±20% 16-39 ±15% 40+ ±10%
Part Part Bolted to
Torque ft-lb N-m
EXHAUST COMPONENTS
Exhaust Pipe Cylinder Head 20 27 Heat Shield Frame 48 5.4 in-lb Spark Arrester Muffler 6 8 O2 Sensor Exhaust Pipe 18 23
BRAKE COMPONENTS
Brake Disc** Hub 15 20 Brake Hose Caliper 20 27 Brake Hose Master Cylinder 20 27 Master Cylinder Frame 25 34 Caliper Knuckle 20 27 Front Brake Caliper Knuckle 35 48
SUSPENSION COMPONENTS (Front)
A-Arm Frame 38 52
Torque
Part Part Bolted to
ft-lb N-m SUSPENSION COMPONENTS (Front) (cont.)
Knuckle**** Ball Joint 35 48 Shock Absorber Frame/Lower A-Arm 38 52 Limiter Strap Lower A-Arm/Frame 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 Trailing Arm Cross-Mounts Frame 60 81 Shock Absorber (Lower) Trailing Arm 35 48 Shock Absorber (Upper) Frame 40 54 Knuckle Lower Trailing Arm 60 81 (min) Knuckle Upper Trailing Arm 35 48 Upper/Lower Lateral Link Knuckle 40 54 Upper/Lower Lateral Link Frame 40 54
CHASSIS/ROPS ASSEMBLY
Shift Knob (nut) Shift Lever 12 16 Shift Cable Shift 8 11 Shift Cable (nut) Frame + Engine Mount 20 27 Bracket Shift Lever Frame 8 11 Front ROPS Tube Frame 35 48 Top ROPS Support Front/Rear ROPS 35 48 Tubes Rear ROPS Tube Lower ROPS Support 35 48 Cargo Box Cargo Box Support 6 8 Cargo Box Supports Frame 20 27 Seat Belt Retractor Frame 60 81 Seat Belt Flange Frame 60 81 Seat Belt Buckle Frame 60 81 Shoulder Anchor ROPS Hoop 35 48 Rear Seat Frame 15 20 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 5.5 in.-lb 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 Input Coupler Steering Wheel Shaft 7 9
DRIVE TRAIN COMPONENTS
Rear Drive/Gear Case Frame 35 47 Drive Coupler (Front)**** Drive Flange 50 68 Front Differential Frame/Differential 35 47 Bracket Set Screw** Carrier Bearing 75 8.5 in.-lb Center Front Driveshaft Drive Coupler 50 68 Center Rear Driveshaft Drive Coupler 50 68 Carrier Bearing Bracket 35 52 Carrier Bearing Support Frame 20 27 Bracket Input Shaft Assembly Gear Case Housing 23 31 Pinion Housing Differential Housing 23 31 Thrust Button** Gear Case Cover 8 11 Differential Housing Cover*** Differential Housing 23 31 Hub***** Axle (min) 250 340 Oil Drain Plug Front Differential — 45 5 Rear Drive in.-lb Oil Fill Plug Front Differential — 16 22 Rear Gear Case Drain + Level Plug Front Differential 45 5 in-lb Drain Plug Rear Gear Case 16 22 Wheel (lug nut) Hub (20 ft-lb 80 108 increments) 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 Cover/Housing Crankcase 10 14 Assembly**** Crankcase Half (6 mm) Crankcase 10 14 Crankcase Half (8 mm) Crankcase 21 28 Cylinder Head (Cap Screw) Crankcase(step 1) 20 27 (step 2) 30 41 (final) 37 50 Cylinder Head Nut (6 mm) Cylinder 10 14 Cylinder Head Nut (8 mm) Cylinder 19 25 Valve Cover Cylinder Head 8.5 11.5 Driven Clutch Bolt** Input Shaft 60 81 Driven Cam Driven Clutch 11 15 Drive Clutch Bolt Crankshaft 60 81 Drive Clutch Cover Drive Clutch 10 14 Magneto Cover Crankcase 10 14 Crankshaft Spacer Crankshaft 28 38 Oil Pump Drive Gear** Crank Balancer Shaft 62 84 Rotor/Flywheel Nut** Crankshaft 107 145 Cam Sprocket** Camshaft 10 14 V-Belt Cover Inner Clutch Cover 9.5 13 Secondary Drive Gear Nut* Secondary Drive 200 270 Output Shaft Output Joint Flange Nut Secondary Driven Shaft 200 270 (front) Oil Filter Engine 8.5 11.5 Shift Cam Stopper Support Crankcase 8.5 11.5
ENGINE/TRANSMISSION (cont.)
Shift Cam Stopper Spring Shift Cam Stopper 8.5 11.5 Shift Cam Plate Shift Cam Shaft 8.5 11.5 Speed Sensor Housing Crankcase 9.5 13 Starter Motor Crankcase 10 14 Oil Pump Housing Crankcase 8 11 Oil Strainer Cap Crankcase 11 15 Intake Boot Clamp Intake Boot 30 3.4 in.-lb Starter One-Way Clutch** Rotor/Flywheel 26 35 Fuel Rail Engine 6 8 Air Filter Housing Engine 6 8 Ground Wire Engine 8 11 Stator Coil Magneto Cover (New) 15 20 Stator Coil Magneto Cover 13 18 (Original) Shift Cable Bracket (hex) Engine 10 13.5 Shift cable Bracket (Torx) Engine 20 27 Gear Select Arm Gear Shift Shaft 8 11
*w/Red Loctite #263 **w/Red Loctite #271 ***w/Green Loctite #270 ****w/“Patch-Lock” *****w/Primer #7649 and Loctite #277
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 91 minimum octane regular unleaded. In many areas, oxygenates are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol or 5% methanol 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 ACX All Weather synthetic engine oil, which has been specifically formulated for use in this engine. Although 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. CAUTION
Do not use white gas. Only approved gasoline additives should be used.
OILCHARTJ
RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT The recommended lubricant is Gear Lube which is SAE-approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of the vehicle front differential and rear drive.
CAUTION
Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive damage.
Preparation for Storage
The manufacturer 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.Change the engine oil. 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 sub-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 ensure many miles and hours of trouble-free riding. The manufacturer 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/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 making sure to connect the positive cable first.
7.Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brake light, 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.
CAUTION
