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April 2018 1
Notes
2 April 2018
SPECIFICATIONS
ENGINE
Type 4-cycle, 3-cylinder, liquid cooled, DOHC
Bore x Stroke 80 mm x 66.2 mm (3.14 x 2.60 in.)
Displacement 998 cc (60.9 cu. in.)
Spark Plug Type NGK CR9EB
Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.)
Alternator 65 Amp
CHASSIS
Length (Overall) 136 in (345.4 cm)
Height (Overall) 68 in (172.7 cm)
Width (Overall) 64 in (162.6 cm)
Suspension Travel 18.0 in (45.7 cm) — front
18.0 in (45.7 cm) — rear
Tire Size 30 x 10-15 — front
30 x 10-15 — rear
Wheel Lug Pattern 4 x 156mm
Tire Inflation Pressure 14 psi (96.5 kPa) — front
22 psi (151.7 kPa) — rear
Brake Type Four Wheel Hydraulic Disc
MISC.
Dry Weight (Approx) 1812 lb (821 kg)
ROPS Tested Curb Weight 2600 lb (1179.4 kg)
Engine Oil (Recommended) ACX All Weather (Synthetic)
Engine Oil Change with Oil 3.75 U.S. qt (3.55 L)
Filter (Approx. Capacity)
Gasoline (Recommended) 91 or higher/ethanol content not to exceed 10%
Gas Tank Capacity 10 U.S. gal. (37.85 L)
Coolant Capacity 2.5 U.S. gal. (9.5 L) (60% Antifreeze/40% Water Mixture)
Front Differential Oil SAE Approved 80W-90 Hypoid GL-5
Front Differential Capacity 13.5 fl oz (400 ml)
Rear Transaxle Oil Synthetic Transaxle Fluid with EP
Rear Transaxle Capacity 40.5 fl oz (1.2 L)
Brake Fluid DOT 4
Belt Dimensions Width: 38.4 mm | Outside Circumference: 126.8 cm
Headlight Halogen H13 with LED
Taillight/Brake Light LED
April 2018 3
ENGINE
998 3 Cylinder
1. Intake 7. Coolant Line
2. Exhaust 8. Water Pump
3. Valve Cover 9. PTO
4. Cylinder Head 10. Thermostat Housing
5. Starter Motor 11. Oil Pan
6. Oil Filter 12. Ignition Coils
12
3
1 4 2
7 5
8
10
9
6
11
4 April 2018
ENGINE
Engine Oil
ACX All Weather 0W-40 Synthetic oil is recommended to ensure proper protection of engine parts. If
ACX oil is not available, any API-certified SM 0W-40 oil is acceptable.
The oil & oil filter should be replaced every 100 hours / 1600 miles or once every 6 months, which-
ever occurs first. Changing of the oil at shorter intervals is recommended if the vehicle idles for long
periods of time, or for very extreme use.
The initial oil change must occur between the first 12-25 hours or 250 miles of vehicle use, whichever
occurs first.
Oil Change
Run the engine until the oil is at operating temp.
Remove the rear cargo tray by removing the four
hand screws.
April 2018 5
ENGINE
Using a 12mm wrench, remove the drain plug and
allow the reservoir to drain completely.
Replace the drain plug with a new washer. Tighten
to 12 ft-lb. Do Not over tighten.
6 April 2018
ENGINE
Using a filter wrench, remove the oil filter. ensure
the filter seal comes off with the filter.
April 2018 7
ENGINE
Engine Air Filter
The engine air filter assembly consists of a single dry paper filter element. This filter is not wash-
able or reusable. The air filter element is an important factor in engine longevity. The filter must
be checked every day during normal use. Under normal use, the filter should be replaced every 6
months/100hours/1600 miles. For heavy use or use in dirty/dusty environments, the checking/replac-
ing intervals may need to be done more frequently.
Remove the rear cargo tray by removing the four
hand screws. Locate the filter above the engine.
8 April 2018
ENGINE
Inspect and clean the filter housing if needed.
April 2018 9
ENGINE
Engine Valve Lash
Valve shims are needed to adjust valve tappet/lash on the 998 engine. Consult the following chart for
available shims. Below is a tip for how to replace the shims without having to set timing on the en-
gine, since the cams have to be removed to replace the shims.
Valve Lash
Intake: 0.15 mm - 0.22 mm (0.006” - 0.009”)
Exhaust: 0.21 mm - 0.27 mm (0.008” - 0.011”)
PTO
Cylinder 1 2 3
10 April 2018
ENGINE
Then remove the timing inspection plug from the
mag side of the engine. This will allow you to turn
the engine. On the XX only the timing plug will
be removed. To turn the engine, remove the cov-
er for the alternator to access the v-belt pulley.
