Arctic Cat 2008 Prowler XT XTX Service Manual

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2008 Arctic Cat UTV models. 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. The service technician should become familiar with the operation and construction of each component or system by carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor. 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 severe personal injury or even death. The symbol ! 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. Keep this manual accessible in the shop area for reference. Product Service and Warranty Department Arctic Cat Inc.
2008 Arctic Cat Inc. www.mymowerparts.com Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
March 2008
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TABLE OF CONTENTS
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Foreword
MORE TO GO ON.
1. 2. 3. 4. 5. 6. 7. 8. 9. General Information/Specifications Periodic Maintenance/Tune-Up Engine/Transmission Fuel/Lubrication/Cooling Electrical System Drive System Suspension Steering/Frame
TM
Prowler PRowler 1 Prowler XT 2 PROWLER XTX 3 4 5 6 7 8 9
08
Controls/Indicators
www.mymowerparts.com
UTV Service Manual
SECTION 1 - GENERAL INFORMATION
TABLE OF CONTENTS
General Specifications ............................................ 1-2 Torque Specifications .............................................. 1-2 Torque Conversions (ft-lb/N-m) ............................... 1-3 Tightening Torque (General Bolts) .......................... 1-3 Break-In Procedure ................................................. 1-4 Gasoline - Oil - Lubricant ........................................ 1-4 Genuine Parts ......................................................... 1-5 Preparation For Storage.......................................... 1-5 Preparation After Storage........................................ 1-6
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1-1
General Specifications*
CHASSIS
Dry Weight (approx) Length (overall) Height (overall) Width (overall) Suspension Travel Brake Type Wheelbase Tire Size Tire Inflation Pressure Gas Tank Capacity (rated) Coolant Capacity Differential Capacity Rear Drive Capacity Engine Oil Capacity Gasoline (recommended) Engine Oil (recommended) Front Differential Lubricant Rear Drive Lubricant (Prowler/XT) Rear Differential Lubricant (XTX) Belt Width Brake Fluid Taillight/Brakelight Headlight Starting System 526 kg (1160 lb) 292 cm (115 in.) 197 cm (77.5 in.) 156 cm (61.3 in.) 25.4 cm (10 in.) 25.4 cm (10 in.) Hydraulic 190 cm (75 in.) 26 x 9-14 26 x 11-14 0.70 kg/cm (10 psi) 31 L (8.2 U.S. gal.) 2.9 L (3.0 U.S. qt) 275 ml (9.3 fl oz)** 250 ml (8.5 fl oz)** 2.5 L (2.6 U.S. qt) 87 Octane Regular Unleaded Arctic Cat ACX AllWeather Synthetic SAE Approved 80W-90 Hypoid SAE Approved 80W-90 Hypoid Arctic Cat 80W-90 Hypoid Friction Modified 35.0 mm (1.38 in.) DOT 4 12V/8W/27W 12V/27W (2) Electric
Torque Specifications
DRIVE TRAIN COMPONENTS Part
Engine Cradle Engine Cradle Front Differential*
Part Bolted To
Engine Rubber Mount Frame/Differential Bracket Rear U-Joint Flange Differential Housing Differential Housing
Torque ft-lb N-m

40 25 38 54 34 52
(front) (rear)
(front) (rear)
MISCELLANY
Rear Output Flange 40 54 Input Housing 23 31 Differential Housing 23 31 Cover*** Drive Bevel Gear Nut*** Shaft 87 118 Lock Collar Differential Housing 125 170 Hub Nut Front/Rear Shaft/Axle 200 272 (min) Oil Drain Plug Front Differential 45 in.-lb 5 Rear Drive/Differential Oil Fill Plug Front Differential 16 22 Rear Drive/Differential Oil Drain Plug Engine 16 22 Wheel Hub 45 61 Front Shaft Flange Front U-Joint 20 27
EXHAUST COMPONENTS
Exhaust Pipe Spark Arrester Coil* Ground Wire Engine Muffler 20 48 in.-lb 8 8 25 36 36 50 30 8 15 20 20 25 20 20 20 12 27 5 11 11 34 49 49 68 41 11 20 27 27 34 27 27 27 16
ELECTRICAL COMPONENTS
Frame Engine
STEERING COMPONENTS
Steering Wheel Shaft** Steering Wheel Steering Wheel Shaft Intermediate Shaft (Upper) Intermediate Shaft Steering Pinion Shaft (Lower) Rack and Pinion Assem- Frame bly Tie Rod End** Knuckle Jam Nut Tie Rod End
* Specifications subject to change without notice. ** Visible at plug threads.
BRAKE COMPONENTS
Brake Disc* Brake Hose Brake Hose Master Cylinder Parking Brake Mechanism Hydraulic Caliper Rear Caliper Driveline Brake Hub Caliper Master Cylinder Frame Frame Knuckle Rear Drive Gear Case Rear Drive Input Flange Shift Axle Bracket
CHASSIS COMPONENTS
Shift Lever* 20 27
1-2
* w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609
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SUSPENSION COMPONENTS (Front) Part
A-Arm Ball Joint Cap Screw Shock Absorber (Upper) Shock Absorber (Lower) Knuckle Sway Bar Bracket A-Arm Shock Absorber (Upper) Shock Absorber (Lower) Knuckle Cargo Box Hinge Cargo Box Latch Pivot Bushing Latch Striker Front/Rear Canopy Tube Top Canopy Support Rear Canopy Tube Clutch Shoe** Clutch Cover/ Housing Assembly Crankcase Half (6 mm) Crankcase Half (8 mm) Cylinder Head (Cap Screw) Cylinder Head Nut (6 mm) Cylinder Head Nut (8 mm) Cylinder Head Cover Driven Pulley Nut Drive Pulley Ground Wire Magneto Cover Oil Pump Drive Gear Output Shaft Flange Nut Outer Magneto Cover Rotor/Flywheel Nut Cam Sprocket** V-Belt Cover
Part Bolted To
Frame Knuckle Frame Upper A-Arm A-Arm Frame Frame Frame Lower A-Arm A-Arm Cargo Box Frame Cargo Box Frame Cargo Box Frame Cargo Box Liner Arm Rest/Steering Post Support Front/Rear Canopy Tubes Lower Canopy Support Crankshaft Crankcase Crankcase Half Crankcase Half Crankcase Cylinder Cylinder Cylinder Head Driveshaft Clutch Shaft Engine Crankcase Crank Balancer Shaft Output Shaft** Magneto Cover Crankshaft Camshaft Crankcase
Torque ft-lb N-m

33 35 33 33 33 33 33 33 20 33 20 20 15 5 20 8 8 221 10 10 20 40 8 18 9 80 165 8 8 62 62 8 105 11 8 45 48 45 45 45 45 45 45 27 45 27 27 20 7 27 11 11 300 14 14 27 54 11 24 12 109 224 11 11 84 84 11 143 15 11
Torque Conversions
(ft-lb/N-m)
ft-lb
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
N-m
1.4 2.7 4.1 5.4 6.8 8.2 9.5 10.9 12.2 13.6 15 16.3 17.7 19 20.4 21.8 23.1 24.5 25.8 27.2 28.6 29.9 31.3 32.6 34
ft-lb
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
N-m
35.4 36.7 38.1 39.4 40.8 42.2 43.5 44.9 46.2 47.6 49 50.3 51.7 53 54.4 55.8 57.1 58.5 59.8 61.2 62.6 63.9 65.3 66.6 68
ft-lb
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
N-m
69.4 70.7 72.1 73.4 74.8 76.2 77.5 78.9 80.2 81.6 83 84.3 85.7 87 88.4 89.8 91.1 92.5 93.8 95.2 96.6 97.9 99.3 100.6 102
ft-lb
76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
N-m
103.4 104.7 106.1 107.4 108.8 110.2 111.5 112.9 114.2 115.6 117 118.3 119.7 121 122.4 123.8 125.1 126.5 127.8 129.2 130.6 131.9 133.3 134.6 136
SUSPENSION COMPONENTS (Rear)
CANOPY ASSEMBLY
ENGINE/TRANSMISSION
Tightening Torque
(General Bolts)
* w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609
Type of Bolt
(Conventional or 4 Marked Bolt)
Thread Diameter A (mm)

5 6 8 10
Tightening Torque
12-36 in.-lb 36-60 in.-lb 7-11 ft-lb 16-25 ft-lb 24-48 in.-lb 6-8 ft-lb 13-20 ft-lb 29-43 ft-lb
(7 Marked Bolt)
5 6 8 10
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Break-In Procedure
A new vehicle and an overhauled engine require a break-in period. The first 10 hours (or 200 miles) are most critical to the life of this vehicle. Proper operation during this break-in period will help assure maximum life and performance from the vehicle. During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle. Varying the engine RPM during the break-in period allows the components to load (aiding the mating process) and then unload (allowing components to cool). Although it is essential to place some stress on the engine components during break-in, care should be taken not to overload the engine too often. Do not pull a trailer or carry heavy loads during the 10-hour break-in period. When the engine starts, allow it to warm up properly. Idle the engine several minutes until the engine has reached normal operating temperature. Do not idle the engine for excessively long periods of time. During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in. After the completion of the break-in period, the engine oil and oil filter should be changed. Other maintenance after break-in should include checking of all prescribed adjustments and tightening of all fasteners.
RECOMMENDED ENGINE/ TRANSMISSION OIL
! CAUTION
Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation. Also, not recommended are racing, vegetable, non-detergent, and castor-based oils.
The recommended oil to use is Arctic Cat ACX AllWeather 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 5W-50 oil is acceptable.
OILCHARTI
Gasoline - Oil Lubricant

RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol, 5% methane, or 5% MTBE 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 FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT (Prowler/XT) 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/rear drive damage.
RECOMMENDED DIFFERENTIAL LUBRICANT (Prowler XTX)

NOTE: Arctic Cat recommends the use of genuine Arctic Cat lubricants.
! CAUTION
Do not use white gas. Only Arctic Cat approved gasoline additives should be used.
The recommended lubricant for the front differential is SAE approved 80W-90 hypoid. This lubricant meets all of the front diffrential lubrication requirements of this vehicle.
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The recommended lubricant for the rear differential is Arctic Cat 80W-90 Hypoid Friction Modified. This lubricant meets all of the rear differential lubrication requirements of this vehicle.
Preparation For Storage

! CAUTION
Prior to storing the vehicle, it must be properly serviced to prevent rusting and component deterioration.
! CAUTION
Any lubricant used in place of the recommended lubricant could cause serious differential damage.
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.
1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry. 2. Clean the vehicle thoroughly by washing dirt, oil, grass, and other foreign matter from the entire vehicle. Allow it to dry thoroughly. DO NOT get water into any part of the engine or air intake. 3. Either drain the gas tank or add Fuel Stabilizer to the gas in the gas tank. Remove the air filter housing cover and air filter. Start the engine and allow it to idle. Using Arctic Cat Engine Storage Preserver, rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds; then stop the engine. Install the air filter and housing cover.
! CAUTION
If the interior of the air filter housing is dirty, clean the area before starting the engine.
ATV0049B
Since gasoline expands as its temperature rises, the gas tank must be filled to its rated 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.
4. On the carbureted models, drain the carburetor float chamber. 5. Plug the exhaust hole in the exhaust system with a clean cloth. 6. Apply light oil to the plungers of the shock absorbers. 7. Tighten all nuts, bolts, cap screws, and screws. Make sure rivets holding components together are tight. Replace all loose rivets. 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; then remove the battery, clean the battery posts and cables, and store in a clean, dry area. 10. Store the vehicle indoors in a level position.
! 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.
Tighten the gas tank cap securely after filling the tank.
! WARNING
Do not over-fill the gas tank.
Genuine Parts
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.
! CAUTION
Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the vehicle causing rusting.
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Preparation After Storage

Taking the vehicle out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. 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.
! CAUTION
The ignition switch must be in the OFF position prior to installing the battery or damage may occur to the ignition system.
! CAUTION
Connect the positive battery cable first; then the negative.
7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, and headlight aim; adjust or replace as necessary. 8. Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap screws, and bolts are tightened to specifications. 9. Check tire pressure. Inflate to recommended pressure as necessary. 10. Make sure the steering moves freely and does not bind. 11. Check the spark plug. Clean or replace as necessary.
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SECTION 2 PERIODIC MAINTENANCE/TUNE-UP
2
TABLE OF CONTENTS
Periodic Maintenance Chart .................................... 2-2 Periodic Maintenance.............................................. 2-3 Lubrication Points.................................................... 2-3 Battery..................................................................... 2-3 Fuses ...................................................................... 2-4 Air Filter ................................................................... 2-5 Valve/Tappet Clearance (Feeler Gauge Procedure) ................................... 2-6 Valve/Tappet Clearance (Valve Adjuster Procedure) .................................. 2-6 Testing Engine Compression................................... 2-7 Spark Plug............................................................... 2-8 Muffler/Spark Arrester ............................................. 2-8 Gas/Vent Hoses ...................................................... 2-8 Adjusting Engine RPM (Idle) ................................... 2-8 Engine/Transmission Oil - Filter............................... 2-9 Front Differential - Rear Drive/ Differential Lubricant .......................................... 2-10 Tires ...................................................................... 2-10 Steering Components ........................................... 2-11 Driveshaft/Coupling ............................................... 2-11 Suspension/Shock Absorbers/Bushings ............... 2-11 Nuts/Bolts/Cap Screws.......................................... 2-11 Ignition Timing ....................................................... 2-11 Headlight/Taillight-Brakelight ................................. 2-12 Switches ................................................................ 2-12 Shift Lever ............................................................. 2-13 Frame/Welds ......................................................... 2-13 Electrical Connections........................................... 2-13 Hydraulic Brake System ........................................ 2-13 Parking Brake ........................................................ 2-15 Burnishing Brake Pads .......................................... 2-17 Coolant .................................................................. 2-17 Checking/Replacing V-Belt .................................... 2-17 Troubleshooting Brake System.............................. 2-19
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2-1
Periodic Maintenance Chart
A = Adjust C = Clean D = Drain T = Tighten
I = Inspect L = Lubricate R = Replace
Item
Initial Every Month Every 3 Every 6 Every Year Service After or Months or Months or Every or Every Break-In Every 100 Every 300 Every 500 Day 1500 Miles (First Mo or Miles Miles Miles 100 Mi)
I I I I I I C* I I I I I C I I I I D* I I R I I I I I I I I I I l I R* I I C-L
As Needed
C R R A
Battery Fuses Air Filter/Drain Tube Valve/Tappet Clearance Engine Compression Spark Plug Muffler/Spark Arrester Gas/Vent Hoses Throttle Cable Ends/Accelerator Pedal Pivot Float Chamber (Prowler/XT) Engine RPM (Idle) (Prowler/XT) Engine-Transmission Oil Level Engine-Transmission Oil/Filter Oil Strainer Front Differential - Rear Drive/Differential Lubricant Tires/Air Pressure Steering Components V-Belt Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows) Nuts/Bolts/Cap Screws Ignition Timing Headlight/Taillight-Brakelight Switches Shift Lever Gauges/Indicators Frame/Welds Electrical Connections Complete Brake System (Hydraulic & Parking) Brake Pads Brake Fluid Brake Hoses Coolant/Cooling System Wheel Lug Nuts
R (4000 Mi or 18 Mo) R R (2 Yrs) A-R
A A R C R (4 Yrs) R R R R
T I
I I
I I I
R R A-L R I l l C
I I
I I I I I T
I I* I I I T R R (2 Yrs) R (4 Yrs) R (2 Yrs)
* Service/Inspect more frequently when operating in adverse conditions.
2-2
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Periodic Maintenance
This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat UTV.
NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. NOTE: Critical torque specifications are located in Section 1.
Battery
The battery is located in a compartment in front of the left-rear wheel under the driver seat.
NOTE: To access the battery box, the left-rear fender splash panel must be removed.
After being in service, batteries require regular cleaning and recharging in order to deliver peak performance and maximum service life. The following procedures are recommended for cleaning and maintaining lead-acid batteries. Always read and follow instructions provided with battery chargers and battery products.
! WARNING
Anytime service is performed on a battery, the following must be observed: keep sparks, open flame, cigarettes, or any other flame away. Always wear safety glasses. Protect skin and clothing when handling a battery. When servicing battery in enclosed space, keep the area well-ventilated. Make sure battery venting is not obstructed.
SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section.
Description
Compression Tester Kit Oil Filter Wrench Timing Light Valve Clearance Adjuster
p/n
0444-213 0644-389 0644-296 0444-078
1. Remove the battery hold-down; then disconnect the battery cables (negative cable first). 2. Disconnect the vent hose. 3. Remove the battery from the vehicle; then thoroughly wash the battery and battery compartment with soap and water.
NOTE: If battery posts, cable ends, or the battery case has a build-up of white/green powder residue, apply water and baking soda to neutralize acid; then flush off with warm soapy water.
NOTE: Special tools are available from the Arctic Cat Service Parts Department.
Lubrication Points
It is advisable to lubricate certain components periodically to ensure free movement. Apply light oil to the components using the following list as reference. A. Accelerator Pedal Pivot/Cable Ends B. Brake Pedal Pivot C. Parking Brake Cable Ends D. Shift Linkage E. Differential Lock Cable End F. Idle RPM Screw (Prowler/XT)
4. Using a wire brush, clean the battery posts and cable ends removing all corrosive buildup. Replace damaged cables or cable ends. 5. Add clean distilled water to bring fluid level to the UPPER level line.
! WARNING
Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery.
! CAUTION
Never use electrolyte (sulfuric acid) to top off the battery. Use only distilled water or severe battery damage may occur.
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6. Using a multimeter, test the battery voltage. The meter must read at least 12.5 DC Volts for a fully charged battery.
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NOTE: At this point, if the meter reads as specified, the battery may be returned to service (see step 10).
10. Place the battery in the battery compartment; then coat the battery posts and cable ends with a light coat of multi-purpose grease.
7. If the meter reads less than specified voltage, charge the battery using the following guidelines. A. When using an automatic battery charger, always follow the charger manufacturers instructions. B. When using a constant-current battery charger, use the following Battery Charging Chart.
! CAUTION
Before installing the battery, make sure the ignition switch is in the OFF position.
11. Connect the battery cables (positive cable first); then install the battery hold-down.
! CAUTION
Connecting cables in reverse (positive to negative and negative to positive) can cause serious damage to the electrical system.
! CAUTION
Never exceed the standard charging rate.
! WARNING
An overheated battery could explode causing severe injury or death. Always monitor charging times and charge rates carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.
Battery Charging Chart (Constant-Current Charger) Battery Voltage (DC)
12.5 or more 12.2-12.4 12.0-12.2 11.0-11.9 11.5 or less
Fuses
The main fuses are located in a power distribution module under the operators seat. If there is any type of electrical system failure, always check the fuses first.
NOTE: To remove the fuse, compress the locking tabs on either side of the fuse case and lift out.
Prowler/XT
Charge State
100% 75%-99% 50%-74% 25%-49% 0-24%
Charge Time Required (at 1.5-2.0 Amps)

None 3-6 hours 5-11 hours 13 hours (minimum) 20 hours (minimum)
NOTE: If the battery voltage is 11.5 DC Volts or less, some chargers may cut off and fail to charge. If this occurs, connect a fully charged booster battery in parallel (positive to positive and negative to negative) for a short period of time with the charger connected. After 10-15 minutes, disconnect the booster battery leaving the charger connected and the charger should continue to charge. If the charger cuts off, replace the battery.
1411-576
XTX
8. After charging the battery for the specified time, remove the battery charger and allow the battery to sit for 1-2 hours. 9. Connect the multimeter and test the battery voltage. The meter should read at least 12.5 DC Volts. If the voltage is as specified, the battery is ready for service.
NOTE: If voltage in step 9 is below specifications, charge the battery an additional 1-5 hours; then retest. Recheck electrolyte level and the battery is ready for service.
1411-526
! CAUTION
Always replace a blown fuse with a fuse of the same type and rating.
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Air Filter
Use the following procedure to remove the filter and inspect and/or clean it. CLEANING AND INSPECTING FILTER
6. Put the filter in a plastic bag; then pour in air filter oil and work the filter. Reattach the filter to the filter screen.
! CAUTION
A torn air filter can cause damage to the vehicle engine. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after cleaning it. Replace the element with a new one if it is torn.
! CAUTION
Failure to inspect the air filter frequently if the vehicle is used in dusty, wet, or muddy conditions can damage the engine.
7. Clean any dirt or debris from inside the air cleaner. Be sure no dirt enters the carburetor (Prowler/XT). 8. Place the filter assembly in the air filter housing making sure it is properly positioned and properly seated with the filter screen down.
1. Remove the seats; then remove the center console. 2. Unsnap the four fasteners securing the air cleaner housing cover and remove the cover. 3. Remove the air filter/filter screen assembly and separate the foam filter from the screen.
PR090
9. Install the air filter housing cover and secure with the retaining clips; then install the center console and seats making sure the seats lock securely.
PR101
CD670
CD747
4. Fill a wash pan larger than the filter with a non-flammable cleaning solvent; then dip the filter in the solvent and wash it.
NOTE: Foam Filter Cleaner and Foam Filter Oil are available from Arctic Cat.
CHECKING AND CLEANING DRAINS 1. Inspect one-way drains beneath the main housing for debris and for proper sealing.
5. Dry the filter.
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! CAUTION
The feeler gauge must be positioned at the same angle as the valve and valve adjuster for an accurate measurement of clearance. Failure to measure the valve clearance accurately could cause valve component damage.
VALVE/TAPPET CLEARANCE
Intake Exhaust
KX045A
0.1016 mm (0.004 in.) 0.1524 mm (0.006 in.)
2. Replace any one-way drain that is cracked or shows any signs of hardening or deterioration.
! CAUTION
The one-way drain to the left is the clean air section of the filter housing. Any leak of this drain will allow dirt into the engine intake causing severe engine damage.
3. Wipe any accumulation of oil or gas from the filter housing and one-way drains.
CC007D
(Feeler Gauge Procedure)

To check and adjust valve/tappet clearance, use the following procedure.
NOTE: The engine must be cold for this procedure. NOTE: The seats, center console, spark plug, and air filter housing must be removed for this procedure.
Valve/Tappet Clearance
4. Install the spark plug; then install the timing inspection plug. 5. Place the two tappet covers with O-rings into position. Tighten the cap screws securely.
Valve/Tappet Clearance
(Valve Adjuster Procedure)
To check and adjust valve/tappet clearance, use the following procedure.
NOTE: The engine must be cold for this procedure. NOTE: The seats, center console, spark plug, and air filter housing must be removed for this procedure.
1. Remove the spark plug and timing inspection plug; then remove the tappet covers (for more detailed information, see Section 3 - Servicing Top-Side Components). 2. Rotate the crankshaft to the TDC position on the compression stroke.
NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them.
1. Remove the spark plug and timing inspection plug; then remove the tappet covers (for more detailed information, see Section 3 - Servicing Top-Side Components). 2. Rotate the crankshaft to the TDC position on the compression stroke.
NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. NOTE: Use Valve Clearance Adjuster for this procedure.
3. Using a feeler gauge, check each valve/tappet clearance. If clearance is not within specifications, loosen the jam nut and rotate the tappet adjuster screw until the clearance is within specifications. Tighten each jam nut securely after completing the adjustment.
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3. Place the valve adjuster onto the jam nut securing the tappet adjuster screw; then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw. 4. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut; then rotate the tappet adjuster screw clockwise until friction is felt. 5. Align the valve adjuster handle with one of the marks on the valve adjuster dial. 6. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise until proper valve/tappet clearance is attained.
NOTE: Refer to the appropriate specifications in Feeler Gauge Procedure sub-section for the proper valve/tappet clearance. NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by 0.05 mm (0.002 in.) per mark.
Testing Engine Compression

To test engine compression, use the following procedure.
NOTE: The engine must be warm and the battery must be fully charged for this test. NOTE: The seats and center console must be removed for this procedure.
1. Remove the high tension lead from the spark plug. 2. Using compressed air, blow any debris from around the spark plug.
! WARNING
Always wear safety glasses when using compressed air.
7. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely with the valve adjuster handle. 8. Place the two tappet covers with O-rings into position. Tighten the cap screws securely.
3. Remove the spark plug; then attach the high tension lead to the plug and ground the plug on the cylinder head well away from the spark plug hole. 4. Attach the Compression Tester Kit. 5. While holding the throttle in the full-open position, crank the engine over with the electric starter until the gauge stops climbing (five to 10 compression strokes).
NOTE: The compression should be within a range of 155-170 psi in the full-open throttle position.
6. If compression is abnormally low, inspect the following items. A. Starter cranks engine over.
CF006A
B. Gauge is functioning properly. C. Throttle lever in the full-open position. D. Valve/tappet clearance correct. E. Valve bent or burned. F. Valve seat burned.
NOTE: To service valves, see Section 3.
7. Pour 29.5 ml (1 fl oz) of oil into the spark plug hole, reattach the gauge, and retest compression.
CF005
9. Install the spark plug; then install the timing inspection plug.
8. If compression is now evident, service the piston rings (see Section 3).
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Spark Plug
A light brown insulator indicates that the plug is correct. A white or dark insulator indicates that the engine may need to be serviced or the carburetor (if applicable) may need to be adjusted. To maintain a hot, strong spark, keep the plug free of carbon.
1. Remove the cap screws securing the spark arrester screen assembly to the muffler; then loosen and remove the spark arrester. Account for a gasket.
PR498
ATV-0051
! CAUTION
Before removing the spark plug, be sure to clean the area around the spark plug. Dirt could enter engine when removing or installing the spark plug.
Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.).
PR499
2. Using a suitable brush, clean the carbon deposits from the screen taking care not to damage the screen.
NOTE: If the screen or gasket is damaged in any way, it must be replaced.
3. Install the spark arrester assembly and gasket and secure with the cap screws. Tighten the cap screws to 48 in.-lb.
Gas/Vent Hoses
ATV0052C
When installing the spark plug, be sure to tighten it securely. A new spark plug should be tightened 1/2 turn once the washer contacts the cylinder head. A used spark plug should be tightened 1/8-1/4 turn once the washer contacts the cylinder head.
Replace the gas hose every two years. Damage from aging may not always be visible. Do not bend or obstruct the routing of the carburetor vent hose (Prowler/XT). Make certain that the vent hose is securely connected to the carburetor and the opposite end is always open.
Muffler/Spark Arrester Adjusting Engine RPM

