Arctic Cat Wildcat 4 ROV 2013 Service Manual (P/N 2259-577)

This is Arctic Cat's February 2013 service manual for the 2013 Arctic Cat Wildcat 4 ROV, P/N 2259-577, supplied as a 150-page PDF. Arctic Cat states that the manual was designed to aid service personnel. Its shop-level procedures, measuring work, and special-tool requirements also make it suited to experienced owners who already understand engine, driveline, brake, and electrical repair.

• Organizes routine service around the factory maintenance chart, with valve-clearance checks, compression testing, oil and filter service, driveline lubrication, brake work, and shift adjustment.
• Covers engine/transmission removal and installation, top-end disassembly, valve and camshaft inspection, piston and cylinder service, crankcase separation, countershaft work, and final assembly.
• Details V-belt replacement, drive-clutch and driven-pulley service, oil-pump inspection, shift-component repair, and secondary bevel-gear tooth-contact and backlash setup.
• Walks through throttle-body removal, oil-pressure and fuel-pump testing, radiator and thermostat service, cooling-fan checks, and water-pump replacement.
• Provides component tests for the ECT, MAP/IAT, TPS, CKP/stator, ECM, charging and starting circuits, front drive actuator, and electronic power steering, backed by digital-gauge diagnostics and DTC tables.
• Includes front-differential and rear gear-case disassembly and shimming, axle and CV-joint work, hydraulic brake-caliper overhaul and bleeding, suspension service, steering-rack removal, and front wheel alignment.
• Supplies component-specific torque data, fluid capacities, inspection and wear limits, electrical test specifications, symptom/cause/remedy charts, special-tool part numbers, and a full-page main-harness wiring schematic.

Engine Access, Internal Service, and CVT Setup

The engine section makes an important access distinction: top-side, left-side, and right-side components can be serviced with the engine/transmission in the frame, while center-crankcase repair requires removal of the complete power unit. The top-end material covers the rocker arms, camshafts, valves and guides, cylinder heads, cam-chain guides, pistons, rings, and cylinders, with inspection procedures for runout, distortion, clearances, and wear. Internal transmission coverage extends to the crankshaft, connecting rods, oil pump, secondary output gears, countershaft, shift forks, and crankcase reassembly.

CVT coverage goes beyond a routine belt change. Separate drive-clutch and driven-pulley chapters show disassembly, inspection, reassembly, timing-mark alignment, and installation. The secondary output drive section explains gear-tooth contact and backlash correction rather than giving only a finished specification.

EFI, Electrical, and Driveline Diagnostics

The LCD gauge is used as a diagnostic tool for coolant temperature, fuel-sender output, engine and vehicle speed, throttle position, manifold pressure, intake-air temperature, and system voltage. The DTC tables identify the affected circuit, ECM pin where applicable, warning-icon behavior, likely open or short conditions, and code-clearing requirements. Dedicated procedures cover TPS adjustment, EPS fault codes, ignition timing verification, and voltage or resistance testing across the starting, charging, sensor, switch, and actuator circuits.

The drive-system chapters document front-differential removal, pinion and input-shaft service, shim selection, backlash and end-play setup, axle disassembly, rear gear-case work, hub service, and brake-caliper rebuilding. Named factory tools include the Crankcase Separator/Crankshaft Remover 0444-152, Secondary Drive Gear Holder 0444-253, Oil Pressure Test Kit 0644-495, and the 24- and 27-spline Backlash Measuring Tools 0544-010 and 0544-011.

Reference graphics include the full main-harness schematic, camshaft and cam-sprocket timing views, drive-clutch and driven-pulley assembly views, secondary bevel-gear tooth-contact charts, and front-differential pinion-shimming illustrations.

Replacement-Only Limits and Critical Repair Notes

The manual identifies several scope limits before parts are opened unnecessarily. The starter and water-pump assemblies, fuel pump/fuel-level sensor, and EPS assembly are treated as non-serviceable replacement units; valve, guide, or seat machining is referred to a qualified machine shop.

Two assembly cautions are especially relevant to major repair work. Misaligning the drive-clutch spider and movable-sheave timing marks can leave the clutch out of balance and damage both the clutch and crankshaft. Reversing a countershaft dog or gear can damage the transmission or require another complete teardown.

Support the vehicle securely before underbody, suspension, or driveline work. Disconnect the battery before opening the fuel system, since unintended electric fuel-pump operation can release gasoline.