April 2018 11
ENGINE
Remove the camshaft caps by loosening each
fastener evenly and carefully, as there is tension
on the cams.
12 April 2018
DRIVETRAIN
DRIVETRAIN
Clutching
The drive and driven clutches used are made by TEAM.
Other Information:
• The drive belt (P/N: 0823-529) is directional.
• The drive belt is 38.4 mm wide with a 26º taper. The outside circumference is 126.8 cm.
• The recommended break in period for a belt is no more that 3/4 throttle and 40 mph for 25 miles.
• Clutch puller 0744-080 should be used.
• The drive clutch contains an idler bearing.
• There is no deflection adjustment on the driven clutch. The clutch automatically adjusts.
• The clutch tool 0744-098 should be used to spread the sheaved on the driven clutch to remove
the belt.
• Used Clutch Retention Tool 0444-321 to secure both clutches while torquing to the engine/tran-
saxle. The existing spanner wrench 0644-136 is also suitable for the drive clutch.
• DO NOT torque the driven clutch to the transaxle with the belt in place. This will lead to improper
torque and may lead to damage to the driven clutch/vehicle.
April 2018 13
DRIVETRAIN
Remove the cover out the back of the vehicle.
14 April 2018
DRIVETRAIN
Place the belt over the drive clutch.
April 2018 15
DRIVETRAIN
Transaxle
The Transaxle used on the Wildcat XX functions as a sec-
ondary transmission and rear gear case. There is no differ-
ential for the rear axles.
The 5 basic functions as a secondary transmission are:
Because the engine and transaxle are separate, the alignment of the two components is critical for
CVT durability and efficiency.
Only use Sythetic Transaxle Fluid with EP (PN: 2436-728). The transaxle holds 40.5 oz (1.2 L) of flu-
id, and is full when the fluid is approximately level with the bottom of the fill hole threads.
Transaxle Cover Removal and Gear Assembly
When removing the transaxle from the vehicle, make sure to drain the oil, then remove the speed
sensor, gear position sensor and the shifter linkage/arm prior to removal. This will prevent damage to
these components.
Cover Removal
Remove the plug and spring that keeps tension
on the shifter mechanism,
16 April 2018
DRIVETRAIN
Using a soft pry bar, carefully work the two
sections apart at the various points around the
case as shown. You may need to tap on the gear
shifter shaft and gear select shaft to free them
from the cover.
Gearset Installation
This is designed to be a guide for installing each
assembled gearset into the case. There is no
chain for reverse gear in this transaxle. For more
information, consult the service manual.
April 2018 17
DRIVETRAIN
Place the idler gearset in the case as shown.
Make sure the 52T gear is under the 61T gear of
the shift assembly.
18 April 2018
DRIVETRAIN
Install the single 45T gear assembly into the
case.
April 2018 19
DRIVETRAIN
Place the park pawl spring over the park pawl as
shown.
20 April 2018
DRIVETRAIN
Front Differential with Electronic Actuator:
In 2WD, the 4WD coupler is held away from the input
shaft.
The differential holds 13.5 oz of SAE Approved 80W-90 Hypoid GL-5 fluid. When full, the fluid
should be at the bottom of the threads on the fill hole.
Differential Disassembly
Remove the 8 cap screws that secure the cover
to the differential case.
April 2018 21
DRIVETRAIN
Inspect the o-ring for the cover. Replace if dam-
aged. When assembling the differential, make
sure the o-ring is seated on the cover as shown.
22 April 2018
DRIVETRAIN
To take the input assembly off the case, remove
the four cap screws and slide the assembly off
the case. The shifter assembly, along with the
4wd shift fork and gear will be removed with the
assembly.
April 2018 23
DRIVETRAIN
To remove the locker assembly, remove the lock-
er assembly cover on the side of the case. This
will expose the end of the locker shaft. Remove
the clip to release the spring and locker shaft.
24 April 2018
DRIVETRAIN
Axle Pin Explained
Front Axles
The design of the axle utilizes the axle shaft to act as a tool that pushes the on the internal pin of the
splined portion of the CV cup. When the pin is pushed in it allows the detent pins to travel into the
recessed area and relieves tension on the C-clip.
The first stop point that you will feel is when the axle shaft first contacts the internal pin. After that ini-
tial stop point, you should be able to move the axle in a little bit further before you hit the second stop
point. The axle shaft must be pushing straight into the cup for this to work properly. If you cannot push
the axle in past the first stop, the axle is likely not lined up properly. Release pressure on the axle
shaft and try again. Pressure must be kept on the pin until the axle is out of the gear case.