Clean the spark arrester using the following procedure.
(Idle)
! WARNING
Wait until the muffler cools to avoid burns.
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NOTE: Idle RPM is not adjustable on the XTX model.
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To properly adjust the idle RPM, a tachometer is necessary. To adjust idle RPM, use the following procedure.
NOTE: To access the idle adjustment screw, it will be necessary to remove the seats and center console. The idle adjustment screw is located on the left-side of the carburetor.
1. Set the parking brake. With the transmission in neutral, start the engine and warm it up to normal operating temperature. 2. Turn the idle adjustment screw clockwise one turn past the recommended RPM setting; then turn it counterclockwise to 1250-1350 RPM.
PR053B
3. Remove the drain plug from the bottom of the engine and drain the oil into a drain pan.
PR081A
! WARNING
Adjust the idle to the correct RPM. Make sure the engine is at normal operating temperature before adjusting the idle RPM.
PR078A
4. Using the Oil Filter Wrench and a ratchet handle (or a socket or box-end wrench), remove the old oil filter.
NOTE: Clean up any excess oil after removing the filter.
Engine/Transmission Oil - Filter

OIL - FILTER Change the engine oil and oil filter at the scheduled intervals. The engine should always be warm when the oil is changed so the oil will drain easily and completely.
NOTE: To change oil and filter, the seats and center console must be removed.
5. Apply oil to a new filter O-ring and check to make sure it is positioned correctly; then install the new oil filter. Tighten securely. 6. Install the engine drain plug and tighten to 16 ft-lb. Pour the specified amount of the recommended oil in the filler hole. Install the oil level stick/filler plug.
! CAUTION
Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation. Also, not recommended are racing, vegetable, non-detergent, and castor-based oils.
1. Park the vehicle on level ground. 2. Remove the oil level stick/filler plug.
7. Start the engine (while the vehicle is outside on level ground) and allow it to idle for a few minutes. 8. Turn the engine off and wait approximately one minute.
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9. Unscrew the oil level stick and wipe it with a clean cloth.
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10. Install the oil level stick and thread into the engine case.
NOTE: The oil level stick should be threaded into the case for checking the oil level.
1. Place the vehicle on level ground. 2. Remove each fill/level plug. 3. Drain the lubricant into a drain pan by removing in turn the drain plug from each.
Front Differential
11. Remove the oil level stick; the engine oil level should be above the illustrated L mark but not higher than the illustrated F mark.
! CAUTION
Do not over-fill the engine with oil. Always make sure that the oil level is above the L mark but not higher than the F mark.
ATV0082A
Rear Drive/Differential
ATV-0100AA
12. Inspect the area around the drain plug and oil filter for leaks.
Front Differential - Rear Drive/Differential Lubricant

To check lubricant, use the following procedure. 1. Remove the level plug; the lubricant level should be visible at the plug threads.
PR530B
4. After all the lubricant has been drained, install the drain plugs and tighten to 45 in.-lb. 5. Pour the appropriate amount of recommended lubricant into the fill/level hole. 6. Install the fill/level plugs.
NOTE: If the lubricant is contaminated with water, inspect the drain plug, fill/level plug, and/or bladder.
Tires
TIRE SIZES The UTV models are equipped with low-pressure tubeless tires of the size and type listed in Section 1. Do not under any circumstances substitute tires of a different type or size.
PR530A
2. If low, add SAE approved 80W-90 hypoid gear lube as necessary.
! WARNING
Always use the size and type of tires specified. Always maintain proper tire inflation pressure.
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To change the lubricant, use the following procedure.
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TIRE INFLATION PRESSURE Front and rear tire inflation pressure should be 0.70 kg-cm (10 psi). A low-pressure gauge is provided in the tool kit to measure the air pressure in the tires. Check the air pressure in all tires before each use of the vehicle. D. Shock absorber eyelets broken, bent, or cracked. E. Shock absorber eyelet bushings worn, deteriorated, cracked, or missing. F. Shock absorber spring broken or sagging. G. Sway bar mountings tight and bushings secure.
Steering Components
The following steering components should be inspected periodically to ensure safe and proper operation. A. Steering wheel secure. B. Steering has equal and complete full-left and full-right capability. C. Steering sector mounting bolts tight. D. Ball joints not worn, cracked, or damaged. E. Tie rods not bent or cracked. F. Knuckles not worn, cracked, or damaged. G. Cotter pins not damaged or missing. H. Steering wheel tilt locks securely (XTX).
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, bolts, and cap screws are tightened to specifications.
Ignition Timing
The ignition timing cannot be adjusted; however, verifying ignition timing can aid in troubleshooting other components. To verify ignition timing, use the following procedure.
NOTE: To check ignition timing, the seats and center console must be removed.
Driveshaft/Coupling
The following drive system components should be inspected periodically to ensure proper operation. A. Spline lateral movement (slop). B. Coupling cracked, damaged, or worn. C. Universal joints worn or missing bearings.
1. Attach the Timing Light to the spark plug high tension lead; then remove the timing inspection plug from the left-side crankcase cover. 2. Start the engine and using the RPM function on the speedometer/tachometer (XT/XTX) or using a suitable tachometer (Prowler), run at 1500 RPM; ignition timing should be 10 BTDC. 3. Install the timing inspection plug. If ignition timing cannot be verified, the rotor may be damaged, the key may be sheared, the trigger coil bracket may be bent or damaged, or the CDI unit/ECU may be faulty.
Suspension/Shock Absorbers/Bushings
The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods bent, pitted, or damaged. B. Rubber damper cracked, broken, or missing. C. Shock absorber body damaged, punctured, or leaking.
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Headlight/TaillightBrakelight
HEADLIGHT
NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE. When replacing the headlight bulb, do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing. Skin oil residue on the bulb will shorten the life of the bulb.
NOTE: There should be an average operating load on the vehicle when adjusting the headlight aim.
2. Measure the distance from the floor to the mid-point of each headlight. 3. Using the measurements obtained in step 2, make horizontal marks on the aiming surface. 4. Make vertical marks which intersect the horizontal marks on the aiming surface directly in front of the headlights. 5. Switch on the lights. Make sure the HIGH beam is on. DO NOT USE LOW BEAM. 6. Observe each headlight beam aim. Proper aim is when the most intense beam is centered on the vertical mark 5 cm (2 in.) below the horizontal mark on the aiming surface.
! WARNING
Do not attempt to remove the bulb when it is hot. Severe burns may result.
To replace the headlight bulb, use the following procedure. 1. Remove the wiring harness connector from the back of the headlight. 2. Grasp the bulb socket, turn it counterclockwise and remove, and pull the bulb straight out of the socket. 3. Install the new bulb into the socket and rotate it completely clockwise in the housing. 4. Install the wiring harness connector.
0740-647
TAILLIGHT-BRAKELIGHT To replace the taillight-brakelight bulb, use the following procedure. 1. Remove the two machine screws and remove the light assembly. 2. Rotate the bulb socket counterclockwise to remove it from the light assembly; then pull straight out on the bulb. Push the new bulb straight into the socket. 3. Install the bulb and socket into the light assembly and turn clockwise to lock in place. 4. Install the taillight-brakelight assembly on the canopy support. CHECKING/ADJUSTING HEADLIGHT AIM The headlights can be adjusted vertically. The geometric center of the HIGH beam light zone is to be used for vertical aiming. 1. Position the vehicle on a level floor so the headlights are approximately 6.1 m (20 ft) from an aiming surface (wall or similar aiming surface).
7. Using the adjuster knob, adjust each headlight until correct aim is obtained.
CD714A
Switches
Each time the vehicle is used, switches should be checked for proper operation. Use the following list for reference. A. Ignition/start switch engine will run; starter will engage.
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B. 2WD/4WD selector switch differential will engage (4WD)/disengage (2WD). C. Reverse/neutral/high/low switch R/N/H/L will be indicated on the LCD. D. Headlight switch high beam, low beam, and lights off can be selected. E. Brake switch brakelight illuminates and starter can be engaged with vehicle in gear.
Shift Lever
CHECKING SHIFT LEVER LINKAGE Set the parking brake and turn the ignition switch on; then with the shift lever in the neutral position, look for the (N) indication on the LCD. Shift into high range and look for the (H) indication, low range for the (L) indication, and reverse for the (R) indication. Shift the transmission into neutral and turn the ignition switch off.
PR461A
4. Turn the linkage rod clockwise or counterclockwise until the lower linkage hole aligns with the shift arm pin. 5. Install the bushing and linkage and secure with the washer and E-clip; then tighten the jam nut securely. Check each gear shift position for proper gear selection and make sure the proper icon illuminates on the LCD.
Frame/Welds
The frame and welds should be checked periodically for damage, bends, cracks, deterioration, broken components, and missing components. If replacement or repair constitutes removal, see Section 8.
Electrical Connections
PR094
ADJUSTING SHIFT LEVER LINKAGE To adjust the shift lever linkage, use the following procedure. 1. Set the parking brake; then remove the seats and center console. 2. Make sure the shift lever is in neutral; then loosen the jam nut on the linkage. 3. Remove the E-clip on the transmission shift arm; then remove the linkage from the shift arm. Account for a washer and a bushing.
The electrical connections should be checked periodically for proper function. In case of an electrical failure, check fuses, connections (for tightness, corrosion, damage), and/or bulbs. If an electrical component needs to be tested for proper function, see Section 5.
Hydraulic Brake System

CHECKING/BLEEDING The hydraulic brake system has been filled and bled at the factory. To check and/or bleed a hydraulic brake system, use the following procedure. 1. With the master cylinder in a level position, check the fluid level in the reservoir. If the level in the reservoir is not above the MIN, add DOT 4 brake fluid.
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NOTE: During the bleeding procedure, watch the reservoir very closely to make sure there is always a sufficient amount of brake fluid. When the level falls below MIN, refill the reservoir before the bleeding procedure is continued. Failure to maintain a sufficient amount of fluid in the reservoir will result in air in the system.
D. At this point, perform steps B and C on the other FRONT bleeder screw; then move to the REAR bleeder screw and follow the same procedure.
PR095
2. Depress the brake pedal several times to check for a firm brake. If the brake is not firm, the system must be bled. 3. To bleed the brake system, use the following procedure. A. Remove the cover and fill the reservoir with DOT 4 Brake Fluid. B. Install and secure the cover; then slowly depress the brake pedal several times. C. Remove the protective cap, install one end of a clear hose onto one FRONT bleeder screw, and direct the other end into a container; then while holding slight pressure on the brake pedal, open the bleeder screw and watch for air bubbles. Close the bleeder screw before releasing the brake pedal. Repeat this procedure until no air bubbles are present.
E. Repeat steps B and C until the brake pedal is firm. 4. Carefully check the entire hydraulic brake system that all hose connections are tight, the bleed screws are tight, the protective caps are installed, and no leakage is present.
! CAUTION
This hydraulic brake system is designed to use DOT 4 brake fluid only. If brake fluid must be added, care must be taken as brake fluid is very corrosive to painted surfaces.
INSPECTING HOSES Carefully inspect the hydraulic brake hoses for cracks or other damage. If found, the brake hoses must be replaced. CHECKING/REPLACING PADS The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear. The only maintenance that is required is replacement of the brake pads when they show excessive wear. Check the thickness of each of the brake pads as follows. 1. Remove a front wheel. 2. Measure the thickness of each brake pad.
AF637D
PR376A
3. If thickness of either brake pad is less than 1.0 mm (0.039 in.), the brake pads must be replaced.
PR377C
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NOTE: The brake pads should be replaced as a set.
2. If the rear wheels are locked, it is adjusted properly. 3. If the rear wheels are not locked, it must be adjusted (set up). ADJUSTING To adjust (set up) the parking brake, use the following procedure.
NOTE: Remove the four rear body screws securing the belly panel to the frame and allow it to drop down for better access to the parking brake actuator.
4. To replace the brake pads, use the following procedure. A. Remove the wheel. B. Remove the cap screws securing the caliper holder to the knuckle; then remove the pads from the caliper.
2
PR237
C. Install the new brake pads. D. Secure the caliper holder to the knuckle with the cap screws. Tighten to 20 ft-lb.
PR096
1. Remove the parking brake cable from the actuator lever; then remove the actuator nut and actuator lever. Note the position of the lever before removing.
PR377B
E. Install the wheel. Tighten to 45 ft-lb. 5. Burnish the brake pads (see Burnishing Brake Pads in this section).
PR098
Parking Brake
CHECKING Although the parking brake has been adjusted at the factory, the brake should be checked for proper operation. The brake must be maintained to be fully functional. 1. With the engine off, transmission in neutral, and the parking brake set, attempt to move the vehicle.
2. Rotate the actuator clockwise (hand tight) until it contacts the back of the piston; then rotate counterclockwise approximately one spline.
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2. Lift the cargo box; then disconnect the lower lift support and allow the cargo box to tilt all the way back. Account for the washer.
PR089A
3. Install the actuator lever in the position noted in step 1; then install the actuator nut and tighten to 35 ft-lb.
PR473A
3. Remove the two cap screws securing the brake caliper to the rear drive housing and remove the caliper. 4. Remove the anti-rattle springs; then push in on the caliper holder and remove the outer brake pad. Remove the inner pad.
PR098A
4. Install the parking brake cable and adjust nuts so the parking brake holds the vehicle when set and fully releases it when released.
PR466A
Inspecting and Measuring 1. Inspect the pads for gouges, chips, or wear. 2. Inspect the disc for gouges, grooves, cracks, and warpage. 3. Using a calipers, measure the thickness of each brake pad.
PR097A
! CAUTION
If after adjusting the parking brake cable the parking brake will not hold the vehicle, the brake pads must be replaced.
4. If the thickness of either brake pad is less than 1.0 mm (0.039 in.), the brake pads must be replaced.
NOTE: The brake pads should be replaced as a set.
MEASURING/REPLACING BRAKE PADS Removing 1. Remove the parking brake cable (see Adjusting in this sub-section). www.mymowerparts.com
Installing 1. Place the brake pads into the caliper; then install the anti-rattle springs.
NOTE: The metal backing of the pad will be facing the actuator when installed properly.
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2. Slide brake caliper assembly over the brake disc and into position on the knuckle; then secure the caliper with the cap screws tightened to 20 ft-lb. 3. Connect the parking brake cable (see Adjusting in this sub-section). 4. Adjust the parking brake (see Adjusting in this sub-section). 5. Connect the lift support to the cargo box.
NOTE: Whenever installing new pads, the new pads must be burnished (see Burnishing Brake Pads in this section).
Checking/Replacing V-Belt
REMOVING 1. Remove the seats and center console; then remove the left-side seat-base.
Burnishing Brake Pads

Brake pads must be burnished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure.
2
PR104
! WARNING
Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss. Brake loss can result in severe injury.
2. Remove the cap screws securing the V-belt cover noting the location of the different-lengthed cap screws for installing purposes; then using a rubber mallet, gently tap on the cover tabs to loosen the cover. Remove the cover. 3. Remove the nut securing the movable drive face; then remove the face. Account for the flat washer and spacer.
NOTE: Keep the drive face plate in contact with the drive face when removing or installing the drive face to prevent the rollers from falling out.
1. Choose an area large enough to safely accelerate the vehicle to 30 mph and to brake to a stop. 2. Accelerate to 30 mph; then depress the brake pedal to decelerate to 0-5 mph. 3. Repeat procedure five times until brake pads are burnished. 4. Adjust the parking brake (if necessary). 5. Verify that the brakelight illuminates when the brake pedal is depressed.
Coolant
When filling the cooling system, use premixed Arctic Cat Antifreeze. While the cooling system is being filled, air pockets may develop; therefore, run the engine for five minutes after the initial fill, shut the engine off, and then fill the cooling system to the bottom of the stand pipe in the radiator neck.
CD963
! CAUTION
After operating the vehicle for the initial 5-10 minutes, stop the engine, allow the engine to cool down, and check the coolant level. Add coolant as necessary.
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CD966A
PR109
4. Install one of the V-belt cover cap screws into the driven pulley fixed face; then turn the cap screw clockwise to spread the pulley faces. Remove the V-belt.
NOTE: The arrows on the V-belt should point rearward.
2. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the driveshaft. Secure the drive face with a washer and nut (coated with red Loctite #271). Tighten the nut to 165 ft-lb.
! CAUTION
Make sure the drive belt does not prevent the movable face from contacting the spacer when tightening the nut or false torque readings could occur. The assembly could loosen after starting the engine causing damage to the shaft and pulley.
PR476A
PR108 PR109
NOTE: At this point, remove the cap screw from the driven pulley face.
INSTALLING 1. Place the V-belt into position on the driven pulley and over the front shaft.
3. Rotate the V-belt and driven pulley/clutch until the V-belt is flush with the top of the driven pulley. 4. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws making sure the different-lengthed cap screws are in their proper location. Tighten the cap screws to 8 ft-lb. 5. Secure the seat-base with the four cap screws. Tighten securely. 6. Install the seats and center console making sure the seats lock securely.
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Troubleshooting Brake System

Problem: Braking poor Condition
1. Pad worn 2. Pedal free-play excessive 3. Brake fluid leaking 4. Hydraulic system leaking air 5. Master cylinder/brake cylinder seal worn
Remedy
1. Replace pads 2. Adjust free-play 3. Repair - replace hydraulic system 4. Bleed hydraulic system 5. Replace seal(s)
Problem: Brake pedal travel excessive Condition

1. Hydraulic system entrapped air 2. Brake fluid low 3. Brake fluid incorrect 4. Piston seal - cup worn
Remedy
1. Bleed hydraulic system 2. Add fluid to proper level 3. Replace with correct fluid 4. Replace seal - cup
Problem: Brake fluid leaking Condition

1. Connection joints loose 2. Hose cracked 3. Piston seal worn
Remedy
1. Tighten joint 2. Replace hose 3. Replace seal
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2-19
SECTION 3 - ENGINE/TRANSMISSION
TABLE OF CONTENTS
Engine/Transmission ............................................... 3-2 Specifications .......................................................... 3-2 Prowler/XT/XTX (Table of Contents) ....................... 3-3 Troubleshooting ..................................................... 3-48
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3-1
Engine/Transmission
This section has been organized into sub-sections which show a progression for the complete servicing of the Arctic Cat UTV engine/transmission. To service the center crankcase halves, the engine/transmission must be removed from the frame. To service top-side, left-side, and right-side components, the engine/transmission does not have to be removed from the frame.
NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/ transmission. NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. NOTE: Critical torque specifications are located in Section 1.
Specifications*
VALVES AND GUIDES
(intake) (exhaust) Valve/Tappet Clearance (intake) (cold engine) (exhaust) Valve Guide/Stem (intake/exhaust) Clearance Valve Guide/Valve Stem (max) Deflection (wobble method) Valve Guide Inside Diameter Valve Stem Outside (intake/exhaust) Diameter Valve Stem Runout (max) Valve Head Thickness (min) Valve Stem End Length (min) Valve Face/Seat Width (intake) (exhaust) Valve Seat Angle (intake/exhaust) Valve Face Radial Runout (max) Valve Spring Free Length (min) Valve Spring Tension (outer) @ 31.5 mm (1.24 in.) Valve Face Diameter 31.6 mm (1.24 in.) 27.9 mm (1.10 in.) 0.1016 mm (0.004 in.) 0.1524 mm (0.006 in.) 0.013 mm (0.0005 in.) 0.35 mm (0.014 in.) 5.000-5.012 mm (0.1969-0.1973 in.) 4.972-4.987 mm (0.1957-0.1963 in.) 0.1 mm (0.0039 in.) 2.3 mm (0.0906 in.) 3.97 mm (0.156 in.) 2.25 mm (0.0886 in.) 2.60 mm (0.1024 in.) 45 15-45 30 0.2 mm (0.0079 in.) 38.7 mm (1.524 in.) 19.0 kg (42 lb)
Description
Connecting Rod Holder Crankcase Separator/Crankshaft Remover Magneto Rotor Remover Set Piston Pin Puller Side Case Puller Spanner Wrench Spanner Wrench Surface Plate V Blocks
CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min) (intake/exhaust) 13.97 mm (0.55 in.) Camshaft Journal Oil (max) 0.04 mm (0.0016 in.) Clearance Camshaft Journal (right & center) 21.98-22.04 mm Holder Inside Diameter (0.8654-0.8677 in.) (left) 17.48-17.53 mm (0.6882-0.6902 in.) Camshaft Journal (right & center) 21.96-21.98 mm Outside Diameter (0.8646-0.8654 in.) (left) 17.47-17.48 mm (0.6878-0.6882 in.) Camshaft Runout (max) 0.05 mm (0.002 in.) Rocker Arm Inside Diameter 12.000-12.018 mm (0.4724-0.4731 in.) Rocker Arm Shaft Outside Diameter 11.97-11.98 mm (0.4713-0.4717 in.) Cylinder Head/Cover Distortion (max) 0.05 mm (0.002 in.)
p/n
0444-006 0444-009 0444-206 0644-328 0644-365 0444-205 0544-005 0644-016 0644-022
3-2
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CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder Clearance Piston Diameter 15 mm (0.6 in.) from Skirt End (Prowler/XT) Piston Diameter 12 mm (0.47 in.) from Skirt End (XTX) Piston Ring Free End Gap (1st/2nd) Bore x Stroke (Prowler/XT) Bore x Stroke (XTX) Cylinder Trueness (max) Piston Ring End Gap - Installed Piston Ring to Groove (1st/2nd) Clearance (max) Piston Ring Groove Width (1st/2nd) (oil) Piston Ring Thickness Piston Pin Bore Piston Pin Outside Diameter (1st/2nd) (max) (min) 0.045 mm (0.0018 in.) 97.948-97.962 mm (3.856-3.857 in.) 101.930-101.949 mm (4.013-4.014 in.) 12.5 mm (0.492 in.) 97.9 x 85 mm (3.86 x 3.35 in.) 102 x 82 mm (4.01 x 3.22 in.) 0.01 mm (0.004 in.) 0.36 mm (0.014 in.) 0.03 mm (0.0012 in.) 1.202-1.204 mm (0.0473-0.0474 in.) 2.01-2.03 mm (0.0791-0.0799 in.) 1.970-1.990 mm (0.0776-0.0783 in.) 23.0 mm (0.9055 in.) 22.99 mm (0.9051 in.) 23.021 mm (0.9063 in.) 0.6 mm (0.024 in.) 25 mm (0.9843 in.) 0.3 mm (0.0118 in.) 71 mm (2.79 in.) 0.03 mm (0.0012 in.) 1.40-2.11 kg/cm (20-30 psi)
Removing Engine/ Transmission

Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information.
AT THIS POINT
If the technician's objective is to service/replace left-side cover oil seals, front output joint oil seal, rear output joint oil seal, and/or the oil strainer (from beneath the engine/transmission), the engine/transmission does not have to be removed from the frame.
Support the vehicle on a suitable lift or jack stands allowing room to perform work from the underside.
NOTE: Locate the jack stands to allow removing of the center belly panel.
CRANKSHAFT
Connecting Rod (max) (small end inside diameter) Connecting Rod (big end side-to-side) Connecting Rod (big end width) Connecting Rod @ 150 mm (max) (5.9 in.) (small end deflection) Crankshaft (web-to-web) Crankshaft Runout (max) Oil Pressure @2500 RPM (Cooling Fan Cycling)
! WARNING
Make sure the vehicle is solidly supported on the support stands to avoid injury.
1. Remove the seats and center console; then remove the left-side and right-side seat-bases. 2. Remove the center belly panel; then drain the oil and coolant.
NOTE: Use a small funnel between the frame and coolant drain plug to prevent coolant from draining on the frame and splashing.
* Specifications subject to change without notice.
Prowler/XT/XTX
(Table of Contents)
Removing Engine/Transmission.............................. 3-3 Top-Side Components............................................. 3-7 Removing Top-Side Components ........................... 3-7 Servicing Top-Side Components........................... 3-11 Installing Top-Side Components ........................... 3-18 Right-Side Components ........................................ 3-24 Removing Right-Side Components....................... 3-24 Installing Right-Side Components......................... 3-26 Left-Side Components .......................................... 3-29 Removing Left-Side Components ......................... 3-29 Servicing Left-Side Components ......................... 3-32 Installing Left-Side Components ........................... 3-33 Center Crankcase Components............................ 3-36 Separating Crankcase Halves............................... 3-36 Disassembling Crankcase Half ............................. 3-37 Servicing Center Crankcase Components ........... 3-38 Assembling Crankcase Half .................................. 3-42 Joining Crankcase Halves..................................... 3-44 Installing Engine/Transmission.............................. 3-44
PR122A
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PR156A
PR157A
3. Remove the negative cable from the battery; then remove the positive cable. 4. From the left-side, remove the spark plug cap; then disconnect the temperature sensor lead, speed sensor connector (XT/XTX), fuel level sensor connector (XT/XTX), and reverse override switch connector.
5. From the left-side, disconnect the starter wire, alternator connector, CDI connector (Prowler/XT), gear shift position switch, and electric choke connector; then remove the cap screw securing the main harness ground and the battery ground wires to the starter.
PR145A PR130A
PR128A PR155C
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PR474B
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6. Remove the E-clip from the transmission shift arm; then disconnect the shifter linkage. Account for a washer and a bushing.
PR118
PR461B
9. Remove four self-tapping screws securing the air filter mounting bracket to the frame; then remove the air filter and mounting bracket as an assembly.
7. Remove four machine screws securing the shifter mount to the frame; then remove the shifter assembly.
PR140A
PR123A
10. Remove the throttle arm cover from the carburetor/throttle body; then disconnect and remove the throttle cable and the carburetor/throttle body.
8. Loosen the clamp securing the air intake boot to the carburetor/throttle body and the clamp securing the air filter housing to the inlet housing boot; then remove the crankcase breather hose from the crankcase.
PR154A
11. Remove the coolant hoses from the water pump and thermostat housings; then position the upper coolant line to the left-side of the engine compartment.
PR127A
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PR150A
PR152A
12. Remove the exhaust duct from the V-belt housing; then remove the inlet boot connecting the inlet duct to the V-belt housing.
PR120A
PR144B
15. Separate the drive coupler flanges; then remove the driveshafts from the splined slip-joints being careful not to damage the rubber boots. The front boot should be removed with the driveshaft.
PR153B
13. Remove the muffler; then remove the exhaust pipe. 14. Set the parking brake; then from the underside of the vehicle, mark the flanges of the drive-line couplers for assembling and remove the cap screws (three on the front drive coupler and three on the rear drive coupler) securing the driveshafts to the drive couplers.
NOTE: Remove the front driveshaft first or the parking brake will not hold the coupler stationary and cap screw removing will be more difficult.
PR148A
16. Remove two flange nuts from the underside of the rear engine mounts.
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PR153A
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17. Remove two flange nuts securing the engine mounting bracket to the front engine mounts.
Top-Side Components
NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment.
AT THIS POINT
To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section.
PR147
18. Attach suitable lifting chains to the engine/transmission; then using an engine hoist, lift the assembly out of the engine compartment.
NOTE: The engine/transmission does not have to removed from the frame for this procedure.
Removing Top-Side Components

