1
2016 Wildcat X/4X Service Manual
Table Of Contents
General Information/Foreword.......................................... 2
Specifications..................................................................... 2
Torque Specifications......................................................... 3
Torque Conversions (ft-lb/N-m) .......................................... 4
Drive Belt Break-In Procedure ........................................... 4
Gasoline - Oil - Lubricant ................................................... 4
Preparation For Storage..................................................... 5
Preparation After Storage .................................................. 5
Periodic Maintenance/Tune-Up......................................... 7
Air Filter.............................................................................. 7
Valve/Tappet Clearance ..................................................... 8
Testing Engine Compression ............................................. 9
Spark Plugs........................................................................ 9
Muffler/Spark Arrester...................................................... 10
Engine/Transmission Oil - Filter ....................................... 10
Front Differential - Rear Drive Lubricant........................... 11
Driveshaft/Coupling.......................................................... 11
Headlight - Taillight/Brakelight.......................................... 12
Shift Lever/Shift Cable...................................................... 13
Hydraulic Brake System................................................... 13
Burnishing Brake Pads..................................................... 15
Replacing V-Belt............................................................... 15
Steering/Body/Controls................................................... 17
Hood ................................................................................ 17
Front Bumper Assembly................................................... 17
Rear Body Panel .............................................................. 17
Steering Assembly ........................................................... 19
Steering Wheel ................................................................ 18
Steering Shaft .................................................................. 22
Steering Knuckles ............................................................ 25
Checking/Adjusting Front Wheel Alignment..................... 26
Accelerator Pedal............................................................. 27
Shift Lever ........................................................................ 27
Shift Cable........................................................................ 28
LCD Gauge ...................................................................... 28
Muffler .............................................................................. 28
Cargo Box ........................................................................ 29
Seats................................................................................ 29
Doors ............................................................................... 30
Roof (X Limited) ............................................................... 30
Troubleshooting................................................................ 32
Engine/Transmission....................................................... 33
Troubleshooting................................................................ 34
Removing Engine/Transmission....................................... 36
Top-Side Components ..................................................... 40
Removing Top-Side Components .................................... 40
Servicing Top-Side Components...................................... 44
Installing Top-Side Components ...................................... 49
Left-Side Components ..................................................... 56
Removing Left-Side Components .................................... 56
Servicing Left-Side Components ..................................... 58
Installing Left-Side Components ...................................... 60
Right-Side Components................................................... 62
Removing Right-Side Components.................................. 63
Servicing Right-Side Components ................................... 64
Installing Right-Side Components ....................................70
Center Crankcase Components .......................................71
Separating Crankcase Halves ..........................................71
Disassembling Crankcase Half.........................................72
Servicing Center Crankcase Components .......................74
Assembling Crankcase Half..............................................81
Joining Crankcase Halves ................................................83
Installing Engine/Transmission .........................................85
Fuel/Lubrication/Cooling .................................................89
Throttle Body ....................................................................89
Gas Tank ..........................................................................90
Oil Pump...........................................................................91
Oil Cooler..........................................................................92
Liquid Cooling System......................................................92
Radiator ............................................................................92
Thermostat .......................................................................94
Fans..................................................................................94
Water Pump......................................................................94
Troubleshooting ................................................................95
Electrical System..............................................................96
Battery ..............................................................................96
Electronic Power Steering (EPS)......................................97
Ignition Switch ..................................................................99
Ignition Coil.......................................................................99
Ignition Timing ..................................................................99
Accessory Receptacle/Connector ..................................100
Switches .........................................................................100
Fan Motor .......................................................................101
Power Distribution Module (PDM) ..................................102
EFI Sensor/Components ................................................102
Stator Coil.......................................................................108
RPM Limiter....................................................................108
Starter Motor ..................................................................109
Starter Relay...................................................................109
Engine Control Module (ECM)........................................109
Regulator/Rectifier..........................................................108
EFI Diagnostic System ...................................................110
Troubleshooting ..............................................................115
Drive and Brake Systems ..............................................116
Front Drive Actuator........................................................116
Front Differential .............................................................117
Driveshaft (4X)................................................................129
Drive Axles .....................................................................132
Rear Gear Case .............................................................135
Hub .................................................................................140
Hydraulic Brake Caliper ..................................................142
Master Cylinder Assembly..............................................146
Troubleshooting Drive System ........................................148
Troubleshooting Brake System .......................................148
Suspension .....................................................................149
Shock Absorbers ............................................................149
Front A-Arms ..................................................................153
Rear Trailing Arms ..........................................................155
Wheels and Tires............................................................157
Troubleshooting ..............................................................158
To Next Page
Loading...