April 2018 25
DRIVETRAIN
Rear Axle
The rear axle on the Wildcat XX use the same principle to secure the axles into the transaxle as the
front, however, the method of releasing the pins is different. There is a shaft that runs across the cup
with curve cut in it. This allows for the pin to be pushed into the lock position by a spring. When the
shaft is turned 90º (1/4) it will push the pin out and release the pressure on the c-ring.
There are two Allen set screws used in the lock. The more recessed set screw should not be turned
for any reason. Tightening this set screw can push the locking pin out of the cup, and into the un-
locked position.
The larger, more exposed set screw should only be turned 90º. There are stops to prevent going too
far, but it is still possible to turn the set screw past them with enough force. Counter clockwise will
unlock the pin, and clockwise will lock the pin.
26 April 2018
DRIVETRAIN
Rear Axle Removal
Lift the vehicle off the ground and remove the
tire, castle nut lock, castle nut and washer to
release the axle.
Firmly grasp the inner cup and pull the axle from
the transaxle.
April 2018 27
DRIVETRAIN
Compress the inner CV joint and move it to the
shown position.
28 April 2018
SUSPENSION
Rear Trailing arm Replacement and Adjustment
The rear trailing arms must be adjusted properly when replaced to ensure proper suspension move-
ment. If the trailing arm is not properly adjusted, damage may occur.
April 2018 29
SUSPENSION
Install the inner pivot to the frame. Torque the
bolt to 170 lb-ft.
Install but do not tighten the bolt for the rod end.
28 3/4”
Install the wheel bearing housing. Hand tighten each of the 6 fasteners evenly before applying a final
torque of 35 lb-ft in a criss cross pattern.
Install the wheel hub. Using red Loctite, tighten the hub nut to 250 ft-lbs. Increase the torque until the
hub plate fits.
30 April 2018
Install the shock onto the trailing arm, then the
upper mount to the chassis. DO NOT allow the
trailing arm to drop below the full drop level. Do-
ing so will damage the axle.
April 2018 31
Pull back on the rubber cover on the rod end to
access the flat area to hold it in the proper posi-
tion with a wrench.
32 April 2018
SUSPENSION
Suspension Adjustment FOX QS3
The FOX QS3 shocks on the XX have three position
adjustment and adjustable dual rate springs with
adjustable spring crossover.
April 2018 33
SUSPENSION
The adjustable spring crossover changes when the
spring goes from a dual rate to a single rate spring,
and allows the user to fine tune exactly when this
happens during suspension travel. Adjustments
made on the crossover will also change body roll
and bottom out resistance. The two rings must be
tightened against each other after adjustments
are made. The rear shocks should be at the same
position, and the front shocks should be at the same
position.
Front of Vehicle
Rear of Vehicle
34 April 2018
STEERING
POWER STEERING
The steering system has electric power steering. The power steering unit is
located under the hood, at the top of the frame. This protects the unit from
water and damage. The links from the Steering wheel to the EPS unit,
to the steering rack are solid shafts with universal joints.
The steering rack is positioned in front of the front differen-
tial to reduce bump steer and feedback.
Main components in the system
• Steering Wheel
• Adjustable Column
• EPS unit
• Steering Shaft
• Rack and Pinion Assembly
-- Rack & Tie Rods
-- Steering knuckles
EPS (Electronic Power Steering) systems can
vary the amount of power assist. The power steer-
ing is designed to maintain a light steering input effort,
but maintains enough feel for the rider to have a better under-
standing of what the tire contact patch is doing in relation to the terrain.
April 2018 35
BRAKES
BRAKES
The Wildcat XX has a four wheel hydraulic
brake system with dual piston front calipers
and single piston rear calipers.
36 April 2018
BRAKES
Brake Calipers
The force from the master cylinder is converted to
clamping force by the caliper where pressure is exerted
on the piston to cause the pads to clamp against the
rotor. As pressure from the master cylinder is released
the pads slightly move inward to release pressure from
the rotor. The front calipers are dual bore, and the rear
calipers are single bore.
Areas to check:
• Piston Movement
• Grease Pins of Bracket
• Leaks
• Banjo Bolt Fitting
Brake Pads/Rotor
When the brake pads are pushed against the rotor, friction is caused
and vehicle momentum is decreased. Pad material composition can
change braking ability, it is recommended to always replace brake
pads with OEM pads.
Rotors can have an equal effect on braking ability. The diameter, ma-
terial and flatness can all change braking ability.