A. Valve Cover B. Cylinder Head
NOTE: Remove the spark plug and timing inspection plug; then using an appropriate wrench, rotate the crankshaft to top-dead-center of the compression stroke.
PR114
NOTE: The front engine mounting bracket should slide free of the engine mounts first; then the rear engine mounting bracket and two rear engine mounts will lift free of the frame.
1. Remove the two tappet covers.
CC001D
PR146
NOTE: Keep the mounting hardware with the covers for assembly purposes or thread them back into the head to keep them separated.
2. Remove the 12 cap screws securing the valve cover to the head; account for the four rubber washers on the top side cap screws. Remove the valve cover. Account for and note the orientation of the cylinder head plug. Note the location of two alignment pins.
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4. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring.
NOTE: Care should be taken not to drop the C-ring down into the crankcase.
CD205
CC012D
5. Bend the washer tabs down and remove the two cap screws securing the sprocket to the camshaft; then drop the sprocket off the camshaft.
CD206
CC013D
CD211A
6. Remove the cap screw securing the chain tensioner (account for a washer); then remove the tensioner.
3. Loosen the cap screw on the end of the tensioner; then remove the two cap screws securing the tensioner adjuster assembly and remove the assembly. Account for a gasket.
CC014D
7. While holding the chain, slide the sprocket and camshaft out of the cylinder head.
CC009D
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CC266D
CC016D
NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase.
9. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins; then remove the cam chain guide.
8. Remove the five nuts securing the cylinder head to the cylinder; then remove the four cylinder head cap screws with washers (note location of the different-sized cap screws and nuts).
CC020D
AT THIS POINT
CC017D
To service valves and cylinder head, see Servicing Top-Side Components sub-section.
AT THIS POINT
To inspect cam chain guide, see Servicing Top-Side Components sub-section.
CC018D
CC022D
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C. Cylinder D. Piston
NOTE: Steps 1-9 in the preceding sub-section must precede this procedure.
10. Loosen the clamp securing the coolant hose to the union; then detach the hose. 11. Remove the two nuts securing the cylinder to the crankcase.
CC026D
AT THIS POINT
To service cylinder, see Servicing Top-Side Components sub-section.
! CAUTION
When removing the cylinder, be sure to support the piston to prevent damage to the crankcase and piston.
CC023D
13. Using an awl, remove one piston-pin circlip.
12. Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase. Account for the gasket and two alignment pins.
CC032D
CC024D
14. Using the Piston Pin Puller, remove the piston pin. Account for the opposite-side circlip. Remove the piston.
NOTE: It is advisable to remove the opposite-side circlip prior to using the puller.
CC025D
CC033D
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NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the Connecting Rod Holder.
! CAUTION
Do not allow the connecting rod to go down inside the crankcase. If the rod is down inside the crankcase and the crankshaft is rotated, severe damage will result.
2. Place the valve cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained.
! CAUTION
Do not remove an excessive amount of the sealing surface or damage to the camshaft will result. Always check camshaft clearance when resurfacing the valve cover.
NOTE: If the existing rings will not be replaced with new rings, note the location of each ring for proper installation. When replacing with new rings, replace as a complete set only. If the piston rings must be removed, remove them in this sequence.
A. Starting with the top ring, slide one end of the ring out of the ring-groove. B. Remove each ring by working it toward the dome of the piston while rotating it out of the groove.
AT THIS POINT
To service piston, see Servicing Top-Side Components sub-section.
AT THIS POINT
To service center crankcase components only, proceed to Removing Left-Side Components.
CC130D
! CAUTION
Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result.
Servicing Top-Side Components

NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
Removing Valves
NOTE: Keep all valves and valve components as a set. Note the original location of each valve set for use during installation. Return each valve set to its original location during installation.
VALVE ASSEMBLY When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear.
NOTE: Whenever a valve is out of tolerance, it must be replaced.
1. Using a valve spring compressor, compress the valve springs and remove the valve cotters. Account for an upper spring retainer.
Cleaning/Inspecting Valve Cover

NOTE: If the valve cover cannot be trued, the cylinder head assembly must be replaced.
1. Wash the valve cover in parts-cleaning solvent.
CC132D
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2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal.
ATV-1004
CC136D
2. Acceptable width range must be within specifications. Measuring Valve Face Radial Runout 1. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks. 2. Position the dial indicator contact point on the outside edge of the valve face; then zero the indicator.
NOTE: The valve seals must be replaced.
3. Remove the valve springs; then invert the cylinder head and remove the valves. Measuring Valve Stem Runout 1. Support each valve stem end with the V Blocks; then check the valve stem runout using a dial indicator.
ATV1082A
3. Rotate the valve in the V blocks.

ATV-1082
2. Maximum runout must not exceed specifications. Measuring Valve Stem Outside Diameter 1. Using a micrometer, measure the valve stem outside diameter. 2. Acceptable diameter range (intake valve) must be within specifications. 3. Acceptable diameter range (exhaust valve) must be within specifications. Measuring Valve Face/Seat Width 1. Using a micrometer, measure the width of the valve face.
4. Maximum runout must not exceed specifications. Measuring Valve Guide/Valve Stem Deflection (Wobble Method) 1. Mount a dial indicator and base on the surface plate; then place the cylinder head on the surface plate. 2. Install the valve into the cylinder head; then position the dial indicator contact point against the outside edge of the valve face. Zero the indicator.
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Installing Valves 1. Apply grease to the inside surface of the valve seals; then place a lower spring seat and valve guide seal over each valve guide.
CC131D
3. Push the valve from side to side; then from top to bottom. 4. Maximum wobble deflection must not exceed specifications. Measuring Valve Guide (Inside Diameter) 1. Insert a snap gauge 1/2 way down into each valve guide bore; then remove the gauge and measure it with a micrometer. 2. Acceptable inside diameter range must be within specifications. 3. If a valve guide is out of tolerance, it must be replaced. Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the components be taken to a qualified machine shop for servicing.
CC144D
2. Insert each valve into its original location. 3. Install the valve springs with the painted end of the spring facing away from the cylinder head.
NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head.
! CAUTION
If valves are discolored or pitted or if the seating surface is worn, the valve must be replaced. Do not attempt to grind the valves or severe engine damage may occur.
ATV-1011A
4. Place a spring retainer over the valve springs; then using the valve spring compressor, compress the valve springs and install the valve cotters.
Measuring Rocker Arm (Inside Diameter) 1. Using a dial calipers, measure the inside diameter of the rocker arm. 2. Acceptable inside diameter range must be within specifications. Measuring Rocker Arm Shaft (Outside Diameter) 1. Using a micrometer, measure the outside diameter of the rocker arm shaft. specifications. www.mymowerparts.com 2. Acceptable outside diameter range must be within
CC132D
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PISTON ASSEMBLY
NOTE: Whenever a piston, rings, or pin are out of tolerance, they must be replaced.
2. Using the sharpened ring as a tool, clean carbon from the ring-grooves. Be sure to position the ring with its tapered side up.
Cleaning/Inspecting Piston 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the dome of the piston. 2. Inspect the piston for cracks in the piston pin, dome, and skirt areas. 3. Inspect the piston for seizure marks or scuffing. Repair with #400 grit wet-or-dry sandpaper and water or honing oil.
NOTE: If scuffing or seizure marks are too deep to correct with the sandpaper, replace the piston.
! CAUTION
Improper cleaning of the ring-grooves by the use of the wrong type of ring-groove cleaner will result in severe damage to the piston.
Measuring Piston-Ring End Gap (Installed) 1. Place each compression ring in the wear portion of the cylinder. Use the piston to position each ring squarely in the cylinder. 2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must be within specifications.
4. Inspect the perimeter of each piston for signs of excessive blowby. Excessive blowby indicates worn piston rings or an out-of-round cylinder. Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove.
CC280D
Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore 1. Measure the piston pin outside diameter at each end and in the center. If measurement is not within specifications, the piston pin must be replaced.
CC400D
2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove.
NOTE: If the existing rings will not be replaced with new ones, note the location of each ring for proper installation. When installing new rings, install as a complete set only.
Cleaning/Inspecting Piston Rings 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45 angle and to a sharp edge.
ATV-1070
2. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy.
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NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation.
2. The ring with the orientation mark (MTOP) should be installed in the second (middle) groove and the ring with the orientation mark (M) should be installed in the first (top) groove.
ATV-1069
Measuring Piston Skirt/ Cylinder Clearance 1. Measure the cylinder front to back in six places.
ATV-1024A
! CAUTION
Incorrect installation of the piston rings will result in engine damage.
CYLINDER/CYLINDER HEAD ASSEMBLY

NOTE: If the cylinder/cylinder head assembly cannot be trued, they must be replaced.
CC127D
2. Measure the corresponding piston diameter at a point 15 mm (0.6 in.) above the piston skirt at a right angle to the piston-pin bore. Subtract this measurement from the measurement in step 1. The difference (clearance) must be within specifications. Installing Piston Rings 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration.
Cleaning/Inspecting Cylinder Head
! CAUTION
The cylinder head studs must be removed for this procedure.
1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber being careful not to nick, scrape, or damage the combustion chamber or the sealing surface. 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a heli-coil insert. 3. Place the cylinder head on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder head in a figure eight motion until a uniform bright metallic finish is attained.
! CAUTION
ATV-1085B
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! CAUTION
CC128D
Measuring Cylinder Head Distortion 1. Remove any carbon buildup in the combustion chamber. 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion factor between the head and the straightedge. 3. Maximum distortion must not exceed specifications. Inspecting Cam Chain Guide 1. Inspect cam chain guide for cuts, tears, breaks, or chips. 2. If the chain guide is damaged, it must be replaced. Honing Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90 from the first measurements for a total of six measurements. The trueness (out-of-roundness) is the difference between the highest and lowest reading. Maximum trueness (out-of-roundness) must not exceed specifications.
CC129D
CC141D
Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent. 2. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion. If marks are found, repair the surface using a cylinder hone (see Honing Cylinder in this sub-section). 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder in a figure eight motion until a uniform bright metallic finish is attained.
CC127D
2. Wash the cylinder in parts-cleaning solvent. 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface using a ball hone.
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NOTE: To produce the proper 60 cross-hatch pattern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute. If honing oil is not available, use a lightweight petroleum-based oil. Thoroughly clean cylinder after honing using soap and hot water. Dry with compressed air; then immediately apply oil to the cylinder bore. If the bore is severely damaged or gouged, replace the cylinder.
ATV1013A
2. The lobe heights must not exceed minimum specifications. Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting.
CC390D
4. If any measurement exceeds the limit, replace the cylinder and piston. Measuring Camshaft Runout
NOTE: If the camshaft is out of tolerance, it must be replaced.
2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced. Measuring Camshaft to Cylinder Head Clearance 1. Remove the adjuster screws and jam nuts.
1. Place the camshaft on a set of V blocks; then position the dial indicator contact point against the shaft and zero the indicator.
CC005D
2. Place a strip of plasti-gauge in each of the camshaft lands in the cylinder head.
CC283D
2. Rotate the camshaft and note runout; maximum tolerance must not exceed specifications. Measuring Camshaft Lobe Height 1. Using a calipers, measure each cam lobe height.
3. Place the valve cover on the cylinder head and secure with the valve cover cap screws. Tighten securely.
NOTE: Do not rotate the camshaft when measuring clearance.
4. Remove the cap screws securing the valve cover to the cylinder; then remove the valve cover and camshaft.
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CC003D
CF061A
5. Match the width of the plasti-gauge with the chart found on the plasti-gauge packaging to determine camshaft to cylinder head and valve cover clearance.
CF060A
2. If damaged, the camshaft must be replaced.
CC145D
6. If clearance is excessive, measure the journals of the camshaft.
Installing Top-Side Components

A. Piston B. Cylinder
KEY 1. 2. 3. 4. 5. 6. 7. 8.
Cylinder Stud Bolt Nut Cylinder Gasket Pin Water Hose Union Cap Screw O-Ring
CC287D
NOTE: If the journals are worn, replace the camshaft; then measure the clearance again. If it is still out of tolerance, replace the cylinder head.
0732-301
Inspecting Camshaft Spring/Drive Pin 1. Inspect the spring and drive pin for damage.
NOTE: If the piston rings were removed, install them in this sequence.
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A. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration.
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ATV-1085B
CC032D
NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation.
B. Install the compression rings (1 and 2) so the letter on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring end gaps are on directly opposite sides of the piston (see illustration).
NOTE: The ring with the orientation mark (MTOP) should be installed in the second (middle) groove and the ring with the orientation mark (M) should be installed in the first (top) groove.
2. Place the two alignment pins into position. Place the cylinder gasket into position; then place a piston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase.
CC025D
3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase.
ATV-1024A
! CAUTION
The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur.
! CAUTION
Incorrect installation of the piston rings will result in engine damage.
1. Install the piston on the connecting rod making sure there is a circlip on each side and the open end of the circlip faces upwards.
NOTE: The piston should be installed so the arrow points toward the exhaust.
CC024D
4. Loosely install the two nuts which secure the cylinder to the crankcase.
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NOTE: The two cylinder-to-crankcase nuts will be tightened in step 10.
CC020D
CC023D
5. Install the coolant hose onto the crankcase union and tighten the clamp. C. Cylinder Head D. Valve Cover
NOTE: Steps 1-5 in the preceding sub-section must precede this procedure.
6. Place the chain guide into the cylinder.

CF057A
! CAUTION
Care should be taken that the bottom of the chain guide is secured in the crankcase boss.
8. Install the four cylinder head cap screws with washers (note the locations of the different-lengthed cap screws). Tighten only until snug.
CC272D CC022D
7. Place the head gasket into position on the cylinder. Place the alignment pins into position; then place the head assembly into position on the cylinder.
9. Loosely install the five cylinder head nuts. 10. In a crisscross pattern, tighten the four cylinder head cap screws (from step 8) to 40 ft-lb; then tighten the 8 mm nut (from step 9) to 18 ft-lb. Using a crisscross pattern, tighten the 6 mm nuts (from step 9) to 8 ft-lb. Tighten the two cylinder-to-crankcase nuts (from step 4) securely. 11. With the timing inspection plug removed and the chain held tight, rotate the crankshaft until the piston is at top-dead-center. 12. With the alignment pin installed in the camshaft, loosely place the cam sprocket (with the recessed side facing the cam shaft lobes) onto the camshaft. At this point, do not seat the sprocket onto the shaft.
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15. Seat the cam sprocket onto the camshaft making sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket; then place the camshaft/sprocket assembly onto the cylinder ensuring the following.
732-307B
NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder.
13. While holding the cam chain sprocket to the side, install the rear cam chain tensioner guide into the cylinder head. Install the pivot cap screw and washer.
CF013A
A. Piston still at top-dead-center. B. Camshaft lobes directed down (toward the piston). C. Camshaft alignment marks parallel to the valve cover mating surface. D. Recessed side of the sprocket directed toward the cam lobes. E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned.
! CAUTION
If any of the above factors are not as stated, go back to step 11 and carefully proceed.
CD461
14. With the cam lobes directed down (toward the piston), maneuver the camshaft/sprocket assembly through the chain and towards its seating position; then loop the chain over the sprocket.
NOTE: Note the position of the alignment marks on the end of the camshaft. They must be parallel with the valve cover mating surface. If rotating the camshaft is necessary for alignment, do not allow the chain and sprocket to rotate and be sure the cam lobes end up in the down position.
16. Place the tab-washer onto the sprocket making sure it covers the pin in the alignment hole.
ATV1027
! CAUTION
Care must be taken that the tab-washer is installed correctly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result.
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CD463
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17. Install the first cap screw (threads coated with red Loctite #271) securing the sprocket and tab-washer to the camshaft. Tighten only until snug.
CC012D
21. Install the cylinder head plug in the cylinder head with the open end facing downward and toward the inside.
CD464
18. Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed; then install the cap screw (threads coated with red Loctite #271) and tighten to 11 ft-lb. Bend the tab to secure the cap screw.
! CAUTION
The open end of the plug must be positioned downward.
CD468 CD465
19. Rotate the crankshaft until the first cap screw (from step 17) can be addressed; then tighten to 11 ft-lb. Bend the tab to secure the cap screw.
22. Remove the cap screw from the end of the chain tensioner; then using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner clockwise until the screw bottoms.
CD501 CD466
20. Place the C-ring into position in its groove in the cylinder head.
NOTE: The adjuster shaft will be drawn into the tensioner as the adjuster screw is rotated clockwise. The adjuster shaft tension will be released in step 24.
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23. Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the two cap screws.
CC005D
CD469
26. Apply a thin coat of Three Bond Sealant to the mating surfaces of the cylinder head and valve cover.
24. Using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner counterclockwise until all tension is released; then install the cap screw into the end of the chain tensioner.
CC275D
27. Place the valve cover into position.

NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them.
CD470
28. Install the four top side cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug.
CD471
25. Loosen the four adjuster screw jam nuts; then loosen the four adjuster screws on the rocker arms in the valve cover.
CC003D
29. In a crisscross pattern starting from the center and working outward, tighten the cap screws securely. 30. Adjust valve/tappet clearance (see Section 2). 31. Place the two tappet covers into position making sure the proper cap screws are with the proper cover. Tighten the cap screws securely.
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CC001D
PR465
32. If removed, install the spark plug. Tighten to 12 ft-lb.
3. Using a cold chisel, scribe a mark showing the relative position of the shift arm to the shift arm shaft to aid in installing; then remove the shift arm.
Right-Side Components
AT THIS POINT
PR429A
NOTE: The engine/transmission does not have to be removed from the frame for this procedure.
4. Remove the two cap screws securing the speed sensor housing; then remove the housing. Account for the gasket and two seal washers.
Removing Right-Side Components

A. Water Pump B. Right-Side Cover C. Rotor/Flywheel 1. Remove the four screws securing the outer magneto cover to the right-side cover; then remove the cover. Account for the gasket. 2. Remove the flange nut securing the spacer to the crankshaft; then remove the spacer. Account for the O-ring.
CD920A
5. Loosen the clamps securing the coolant hose to the water pump; then remove the crossover tube from the cylinder head. Account for an O-ring.
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CD214
CD939A
6. Remove the two cap screws securing the water pump to the engine; then remove the water pump.
NOTE: The water pump is not a serviceable component. If the pump is defective or if the mechanical seal is leaking (coolant dripping from the discharge hole), the water pump must be replaced (see Section 4).
7. Remove the cap screws securing the right-side cover to the crankcase noting the location of the different-sized cap screws for installing purposes. 8. Using Side Case Puller, remove the side cover. Account for a gasket and two alignment pins.
NOTE: Inspect the inside of the right-side cover for any shaft washers that may have come off with the cover. Make sure they are returned to their respective shafts and that the starter idler gear spacer is on the shaft or in the cover (see Section 4).
CD940A
3
AT THIS POINT
To service the magneto assembly, see Section 5.
11. Remove the two starter gears from the crankcase noting the direction of the beveled side of the gears for installing purposes; then remove the two starter gear shafts.
CF075A
CD136
9. Remove the nut securing the magneto rotor to the crankshaft; then install the magneto rotor puller adapter.
NOTE: The puller has left-hand threads.
10. Using Magneto Rotor Remover Set, remove the rotor/flywheel assembly from the crankshaft. Account for the key; then remove the starter clutch gear assembly and washer.
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3-25 Next
CD140
PR430A
12. Remove the snap ring securing the water pump drive gear; then remove the gear noting the direction of the sides of the gear for installing purposes. Account for the drive gear alignment pin.
15. Remove the gear shift cam plate; then remove the cam stopper and cam stopper spring. Account for two washers.
PR434A CD944
13. Remove the snap ring securing the water pump driven gear; then remove the gear noting the direction of the sides of the gear for installing purposes. Account for the driven gear alignment pin.
Installing Right-Side Components

NOTE: Plug the oil passage in the crankcase housing prior to installing the drive gear/driven gear assembly to prevent loss of an alignment pin.
1. Install the water pump driven gear alignment pin and the driven gear (with the beveled side of the gear facing outward as noted in removing); then secure with the snap ring.
CD952A
NOTE: There is an oil passage beneath the driven gear/drive gear assembly. This passage should be plugged prior to removing the driven gear and drive gear. Failure to do so could result in the loss of an alignment pin into the crankcase.
14. Remove the shift shaft noting the timing marks for assembling purposes. Account for two washers.
CD950A
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CD952A
CD944
NOTE: The sharp side of the snap ring should be facing outward. NOTE: Once the gears are secured, remove the oil passage plug from the crankcase.
3. Install the two starter gear shafts; then install the two starter gears (with the beveled side of the intermediate gear facing inward as noted in removing).
CD949
NOTE: The sharp side of the snap ring should be facing outward.
2. Install the water pump drive gear drive pin and the drive gear (with the flat side of the gear facing outward as noted in removing); then secure with the snap ring.
CD139
CD946A
PR447A
4. In order on the crankshaft, install a washer, ring gear, key, and the magneto rotor. Secure with the nut (threads coated with red Loctite #271). Tighten to 105 ft-lb.
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3-27 Next

6. Install the shift cam stopper, spring, and two washers; then coat the threads on the mounting stud with red Loctite #271 and install the nut. Tighten securely.
CD948A
PR434A
7. Install the shift shaft with two washers making sure to align the timing mark on the shift shaft with the mark on the shift cam plate.
CD940B
5. Install the shift cam plate onto the shift cam shaft; then coat the cap screw threads with red Loctite #271 and tighten securely.
CD954A
CD935A
CD927A
8. Lubricate the magneto cover gasket with fresh engine oil; then place it into position on the two alignment pins. Make sure the outer shift shaft washer is in place.
CD934
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15. Install the shift arm on the shift arm shaft making sure the scribed marks (from removing) are aligned. Tighten securely. 16. Place the gasket and outer magneto cover into position on the right-side cover; then tighten four screws to 8 ft-lb.
Left-Side Components
PR431A
9. Install the magneto cover and secure with the cap screws. Tighten only until snug. 10. Place the spacer into position on the crankshaft making sure a new, lubricated O-ring is inside the spacer. Tighten the flange nut to 28 ft-lb.
AT THIS POINT
NOTE: The engine/transmission does not have to be removed from the frame for this procedure.
Removing Left-Side Components

PR465
11. Tighten the cap screws (from step 9) to 8 ft-lb. 12. Place the speed sensor housing and gasket into position and secure with the two cap screws. Tighten securely.
A. V-Belt Cover B. Driven Pulley C. Clutch Cover 1. Remove the cap screws securing the V-belt cover noting the location of the different-lengthed cap screws for installing purposes; then using a rubber mallet, gently tap on the cover tabs to loosen the cover.
CD069
13. Place the water pump into position and secure with two cap screws. Tighten securely. 14. Install the crossover tube on the water pump and cylinder head making sure the O-ring is properly positioned.
CD079
2. Remove the nut securing the movable drive face; then remove the face. Account for a flat washer and spacer.
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CD963
PR393
6. Remove the cap screws securing the clutch cover. Note the location of the different-lengthed cap screws for installing purposes. Using a rubber mallet, carefully remove the cover. Account for two alignment pins.
CD966A
3. Remove the nut securing the fixed driven assembly; then remove the assembly.
CD973A
! CAUTION
Care must be taken when removing the cover so the cover gasket is not damaged.
PR388
4. Remove the fixed drive face and V-belt. 5. Using an impact driver, remove the cap screws securing the air intake plate; then remove the plate cushion.
CD974A
NOTE: For steps 7-13, refer to illustration CC829B. NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER.
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KEY A. Oil Pump Driven Gear B. Oil Pump Drive Gear C. Clutch Shoe Assembly
CF088A D. One-Way Clutch (Green Dot MUST Show) E. Final Drive Carrier Bearing Housing CC829B
9. Remove the two Allen-head screws securing the gear shift position switch; then remove the sensor. Account for two neutral contact pins and two springs.
7. Remove the one-way clutch (D) from the clutch housing. Note the location of the green dot (or the word OUTSIDE) for installing purposes. 8. Using a hydraulic press, remove the clutch housing assembly from the clutch cover. Account for the left fixed drive spacer and an O-ring inside the fixed drive spacer.
CD997
10. Remove the nut (left-hand threads) securing the clutch shoe assembly (C).
CF085
FI279A
11. Remove the cap screw securing the oil pump drive gear (B). Account for a cap screw, washer, pin, and spacer.
CC596
NOTE: Account for and inspect the clutch housing seal.
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13. Remove the snap ring securing the oil pump driven gear (A); then remove the gear noting the direction of the sides of the gear for installing purposes. Account for a pin and a washer.
CC606
CD984
CD987
CD895A
14. Remove the cap screws securing the oil pump; then remove the pump.
CD993
12. Using an impact driver, remove the Allen-head screws securing the final drive carrier bearing housing (E); then remove the housing and account for two alignment pins.
CD988
Servicing Left-Side Components

NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary.
CD999
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INSPECTING CENTRIFUGAL CLUTCH SHOE 1. Inspect the clutch shoes for uneven wear, chips, cracks, or discoloration. If any shoe is damaged, replace the complete set. 2. Inspect the clutch shoes for wear or damage. If any shoe is worn to the bottom of the groove, replace the complete set.
! CAUTION
Always replace the clutch shoes as a complete set or severe imbalance could occur.
CD988A
DRIVEN PULLEY
NOTE: The driven pulley is a non-serviceable component. If pulley faces, cam ramps, or sheave bushings are worn, the assembly must be replaced. Do not to disassemble the driven pulley.
Installing Left-Side Components

ATV1014
INSPECTING CLUTCH HOUSING 1. Inspect the clutch housing for burns, grooving, cracks, or uneven wear. 2. If the housing is damaged in any way, the housing must be replaced. INSPECTING PRIMARY ONE-WAY DRIVE 1. Insert the drive into the clutch housing. 2. Rotate the inner race by hand and verify the inner race rotates only one direction. 3. If the inner race is locked in place or rotates both directions, the drive assembly must be replaced. INSPECTING OIL PUMP 1. Inspect the pump for damage. 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced.
1. Install the gear shift position switch making sure the two neutral contact pins and the two springs are properly positioned. Tighten the Allen-head screws securely.
CD997
CD994
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2. Install the secondary shaft bearing housing making sure the two alignment pins are properly positioned. Tighten the Allen-head screws securely.
CD991
CD999
3. Install the oil pump onto the engine; then tighten the cap screws securely.
5. Grease the driven gear pin and insert it into the oil pump shaft; then install the driven gear (noting the direction of the sides of the gear from removing). Secure with a snap ring.
CD985A CD988
4. Install the oil pump drive gear spacer onto the crank balancer shaft. Grease the pin and insert it into the shaft; then install the drive gear making sure the raised side of the gear is facing toward the inside. Secure the gear with the cap screw (threads coated with red Loctite #271) and the washer. Tighten the cap screw to 62 ft-lb.
CD984
NOTE: When installed correctly, the sides of the drive and driven gears will be flush with each other.
6. Install the clutch shoe assembly and secure with the flange nut (threads coated with red Loctite #271). Tighten to 221 ft-lb.
CD992
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PR410A
PR399A
7. Lightly grease the clutch housing seal; then insert the left fixed drive spacer.
! CAUTION
When installed correctly, the green dot (or the word OUTSIDE) on the one-way clutch is visible.
11. Place the clutch cover/clutch housing assembly into position on the crankcase; then secure with the cap screws making sure the different-lengthed cap screws are in their proper location. Tighten to 8 ft-lb. 12. Place the air intake plate cushion into position; then install the air intake plate. Tighten the cap screws (threads treated with a small amount of red Loctite #271) securely.
CF088A
CD971
CF086
8. Install the clutch cover alignment pins into the crankcase, apply oil to the cover gasket, and install the gasket onto the crankcase. 9. Apply grease to the outer edges of the clutch housing; then from inside the clutch cover, install the clutch housing into the cover using a rubber mallet. 10. Install the one-way clutch onto the clutch shoe assembly.
CD970
13. Place the driven pulley assembly into position and secure with the nut. Using Spanner Wrench, tighten to 80 ft-lb. 14. Slide the fixed drive face onto the shaft.
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15. Spread the faces of the driven pulley by threading a 6 mm cap screw into the threaded boss; then turn clockwise until pulley faces are opened approximately 1/2 in. 16. Place the V-belt into position on the driven pulley and over the front shaft.
CD083
Center Crankcase Components

PR389
NOTE: The arrows on the V-belt should point forward.
17. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the driveshaft. Secure the drive face with a washer and nut (coated with red Loctite #271). Using Spanner Wrench, tighten the nut to 165 ft-lb.
NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment.
Separating Crankcase Halves

1. Remove the left-side cap screws securing the crankcase halves. Note the location of the different-lengthed cap screws.
CF261
! CAUTION
Make sure the splines extend beyond the drive face or a false torque reading and spline damage may occur.
2. Remove the right-side cap screws securing the crankcase halves. Note the location of the different-lengthed cap screws. 3. Using the Crankcase Separator/Crankshaft Remover and tapping lightly with a rubber mallet, separate the crankcase halves. Account for four alignment pins.
NOTE: To keep the shaft/gear assemblies intact for identification, tap the shafts toward the right-side crankcase half when separating the halves.
NOTE: At this point, the cap screw can be removed from the driven pulley face.
18. Rotate the V-belt and driven pulley/clutch until the V-belt is flush with the top of the driven pulley. 19. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws making sure the different-lengthed cap screws are in their proper location. Tighten the cap screws to 8 ft-lb.
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2. Remove the reverse idler gear assembly (F). Account for all washers, shaft, bushing, and the gear.
CC665
Disassembling Crankcase Half

NOTE: For steps 1-7, refer to illustration CC821B.
CC668
3. Remove the shift shaft (H); then remove the two forks taking note of the direction of the tabs on the forks for assembling purposes. 4. Remove the gear shift shaft (G) noting the location of the two holes on the end of the shaft. Account for two washers.
KEY A. Secondary Driven Shaft Assembly B. Crank Balancer Gear C. Crankshaft Gear D. Countershaft Assembly
E. F. G. H.
Driveshaft Reverse Idler Gear Assembly Gear Shift Shaft Shift Shaft with 2 Forks CC821B
PR380A
5. Remove the countershaft assembly (D). Account for a washer on each end of the countershaft.
NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER.
1. Remove the secondary driven shaft assembly (A) noting the location of the bearing locating pins. Account for the bearing C-ring.
CC674
NOTE: Do not disassemble the countershaft assembly unless necessary. If necessary, see Servicing Center Crankcase Components sub-section.
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CD267
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6. Using a rubber mallet, tap on the crankcase to remove the driveshaft (E). 11. Remove the cap screws securing the oil strainer cap; then remove the cap. 12. Remove the two cap screws securing the oil strainer; then remove the strainer.
CC675
7. Note the timing marks on the crank balancer gear (B) and crankshaft gear (C) for assembling purposes; then slide the crank balancer gear off the crank balancer. Account for the key in the keyway.
PR406
! CAUTION
Do not remove the remaining output shaft assembly unless absolutely necessary. If the shaft is removed, the shaft nut must be replaced with a new one and the shaft must be re-shimmed.
13. To remove the assembly, remove the nut securing the secondary drive gear and secondary driven gear; then from the inside of the crankcase using a rubber mallet, remove the output shaft assembly. Account for the output shaft, two gears, a shim, a washer, and the nut.
CD826
8. Remove the crank balancer.

NOTE: There is a flat spot on the crank balancer bearing flange to allow clearance past the crankshaft.
CC686
Servicing Center Crankcase Components

CD832B
9. Remove the snap ring securing the water pump driven gear shaft. 10. Using a hydraulic press, remove the crankshaft assembly.
NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary.
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NOTE: Use a protective end cap to prevent damage to the crankshaft threads.
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SECONDARY GEARS
NOTE: When checking and correcting secondary gear backlash and tooth contact, the universal joint must be secured to the front shaft or false measurements will occur.
3. Apply a thin, even coat of a machinist-layout dye to several teeth of the gear. 4. Install the secondary driven output shaft assembly. 5. Rotate the secondary driven bevel gear several revolutions in both directions. 6. Examine the tooth contact pattern in the dye and compare the pattern to the illustrations.
Checking Backlash
NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft.
1. Place the left-side crankcase cover onto the left-side crankcase half to prevent runout of the secondary transmission output shaft. 2. Install the secondary driven output shaft assembly onto the crankcase. 3. Mount the dial indicator so the tip is contacting a tooth on the secondary driven bevel gear. 4. While rocking the driven bevel gear back and forth, note the maximum backlash reading on the gauge. 5. Acceptable backlash range is 0.05-0.33 mm (0.002-0.013 in.). Correcting Backlash
NOTE: If backlash measurement is within the acceptable range, no correction is necessary.
ATV-0103
1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thinner shim. 2. If backlash measurement is more than specified, remove an existing shim, measure it, and install a thicker shim.
NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart.
Backlash Measurement
Under 0.05 mm (0.002 in.) At 0.05-0.33 mm (0.002-0.013 in.) Over 0.33 mm (0.013 in.)
ATV-0105
Shim Correction
Decrease Shim Thickness No Correction Required Increase Shim Thickness
ATV-0104
Checking Tooth Contact

NOTE: After correcting backlash of the secondary driven bevel gear, it is necessary to check tooth contact.
Correcting Tooth Contact

NOTE: If tooth contact pattern is comparable to the correct pattern illustration, no correction is necessary.
1. Remove the secondary driven output shaft assembly from the left-side crankcase half.
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2. Clean the secondary driven bevel gear teeth of old oil and grease residue.
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If tooth contact pattern is comparable to an incorrect pattern, correct tooth contact according to the following chart.
Tooth Contact
Contacts at Top Contacts at Root
Measuring Connecting Rod (Big End Side-to-Side) 1. Push the lower end of the connecting rod to one side of the crankshaft journal. 2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal.
Shim Correction
Decrease Shim Thickness Increase Shim Thickness
NOTE: To correct tooth contact, steps 1 and 2 (with NOTE) of Correcting Backlash must be followed and the above Tooth Contact/Shim Correction chart must be consulted.
! CAUTION
After correcting tooth contact, backlash must again be checked and corrected (if necessary). Continue the correcting backlash/correcting tooth contact procedures until they are both within tolerance values.
CRANKSHAFT ASSEMBLY Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and measure it with micrometer.
CC289D
3. Acceptable gap range must be within specifications. Measuring Connecting Rod (Big End Width) 1. Using a calipers, measure the width of the connecting rod at the big-end bearing. 2. Acceptable width range must be within specifications. Measuring Crankshaft (Runout) 1. Place the crankshaft on a set of V blocks. 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crankshaft.
CC290D
2. Maximum diameter must not exceed specifications. Measuring Connecting Rod (Small End Deflection) 1. Place the crankshaft on a set of V-blocks and mount a dial indicator and base on the surface plate. Position the indicator contact point against the center of the connecting rod small end journal. 2. Zero the indicator and push the small end of the connecting rod away from the dial indicator. 3. Maximum deflection must not exceed specifications.
ATV-1074
3. Zero the indicator and rotate the crankshaft slowly.
! CAUTION
Care should be taken to support the connecting rod when rotating the crankshaft.
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4. Maximum runout must not exceed specifications.
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NOTE: Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 3-4.
Disassembling From the right side: 1. Remove the right drive gear washer (17); then remove drive gear #2 (2). 2. Remove the reverse driven gear dog (3); then remove the circlip (4). 3. Remove the reverse driven gear spacer (5); then remove the circlip (4). 4. In order, remove washer (6), reverse driven gear (7), bearing (8), and bushing (9). 5. In order, remove washer (6), lock washer (10), lock washer (11), and low driven gear (12). 6. In order, remove bearing (8), bushing (9), and driven gear washer (13). From the left side: 1. Remove the left drive gear washer (16); then remove the high driven gear (15) and bearing (8).
Measuring Crankshaft (Web-to-Web) 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web.
ATV-1017
2. Acceptable width range must be within specifications. COUNTERSHAFT
2. In order, remove bushing (9), driven gear washer (13), and sliding dog (14). Assembling From the left side: 1. Install the sliding dog (14), driven gear washer (13), and bushing (9). 2. Install bearing (8) and high driven gear (15); then install the left drive gear washer (16). From the right side: 1. Install driven gear washer (13), bushing (9), bearing (8), and low driven gear (12). 2. Install lock washer (11), lock washer (10), washer (6), and bushing (9). 3. Install bearing (8), reverse driven gear (7), washer (6), and the circlip (4).
! CAUTION
When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces. If a major component is installed facing the wrong direction, transmission damage may occur and/or the transmission will malfunction. In either case, complete disassembly and assembly will be required.
KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Countershaft Drive Gear #2 Reverse Driven Gear Dog Circlip Reverse Driven Gear Spacer Washer Reverse Driven Gear Bearing Bushing Lock Washer Lock Washer
4. Install reverse driven gear spacer (5), circlip (4), reverse driven gear dog (3), and drive gear #2 (2); then install the right drive gear washer (17).
NOTE: When installing the countershaft assembly, account for the washer on each end of the shaft.
12. 13. 14. 15. 16. 17.
Low Driven Gear Driven Gear Washer Sliding Dog High Driven Gear Drive Gear Washer (L) Drive Gear Washer (R) 739-954A
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Assembling Crankcase Half

1. Install the output shaft assembly into the crankcase making sure the two gears, shim, washer, and nut are properly sequenced.
CC688
CC686
NOTE: The beveled side of the secondary drive gear must face upward.
CC689
2. Apply red Loctite #271 to the threads of the output shaft; then secure with the flange nut. Tighten nut to 62 ft-lb; then using a punch, peen the nut.
NOTE: If heating the bearing is not possible, the crankshaft can be installed using a crankshaft installing tool.
4. Install the crank balancer.
CC687
3. Apply a liberal amount of engine oil to the crankshaft bearing. Using a propane torch, heat the bearing until the oil begins to smoke; then slide the crankshaft assembly into place.
CD832B
NOTE: It will be necessary to rotate the crank balancer until the counterweight is facing away from the crankshaft; then rotate the crankshaft clockwise into the journal area to allow the crank balancer to be fully seated.
5. Place the key into the crank balancer keyway; then install the crank balancer gear making sure the alignment dots on the crank balancer gear and the crankshaft gear align.
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CD826A
CC669
6. Install the driveshaft.
10. Install the reverse idler gear assembly noting the positioning of the two washers, gear, bushing, and shaft.
CC675
7. Place a washer on each end of the countershaft assembly; then install the assembly.
CC668
11. Install the front and rear secondary driven shaft assemblies into the left side of the crankcase making sure the bearing locating pins are facing upward and the bearing C-ring is fully seated in the crankcase.
CC674
8. Place a washer on each end of the gear shift shaft; then install the shaft assembly making sure the two holes on the end of the shaft are positioned vertically.
CD268A
9. Insert the two shift forks into the sliding dogs noting the direction of the tabs from disassembling; then install the shift fork shaft.
NOTE: Make sure the shift fork tabs face upward and that they are properly seated into the shift cams.
12. Place the oil strainer into position; then secure with the two screws. 13. Place the oil strainer cap into position making sure the O-ring is in position; then secure the cap with cap screws. Tighten securely.
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Joining Crankcase Halves

1. Apply High-Temp Sealant to the right-side mating surface. 2. Lightly oil all bearings and grease all shafts in the left-side crankcase. 3. Using a propane torch, heat the left-side crankshaft bearing until the oil begins to smoke; then join the two crankcase halves.
10. In a crisscross/case-to-case pattern, tighten the 6 mm cap screws (from steps 7-8) to 8 ft-lb.
NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs.
AT THIS POINT
After completing center crankcase components, proceed to Installing Left-Side Components, to Installing Right-Side Components, and to Installing Top-Side Components.
Installing Engine/Transmission
NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the vehicle.
1. Attach suitable lifting chains to the engine/transmission; then using an engine hoist, lower the assembly into the engine compartment.
! WARNING
CC695
4. Using a plastic mallet, lightly tap the case halves together until cap screws can be installed. 5. From the left side, install the 8 mm cap screws; then tighten only until snug.
Keep hands and fingers clear when lowering the engine/transmission into place. The chains could shift causing severe injury.
! CAUTION
Make sure that all wiring, hoses, and brake lines are routed away from engine mounts and engine brackets. Pinching or breaking of lines or shorting of wiring could occur.
6. From the right side, install the remaining 8 mm cap screws (two inside the case); then tighten only until snug.
7. From the right side, install the case half 6 mm cap screws; then tighten only until snug.
8. From the left side, install the 6 mm cap screws; then tighten only until snug.
PR114
9. In a crisscross/case-to-case pattern, tighten the 8 mm cap screws (from steps 5-6) until the halves are correctly joined; then tighten to 20 ft-lb.
NOTE: The rear engine mounting bracket and rear engine mounts should be attached to the engine. The front engine mounting bracket should be attached to the engine, and the front engine mounts should be in the frame.
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2. Align the rear engine mount studs with the holes in the frame and slowly lower into place. The front engine mounting bracket will then slip over the engine mount studs.
PR148
PR146
3. Install the flange nuts on the rear engine mount studs; then secure the front engine mounting bracket to the front engine mount studs with two flange nuts. Tighten the four flange nuts to 25 ft-lb.
3
PR151A
! CAUTION
The drive-line yokes must be aligned (timed) or damage will occur to the universal joints and gears.
5. Install the cap screws securing the drive-line couplers to the drive flanges and tighten to 40 ft-lb.
PR153A
PR120A
PR147
4. Apply multi-purpose grease to the driveshaft splines; then align the flange marks and slide the splines into the slip-joints.
6. Set the exhaust pipe in place; then install the muffler and align the assembly to the engine. Install two cap screws securing the exhaust pipe to the cylinder head and tighten to 20 ft-lb. 7. Install the inlet boot on the V-belt housing; then install the exhaust duct connecting the outlet housing to the V-belt housing. Tighten all clamps securely.
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PR153B
PR128A
10. From the left-side, connect the speed sensor connector (XT/XTX), fuel level sensor connector (XT/XTX), and temperature sensor lead; then install the spark plug cap.
PR144B
8. Connect the lower coolant hose to the water pump housing; then connect the upper coolant hose to the thermostat housing. Tighten the hose clamps securely. 9. Install the starter wire on the starter and tighten the nut securely; then connect the CDI connector (Prowler/XT), alternator connector, gear shift position switch, and electric choke connector.
PR155B
PR130A
NOTE: Make sure the main harness ground and battery ground wires are installed and secured in the proper location with the unpainted cap screw.
PR145A
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12. Place the air filter assembly into position and secure with the self-tapping screws; then connect the intake boot to the carburetor/throttle body and the inlet housing boot to the air filter housing. Tighten the clamps securely.
PR474B
11. Install the carburetor/throttle body and tighten the intake boot clamp securely; then connect the gasline hose, vacuum line, and throttle cable.
PR127A
13. Place the shifter assembly into position and secure with the four machine screws. Tighten securely. 14. Connect the shifter linkage to the transmission shift arm placing the washer and bushing in appropriate locations; then secure with the E-clip.
NOTE: Before operating vehicle, check and adjust shifter linkage as required (see Section 2).
PR117
15. Fill the engine/transmission with the appropriate lubricant. 16. Fill the cooling system with the appropriate coolant. 17. Connect the positive battery cable to the battery; then connect the negative cable. 18. Install the left-side and right-side seat-bases; then install the center console and seats. Make sure the seats lock securely. 19. Start the engine and warm up to operating temperature. Check for fluid leaks; then shut off engine and check oil and coolant levels (see Section 2).
PR140B
PR154
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Troubleshooting
Problem: Engine will not start or is hard to start (Compression too low) Condition
1. 2. 3. 4. 5. 6. Valve clearance out of adjustment Valve guides worn - seated poorly Valves mistimed Piston rings worn - broken Cylinder bore worn Starter motor cranks too slowly - does not turn
Remedy
1. 2. 3. 4. 5. 6. Adjust clearance Repair - replace guides Replace camshaft Replace rings Replace - rebore cylinder See Section 5
Problem: Engine will not start or is hard to start (No spark) Condition
1. 2. 3. 4. 5. 6. Spark plug fouled Spark plug wet Magneto defective CDI unit/ECU defective Ignition coil defective High-tension lead open - shorted
Remedy
1. 2. 3. 4. 5. 6. Clean - replace plug Clean - dry plug Replace magneto Replace CDI unit/ECU Replace ignition coil Replace high tension lead
Problem: Engine will not start or is hard to start (No fuel reaching the carburetor/fuel injector) Condition
1. 2. 3. 4. 5. Gas tank vent hose obstructed Carburetor float valve defective (Prowler/XT) Fuel hose obstructed Fuel screens obstructed Fuel pump defective
Remedy
1. 2. 3. 4. 5. Clean vent hose Replace valve Clean - replace hose Clean - replace inlet screen - valve screen Replace fuel pump
Problem: Engine stalls easily Condition

1. 2. 3. 4. 5. Spark plug fouled Magneto defective CDI unit/ECU defective Carburetor jets/fuel injector obstructed Valve clearance out of adjustment
Remedy
1. 2. 3. 4. 5. Clean - replace plug Replace magneto Replace CDI unit/ECU Clean jets/replace fuel injector Adjust clearance
Problem: Engine noisy (Excessive valve chatter) Condition

1. 2. 3. 4. Valve clearance excessive Valve spring(s) weak - broken Rocker arm - rocker arm shaft worn Camshaft worn
Remedy
1. 2. 3. 4. Adjust clearance Replace spring(s) Replace arm - shaft Replace camshaft
Problem: Engine noisy (Noise seems to come from piston) Condition

1. 2. 3. 4. Piston - cylinder worn Combustion chamber carbon buildup Piston pin - piston pin bore worn Piston rings - ring groove(s) worn
Remedy
1. 2. 3. 4. Replace - service piston - cylinder Clean chamber Replace - service pin - bore Replace rings - piston
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Problem: Engine noisy (Noise seems to come from timing chain) Condition
1. Chain stretched 2. Sprockets worn 3. Tension adjuster malfunctioning
Remedy
1. Replace chain 2. Replace sprockets 3. Repair - replace adjuster
Problem: Engine noisy (Noise seems to come from crankshaft) Condition

1. 2. 3. 4. 5. Bearing worn - burned Lower rod-end bearing worn - burned Connecting rod side clearance too large Centrifugal clutch loose Rotor/flywheel loose
Remedy
1. 2. 3. 4. 5. Replace bearing Replace bearing Replace thrust washer(s) Tighten - replace clutch Tighten - replace flywheel - crankshaft
Problem: Engine noisy (Noise seems to come from transmission) Condition

1. 2. 3. 4. 5. Gears worn - rubbing Splines worn Primary gears worn - rubbing Bearings worn Bushing worn
Remedy
1. 2. 3. 4. 5. Replace gears Replace shaft(s) Replace gears Replace bearings Replace bushing
Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition
1. 2. 3. 4. 5. 6. 7. Drive - driven bevel gears damaged - worn Backlash excessive Tooth contact improper Bearing damaged Gears worn - rubbing Splines worn Final driven shaft thrust clearance too large
Remedy
1. 2. 3. 4. 5. 6. 7. Replace gears Adjust backlash Adjust contact Replace bearing Replace gears Replace shaft(s) Replace thrust washer(s)
Problem: Engine idles poorly Condition

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Valve clearance out of adjustment Valve seating poor Valve guides defective Rocker arms - arm shaft worn Magneto defective CDI unit/ECU defective Spark plug fouled - gap too wide Ignition coil defective Float out of adjustment (Prowler/XT) Jets/fuel injector obstructed Pilot screw setting improper (Prowler/XT)
Remedy
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Adjust clearance Replace - service seats - valves Replace guides Replace arms - shafts Replace magneto Replace CDI unit/ECU Adjust gap - replace plug Replace ignition coil Adjust float height Clean jets/replace fuel injector Adjust pilot screw
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Problem: Engine runs poorly at high speed Condition
1. 2. 3. 4. 5. 6. 7. 8. 9. High RPM cut out against RPM limiter Valve springs weak Valve timing out of adjustment Cams - rocker arms worn Spark plug gap too narrow Ignition coil defective Float level too low (Prowler/XT) Air cleaner element obstructed Fuel hose obstructed
Remedy
1. 2. 3. 4. 5. 6. 7. 8. 9. Shift into higher gear - decrease speed Replace springs Adjust timing Replace cams - arms Adjust gap Replace ignition oil Adjust float height Clean element Clean - prime hose
Problem: Exhaust smoke dirty or heavy Condition

1. 2. 3. 4. 5. 6. Oil (in the engine) overfilled - contaminated Piston rings - cylinder worn Valve guides worn Cylinder wall scored - scuffed Valve stems worn Stem seals defective
Remedy
1. 2. 3. 4. 5. 6. Drain excess oil - replace oil Replace - service rings - cylinder Replace guides Replace cylinder Replace valves Replace seals
Problem: Engine lacks power Condition

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Valve clearance incorrect Valve springs weak Valve timing out of adjustment Piston ring(s) - cylinder worn Valve seating poor Spark plug fouled Rocker arms - shafts worn Spark plug gap incorrect Carburetor jets/fuel injector obstructed Float level out of adjustment (Prowler/XT) Air cleaner element obstructed Oil (in the engine) overfilled - contaminated Intake manifold leaking air Cam chain worn
Remedy
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Adjust clearance Replace springs Time camshaft Replace - service rings - cylinder Repair seats Clean - replace plug Replace arms - shafts Adjust gap - replace plug Clean jets/replace fuel injector Adjust float height Clean element Drain excess oil - change oil Tighten - replace manifold Replace cam chain - sprockets
Problem: Engine overheats Condition

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Remedy
1. Clean piston Carbon deposit (piston crown) excessive 2. Add oil Oil low 3. Drain - replace gasoline Octane low - gasoline poor 4. Replace pump Oil pump defective 5. Clean circuit Oil circuit obstructed Gasoline level (in float chamber) too low (Prowler/XT) 6. Adjust float height 7. Tighten - replace manifold Intake manifold leaking air 8. Fill - examine system for leaks Coolant level low 9. Check fan fuse - replace fan Fan malfunctioning 10. Replace fan switch Fan switch malfunctioning 11. Replace thermostat Thermostat stuck - closed 12. Clear obstruction - replace hoses Radiator hoses - cap damaged - obstructed
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SECTION 4 FUEL/LUBRICATION/COOLING
TABLE OF CONTENTS
Fuel/Lubrication/Cooling ......................................... 4-2 Carburetor Specifications (Prowler/XT)................... 4-2 Carburetor Schematic (Prowler/XT) ........................ 4-2 Carburetor (Prowler/XT) .......................................... 4-2 Electronic Fuel Injection (XTX)................................ 4-6 Engine RPM (Idle) (Prowler/XT).............................. 4-8 Gas Tank ................................................................. 4-8 Gas/Vent Hoses .................................................... 4-11 Oil Filter/Oil Pump ................................................. 4-11 Oil Cooler (XTX) .................................................... 4-12 Liquid Cooling System........................................... 4-12 Radiator................................................................. 4-13 Thermostat ............................................................ 4-14 Fan ........................................................................ 4-15 Water Pump .......................................................... 4-15 Electric Fuel Pump/Fuel Level Sensor (XTX) ........ 4-16 Vacuum Pulse Fuel Pump (Prowler/XT)................ 4-18 Fuel Level Sensor (XT).......................................... 4-18 Troubleshooting (Prowler/XT) ................................ 4-20 Troubleshooting (XTX)........................................... 4-20
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4-1
Fuel/Lubrication/ Cooling
NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. NOTE: Critical torque specifications are located in Section 1.
Carburetor Schematic
(Prowler/XT)
Carburetor Specifications
(Prowler/XT)
Type Main Jet Slow Jet Pilot Screw Setting (turns) Needle Jet Jet Needle Idle RPM Starter Jet Float Arm Height
Keihin CVK36 138 40 2 6.0/4.0 Fixed 1250-1350 85 17 mm (0.7 in.)
KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Cover Screw Spring Vacuum Piston Spring Seat Jet Needle Needle Jet Jet Holder Main Jet Slow Jet Starter Jet Float Valve Clip
14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Float Set Float Pin Pilot Screw Spring Washer O-Ring Idle Adjust Screw Washer Spring Plate Screw Electric Choke Choke Cover
27. Float Chamber Assy 28. Screw 29. Spring 30. Diaphragm Assy 31. Pump Housing 32. U-Ring 33. Screw 34. O-Ring 35. Screw 36. Screw 37. Cover 38. Vent Hose 0741-115
Carburetor
(Prowler/XT)
! WARNING
Whenever any maintenance or inspection is performed on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area.
REMOVING 1. Remove the seats and center console; then remove the left-side seat-base. 2. Loosen the clamps on the inlet boot; then remove the boot from the left-side.
4-2
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PR160A
CH015D
3. Loosen the clamp securing the intake boot to the carburetor; then separate the carburetor from the boot. 4. Remove the gas hose and carburetor float chamber vent hose. 5. Remove the throttle arm cover; then loosen the outer jam nut on the throttle cable and disconnect the throttle cable from the carburetor.
2. Remove the vacuum piston assembly from the carburetor body. Account for a spring, spring seat, and the jet needle.
4
CC746
3. Remove the three screws securing the pump housing. Account for the diaphragm assembly, spring, and U-ring (in the housing).
PR154A
CC748
PR162A
6. Disconnect the electric choke connector; then remove the carburetor from the engine. DISASSEMBLING 1. Remove the four Phillips-head screws securing the top cover; then remove the cover.
4. Remove the Phillips-head screws securing the float chamber; then remove the chamber. Account for the O-ring.
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CC749
CC761A
7. Secure the needle jet holder with a wrench; then remove the main jet. 8. Remove the needle jet holder; then remove the needle jet, slow jet, and the starter jet. 9. Remove the pilot screw. Account for a spring, a washer, and an O-ring.
CC750
5. Remove the float pin.
CC758
10. Unscrew and remove the idle adjust screw assembly. Account for the spring and washer. CLEANING AND INSPECTING
CC752
6. Lift the float assembly from the carburetor. Account for the float valve.
! WARNING
When drying components with compressed air, always wear safety glasses.
! CAUTION
DO NOT place any non-metallic components in parts-cleaning solvent because damage or deterioration will result.
1. Place all metallic components in a wire basket and submerge in carburetor cleaner. 2. Soak for 30 minutes; then rinse with clean, hot water. 3. Wash all non-metallic components with soap and water. Rinse thoroughly.
CC753
NOTE: Note the locations of the jets, pilot screw, and holder for disassembling procedures. www.mymowerparts.com
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4. Dry all components with compressed air only making sure all holes, orifices, and channels are unobstructed. 5. Inspect the carburetor body for cracks, nicks, stripped threads, and any other imperfections in the casting. 6. Inspect the vacuum piston/diaphragm for cracks, imperfections in the casting, or cracks and tears in the rubber. 7. Inspect float for damage. 8. Inspect gasket and O-rings for distortion, tears, or noticeable damage. 9. Inspect tips of the jet needle, pilot screw, and the needle jet for wear, damage, or distortion. 10. Inspect the slow jet and main jet for obstructions or damage.
NOTE: If the slow jet is obstructed, the mixture will be extremely lean at idle and part-throttle operation.
CC761A
3. Install the slow jet. Tighten securely. 4. Install the main jet into the needle jet holder and tighten securely; then install the needle jet and needle jet holder assembly into the carburetor and tighten securely. 5. Place the float assembly (with float valve) into position and secure to the carburetor with the float pin.
11. Inspect the float valve for wear or damage. 12. Inspect the carburetor mounting flange for damage and tightness. ASSEMBLING 1. Thread the idle adjust screw assembly into the carburetor making sure the washer and spring are properly positioned. 2. Install the pilot screw with the spring, the washer, and the O-ring in this order.
CC753
NOTE: Check float arm height by placing the carburetor on its side w/float contacting the needle; then measure with a caliper the height when the float arm is in contact with the needle valve. Float arm height should be 17 mm (0.7 in.).
6. Place the float chamber into position making sure the O-ring is properly positioned; then secure with the Phillips-head screws.
CC758
NOTE: Turn the pilot screw clockwise until it is lightly seated; then turn it counterclockwise the recommended number of turns as an initial setting. NOTE: Note the locations of the jets and holder during assembling procedures.
CC750
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CC749
CH015D
7. Place the U-ring into the pump housing. Position the spring and diaphragm assembly (lip toward the carburetor) onto the carburetor; then secure the assembly with the pump housing and three screws. Tighten securely.
INSTALLING 1. Place the carburetor into position on the engine; then connect the electric choke connector to the main harness. 2. Connect the throttle cable to the carburetor. Tighten the jam nut securely. 3. Connect the gas hose; then connect the carburetor float chamber vent hose. 4. Place the carburetor into the intake boot and tighten the clamp securely. 5. Install the inlet boot between the air filter housing and the carburetor; then tighten the clamps securely.
CC748
! CAUTION
It is important to press down on the pump housing until it contacts the carburetor to make sure the diaphragm lip is properly seated in the groove in the carburetor. If the diaphragm is not properly seated, leakage will occur.
6. Install the left-side seat-base; then install the center console and the seats making sure the seats lock securely.
Electronic Fuel Injection

(XTX)
8. Place the jet needle, spring seat, and spring into the vacuum piston; then place the assembly down into the carburetor.
! WARNING
Whenever the gasline hoses are removed (other than for pressure testing), the battery must be disconnected to prevent inadvertent activation of the electronic fuel pump.
! WARNING
Whenever any maintenance or inspection is performed on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area.
CC746
9. Place the top cover into position; then secure with the Phillips-head screws. Tighten securely.
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TROUBLESHOOTING 1. Verify that the electric fuel pump is operating by listening for a whirring sound for approximately three seconds after the ignition switch is turned to the ON position. If no sound can be heard, see Electric Fuel Pump/Fuel Level Sensor (XTX) in this section. 2. Check for a flashing EFI icon on the LCD. If EFI is flashing, see ECU Error Codes (XTX) in Section 5. 3. Make sure there is sufficient, clean gas in the gas tank. 4. Verify that the battery is sufficiently charged to crank the engine over at normal speed. 5. Check the air filter housing and air filter for contamination. Clean or replace as necessary (see Section 2). REMOVING THROTTLE BODY 1. Turn the ignition switch to the OFF position; then remove the ignition switch key.
PR487A
5. Slowly disconnect the gasline hose connector from the fuel rail.
! WARNING
Gasoline may be under pressure. Place an absorbant towel under the connector to absorb any gasoline spray when disconnecting.
! WARNING
Do not turn the ignition switch to the ON position with the hoses removed. Gasoline will be pumped by the electric fuel pump causing a safety hazard.
2. Remove the left and right seats; then remove the center console and disconnect the battery. 3. Remove the connector from the IAT sensor (A); then loosen the inlet boot clamp (B) and remove the mounting screw (C).
FI092A
6. Remove the screw securing the throttle actuator cover to the throttle body; then remove the cover. 7. Remove the throttle cable from the actuator arm. 8. Loosen the outer jam nut securing the throttle cable to the throttle body; then route the cable out of the way. 9. Remove the electrical connectors from the throttle body components. 10. Remove the throttle body assembly from the intake pipe.
PR486A
4. Disconnect the crankcase breather hose from the air filter housing; then remove the air filter assembly from the vehicle.
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Gas Tank
! WARNING
Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area.
FI104A
REMOVING 1. Remove the seats and center console; then remove the left-side and right-side seat-bases. 2. Remove twelve cap screws and two self-tapping screws securing the floorboard to the frame. 3. While pulling forward on the upper portion of the floorboard, lift the rear panel above the seat lock studs; then insert a small wood block to hold in position.
11. Use tape to cover and seal the intake opening.
! CAUTION
Any objects or liquid entering the intake opening will fall into the engine causing severe damage if the engine is turned over or started.
INSTALLING THROTTLE BODY 1. Install the throttle body into the intake pipe and secure with the clamp. Tighten securely. 2. Place a new O-ring in the intake pipe; then position the pipe onto the engine and secure with two cap screws. 3. Connect the throttle cable to the throttle body and adjust throttle free-play (see Section 2); then connect the gasline hose. 4. Connect the electrical connectors to the throttle body components. 5. Install the air filter assembly and secure with the existing hardware; then connect the IAT sensor and crankcase breather hose. 6. Install the center console and seats making sure the seats lock securely in place.
PR163
Engine RPM (Idle)

(Prowler/XT)
To adjust idle RPM, see Section 2.
PR164
4. From the opposite side of the vehicle, repeat step 3; then lift the rear of the floorboard up and lift the floorboard out of the vehicle.
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7. Remove four press-nuts securing the gas cap inset; then remove the gas cap and inset. Install the gas cap.
PR165
5. Disconnect the vent hose, gasline hose, and fuel level sensor connector (XT/XTX); then cap the vent fitting and gas hose fitting.
PR168
8. Remove the joining cap screw and nut from the rear gas tank hold-down strap; then remove the inside hold-down strap.
4
PR166E
6. Remove the outer cap screw securing the front tank hold-down; then swing the hold-down to the left.
PR172A
9. Lift and slide the tank forward raising the front of the tank first; then turn the tank and lift out the right side. CLEANING AND INSPECTING
1. Clean all gas tank components with parts-cleaning solvent.

PR167A
2. Inspect all hoses for cracks or leaks. 3. Inspect gas tank cap and tank for leaks, holes, and damaged threads. 4. On the XT/XTX, inspect the fuel level sensor for proper operation (see appropriate Fuel Level Sensor in this section).
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PR170
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4-9 Next

INSTALLING
! WARNING
1. Place the gas tank into position in the vehicle; then install the inside rear hold-down strap.
PR166A
4. Place the gas cap filler panel into position; then if necessary, position the gas tank so the filler panel and filler neck are not binding or rubbing.
PR173
PR176
5. Secure the filler panel with four press-nuts; then tighten the hardware securing the hold-down straps (from steps 2-3) securely.
PR172A
2. Swing the front hold-down to the right into position and install the cap screw and nut. Do not tighten at this time.
PR166A
PR171
3. Install the rear hold-down strap joining cap screw and nut. Do not tighten at this time.
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PR167A
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6. Connect the gasline hose and gas tank vent hose to the proper fittings; then connect the fuel level sensor connector (XT/XTX) to the main harness.
CF264A
PR166E
NOTE: Some oil seepage may occur when installing the oil pressure gauge. Wipe up oil residue with a cloth.
7. Position the floorboard into the vehicle and secure with the appropriate hardware; then install the center console, seat-bases, and seats making sure the seats lock securely.
4. Set the parking brake and start the engine. Allow the engine to warm up to operating temperature (with cooling fan cycling). 5. Set the speedometer/tachometer to RPM (XT/XTX) or connect a suitable tachometer (Prowler). With the engine running at 2500 RPM, the pressure gauge must show 0.7-0.8 kg/cm (10-20 psi). 6. Install the left-side seat-base; then install the center console and seats making sure the seats lock securely.
NOTE: If the oil pressure is lower than specified, check for an oil leak, damaged oil seal, or defective oil pump. NOTE: If the oil pressure is higher than specified, check for too heavy engine oil weight (see Section 2), clogged oil passage, clogged oil filter, or improper installation of the oil filter.
Gas/Vent Hoses
Replace the gas hose every two years. Damage from aging may not always be visible. Do not bend or obstruct the routing of the carburetor vent hose (Prowler/XT). Make certain that the vent hose is securely connected to the carburetor and the opposite end is always open.
Oil Filter/Oil Pump

NOTE: Whenever internal engine components wear excessively or break and whenever oil is contaminated, the oil pump should be replaced.
REMOVING/DISASSEMBLING 1. Remove the oil pump from the engine (see Right-Side Components in Section 3). 2. Remove the Phillips-head screw on the back side of the pump and separate the pump housing and cover. Note the position of the inner and outer rotors and alignment pin for assembly. 3. Remove oil pump components. CLEANING AND INSPECTING
TESTING OIL PUMP PRESSURE

NOTE: The engine must be warmed up to the specified temperature for this test.
1. Remove the seats and center console; then remove the left-side seat-base. 2. Tilt the cargo box back. 3. Remove the upper plug from the base of the oil filter; then using an appropriate adapter, connect an oil pressure gauge to the engine.
1. Clean all oil-pump components. 2. Inspect the rotors for scoring and gouges.
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3. Inspect the alignment pin, driveshaft, and driven sprocket for damage. 4. Inspect the pump housing and cover for cracks or damage. ASSEMBLING/INSTALLING 1. Place the rotors into the pump housing making sure the alignment pin is in the groove of the rotor. 2. Place the cover onto the pump housing. 3. Secure the pump with the Phillips-head screw coated with red Loctite #271. 4. Install the oil pump into the engine (see Right-Side Components in Section 3). CLEANING AND INSPECTING
PR484B
Oil Cooler
(XTX)
This model has an oil cooler in addition to the liquid cooling system. An oil cooler kit may be installed on any Arctic Cat UTV. REMOVING 1. Loosen the clamps securing the oil hoses to the oil cooler; then place a shallow pan or absorbent towel under the connection and remove the hoses.
1. Prior to washing, inspect the oil cooler for signs of leaks such as oily dirt build-up. 2. Wash the cooling fins using a pressure washer or hot, soapy water and a soft brush. 3. Inspect all mounting brackets and the oil inlet and outlet for cracks or bends. INSTALLING 1. Place the oil cooler into position and secure with the existing hardware. Tighten securely. 2. Connect the oil hoses and secure with the hose clamps. Tighten securely.
Liquid Cooling System

When filling the cooling system, use premixed Arctic Cat Antifreeze. While the cooling system is being filled, air pockets may develop; therefore, run the engine for five minutes after the initial fill, shut the engine off, and then fill the cooling system to the bottom of the stand pipe in the radiator neck.
PR484A
2. Remove the flange nuts and cap screws from the oil cooler mountings and remove the oil cooler.
! CAUTION
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Radiator
REMOVING 1. Remove the cap screws securing the dash assembly to the frame and one cap screw and nut from the center support. Slide the dash rearward approximately four inches.
PR186
4. Drain the coolant into a suitable container; then disconnect the cooling fan wire connector from the main harness.
PR181A
4
PR183A
5. Remove the two shoulder bolts and nuts securing the radiator to the frame; then disconnect the upper and lower coolant hoses.
PR475A
2. Remove four torx-head screws (A) securing the under-hood storage box to the frame; then remove two cap screws with nuts (B) at the front of the storage box.
PR184A
6. Lift the radiator assembly from the vehicle. Account for two upper and two lower rubber mounting grommets. CLEANING AND INSPECTING
PR182A
3. While lifting up on the front of the storage box, pry the rear center clear of the center dash mount and remove the storage box.
1. Flush the radiator with water to remove any contaminants. 2. Inspect the radiator for leaks and damage.
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3. Inspect all hoses for cracks and deterioration. 4. Inspect all fasteners and grommets for damage or wear. INSTALLING 1. Place the radiator into position making sure the grommets are correctly installed; then secure to the mounts with the two shoulder bolts and nuts. Tighten securely.
PR187
5. Slide the dash forward into position; then secure the dash with the appropriate hardware. 6. Start the engine and warm up to operating temperature; then check that the coolant level is at the specified level (see Section 2). Add coolant as necessary.
PR184A
Thermostat
REMOVING 1. Drain approximately one quart of coolant from the cooling system. 2. Remove the two cap screws securing the thermostat housing to the cylinder head. Account for a thermostat with seal (Prowler/XT) and O-ring (XTX). INSPECTING
2. Connect the upper and lower coolant hoses to the radiator and secure with the appropriate hose clamps; then connect the cooling fan wire connector to the main harness.
PR183A
3. Pour the recommended coolant into the radiator and secure the radiator cap. 4. Place the storage box into position and using a smooth, flat pry-bar, pry the center of the box past the dash mount; then secure with the appropriate fasteners.
1. Inspect the thermostat for corrosion, wear, or spring damage. 2. Using the following procedure, inspect the thermostat for proper operation. A. Suspend the thermostat in a container filled with water. B. Heat the water and monitor the temperature with a thermometer. C. The thermostat should start to open at 63.5-66.5 C (146-152 F). D. If the thermostat does not open, it must be replaced. 3. Inspect all coolant hoses, connections, and clamps for deterioration, cracks, and wear.
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NOTE: All coolant hoses and clamps should be replaced every four years or 4000 miles.
REMOVING 1. Remove the radiator cap; then remove the water pump coolant drain plug and drain the coolant.
INSTALLING 1. Place the thermostat with seal (Prowler/XT) and O-ring (XTX) into the thermostat housing; then secure the thermostat housing to the cylinder head with the two cap screws.
! CAUTION
When installing the thermostat, make sure the bleed holes are straight up and down or air will remain trapped causing engine damage due to overheating.
PR122A
2. Drain the oil from the engine/transmission. 3. Remove the seats and center console; then remove the right-side seat-base. 4. Loosen the coolant hose clamps and slide the clamps away from the hose ends.
PR281A
2. Fill the cooling system with the recommended amount of antifreeze. Check for leakage.
Fan
REMOVING 1. Remove the radiator (see Radiator in this section). 2. Remove the fan assembly from the radiator. INSTALLING 1. Position the fan assembly on the radiator; then secure with existing hardware.
NOTE: The fan wiring must be in the upper-right position.
PR132
5. Remove the two cap screws securing the water pump to the engine; then remove the water pump.
2. Install the radiator (see Radiator in this section).
Water Pump
CC786A
NOTE: The water pump is not a serviceable component. If the pump is defective or if the mechanical seal is leaking (coolant dripping from the discharge hole), the water pump must be replaced.
INSTALLING 1. Secure the water pump to the engine with the two cap screws tightened securely.
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Electric Fuel Pump/Fuel Level Sensor

(XTX)
The electric fuel pump and fuel level sensor are not serviceable components. If either component fails, it must be replaced.
CC786A
2. Connect the two coolant hoses to the water pump and secure with the clamps; then install the water pump coolant drain plug.
TESTING
! WARNING
AT THIS POINT
Prior to removing the electric fuel pump, the following check should be performed to determine that removal is necessary.
PR132
3. Fill the engine/transmission with the proper amount of recommended oil. 4. Fill the cooling system with the proper amount of recommended coolant.
NOTE: While the cooling system is being filled, air pockets may develop; therefore, run the engine for five minutes after the initial fill, shut the engine off, and then fill the cooling system.
1. Turn the ignition switch ON and listen for a momentary whirring sound of the pump building pressure. If the sound is heard (10 seconds), no electrical checks are necessary. Turn the ignition switch OFF. 2. Disconnect the gasline hose from the fuel rail; then install a suitable pressure gauge.
! WARNING
Gasoline may be under pressure. Place an absorbant towel under the connector to absorb any gasoline spray when disconnecting.
5. Check the entire cooling system for leakage.
! CAUTION
6. Install the right-side seat-base; then install the center console and seats making sure the seats lock securely.
FI092A
3. Turn the ignition switch to the ON position. The fuel pressure should build until the pump shuts off. Pressure should read 3.0 kg-cm2 (43 psi). 4. If the pump is not running, disconnect the fuel pump/sensor connector by reaching under the rear rack from behind.
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5. Connect a multimeter to the power supply leads with the red tester lead to the red wire and the black tester lead to the black wire; then turn the ignition switch to the ON position. The meter should read battery voltage. If battery voltage is indicated and the fuel pump does not run, replace the pump assembly. If no battery voltage is indicated, check the ECU and the vehicle tilt sensor. REMOVING 1. Remove the key from the ignition switch.
! WARNING
Always ensure that power cannot be inadvertently applied to the ignition/ECU when working on the fuel system. If the ignition switch is turned on, the electric fuel pump will start and gas could be rapidly pumped and spilled resulting in fire and severe injury.
ATV2116
NOTE: If readings are erratic, clean the resistor wiper and resistor with clean alcohol and retest. If still not correct, replace the fuel level sensor.
4. To replace the fuel level sensor, use the following procedure. A. Disconnect the two-wire connector (A); then press the fuel level sensor toward the top of the fuel pump to release it from the mounting slot (B).
2. Remove the seats, center console, and right-side seat-base; then disconnect the negative battery cable. 3. Disconnect the electrical plug from the main harness; then disconnect the gasline hose from the fuel pump. 4. Mark the fuel pump mounting and gas tank for installing purposes; then remove the screws securing the fuel pump to the gas tank and remove the fuel pump.
! CAUTION
Take care not to damage the float or float arm or replacement of the entire assembly will be necessary.
5. Using duct tape or other suitable means, cover the fuel pump opening. INSPECTING
FI460A
AT THIS POINT
If the pump has failed earlier test and must be replaced, proceed to INSTALLING.
B. Engage the tabs (C) of the fuel level sensor into the mounting slot (B) and press toward the bottom of the fuel pump to latch in place; then connect the two-wire connector (A). INSTALLING 1. Place the fuel pump assembly into the gas tank with a new gasket aligning the match marks; then secure with the four screws. Tighten securely.
NOTE: It is important to install the fuel pump with the correct orientation to ensure adequate float lever clearance.
1. Inspect the fuel screen and blow clean with low pressure compressed air. 2. Move the float lever and check for free movement. The float assembly should return to the lower position without force. If not, replace the fuel pump assembly. 3. Test the fuel level sensor by connecting a multimeter (A) to the fuel level sensor leads (B); then select OHMS. The multimeter should show 5 ohms at full fuel position (C) and 95 ohms at empty fuel position (D).
2. Connect the gasline hose to the fuel pump pipe and secure with the hose clamp; then connect the electrical plug to the main harness. 3. Connect the negative battery cable; then turn the ignition switch to the ON position and verify that no gas leaks are present, the pump runs for 2-3 seconds, and the gas gauge reading is normal.
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4. Start the engine to verify proper engine operation; then shut off the engine and install the right-side seat-base, center console, and seats making sure the seats lock securely into place.
Vacuum Pulse Fuel Pump

(Prowler/XT)
NOTE: The vacuum pulse fuel pump is a nonserviceable assembly. If the pump fails, it must be replaced.
PR280A
AT THIS POINT
Prior to removing the vacuum pulse fuel pump, the following test should be performed to determine that removal is necessary.
2. Remove the two machine screws and flange nuts securing the fuel pump to the electrical tray; then remove the pump. INSTALLING 1. Place the fuel pump into position on the electrical tray; then secure with the machine screws and flange nuts. Tighten securely. 2. Connect two gas hoses and one vacuum hose; then secure with the clamps.
! WARNING
TESTING 1. Disconnect the fuel pump/carburetor hose at the fuel pump; then connect a hose and suitable pressure gauge to the fuel pump output fitting.
Fuel Level Sensor