Areas to check:
• Pad Wear (1 mm wear limit)
• Rotor Flatness/Warpage
April 2018 37
ELECTRICAL
ECM (Electronic Control Module)
WARNING: Do not disconnect the ECM with the ignition switch in the “ON” position. Damage
may occur.
ECM: The ECM is located between the seats in the XX along with the PDM’s battery and accessory
plugs. They have a protective cover over them. To allow for easier removal and installation of the cov-
er, tilt the drivers seat forward to allow for more room.
Codes associated with the ECM: (note: some of these overlap with other sensors)
P0219 - Engine Over-Speed Condition
P0500 - Vehicle Speed-Sensor
P0503 - Vehicle Speed Sensor Circuit Intermittent/Erratic/High
P0504 - Brake Switch Priority
P0562 - System Voltage Low
P0563 - System Voltage High
P0600 - Serial Communication Link
P0606 - Internal Monitoring Error
P060C - Internal Monitoring 3 Error
P0615 - Starter Relay Circuit
P0616 - Starter Relay Circuit Low
P0617 - Starter Relay Circuit High
P061A - Internal Monitoring of Torque Error
P0630 - VIN Not Programmed or Incompatible
P0641 - Sensor Reference Voltage #1 Circuit Low/Open
P0643 - Sensor Reference Voltage #1 Circuit High
P0651 - Sensor Reference Voltage #2 Circuit Low/Open
P0653 - Sensor Reference Voltage #2 Circuit High
P0685 - EFI/Main Relay Circuit Open
P0686 - EFI/Main Relay Circuit Low/SG
P0687 - EFI/Main Relay Circuit High/SP
P2610 - ECU Warm Reset
U0100 - Lost Communication With ECM
U0155 - LCD Gauge to ECM CAN Communication Lost
U1000 - Vehicle Not Registered or Invalid PIN Entered
U1001 - Vehicle Not Registered, engine hours exceeds 5 hours
38 April 2018
ELECTRICAL
Electronic Throttle Control (ETC) Overview
The ETC Systems utilize inputs from components on the vehicle to control the amount of air enter-
ing the engine. The throttle valve is opened/closed by a DC motor based on demand from the Pedal
Sensor Value.
Note: RPM and vehicle speed limitations are very smooth and not as abrupt as vehicles with
throttle cables.
April 2018 39
ELECTRICAL
Throttle Body
The throttle body houses the throttle valve, dual TPS and a DC
motor to control the throttle valve position. The throttle body bore
size and throttle valve position control the volume of air entering
the intake manifold.
When the key is first turned on, you will hear the throttle actuate,
and is initializing to check full range of operation. If an error oc-
curs, check the intake tract for debris that could cause restricted
motion.
Codes associated with the Throttle body: (note: some of these overlap with other sensors)
P061F - Electronic Throttle Control Driver Temperature Warning
P1120 - Throttle Position Sensor Lower Position
P1121 - Throttle Position Sensor Lower Adaption
P1122 - Throttle Position Sensor Lower Return
P1123 - Throttle Position Sensor Adaption Condition
P1124 - Throttle Position Sensor Limp Home Adaption
P1125 - Throttle Position Sensor Upper Position
P1126 - Throttle Position Sensor Upper Return
P2100 - Throttle Actuator Control Motor Circuit Open
P2102 - Throttle Actuator #1 Control Motor Circuit Low/SG
P2103 - Throttle Actuator #1 Control Motor Circuit High/SP
P2106 - Electronic Throttle Control Output is out of Range
P2107 - Electronic Throttle Control Driver Over-Temperature
P210C - Throttle Actuator #2 Control Motor Circuit Low/SG
P210D - Throttle Actuator #2 Control Motor Circuit High/SP
P2118 - Throttle Actuator Control Motor Range Error
P2119 - Throttle Control Actuator Control Performance Error
P2135 - Throttle Position Sensor Plausibility Error
40 April 2018
ELECTRICAL
Throttle Position Sensor
Purpose: To monitor the throttle position as one of the many
inputs which helps the ECM calculate incoming air volume. It is
located on the throttle shaft end.
As part of the ETC system, there are two Throttle Position Sensors
integrated into the throttle body. A single sensor failure will flash
the error on screen and slightly limit the RPM. If there is a double
TPS failure the ECM will enter limp mode with reduced power.
TPS #1 and TPS #2 sensors are not serviceable, they must be replaced as part of the Throttle Body
Assembly.