(XT)
REMOVING 1. Remove the seats and the center console; then remove the right-side seat-base. 2. Remove the gasline hose and disconnect the fuel level sensor connector; then remove four torx-head machine screws and the fuel level sensor mounting plate.
CD815
2. Start the engine. Fuel pump pressure should show 0.036-0.084 kg/cm2 (0.5-1.2 psi). REMOVING 1. Remove the right-side seat-base; then remove the three clamps securing the gas hoses and vacuum hose and disconnect the hoses.
PR166C
3. Remove the fuel level sensor from the gas tank. Account for a seal.
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INSPECTING 1. Inspect the fuel screen and clean with low pressure compressed air. 2. Move the float lever and check for free movement. The float assembly should drop to the empty position when the fuel level sensor is held vertically. If there is binding or sticking, replace the fuel level sensor. 3. Test the fuel level sensor by connecting a multimeter (A) to the fuel level sensor connector (B); then select OHMS on the multimeter. The multimeter should read 5 ohms of resistance at full fuel position (C) and 95 ohms at the empty fuel position (D).
NOTE: If readings are erratic, clean the resistor wiper and resistor with a clean cloth soaked with alcohol and retest. If the readings shown are not as specified, replace the fuel level sensor assembly.
INSTALLING 1. Using a new seal, place the fuel level sensor into position in the gas tank; then secure the fuel level sensor mounting plate. Tighten the four torx-head machine screws securely. 2. Connect the fuel level sensor connector to the main harness; then install the gasline hose and secure with the clamp. 3. Install the right-side seat-base; then install the center console and seats making sure the seats lock securely into place.
4
ATV2116
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Troubleshooting
(Prowler/XT)
Problem: Starting impaired Condition 1. Starter jet obstructed 2. Starter jet passage obstructed 3. Carburetor leaking air Problem: Idling or low speed impaired Condition 1. Slow jet obstructed - loose 2. Slow jet outlet obstructed 3. Pilot screw setting incorrect 4. Float height incorrect Problem: Medium or high speed impaired Condition 1. High RPM cut out against RPM limiter 2. Main jet obstructed 3. Needle jet obstructed 4. Vacuum piston not operating properly 5. Filter obstructed 6. Float height incorrect Problem: Overflow and fuel level fluctuations Condition 1. Float valve worn - damaged 2. Float valve spring broken 3. Float not working properly 4. Float valve dirty 5. Float height too high - too low
Remedy 1. Clean jet 2. Clean passage 3. Replace gasket Remedy 1. Clean - tighten jet 2. Clean outlet 3. Adjust screw 4. Adjust float height Remedy 1. Shift into higher gear - decrease RPM speed 2. Clean main jet 3. Clean needle jet 4. Check piston operation 5. Clean filter 6. Adjust float height Remedy 1. Replace valve 2. Replace spring 3. Adjust float height - replace float 4. Clean valve 5. Adjust float height
Troubleshooting
(XTX)
Problem: Starting impaired Condition

1. Gas contaminated
Remedy
1. Drain gas tank and fill with clean gas
Problem: Idling or low speed impaired Condition

1. TPS out of adjustment
Remedy
1. Adjust TPS
Problem: Medium or high speed impaired Condition

1. High RPM cut out against RPM limiter
Remedy
1. Decrease RPM speed
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SECTION 5 ELECTRICAL SYSTEM
TABLE OF CONTENTS
Electrical System..................................................... 5-2 Specifications .......................................................... 5-2 Battery..................................................................... 5-2 RPM Limiter............................................................. 5-3 Testing Electrical Components ................................ 5-3 Accessory Receptacle/Connector ........................... 5-3 Brakelight Switch..................................................... 5-3 Coolant Temperature and Cooling Fan Switches (Prowler/XT) ......................................................... 5-4 Engine Coolant Temperature (ECT) Sensor (XTX).................................................................... 5-4 Fan Motor ................................................................ 5-5 Power Distribution Module (PDM) ........................... 5-5 Fuses ...................................................................... 5-5 Ignition Coil ............................................................. 5-6 EFI Sensors/Components (XTX)............................. 5-7 Speed Sensor (XT/XTX).......................................... 5-7 Ignition Switch ......................................................... 5-8 Headlight Switch ..................................................... 5-8 2WD/4WD Selector Switch...................................... 5-8 Differential Lock Switch ........................................... 5-8 Reverse Override Switch......................................... 5-9 Front Drive Actuator ................................................ 5-9 Stator Coils (Prowler/XT)....................................... 5-10 Stator Coil/Crankshaft Position (CKP) Sensor (XTX) .......................................... 5-11 Starter Motor ......................................................... 5-12 Starter Relay ......................................................... 5-12 CDI Unit (Prowler/XT)............................................ 5-13 Electronic Control Unit (ECU) (XTX) ..................... 5-13 Regulator/Rectifier................................................. 5-13 Neutral Start/Start-in-Gear/2WD Relays ............... 5-14 Headlights ............................................................. 5-14 Taillight-Brakelight ................................................. 5-14 Ignition Timing ....................................................... 5-14 ECU Error Codes (XTX) ........................................ 5-14 Tilt Sensor (XTX)................................................... 5-15 Throttle Position Sensor (TPS) (XTX) ................... 5-16 Troubleshooting ..................................................... 5-19
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5-1
Electrical System
NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions.
Specifications
Prowler/XT
Ignition Timing Spark Plug Type 10 BTDC @ 1500 RPM Champion RG6YC 0.7-0.8 mm (0.028-0.032 in.) 5000 ohms (primary) Less than 1 ohm (terminal to ground) (secondary) 5200-7800 ohms (high tension - plug cap removed - to ground)
Description
Diagnostic Harness Fluke Model 73 Multimeter MaxiClips Peak Voltage Reading Adapter Test Plug/Error Code List
Spark Plug Gap Spark Plug Cap Ignition Coil Resistance
p/n
0486-219 0644-191 0744-041 0644-307 0444-216
Ignition Coil Peak (primary/CDI) 142.4-213.6 DC volts Voltage (blue/white to ground) Stator Coil Resistance (trigger) 160-240 ohms (green to blue) (charging) Less than 1 ohm (black to black) (signal) Less than 1 ohm (yellow to white) Peak Voltage (trigger) 4.2-6.3 volts (green to blue) (signal) 0.4-0.6 volts (yellow to white) (no load) 60 AC volts @ 5000 RPM (black to black) (approx) 325W @ 5000 RPM
Charging Coil Output AC Generator Output
XTX
Ignition Timing Spark Plug Type Spark Plug Gap Spark Plug Cap Ignition Coil Resistance N/A NGK CR6E 0.7-0.8 mm (0.028-0.032 in.) 5000 ohms (primary) Less than 1 ohm (terminal (+) to terminal (-)) (secondary) 12k-19k ohms (high tension plug cap to terminal (+)) Battery Voltage (orange (+) to blue/white (-))
Ignition Coil Primary Voltage
Stator Coil Resistance (crankshaft position sensor) 150-250 ohms (blue to white) (AC generator) Less than 1 ohm (yellow to yellow) Crankshaft Position Sensor AC Voltage 5.0 or more (blue to green)
AC Generator Output 75 AC volts @ 5000 RPM (no load) (yellow to yellow)
Battery
For battery-related information, see Section 2.
5-2
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RPM Limiter
NOTE: The UTV is equipped with a CDI unit/ECU that retards ignition timing when maximum RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire.
NOTE: The ignition switch must be in the ON position.
VOLTAGE (Wiring Harness Connector) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the orange wire; then connect the black tester lead to ground.
Testing Electrical Components

All of the electrical tests should be made using the Fluke Model 73 Multimeter and when testing peak voltage, the Peak Voltage Reading Adapter must be used. If any other type of meter is used, readings may vary due to internal circuitry. When troubleshooting a specific component, always verify first that the fuse(s) are good, that the bulb(s) are good, that the connections are clean and tight, that the battery is fully charged, and that all appropriate switches are activated.
NOTE: For absolute accuracy, all tests should be made at room temperature of 68 F.
PR276A
3. The meter must show battery voltage.

NOTE: If the meter shows no battery voltage, troubleshoot the battery, fuse, switch, or the main wiring harness. NOTE: If the meter shows battery voltage, the main wiring harness is good; proceed to test the switch/component, the connector, and the switch wiring harness for resistance.
Accessory Receptacle/Connector
NOTE: This test procedure is for either the receptacles or the connectors.
RESISTANCE (Switch Connector)
! CAUTION
Always disconnect the battery when performing resistance tests to avoid damaging the multimeter.
VOLTAGE 1. Turn the ignition switch to the ON position; then set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the red/white wire or the positive connector; then connect the black tester lead to ground. 3. The meter must show battery voltage.
NOTE: If the meter shows no battery voltage, troubleshoot the battery, fuse, receptacle, connector, or the main wiring harness.
NOTE: The brake pedal must be depressed for this test.
1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to one black wire; then connect the black tester lead to the other black wire.
Brakelight Switch
The switch connector is the two-prong black connector below the master cylinder.
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4. On the coolant temperature switch, allow the oil to cool, and when the temperature is within a temperature range of 107-113 C (225-235 F), the meter should show an open circuit. 5. On the cooling fan switch when the temperature reaches 81-99 C (175-213 F), the meter should show a closed circuit. 6. On the cooling fan switch, allow the oil to cool, and when the temperature is within a temperature range of 67-82 C (150-184 F), the meter should show an open circuit.
AR621D
3. When the lever is depressed, the meter must show less than 1 ohm.
NOTE: If the meter shows more than 1 ohm of resistance, replace the switch.
7. If the readings are not as indicated, the switch must be replaced. 8. Install the switch and tighten securely. 9. Connect the switch leads.
Coolant Temperature and Cooling Fan Switches

(Prowler/XT)
1. Connect the meter leads (selector in the OHMS position) to the switch contacts. 2. Suspend the switch and a thermometer in a container of cooking oil; then heat the oil.
NOTE: Neither the switch nor the thermometer should be allowed to touch the bottom of the container or inaccurate readings will occur. Use wire holders to suspend switch and thermometer.
Engine Coolant Temperature (ECT) Sensor (XTX)

1. Connect the meter leads (selector in OHMS position) to the sensor terminals. 2. Suspend the sensor and a thermometer in a container of cooking oil; then heat the oil.
NOTE: Neither the sensor nor the thermometer should be allowed to touch the bottom of the container or inaccurate readings will occur. Use wire holders to suspend the sensor and thermometer.
! WARNING
Wear insulated gloves and safety glasses. Heated oil can cause severe burns.
! WARNING
Wear insulated gloves and safety glasses. Heated oil can cause severe burns.
3. On the ECT sensor when the temperature reaches 40 C (104 F), the meter should read approximately 1136 ohms. 4. On the ECT sensor when the temperature reaches 100 C (212 F), the meter should read approximately 155 ohms. 5. If the readings are not as indicated, the sensor must be replaced. 6. Install the sensor and tighten securely. 7. Connect the leads.
733-554E
3. On the coolant temperature switch when the oil temperature reaches 112-118 C (234-244 F), the meter should show a closed circuit.
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Fan Motor
NOTE: The ignition switch must be in the ON position.
NOTE: To determine if the fan motor is good, connect the red wire from the fan connector to a 12 volt DC power supply; then connect the black wire from the fan connector to ground. The fan should operate.
! WARNING
Care should be taken to keep clear of the fan blades.
VOLTAGE (Main Harness Connector to Fan Motor) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the black/red wire (the black 2-prong at the fan motor); then connect the black tester lead to ground. 3. The meter must show battery voltage.
NOTE: If the meter shows no battery voltage, troubleshoot the battery, fuse, motor, or the main wiring harness. NOTE: If the meter shows battery voltage, the main wiring harness is good. The connector should be checked for resistance.
Power Distribution Module (PDM)

The fuses are located in a power distribution module under the operators seat. If there is any type of electrical system failure, always check the fuses first. 1. Remove all fuses from the power distribution module. 2. Set the meter selector to the DC Voltage position. 3. Connect the black tester lead to ground. 4. Using the red tester lead, contact each end of the fuse holder connector terminals individually. 5. The meter must show battery voltage from one side of the connector terminal ends.
NOTE: Battery voltage will be indicated from only one side of the fuse holder connector terminal; the other side will show no voltage. NOTE: When testing the HI fuse holder, the headlight OFF/HI/LO switch must be in the HI position; when testing the LIGHTS fuse holder, the headlight dimmer switch can be in either the HI or the LO position. NOTE: If the meter shows no battery voltage, troubleshoot the battery, switches, power distribution module, or the main wiring harness.
RESISTANCE (Fan Motor Connector)
! CAUTION
1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the red wire; then connect the black tester lead to the black wire.
Fuses
PR183A
3. The meter must show less than 1 ohm.

NOTE: If the meter shows more than 1 ohm of resistance, troubleshoot or replace the switch/ component, the connector, or the switch wiring harness.
! CAUTION
1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to one spade end of the fuse; then connect the black tester lead to the other spade end.
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3. The meter must show less than 1 ohm resistance. If the meter shows open, replace the fuse.
NOTE: Make sure the fuses are returned to their proper position according to amperage. Refer to the amperage listed under each fuse on the power distribution module.
Spark Plug Cap 1. Connect the red tester lead to one end of the cap; then connect the black tester lead to the other end of the cap.
Ignition Coil
The ignition coil is mounted on the fuel pump mounting plate adjacent to the fuel pump. VOLTAGE (Primary Side) See PEAK VOLTAGE Primary Coil Voltage (Prowler/XT) or Primary Coil Voltage (XTX) in this sub-section. RESISTANCE
AR603D
2. The meter reading must be within specification.

NOTE: If the meter does not show as specified, replace the spark plug cap.
! CAUTION
PEAK VOLTAGE
NOTE: All of the peak voltage tests should be made using the Fluke Model 73 Multimeter with Peak Voltage Reading Adapter. If any other type of tester is used, readings may vary due to internal circuitry. NOTE: The battery must be at full charge for these tests.
NOTE: For these tests, the meter selector should be set to the OHMS position.
Primary Winding 1. Connect the red tester lead to the terminal (with the wire removed); then connect the black tester lead to ground.
Primary Coil Voltage (Prowler/XT) 1. Set the meter selector to the DC Voltage position; then disconnect the blue/white primary wire from the coil. 2. Connect the red tester lead to the primary wire; then connect the black tester lead to ground.
! WARNING
Do not touch the primary wire with the ignition switch turned on or severe electrical shock will occur.
PR278A
3. Turn the ignition switch to the ON position. 4. The meter must be within specification. 5. With the test leads still connected, crank the engine with the electric starter. 6. The meter must show 300-450 DC volts. Primary Coil Voltage (XTX) 1. Set the meter selector to the DC Voltage position; then disconnect the two wires from the coil.
2. The meter reading must be within specification. Secondary Winding 1. Connect the red tester lead to the high tension lead (with the plug cap removed); then connect the black tester lead to ground. 2. The meter reading must be within specification.
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NOTE: If the meter does not show as specified, replace ignition coil.
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NOTE: The coil is located to the right of the engine and may be accessed from behind the right-side seat with the cargo box raised.
2. Connect the red tester lead to the orange wire and the black tester lead to the blue/white wire. 3. Turn the ignition switch to the ON position. The meter must show battery voltage.
EFI Sensors/ Components

(XTX)
3. Turn the ignition switch to the ON position. CRANKSHAFT POSITION (CKP) SENSOR To test the CKP sensor, see Stator Coil/Crankshaft Position (CKP) Sensor (XTX) in this section. MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR 1. Disconnect the MAP connector from the pressure sensor located on the throttle body. 2. Select DC Voltage on the tester and turn the ignition switch to the ON position. 3. Connect the black tester lead to the black/green wire and the red tester lead to the brown/white wire. The meter should read 4.5-5.5 DC volts. If the meter does not read as specified, check the ECU connector or wiring. 4. Connect the MAP to the harness; then using MaxiClips, connect the red tester lead to the brown/white wire and the black tester lead to the black/green wire. With the engine running at idle speed, the meter should read approximately 1.5 DC volts.
NOTE: If the meter does not read as specified, replace the sensor.
PR279A
4. The meter must show approximately 6 DC volts. 5. Leave the black tester lead connected; then connect the red tester lead to the signal lead pin (S). 6. Slowly move the vehicle forward or backward; the meter must show 0 and approximately 6 DC volts alternately.
NOTE: If the sensor tests are within specifications, the speedometer must be replaced (see Section 9).
To replace a speed sensor, use the following procedure. 1. Disconnect the three-wire connector from the speed sensor harness or from the speed sensor; then remove the Allen-head cap screw securing the sensor to the sensor housing. 2. Remove the sensor from the sensor housing accounting for an O-ring.
Speed Sensor
(XT/XTX)
CD070
NOTE: Prior to testing the speed sensor, inspect the three-wire connector on the speed sensor for contamination, broken pins, and/or corrosion.
3. Install the new speed sensor into the housing with new O-ring lightly coated with multi-purpose grease; then secure the sensor with the Allen-head cap screw (threads coated with blue Loctite #242). Tighten securely.
1. Set the meter selector to the DC Voltage position. 2. With appropriate needle adapters on the meter leads, connect the red tester lead to the voltage lead (V); then connect the black tester lead to the ground lead (G). www.mymowerparts.com
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NOTE: If the meter does not show battery voltage, troubleshoot the LIGHTS fuse on the power distribution module, the ignition switch, or the main harness.
3. Connect the red meter lead to the yellow wire; then select the high beam position on the headlight switch. The meter must show battery voltage. 4. Connect the red meter lead to either of the two white wires; then select the low beam position on the headlight switch. The meter must show battery voltage.
CD071
Ignition Switch
To access the ignition switch, dash switches, front accessory connectors, and front switched accessory connector, the dash must be unfastened and slid to the rear.
NOTE: The battery voltage will show lower in steps 3 and 4 due to electrical loading of the headlights.
2WD/4WD Selector Switch

VOLTAGE 1. Connect the red meter lead to the gray wire; then connect the black meter lead to the black wire. Turn the ignition switch to the ON position. The meter must show battery voltage.
NOTE: If the meter does not show battery voltage, troubleshoot the LIGHTS fuse on the power distribution module, the ignition switch, or the main wiring harness.
VOLTAGE 1. Set the meter selector to the DC Voltage position. 2. Connect the red meter lead to the red wire; then connect the black meter lead to ground. 3. Meter must show battery voltage.
NOTE: If the meter shows no battery voltage, troubleshoot the main 30 amp fuse, the battery, or the main wiring harness.
4. Connect the red meter lead to the red/black wire; then with the black lead grounded, turn the ignition switch to the ON position. The meter must show battery voltage. 5. Connect the red meter lead to the yellow/green wire; then with the black lead grounded, turn the ignition switch to the START position. The starter should engage and the meter must show battery voltage.
NOTE: When the starter is engaged, battery voltage will be approximately 10.5 DC volts.
2. Connect the red meter lead to the white/red wire; then select 2WD on the selector switch. The meter must show battery voltage. 3. Connect the red meter lead to the white/green wire. The meter must show approximately 9.5 DC volts. 4. Select 4WD on the selector switch. The meter must show 0 DC volts.
Differential Lock Switch

VOLTAGE 1. Select DC Voltage on the multimeter; then connect the red tester lead to the switch terminal (leaving the wire connected) and the black tester lead to ground.
Headlight Switch
VOLTAGE 1. Connect the red meter lead to the gray wire; then connect the black meter lead to the black wire. 2. Turn the ignition switch to the ON position. The meter must show battery voltage.
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1. Connect the red meter lead to the black/blue wire and the black meter lead to a suitable ground; then select 2WD on the 2WD/4WD selector switch. The meter must show approximately 1.5 DC volts. 2. Depress the reverse override switch. The meter showing should not change from step 1. 3. Select 4WD on the 2WD/4WD selector switch. The meter must show approximately 5 DC volts. 4. Depress the reverse override switch. The meter must show approximately 1.5 DC volts.
CD575
2. Turn the ignition switch to the ON position. The meter must show 12 DC volts.
NOTE: If no voltage is indicated, check the wiring harness, fuse, or battery connections.
5. Connect the red meter lead to the red/yellow wire. The meter must show approximately 1.5 DC volts. Depress the reverse override switch. The meter must show approximately 1.5 DC volts. 6. Connect the red meter lead to the red/green wire. The meter should show 0 DC volts. 7. Depress the reverse override switch. The meter must show approximately 5 DC volts.
3. Select the lock position on the differential. The meter should drop to 0 volts, and the front drive actuator should operate to engage 4-wheel drive.
NOTE: It may be necessary to rock the vehicle slightly to engage the differential lock fully. NOTE: On the XT/XTX, the 4WD and LOCK icons in the upper-left corner of the LCD should illuminate.
Front Drive Actuator

NOTE: With the engine stopped and the ignition switch in the ON position, a momentary whirring sound must be noticeable each time the selector switch is moved to 2WD and 4WD. Test the switch, 30 amp fuse, and wiring connections prior to testing the actuator. NOTE: The differential must be in the unlocked position for this procedure.
VOLTAGE 1. Locate the 4-wire connector for the front drive selector actuator on the frame to the right of the differential; then connect the red meter lead to the orange wire using a MaxiClip.
CF094E
4. If the differential lock engages (front wheels locked) and the voltage does not drop to 0, the switch is faulty and must be cleaned or replaced.
Reverse Override Switch

VOLTAGE
NOTE: To perform the following tests, the ignition switch must be in the ON position and the transmission shifted into reverse gear.
PR293
2. Connect the black lead to the black wire using a MaxiClip; then select 2WD on the 2WD/4WD selector switch.
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3. With the engine running at a constant 5000 RPM (with the headlights on), the meter must show 14-15.5 DC volts.
! CAUTION
Do not run the engine at high RPM for more than 10 seconds.
NOTE: If voltage is lower than specified, test Charging Coil - No Load.
PR295
VOLTAGE (Charging Coil - No Load) The connector is the three-wire one on the left side of the engine just above the centrifugal clutch housing.
NOTE: Test the connector that comes from the engine.
NOTE: The black tester lead can remain connected to the black wire for the remaining tests.
3. Turn the ignition switch to the ON position. The meter must show battery voltage.
NOTE: If battery voltage is not shown, troubleshoot the 10 amp ignition (IGN) fuse on the power distribution module, the ignition switch, or the main wiring harness.
1. Set the meter selector to the AC Voltage position. 2. Test between the three black wires for a total of three tests. 3. With the engine running at the specified RPM, all wire tests must be within specification.
4. Connect the red meter lead to the white/red wire. The meter must show battery voltage. 5. Select 4WD on the 2WD/4WD selector switch. The meter must show 0 DC volts. 6. Connect the red meter lead to the white/orange wire. The meter must show battery voltage. 7. Engage the differential lock. The meter must show 0 DC volts.
NOTE: If the meter does not show 0 DC volts, rock the vehicle to help engage the differential lock; then troubleshoot the differential lock switch (see Differential Lock Switch in this section).
! CAUTION
NOTE: If both stator coil tests failed, replace the stator assembly.
RESISTANCE (Charging Coil)
! CAUTION
Stator Coils
(Prowler/XT)
VOLTAGE (Generator Regulated Output) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the positive battery post; then connect the black tester lead to the negative battery post.
1. Set the meter selector to OHMS position. 2. Test between the three black wires for a total of three tests. 3. The meter reading must be within specification. RESISTANCE (Trigger Coil)
! CAUTION
1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the green wire; then connect the black tester lead to the blue wire. The meter reading must be within specification.
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PEAK VOLTAGE
NOTE: All of the peak voltage tests should be made using the Fluke Model 73 Multimeter with Peak Voltage Reading Adapter. If any other type of tester is used, readings may vary due to internal circuitry. NOTE: The battery must be at full charge for these tests.
Trigger Coil 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the green wire; then connect the black tester lead to the blue wire. 3. Crank the engine over using the electric starter. 4. The meter reading must be within specification.
FI083B
NOTE: Test the connector that comes from the engine.
1. Set the meter selector to the AC Voltage position. 2. Test between the three yellow wires for a total of three tests. 3. With the engine running at a constant 5000 RPM, all wire tests must be within specifications.
Stator Coil/Crankshaft Position (CKP) Sensor

(XTX)
VOLTAGE (AC Generator - Regulated Output) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the positive battery post; then connect the black tester lead to the negative battery post. 3. With the engine running at a constant 5000 RPM (with the headlights on), the meter must show 14-15.5 DC volts.
! CAUTION
NOTE: If both stator coil tests failed, check all connections, etc., and test again. If no voltage is present, replace the stator assembly.
RESISTANCE (AC Generator)
! CAUTION
1. Set the meter selector to OHMS position. 2. Test between the three yellow wires for a total of three tests. 3. The meter reading must be within specification. RESISTANCE (Crankshaft Position Sensor)
! CAUTION
NOTE: If voltage is lower than specified, test AC Generator - No Load.
VOLTAGE (AC Generator No Load) The connector is the black three-pin one on the left side above the shift lever.
! CAUTION
1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the blue wire; then connect the black tester lead to the white wire. The meter reading must be within specification.
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AC VOLTAGE
NOTE: The battery must be at full charge for these tests.
3. With the starter button depressed, the meter must show battery voltage and the starter motor should operate.
Crankshaft Position Sensor 1. Set the meter selector to the AC Voltage position. 2. Connect the red tester lead to the blue wire; then connect the black tester lead to the green wire. 3. Crank the engine over using the electric starter. 4. The meter reading must be within specification.
Starter Motor
NOTE: The starter motor is not a serviceable component. If the motor is defective, it must be replaced.
AR607D
NOTE: If the meter showed battery voltage but the starter did not operate or operated slowly, inspect battery voltage (at the battery), starter motor condition, and/or ground connections. NOTE: If the meter showed no battery voltage, inspect the main fuse, ground connections, starter motor lead, battery voltage (at the battery), starter relay, or the neutral start relay.
REMOVING 1. Disconnect the battery.
! CAUTION
Always disconnect the negative battery cable from the battery first; then disconnect the positive cable.
Starter Relay
1. Remove the operator seat; then using the multimeter set to the DC Voltage position, check the relay as follows. 2. Connect the red tester lead to the positive battery terminal; then connect the black tester lead to the starter cable connection on the starter relay. The meter must show battery voltage.
2. Remove the nut securing the positive cable to the starter; then remove the cable from the starter. 3. Remove the two cap screws securing the starter with ground wires to the crankcase; then remove the starter. Account for the wiring forms and an O-ring. INSTALLING 1. Apply a small amount of grease to the O-ring seal on the starter; then install the starter into the crankcase. Secure with two machine screws and wiring forms. 2. Secure the positive cable to the starter with the nut. 3. Connect the battery. TESTING VOLTAGE Perform this test on the starter motor positive terminal. To access the terminal, slide the boot away.
NOTE: The ignition switch must be in the ON position, and the shift lever in the NEUTRAL position.
PR296
1. Set the meter selector to the DC Voltage position. then connect the black tester www.mymowerparts.com lead to ground. 2. Connect the red tester lead to the starter terminal;
NOTE: Make sure that the ignition switch is in the ON position, transmission in neutral, and parking brake set.
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3. Depress the starter button while observing the multimeter. The multimeter should drop to 0 volts and a click should be heard from the relay.
NOTE: If a click is heard and any voltage is indicated by the multimeter, replace the starter relay. If no click is heard and the multimeter continues to indicate battery voltage, proceed to step 4.
Electronic Control Unit (ECU)

(XTX)
The ECU is located beneath the seat near the battery.
NOTE: The ECU is not a serviceable component. If the unit is defective, it must be replaced.
4. Disconnect the two-wire plug from the starter relay; then connect the red tester lead to the green wire and the black tester lead to the black wire.
The ECU is rarely the cause for electrical problems; however, if the ECU is suspected, substitute another ECU to verify the suspected one is defective. This EFI system has a built-in feature that will only allow an ECU of the same part number to be used in this model. Do not attempt to substitute an ECU from a different model as the system will not allow it to start. Error codes can be cleared by following the procedures located in the ECU Error Codes (XTX) sub-section in this section.
PR297A
5. Depress the starter button and observe the multimeter.