April 2018 41
ELECTRICAL
Intake Air Temperature and Manifold Abso-
lute Pressure Sensor – TMAP Senor
Purpose: To monitor manifold absolute pressure, barometric
pressure and intake air temperature. A 0-5 volt input to the ECM
to calculate atmospheric conditions. The sensor is located on top
of the intake manifold.
Codes associated with the MAP sensor:
P0068 - Throttle position sensor MAP plausibility
P0107 - Manifold Absolute Pressure Circuit Low
P0108 - Manifold Absolute Pressure Circuit High
P0112 - Intake Air Temp Sensor Circuit Low/SG
P0113 - Intake Air Temp Sensor Circuit High/Open
P0114 - Intake Air Temp Sensor Circuit Intermittent
If the operator attempts to engage the brake pedal and the acceler-
ator pedal at the same time, the system will allow this for short pe-
riods of time, like when backing up an incline. If the operator attempts to power brake or aggressively
ride the brakes, the system will reduce power and display code P2299 on the gauge. This code will
clear once one of the pedals is released and power will resume. The power reduction and recovery is
slow and not sudden. once tripped there is a 3 second delay to any corrective action by the ECM.
The brake pedal must be depressed to start the vehicle in any gear. If both brake switches fail the
engine will not start. In the event a brake switch DTC code is present, all connections should be
checked and also ensure the brake system is bleed properly.
42 April 2018
ELECTRICAL
Cooling Fan & Relay
The primary fan switches on at 194º F (90º C) and will turn off at 185º F (85º C). The secondary fan
switches on at 203º F (95º C) and off at 194º F (90º C). This temperature is taken from the engine
coolant temp sensor.
April 2018 43
ELECTRICAL
Alternator
Alternator: While the Wildcat XX has a traditional
stator located on the engine, it is also equipped with
a 65 watt alternator from the factory. It is belt driven
and is located on the Mag side of the engine. The
protective shield should always be in place when
using the vehicle.
Fuel Injector
Purpose: To atomize and control the amount of fuel
entering the combustion chamber. The fuel injector is
an output from the ECM. The ECM controls the pulse,
which is calibrated to deliver a precise amount of fuel,
at a specific fuel pressure.
44 April 2018
ELECTRICAL
Tilt Sensor
Purpose: To stop the supply of fuel if the vehicle exceeds
the tilt sensor’s limits.
April 2018 45
ELECTRICAL
Crankshaft Position Sensor
Crank Position Sensor: As the flywheel slugs pass by the timing
sensor, AC voltage is generated and sent to the ECM. The ECM uses
this AC voltage to determine the crankshaft rotational position, neces-
sary to control the fuel injectors and ignition spark timing.
A misfire can also be caused by very low fuel. The code/gauge will not display which cylinder was
shut off. A misfire will not be detected at idle. The engine must be above 3000 RPM to detect a mis-
fire.
The ECM decides to use the O2 sensor’s feedback based on predetermined parameters built into
the multidimensional engine maps. When the ECM is not using the feedback from the O2 sensor it is
know as Open Loop EFI.
46 April 2018
ELECTRICAL
Coolant Temperature Sensor
Purpose: To monitor coolant temperature, it is an
input to the ECM and operates on 5 DC volts from
the ECM. The CTS is a negative temperature co-
efficient (NTC) sensor, the internal resistance de-
crease as the temperature rises. It is located on the
left side of the cylinder head.
April 2018 47
ELECTRICAL
Ignition Coil
The 998 engine has three coils in a coil at plug configuration.
Purpose: To step up the voltage of the engines primary circuit supplied by battery voltage to 20,000
- 30,000 volts, which is produced in the secondary winding. An ignition coil is made up of a primary
winding, a secondary winding and a laminated core.
That amount of voltage is needed for the spark to jump across its gap and ignite the fuel/air mixture.
The spark happens when the ECM drops the ground going to the ignition coil, which causes the volt-
age to ground through the spark plug.
Codes associated with the IGN Coil: WARNING: When checking spark or
cranking the engine over without the
P2300 Ignition Coil #1 Primary Circuit Low/SG/Open spark plug installed in the cylinder head,
P2301 Ignition Coil #1 Primary Circuit High always ground the spark plug or damage
to the ignition coil may occur.
P2303 Ignition Coil #2 Primary Circuit Low/Open
P2304 Ignition Coil #2 Primary Circuit High WARNING: Never attempt to measure the
ignition coil output voltage with a stan-
P2306 Ignition Coil #3 Primary Circuit Low/Open dard DVOM to prevent damage to the
P2307 Ignition Coil #3 Primary Circuit High tool or ignition system.
48 April 2018
Notes
April 2018 49
Notes
50 April 2018