NOTE: If battery voltage is indicated, replace the starter relay. If no voltage is indicated, proceed to Neutral Start Relay check.
Regulator/Rectifier
The regulator/rectifier is located under the operators seat next to the battery. Try to verify all other charging system components before the regulator/rectifier is replaced. TESTING 1. Start engine and warm up to normal operating temperatures; then connect a multimeter (set at the DC Voltage position) to the battery as follows. 2. Connect the red tester lead to the positive battery post and the black tester lead to the negative battery post. 3. Slowly increase RPM. The voltage should increase with the engine RPM to a maximum of 15.5 DC volts.
NOTE: If voltage rises above 15.5 DC volts, the regulator is faulty or a battery connection is loose or corroded. Clean and tighten battery connections or replace the regulator/rectifier. If voltage does not rise, check Voltage in this section. If charging coil voltage is normal, replace the regulator/rectifier.
(Prowler/XT)
The CDI is located beneath the operators seat near the battery.
NOTE: The CDI unit is not a serviceable component. If the unit is defective, it must be replaced.
CDI Unit
The CDI is rarely the cause for electrical problems; however, if the CDI is suspected, substitute another CDI unit to verify the suspected one is defective.
NOTE: Prior to replacing the CDI unit to assure the CDI unit is defective, it is advisable to perform a CDI peak voltage test (see Ignition Coil in this section) and/or perform a continuity test of the wiring harness from the CDI connector to the CDI unit.
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Neutral Start/ Start-in-Gear/ 2WD Relays

The relays are indentical plug-in type located on the power distribution module. Relay function can be checked by switching relay positions. The relays are interchangeable.
NOTE: The module and wiring harness are not a serviceable component and must be replaced as an assembly.
2. Connect the black tester lead to the black wire; then connect the red tester lead to the white wire. The meter should show battery voltage. 3. With the ignition key in the LIGHTS position, the meter must show battery voltage.
NOTE: If battery voltage is not shown and the headlights are illuminated, inspect the three-wire connector in the left-rear canopy tube at the juncture of the canopy tube and lower frame. If battery voltage is shown on the meter, replace the bulb.
VOLTAGE (Brakelight)
NOTE: Perform this test at the socket end of the taillight/brakelight harness (pigtail). The ignition switch must be in the ON position.
Headlights
The connectors are the four 2-prong ones secured to the headlight bulbs (two on each side). VOLTAGE
NOTE: The low beams are the outside bulbs (black and white wires) and the high beams are the inside bulbs (yellow and black wires). Always connect the black tester lead to the black wires. The ignition switch must be in the ON position.
1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the red/blue wire; then connect the black tester lead to the black wire. 3. With the brake applied, the meter must show battery voltage.
NOTE: If the meter shows no voltage, inspect the 10 amp ignition (IGN) fuse, brakelight switch, wiring harness, or connectors.
1. Set the meter selector to the DC Voltage position. 2. Set the light switch to the correct position for the affected light; then connect the black tester lead to the black wire using a MaxiClip. 3. Connect the red tester lead to the yellow wire (high beam) or white wire (low beam) using a MaxiClip. The meter must show battery voltage.
NOTE: If battery voltage is not shown in any test, inspect the LIGHTS fuse on the power distribution module, headlight switch, ignition switch, switch connectors, or wiring harness.
Ignition Timing
The ignition timing cannot be adjusted; however, verifying ignition timing can aid in troubleshooting other components. To verify ignition timing, see Section 2.
ECU Error Codes

(XTX)
If a sensor fails or an out-of-tolerance signal is sensed by the ECU, an error code will be generated by the ECU. This will result in the analog needle swinging full scale. The EFI icon will flash. To read the error code(s), use the following procedure. 1. Make sure the ignition switch is in the OFF position; then remove the seats 2. Locate the diagnostic plug next to the PDM; then remove the black rubber cap. 3. Connect the Diagnostic Harness to the diagnostic plug.
Taillight-Brakelight
VOLTAGE (Taillight)
NOTE: Perform this test at the socket end of the taillight-brakelight harness (pigtail). The ignition switch must be in the ON position and either high beam or low beam selected on the light switch.
1. Set the meter selector to the DC Voltage position.
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NOTE: If the LCD still displays an error code, continue troubleshooting the appropriate component.
3. Disconnect the diagnostic harness; then install the black rubber cap. 4. Install the seats making sure they lock securely in place.
Tilt Sensor
ATV-112
(XTX)
4. Turn the ignition switch to the ON position and read the error code on the LCD. Refer to the following ECU Error Code List to identify the specific problem area. ECU Error Code List
NOTE: Each of the following numerical codes will have a two-letter prefix. A prefix of AC (Active Code) or SC (Stored Code) will be displayed. Always correct and clear Active Codes before clearing Stored Codes. No Fault Detected (active code only) CKP (Crankshaft Position) Sensor* MAP (Manifold Absolute Pressure) Sensor TPS (Throttle Position Sensor) ECT (Engine Coolant Temperature) Sensor Speed Sensor IAT (Inlet Air Temperature) Sensor Tilt Sensor* Ignition Coil #1* Fuel Injector #1* ISC (Idle Speed Control) Valve Fuel Pump Relay* Cooling Fan Relay Sensor Power Incorrect ECU* ECU Memory Power (constant battery power) 99 = Start/Run Not Possible (active code only)
*Will initiate code 99.
! WARNING
Incorrect installation of the tilt sensor could cause sudden loss of engine power which could result in loss of vehicle control resulting in injury or death.
! CAUTION
Do not drop the tilt sensor as shock can damage the internal mechanism.
00 = 12 = 13 = 14 = 15 = 16 = 21 = 23 = 24 = 32 = 40 = 41 = 60 = 95 = 96 = 97 =
SUPPLY VOLTAGE 1. Disconnect the three-wire connector from the sensor; then select DC Voltage on the multimeter and connect the red tester lead to the orange wire (C) and the black tester lead to the black wire (A).
CD706A
To clear the error code(s), use the following procedure.

NOTE: The ignition switch should be in the OFF position.
2. Turn the ignition switch to the ON position. The multimeter should read battery voltage. If battery voltage is not indicated, check the 30-amp fuse, wiring harness, or the ignition switch. 3. Remove the red tester lead and connect to the blue/brown wire (B). The multimeter should read 0 DC volts. If the specified voltage is not indicated, check wire connections at the ECU or substitute another ECU to verify the test.
1. With the diagnostic harness connected to the diagnostic plug and the drive select switch in the 4WD position, hold the reverse override switch down and turn the ignition switch to the ON position. 2. After ten seconds, release the reverse override switch and turn the ignition switch to the OFF position; then turn the ignition switch to the ON position. The display should read EC00 (no fault detected).
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4. Tilt the sensor 60 or more to the left and right observing the meter. The meter should read 4.0-8.0 DC volts after approximately one second in the tilted position. If the meter readings are not as specified, the tilt sensor is defective.
CD706B
OUTPUT VOLTAGE
NOTE: Needle adapters will be required on the multimeter leads as the following tests are made with the sensor connected.
CD709
1. Connect the three-wire plug to the sensor; then remove the right-side mounting screw securing the sensor to the rear frame.
NOTE: When replacing the sensor after testing, make sure the arrow marking is directed up.
CD705A CD707
2. Install the needle adapters to the multimeter leads; then select DC Voltage on the multimeter. 3. Connect the red tester lead to the blue/brown wire (B) and the black tester lead to the black/yellow wire (A); then turn the ignition switch ON and observe the meter. The meter should read 0.8-3.0 DC volts.
Throttle Position Sensor (TPS)

(XTX)
INSPECTING 1. Remove the seats and center console; then disconnect the three-wire TPS connector plug.
CD705B
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PR533A
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NOTE: Prior to testing the TPS, inspect the three-wire plug connector on the main harness and the three-pin plug on the TPS for contamination, broken pins, and/or corrosion.
2. Make sure the ignition switch is in the OFF position; then select the DC Voltage position on the meter. 3. Connect the black tester lead to terminal A and the red tester lead to terminal B. Turn the ignition switch to the ON position. The meter should read 4.5-5.5 DC volts.
PR535A
NOTE: If any meter reading is not as specified, replace or adjust the TPS (see INSTALLING/ADJUSTING in this sub-section).
7. Connect the positive lead to the battery; then connect the negative lead. 8. Connect the main harness TPS connector to the TPS; then using MaxiClips, connect the black tester lead to the black wire and the red tester lead to the black wire.
PR538A
4. Remove the black tester lead from terminal A and connect it to terminal C. The meter should read 5.0 DC volts.
NOTE: If the meter does not read as specified, check for poor connections at the ECU or open/broken wires in the wiring harness.
! CAUTION
Always make sure the ignition switch is in the OFF position before disconnecting the ECU.
PR546A
5. Turn the ignition switch to the OFF position; then disconnect the battery (negative cable first).
! CAUTION
9. Select the DC Voltage position on the meter and turn the ignition switch to the ON position. The meter should read approximately 0.6 DC volts with the throttle closed and approximately 5.0 DC volts with the throttle in the full-open position.
NOTE: If the meter readings are as specified, check the main harness connector at the ECU main harness wiring. If the meter readings are not as specified, replace the TPS and adjust to specifications (see INSTALLING/ADJUSTING in this sub-section).
6. Select the OHMS position on the meter; then perform the following resistance tests on the TPS.
Throttle Position
Closed
Pins
A, B, or C to Ground A to B A to C B to C
Ohms
Infinity (Open) 5.0k 650 4.5k Infinity (Open) 3.8k 1.3k
! CAUTION
Always make sure the ignition switch is in the OFF position before disconnecting the ECU.
Full-Open
A, B, or C to Ground A to C B to C
10. Clear all ECU error codes after servicing is complete (see ECU Error Codes (XTX) in this section).
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REMOVING 1. Remove the seats and center console; then disconnect the three-wire TPS connector plug.
PR540A
PR533A
2. Remove the screw securing the TPS to the throttle body and remove the TPS. INSTALLING/ADJUSTING 1. Place the TPS into position on the throttle body and secure with the screw. Do not tighten at this time. 2. Connect the main harness to the TPS. 3. Locate the diagnostic connector under the seat next to the PDM; then install the test plug from Test Plug/Error Code List onto the connector. 4. Turn the ignition switch to the ON position and note the position of the TPS indicator icon (A, B, or C); then adjust the TPS until the TPS icon appears in the center position (B).
PR541A
5. Tighten the mounting screws securely; then verify the TPS icon appears in the center position. 6. Remove the test plug; then install the center console and seats making sure the seats lock securely in place.
PR542A
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Troubleshooting
Problem: Spark absent or weak Condition
1. Ignition coil defective 2. Spark plug defective 3. Magneto defective 4. CDI unit/ECU defective 5. Pick-up coil defective
Remedy
1. Replace ignition coil 2. Replace plug 3. Replace magneto 4. Replace CDI unit/ECU 5. Replace pick-up coil
Problem: Spark plug fouled with carbon Condition

1. Mixture too rich (Prowler/XT) 2. Idling RPM too high (Prowler/XT) 3. Gasoline incorrect 4. Air cleaner element dirty 5. Spark plug incorrect (too cold) 6. Valve seals cracked - missing 7. Oil rings worn - broken
Remedy
1. Adjust carburetor 2. Adjust idle RPM 3. Change to correct gasoline 4. Clean element 5. Replace plug 6. Replace seals 7. Replace rings
Problem: Spark plug electrodes overheat or burn Condition

1. Spark plug incorrect (too hot) 2. Engine overheats 3. Spark plug loose 4. Mixture too lean (Prowler/XT)
Remedy
1. Replace plug 2. Service cooling system 3. Tighten plug 4. Adjust carburetor
Problem: Battery does not charge Condition

1. Lead wires/connections shorted - loose - open 2. Magneto coils shorted - grounded - open 3. Regulator/rectifier shorted - punctured
Remedy
1. Repair - replace - tighten lead wires 2. Replace magneto coils 3. Replace regulator/rectifier
Problem: Battery charges, but charging rate is below the specification Condition
1. Lead wires shorted - open - loose (at terminals) 2. Stator coils (magneto) grounded - open 3. Regulator/rectifier defective 4. Electrolyte low 5. Cell plates (battery) defective
Remedy
1. Repair - tighten lead wires 2. Replace stator coils 3. Replace regulator/rectifier 4. Add distilled water 5. Replace battery
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Problem: Magneto overcharges Condition
1. Internal battery short circuited 2. Regulator/rectifier resistor damaged - defective 3. Regulator/rectifier poorly grounded
Remedy
1. Replace battery 2. Replace resistor 3. Clean - tighten ground connection
Problem: Charging unstable Condition

1. Lead wire intermittently shorting 2. Magneto internally shorted 3. Regulator/rectifier defective
Remedy
1. Replace lead wire 2. Replace magneto 3. Replace regulator/rectifier
Problem: Starter button not effective Condition

1. Battery charge low 2. Switch contacts defective 3. Starter motor brushes not seating 4. Starter relay defective 5. Emergency stop - ignition switch off 6. Wiring connections loose - disconnected
Remedy
1. Recharge - replace battery 2. Replace switch 3. Replace starter 4. Replace relay 5. Turn on switches 6. Connect - tighten - repair connections
Problem: Battery sulfation (Acidic white powdery substance or spots on surfaces of cell plates) Condition
1. Charging rate too low - too high 2. Battery electrolyte excessive - insufficient 3. Specific gravity too high - too low 4. Battery run-down - damaged 5. Electrolyte contaminated
Remedy
1. Replace battery 2. Keep electrolyte to prescribed level 3. Charge battery - add distilled water 4. Replace battery 5. Replace battery
Problem: Battery discharges too rapidly Condition

1. Electrolyte contaminated 2. Specific gravity too high 3. Charging system (charging operation) not set properly 4. Cell plates overcharged - damaged 5. Battery short-circuited 6. Specific gravity too low
Remedy
1. Replace battery 2. Charge battery - add distilled water 3. Check magneto - regulator/rectifier - circuit connections - adjust for specified charging operation 4. Replace battery - correct charging system 5. Replace battery 6. Recharge battery
Problem: Battery polarity reversed Condition

1. Battery incorrectly connected
Remedy
1. Reverse connections - replace battery
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SECTION 6 - DRIVE SYSTEM
TABLE OF CONTENTS
Drive System ........................................................... 6-2 Front Drive Actuator ................................................ 6-2 Front Differential ...................................................... 6-3 Drive Axles ............................................................ 6-15 Rear Gear Case (Prowler/XT)/ Rear Differential (XTX)....................................... 6-20 Hub........................................................................ 6-21 Hydraulic Brake Caliper......................................... 6-23 Universal Joints ..................................................... 6-24 Troubleshooting ..................................................... 6-27
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6-1
Drive System
NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. NOTE: Critical torque specifications are located in Section 1.
The front drive actuator is located on the right side of the front drive input housing. With the engine stopped and the ignition switch in the ON position, a momentary whirring sound can be heard each time the front drive selector switch is shifted. If no sound is heard, see Section 5. If the actuator runs constantly or makes squealing or grinding sounds, the actuator must be replaced. REMOVING 1. Select 4WD on the front drive selector switch; then disconnect the connector on the actuator harness. 2. Using a T-30 torx wrench, remove the mounting cap screw from the driveshaft side of the actuator.
GENERAL INFORMATION All gear cases are tagged beneath a cover bolt. This tag is marked with a production date code, sequence code, and a ratio code. All gear cases are 4.0:1 ratio. The die-cast aluminum housings have been assembled with thread-rolling screws (trilobular). When assembling with these screws, start the screws carefully into the housing; then use the following torque values.
Size
M6 (Torx T-30 Recess) M8 (Torx T-40 Recess)
New Housing
9 ft-lb 28 ft-lb
Reassembled Housing
8 ft-lb 23 ft-lb
SPECIAL TOOLS
PR189A
A number of special tools must be available to the technician when performing service procedures in this section.
Description
Boot Clamp Pliers CV Boot Clamp Tool Internal Hex Socket Pinion Gear/Shaft Removal Tool Gear Case Seal Installer Tool U-Joint Separator Tool
3. Remove the mounting cap screw from above the actuator on the suspension side.
p/n
0444-250 0444-120 0444-104 0444-127 0444-224 0444-128
PR190A
Front Drive Actuator

NOTE: The actuator is not a serviceable component. If it is defective, it must be replaced. NOTE: The actuator will operate only when the ignition switch is in the ON position.
4. Loosen but do not remove the mounting cap screw at the front of the actuator; then slide the actuator to the rear enough to clear the slotted mounting tab and the selector shaft. Remove from the right side.
6-2
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AG928
AG926
INSTALLING 1. Lubricate the O-ring on the actuator; then ensure that all mounting surfaces are clean and free of debris. 2. Align the actuator with the selector shaft and slide it forward onto the shaft taking care to engage the cap screw in the slot of the front mounting tab.
NOTE: It is important to tighten this cap screw while the others are loose to ensure proper seating of the actuator.
5. Tighten the remaining cap screws; then connect the electrical plug to the main harness. 6. Turn the ignition switch to the ON position and check the operation by shifting the selector switch several times. 7. Secure the wiring harness to the frame with a nylon cable tie; then install the inner fender panel.
Front Differential
REMOVING 1. Remove the belly panel; then place the vehicle on jack stands adjusted high enough to allow working from the underside of the vehicle.
NOTE: The jack stands should be placed under the main frame to avoid contact with front suspension components.
AG925
3. While holding the actuator firmly forward, tighten the front cap screw to hold the actuator in place; then install but do not tighten the two remaining cap screws.
! WARNING
Make sure the vehicle is solidly supported on the jack stands to avoid injury.
2. Remove the drain plug and drain the gear lubricant into a drain pan; then install the plug and tighten to 45 in.-lb.
AG928
4. Loosen the front cap screw; then tighten the cap screw on the driveshaft side.
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9. Remove two cap screws securing the differential lock cable support; then disconnect the differential lock cable at the differential.
PR022A
3. Remove the front wheels. 4. Set the parking brake; then turn the ignition switch to the ON position and select 4WD on the 2WD/4WD selector switch. 5. Remove the cotter pin securing the hex nut; then remove the hex nut. 6. Release the parking brake.
NOTE: It is not necessary to remove the brake hoses from the calipers for this procedure.
PR194A
7. Remove the two brake calipers. Account for the four cap screws; then remove the hubs.
PR195A
10. Remove the lower and upper ball joint cap screws taking care not to strip the threads on the ball joint shaft; then using a rubber mallet, tap the end of the axle and free it from the knuckle assembly.
AF894D
8. Disconnect the front drive actuator power connector from the main harness; then disconnect the differential lock indicator connector from the differential lock switch located on the right-side of the differential.
PR193
11. Pull the steering knuckle away from the axle taking care not to damage the seals with the axle end.
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PR191
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15. Using a slide hammer, remove the front axles.
PR222
12. Support the axle to not allow it to drop or hang.
PR199
! CAUTION
The axle must be supported. If the axle is allowed to drop or hang, damage to the inner CV joint may occur.
16. Remove the lower differential mounting cap screw. Account for a lock nut and four washers. Note the position of the washers for assembling.
13. Remove the lower shock bolts. Account for the lock nuts; then move the shocks and upper A-arm up and secure them with a strap.
PR205A
17. Remove the upper differential mounting cap screw. Account for a lock nut and two washers.
PR200
14. Scribe match marks on the front input drive flange and the front drive yoke flange; then remove the cap screws securing the yoke and flange. Separate the flanges but do not remove the driveshaft.
CD016
18. Free the differential assembly from the frame mountings; then lower the differential through the frame. Disassembling Input Shaft
PR198A
1. Using a T-40 torx wrench, remove the cap screws securing the pinion housing.
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4. Using a seal removal tool, remove the input shaft seal. Account for a spacer.
PR261A
2. Using a rubber mallet, remove the housing. Account for a gasket. Remove the fork, collar, and spring. Note the location of all the components for assembling purposes.
AF982
5. Remove the snap ring securing the input shaft bearing; then place the pinion housing in a press and remove the bearing.
CD103 AF983
CD106
3. Remove the input shaft from the pinion housing.
AF984
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CD107
KX219
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Assembling Input Shaft 1. Place the pinion housing in a press and install the input shaft bearing. Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside.
KX222
4. Install the input shaft into the pinion housing; then secure in the bearing with a circlip.
AF993
KX210A
5. Place the pinion housing with new gasket onto the gear case housing; then secure with existing cap screws. Tighten to 23 ft-lb.
AF994
2. Install the input shaft seal making sure it is flush with the edge of the housing. 3. Lubricate the input shaft splines with High-Performance #2 Molybdenum Disulphide Grease.
NOTE: Any time drive splines are separated, clean all splines with parts-cleaning solvent and dry with compressed air; then lubricate with recommended grease.
NOTE: If a new gear case housing is being installed, tighten the cap screws to 28 ft-lb.
KX209
KX221
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PR261A
KX174
Disassembling Differential Assembly

NOTE: This procedure can be performed on a rear gear case (Prowler/XT)/rear differential (XTX).
NOTE: If the cover is difficult to remove, pry on the cover in more than one recessed location.
1. Using a T-40 torx wrench, remove the cap screws securing the pinion housing. Account for the coupler, fork, and spring.
4. Remove the splined coupler, shifter fork, pin, and spring of the differential lock assembly and set aside. Note position of parts for assembling purposes.
KX175
KX209
5. Remove the left gear case bearing flange assembly and account for a shim. Mark the shim as left-side.
2. Using a T-40 torx wrench, remove the cap screws securing the gear case cover. Account for and make note of the ID tag location for assembling purposes.
KX177
KX173
3. Using a plastic mallet, tap lightly to remove the differential cover. Account for an O-ring.
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KX178
CC876
6. Place the differential with the open side down; then lift the housing off the spider assembly. Account for shim(s) and mark as right-side.
8. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing.
KX179
CC878
9. Secure the pinion gear in a bearing puller; then remove the pinion bearing using a press. Account for a collar and a bearing.
KX181
7. Using the 48 mm Internal Hex Socket, remove the lock collar securing the pinion gear assembly.
CC879
NOTE: If gears are being replaced, use the existing shims. The numbers are scribed onto the gears: the ring gear has the number on the opposite side of the gears, and the pinion gear has the number on the end of the pinion gear shaft by the splines. If no number is present, it should be considered as being in the 0 category. NOTE: If the gear case housing is being replaced, proceed to the following Shimming Procedure/Shim Selection sub-section.
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CC875
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Shimming Procedure/ Shim Selection 1. Press bearings into bores by outer ring to hard contact with seat. 2. Install the lock collar and tighten to 125 ft-lb; then stake the lock collar edge approximately 1.5 mm (0.060 in.) into the lower oil channel. Assembling Pinion Gear 1. Install the bearing onto the pinion shaft. Install the pinion shaft collar.
CC882
CC891
3. Note the following shim selections (shims are nominally 1.5 mm/0.060 in. thick):
CC883
2. Place the pinion assembly in a bearing puller; then install the bearing using a press.
738-268C
A. Cover Side - add value A on the gear case housing to value B on the gear case cover; then add 1.5 mm (0.060 in.). This will give you the proper shim thickness. B. Gear Case Side - install a 1.3-1.4 mm (0.050-0.055 in.) shim and tighten the bolts to 25-31 ft-lb. Verify backlash to be within a range of 0.28-0.38 mm (0.011-0.015 in.) and end-play to be within a range of 0.10-0.20 mm (0.004-0.008 in.). If not within specification range, reselect shim until backlash specification range can be verified. 4. Prior to final assembling, apply molybdenum disulfide grease to all oil seal lips. 5. Prior to final assembling, prelubricate journal on pinion assembly with SAE 80W-90 hypoid gear lubricant prior to pressing assembly into gear case housing.
CC884
3. Install the pinion gear assembly into the housing. Using the 48 mm Internal Hex Socket, secure the pinion gear assembly with the existing lock collar. Tighten to 125 ft-lb.
NOTE: On a front differential, the lock collar has right-hand threads. On a rear gear case/differential, the lock collar has left-hand threads.
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CC890
CC893
4. Place a punch on the edge of the lock collar in the oil gallery area; then using a hammer, stake the lock collar to ensure that the collar will remain securely tightened.
7. Place the input shaft assembly onto the gear housing; then secure with the existing cap screws. Tighten to 23 ft-lb.
NOTE: If a new gear housing is being installed, tighten the cap screws to 28 ft-lb.
CC891
5. Install the shift fork shaft w/spring into the gear housing making sure the shaft O-ring is positioned to the inside.
CD103
CD110 CC892
6. Install the shift fork assembly making sure the fork leg is facing upward. Apply a small amount of oil to the gasket; then install the gasket.
8. Install the proper shim onto the ring gear spider assembly making sure the chamfer side of the shim is facing toward the ring gear. Install the ring gear in the housing; then install the outside shim with the chamfer side of the shim toward the ring gear.
NOTE: The spider and ring gear assembly must be replaced as a complete unit.
9. Assemble the fork and sliding collar into the cover assembly; then install the left bearing flange/bearing assembly and seat firmly into the cover.
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1. Place a 1/4 in. drill bit on the inside surface of the needle bearing (against the bottom side); then drill through the pinion shaft needle bearing housing.
CF266A
CC885
2. Using a propane torch, heat the area surrounding the needle bearing to soften the Loctite.
CF267A
10. Apply a liberal coat of grease to the O-ring; then install it on the assembled cover assembly making sure to seat the O-ring completely down around the circumference of the bearing flange.
CC886
3. Using a flat-nosed punch, drive the bearing out of the housing.
CF275A
11. Making sure the O-ring is properly positioned on the gear case cover assembly, install the cover with existing hardware. Account for the ID tag. Tighten the cap screws to 23 ft-lb.
NOTE: Grease can be applied to the O-ring for ease of assembling. NOTE: If a new gear case housing is being installed, tighten the cap screws to 28 ft-lb.
CC887
Installing Needle Bearing 1. Apply red Loctite #271 to the outside of a new bearing; then place the new bearing into the housing.
Removing Needle Bearing

NOTE: Removing the needle bearing is rarely necessary. Avoid removing the needle bearing unless the bearing is clearly damaged.
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CC888
CC891
2. Using a suitable driver, install the needle bearing into the gear case housing making sure the bearing is seated.
NOTE: Do not push the bearing too far into the housing.
5. Install the pinion housing. Removing/Installing Axle Seal

1. Remove the seal using a seal removal tool.
CC889
3. Install the pinion shaft and secure with the existing 48 mm lock collar. Tighten to 125 ft-lb.
CC899
2. Using a press, remove the bearing.
CC890
4. Place a punch on the edge of the lock collar in the oil gallery area; then using a hammer, stake the lock collar to ensure that the collar will remain securely tightened.
CC900
3. Using a press, install the new bearing into the housing.
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CC901
PR205A
NOTE: Prior to installing the seal, apply grease to the seal outside diameter.
3. Tighten the nuts to 38 ft-lb. 4. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid lubricant into the differential and install the fill plug. Tighten to 16 ft-lb. 5. Align the scribed match marks on the front input drive flange and the front drive yoke flange; then secure with the cap screws tightened to 20 ft-lb.
4. Using Gear Case Seal Installer Tool, evenly press the seal into the cover bore until properly seated.
CF278
! CAUTION
Make sure the tool is free of nicks or sharp edges or damage to the seal may occur.
PR198A
5. Repeat steps 1-4 for the opposite side. INSTALLING DIFFERENTIAL 1. Place the differential assembly into position in the frame; then install the top mounting through-bolt, two washers, and lock nut. Do not tighten at this time. 2. Install the lower front mounting through-bolt, washers, spacers, and lock nut. Note the correct location for the spacer washers.
6. Install the front axles (see Drive Axles in this section). 7. Install the knuckle assemblies onto the axles and ball joints; then secure with four cap screws taking care not to damage the threads when installing. Tighten to 35 ft-lb.
PR201
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PR193
AF894D
8. Secure the lower shock eyelets with cap screws and lock nuts. Tighten to 35 ft-lb.
13. Install the wheels and tighten to 45 ft-lb. 14. Remove the vehicle from the support stand. 15. Install the belly panel.
Drive Axles
REMOVING REAR DRIVE AXLE 1. Secure the vehicle on a support stand to elevate the wheels.
AF897D
9. Install the brake calipers. Secure with the patch-lock cap screws tightened to 20 ft-lb. 10. Install the differential lock cable support making sure to connect the cable end in the actuator plunger; then secure with two torx-head cap screws and tighten securely.
! WARNING
Make sure the vehicle is solidly supported on the support stand to avoid injury.
2. Set the parking brake; then remove the wheels. 3. Remove the cotter pins securing the hex nuts; then remove the hex nuts.
PR194A
11. Connect the front drive actuator connector to the main harness and the differential lock indicator connector to the differential; then secure the wires to the frame with nylon ties. 12. Apply a light coat of multi-purpose grease to the hub splines; then install the hubs and nuts. Tighten to 200 ft-lb; then install new cotter pins.
KX041
4. Slide the hub out of the knuckle and set aside.
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PR221
AF935
5. Remove the cap screw and lock nut securing the knuckle to the upper A-arm. Discard the lock nut.
REMOVING FRONT DRIVE AXLE

NOTE: For removing a front drive axle, see Front Differential in this section.
CLEANING AND INSPECTING AXLES

NOTE: Always clean and inspect the drive axle components to determine if any service or replacement is necessary.
1. Using a clean towel, wipe away any oil or grease from the axle components.
PR220A
NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut.
6. While holding the drive axle stationary, pull the top of the knuckle out and down until it is free of the drive axle.
CD019
2. Inspect boots for any tears, cracks, or deterioration.

NOTE: If a boot is damaged in any way, it must be replaced with a boot kit.
DISASSEMBLING AXLES
PR218
7. Place a drain pan under the vehicle to contain any oil leakage; then using a slide hammer, remove the drive axle.
1. Using a side-cutters (or suitable substitute), remove the large clamp from the boot.
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CD020
CD022
2. Wipe away excess grease to access the retaining ring. Using an awl or circlip pliers, remove the circlip.
5. Inspect the splines of the shaft, the bearing ring, and the housing for damage.
NOTE: If any damage is apparent to the splines, the bearing ring, and/or the housing, the drive axle must be replaced as an assembly.
6. Using a side-cutters (or suitable substitute), remove the small clamp from the shaft.
CD021
3. Using a snap ring pliers, remove the circlip securing the bearing ring to the shaft. Note the direction of the bearing for assembling purposes.
CD752
6
NOTE: At this point if the outside boot is damaged, continue with step 7.
7. Using a side-cutters (or suitable substitute), remove both outside boot clamps from the shaft. Note the position of the different-sized clamps for assembling purposes.
CD023
4. Note the difference inside each bearing ring end for assembling purposes; then remove the bearing ring.
NOTE: The recess of the bearing must face toward the housing.
CD751
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8. Apply 40 grams (1/3 of contents) of grease from the grease pack included in Front Axle Boot Repair Kit into the knuckles and the new outside boot.
CD024
ASSEMBLING AXLES
ATV-1052
1. Install the inner boot with the small clamp making sure the ends of the clamp are positioned correctly.
NOTE: The boot is positioned correctly when the small end of the boot seats down into the recessed groove.
NOTE: The grease pack contains 120 grams of grease. The inside joint (double-offset) requires approximately 70-90 grams of grease and the outside (bell-type) requires approximately 35-55 grams. When replacing boots, use 2/3 of the pack for inside boots and 1/3 of the pack for outside boots.
! CAUTION
Do no over-fill the joint as boot damage may occur resulting in joint failure.
9. Slide the new outside boot onto the shaft with the new clamps positioned as shown. Note the different-sized clamps from removal.
NOTE: The boot is positioned correctly when the small end of the boot seats down into the recessed groove.
CD754
2. Using the boot clamp tool, secure the small clamp of the inner boot.
CD754
10. Using CV Boot Clamp Tool, secure both outside boot clamps.
ATV-1048
3. Apply 80 grams (2/3 of contents) of grease from the pack into the bearing housing. 4. Install the bearing onto the shaft making sure the recess of the bearing is facing the housing.
! CAUTION
It is important that the clamps are positioned correctly or they may loosen when in motion.
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CD022
CD024
! CAUTION
The bearing ring must go onto the shaft with the side without splines facing toward the small clamp of the inner boot or severe damage will result.
8. Inspect the axle components for correct positioning of the four clamps. Also, inspect the boots for being correctly positioned on the shaft. INSTALLING REAR DRIVE AXLE 1. Slide the drive axle into place in the gear case.
NOTE: To assure proper seating of the axle, give it a light pull; the axle should remain clipped in place.
5. Secure the bearing ring with the snap ring making sure the sharp side of the snap ring faces away from the boot.
2. Swing the knuckle up and onto the drive axle; then place the knuckle into place in the upper A-arm. Secure the knuckle to the A-arm with a cap screw and a new lock nut. Tighten to 33 ft-lb. 3. Place the hub into position on the axle followed by a hex nut. Tighten the hex nut finger-tight at this time. 4. Tighten the hub hex nut (from step 3) to 200 ft-lb; then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut.
CD023
6. Making sure the marks made during disassembling align, slide the housing over the bearing ring; then completely seat the bearing ring into the housing and install the snap ring.
NOTE: Pull the bearing ring out of the housing until it contacts the snap ring; then slide the ring in half way. This will purge air from the housing and ensure the bearing is packed properly.
CD027
5. Install the wheel. Tighten to 45 ft-lb. 6. Remove the vehicle from the support stand and release the parking brake. INSTALLING FRONT DRIVE AXLE 1. Position the drive axle in the gear case and steering knuckle; then insert the ball joints into the steering knuckles. Secure with cap screws tightened to 33 ft-lb.
CD021
7. Slide the boot over the housing; then using the boot clamp pliers, secure www.mymowerparts.com the boot with the clamp.
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2. Secure the lower shock eyelet to the A-arm with a cap screw and a new lock nut. Tighten to 33 ft-lb. 3. Slide the hub w/brake disc into position in the steering knuckle followed by a hex nut. Tighten finger-tight at this time. 4. Install the brake caliper on the steering knuckle. Tighten to 20 ft-lb. 5. Set the parking brake; then turn the ignition switch to the ON position, select 4WD on the 2WD/4WD drive selector switch, and engage the differential lock. Turn the ignition switch to the OFF position. 6. Tighten the hub hex nut (from step 3) to 200 ft-lb; then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut.
Rear Gear Case Rear Differential

REMOVING
NOTE: Release the cargo box latch and allow the cargo box to tilt back; then remove the cargo box lift support by removing the cap screw and nut securing the lower lift support to the frame. The cargo box will tilt fully rearward.
(Prowler/XT)/
(XTX)
1. Drain the lubricant from the rear differential; then remove both rear drive axles (see Drive Axles in this section). 2. Remove the driveline brake caliper; then cut the rear-most propeller shaft boot clamp and slide the boot forward. 3. Remove the boot clamps on the rear driveline boot. 4. Remove the two cap screws and lock nuts securing the rear gear case/differential to the frame; then remove the gear case/differential through the upper left-side of the frame and lift out the top.
CD027
7. Install the wheel and tighten to 45 ft-lb. 8. Remove the vehicle from the support stand. 9. Check the front differential lubricant level and add lubricant as necessary.
PR207
AT THIS POINT
For servicing the input shaft, pinion gear, needle bearing, and axle seal, see Front Differential in this section.
PR065A
INSTALLING 1. Slide the gear case/differential into position down through the upper-left side of the frame; then align the driveline splines to the differential input coupler and engage the driveline and differential. 2. Pack the driveline boot with the appropriate grease; then secure with the boot clamps using Boot Clamp Pliers.
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3. Secure the differential to the frame with two through-bolts and secure with lock nuts and flat washers. 4. Install the rear drive axles (see Drive Axles in this section). 5. Install the driveline brake caliper and tighten the mounting cap screws to 20 ft-lb; then adjust the parking brake (see Parking Brake in Section 2). 6. Fill the differential (XTX) or gear case (Prowler/XT) with the appropriate lubricant.
PR243A
Hub
REMOVING 1. Secure the vehicle on a support stand to elevate the wheel; then remove the wheel.
NOTE: Removing or tightening of the hub nuts requires that the axles be locked. To lock the rear axle, set the parking brake. To lock the front axle, turn the ignition switch to ON, select 4WD on the 2WD/4WD drive selector switch, and engage the differential lock; then set the parking brake and turn the ignition switch to OFF.
5. Remove the hub assembly. 6. Remove the four cap screws securing the brake disc (front hub only).
! WARNING
PR254A
CLEANING AND INSPECTING

2. Remove the cotter pin from the axle.

NOTE: During assembly, new cotter pins should be installed.
1. Clean all hub components. 2. Inspect all threads for stripping or damage. 3. Inspect the brake disc (if applicable) for cracks or warping. 4. Inspect the hub for pits, cracks, loose studs, or spline wear. REPLACING WHEEL STUDS 1. Secure the hub in a suitable holding fixture and remove the brake disc (if applicable).
PR257
3. Remove the flange nut securing the hub. 4. Remove the brake caliper (front only).
2. Drive the damaged stud out of the hub; then place the new stud into the hub and thread on an appropriate flange nut.
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PR250
PR221
3. Using a socket and ratchet handle, tighten the nut until the stud is fully drawn into the hub.
4. Secure the hub assembly with the nut. Tighten to 200 ft-lb; then secure with a new cotter pin.
NOTE: If the cotter pin can not be inserted due to misalignment of the hole in the axle and the slots in the nut, tighten the nut until properly aligned.
PR252A
INSTALLING 1. Secure the brake disc (if applicable) to the hub with the four cap screws coated with red Loctite #271. Tighten to 15 ft-lb. 2. Apply grease to the splines in the hub.
PR258
5. For front hubs, secure the brake calipers to the knuckle with two cap screws tightened to 20 ft-lb.
PR377B PR254B
6. Install the wheel and tighten to 45 ft-lb. 7. Remove the vehicle from the support stand.
3. Install the hub assembly onto the axle; then set the parking brake.
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Hydraulic Brake Caliper

NOTE: The brake caliper is a non-serviceable component; it must be replaced as an assembly.
REMOVING/DISASSEMBLING 1. Secure the vehicle on a support stand to elevate the wheel; then remove the wheel.
PR238
! WARNING
5. Remove the caliper holder from the caliper and account for the brake caliper O-ring. Do not remove the piston from the caliper.
2. Drain the brake fluid from the caliper, hose, and master cylinder.
PR239B
6. Plug the fluid port with a suitable plug to prevent contamination during cleaning.
PR235
! CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the vehicle and do not reuse brake fluid.
3. Remove the brake hose from the caliper; then remove the caliper and plug the brake fluid port. 4. Compress the caliper holder against the caliper and remove the outer brake pad; then remove the inner brake pad.
PR240A
CLEANING AND INSPECTING 1. Clean all caliper components (except the brake pads) with parts-cleaning solvent. 2. Inspect the brake pads for damage and excessive wear.
NOTE: For measuring brake pads, see Section 2.
ASSEMBLING/INSTALLING
PR237
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1. Install the caliper onto the caliper holder making sure the caliper is correctly oriented on the holder.
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Universal Joints
REMOVING
NOTE: The four universal joints can be accessed by removing the belly panel. To remove the belly panel, see Belly Panel in Section 8.
PR239C
2. Compress the caliper holder toward the caliper and install the inner brake pad; then install the outer pad.
1. Support the vehicle on suitable jack stands elevated high enough to allow working from the underside of the vehicle. 2. To aid in installing, match mark drive-line components prior to removing.
PR238
PR152A
3. Remove the cap screws securing the propeller shaft flange to the yoke flange on the appropriate drive-line; then remove the propeller shaft.
PR239
3. Place the brake caliper assembly into position and secure with the patch-lock cap screws. Tighten the caliper to 20 ft-lb. 4. Place a new crush washer on each side of the brake hose fitting and install it on the caliper. Tighten to 20 ft-lb. 5. Fill the reservoir; then bleed the brake system (see Section 2). 6. Install the wheel. Tighten to 45 ft-lb. 7. Remove the vehicle from the support stand and verify brake operation.
PR120A
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PR121
PR375
4. Install U-Joint Separator Tool on the universal joint fixed yoke; then remove the bearing cup retainers.
INSPECTING 1. Inspect the yoke bores for damage or signs of bearing cup looseness. If bearing cups are loose, the yoke must be replaced.
PR354A
5. Using a suitable socket and ratchet handle, rotate the jackscrew to push the bearing cup out of the yoke; then remove the tool and the bearing cup.
PR367B
2. Check that yoke legs are parallel.
PR359
6. Install the separator tool on the opposite side of the yoke to push the second bearing cup from the yoke; then remove the tool and separate the universal joint. 7. Secure the separator tool in a vise and repeat steps 4-6 to remove the bearing cups from the movable yoke.
PR367A
3. Check splines and flanges for excessive wear, thread damage, or warpage.
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PR367C
PR374
INSTALLING 1. Remove the bearing cups from the universal joint; then insert the joint into the yoke and install one bearing cup on the joint.
3. Install the retainer in the bearing cup; then remove the yoke from the separator tool.
NOTE: Repeat steps 2-3 for the opposite-side bearing cup.
! CAUTION
Care must be taken when installing bearing cups that the needle bearings stay in place or severe damage to the universal joint will occur.
4. Remove the separator tool from the vise and install the universal joint, bearing cups, and movable yoke into the fixed yoke using the same procedure as steps 2-3 except the vise cannot be used.
PR355
PR368
2. Secure U-Joint Separator Tool in a vise; then place the yoke, joint, and bearing cup into position and press the cup into the yoke.
5. Check that the universal joint can be flexed freely without binding; then apply multi-purpose grease to the splines and install the propeller shaft noting the match marks made prior to removing.
PR152A
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Troubleshooting
Problem: Power not transmitted from engine to wheels Condition
1. Rear axle shaft serration worn - broken
Remedy
1. Replace shaft
Problem: Power not transmitted from engine to either front wheel Condition
1. Secondary drive - driven gear teeth broken 2. Propeller shaft serration worn - broken 3. Coupling damaged 4. Coupling joint serration worn - damaged 5. Front drive - driven bevel gears broken - damaged 6. Front differential gears/pinions broken - damaged 7. Front drive actuator not operating
Remedy
1. Replace gear(s) 2. Replace shaft 3. Replace coupling 4. Replace joint 5. Replace gear(s) 6. Replace gears - pinions 7. Replace fuse - 2WD/4WD switch - front drive actuator
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6-27
SECTION 7 - SUSPENSION
TABLE OF CONTENTS
Suspension ............................................................. 7-2 Shock Absorbers ..................................................... 7-2 Front A-Arms ........................................................... 7-3 Rear A-Arms ........................................................... 7-5 Wheels and Tires .................................................... 7-7 Troubleshooting ....................................................... 7-8
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7-1
Suspension
NOTE: Critical torque specifications are located in Section 1.
Shock Absorbers
REMOVING 1. Secure the vehicle on a support stand to elevate the wheels and to release load on the suspension.
AF626D
4. Using a suitable spring compression stand, compress the shock absorber spring, remove the retainer, and remove the spring.
! WARNING
! WARNING
Shock absorber springs are under high compression loads. Do not attempt to remove springs without an adequate spring compressor. Sever injury could result.
2. Remove the two cap screws and nuts securing each front shock absorber to the frame and upper A-arm. Account for bushings and sleeves from each.
AF730D

AF605D
! CAUTION
Additional support stands are necessary to support the rear axle when the shock absorbers are removed or damage may occur.
3. Remove the two cap screws and nut securing each rear shock absorber to the frame and lower A-arm. Account for bushings and sleeves from each.
1. Clean all shock absorber parts-cleaning solvent.
components
in
2. Inspect each shock rod for nicks, pits, rust, bends, and oily residue. 3. Inspect all springs, spring retainers, shock rods, sleeves, bushings, shock bodies, and eyelets for cracks, leaks, and bends. INSTALLING 1. Place the shock absorber spring over the shock absorber, compress the spring, and install the retainer.
7-2
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2. Place bushings and sleeves (where appropriate) into shock eyelet; then install shock with two cap screws and nuts. Tighten all nuts to 33 ft-lb. 5. Remove the hub assembly. 6. Remove the cotter pin and slotted nut securing the tie rod end to the knuckle; then remove the tie rod end from the knuckle. 7. Remove the cap screws securing the ball joints to the knuckle.
! CAUTION
Do not tighten the nuts beyond the 33 ft-lb specification or the shock eyelet or mount WILL be damaged.
NOTE: The rear shock absorber-to-lower A-arm torque factor is 20 ft-lb.
! CAUTION
Support the knuckle when removing the cap screws or damage to the threads will occur.
3. Remove the vehicle from the support stand.
Front A-Arms
REMOVING 1. Secure the vehicle on a support stand to elevate the front wheels; then remove the wheels.
! WARNING
PR193
2. Remove the cotter pin from the nut. Discard the cotter pin.
8. Tap the ball joints out of the knuckle; then remove the knuckle. 9. Remove the lower shock absorber eyelet from the upper A-arm.
7
PR257
3. Remove the nut securing the hub. 4. Remove the brake caliper. Account for two cap screws.
AF626D
10. Remove the cap screws securing the A-arms to the frame.
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CD007
AF610D
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11. Remove the snap ring from the ball joint; then remove the ball joint from the A-arm.
AF610D
AF616D
3. Route the brake hose through the upper A-arm shock absorber mount.

1. Clean all A-arm components in parts-cleaning solvent. 2. Clean the ball joint mounting hole of all residual Loctite, grease, oil, or dirt for installing purposes. 3. Inspect the A-arm for bends, cracks, and worn bushings. 4. Inspect the ball joint mounting holes for cracks or damage. 5. Inspect the frame mounts for signs of damage, wear, or weldment damage. INSTALLING 1. Apply green Loctite #609 to the entire outside diameter of the ball joint; then install the ball joint into the A-arm and secure with the circlip.
AF627D
4. Secure the lower eyelet of the shock absorber to the upper A-arm. Tighten nut to 33 ft-lb. 5. Secure the A-arm assemblies to the frame mounts (from step 2). Tighten the cap screws to 33 ft-lb.
! CAUTION
Do not tighten the nut beyond the 33 ft-lb specification or the shock eyelet or mount WILL be damaged.
6. Install the knuckle assembly onto the ball joints and secure with cap screws. Tighten to 35 ft-lb.
AF616D
2. Install the A-arm assemblies into the frame mounts and secure with the cap screws. Only finger-tighten at this time.
AF628D
7. Install the tie rod end and secure with the nut (coated with red Loctite #271). Tighten to 30 ft-lb; then install a new cotter pin and spread the pin to secure the nut.
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NOTE: During assembly, new cotter pins should be installed.
PR260
13. Install the wheel and tighten to 45 ft-lb.

AF618D
14. Remove the vehicle from the support stand.
8. Apply grease to the hub and drive axle splines; then install the hub assembly onto the drive axle.
Rear A-Arms
REMOVING 1. Secure the vehicle on a support stand to elevate the wheels.
! WARNING
PR290A
2. Set the parking brake. 3. Remove the wheel. 4. Remove the cotter pin securing the hex nut; then remove the hex nut. 5. Remove the cap screws and lock nut securing the shock absorber to the frame and lower A-arm; then remove the shock absorber. 6. Remove the cap screws securing the boot guard to the lower A-arm.
9. Secure the hub assembly with the nut. Tighten only until snug. 10. Secure the brake caliper to the knuckle with the two Patch-lock cap screws. Tighten to 20 ft-lb.
PR377B
11. Secure the hub nut (from step 9) to the shaft/axle. Tighten to 200 ft-lb. 12. Install a new cotter pin and spread the pin to secure the nut.
AF934
7. Slide the axle out of the knuckle and set aside.
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8. Remove the cap screws and lock nuts securing the knuckle to the A-arms. Discard the lock nuts.
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PR220A
PR221
NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut.
5. Secure the hub assembly with the nut. Tighten to 200 ft-lb. 6. Install a new cotter pin and spread the pin to secure the nut.
9. Remove the cap screws and lock nuts securing the A-arms to the frame; then remove the A-arms. CLEANING AND INSPECTING
1. Clean all A-arm components in parts-cleaning solvent. 2. Inspect the A-arm for bends, cracks, and worn bushings. 3. Inspect the frame mounts for signs of damage, wear, or weldment damage. INSTALLING 1. Install the A-arm assemblies into the frame mounts and secure with the cap screws and new lock nuts. Finger-tighten only at this time. 2. Slide the knuckle onto the drive axle and into position on the A-arms; then secure the knuckle to the A-arms with cap screws and new lock nuts. Tighten to 33 ft-lb. 3. Tighten the hardware securing the A-arms to the frame mounts (from step 1) to 33 ft-lb. 4. Apply grease on the drive axle splines; then install the hub assembly onto the drive axle.
PR196
7. Secure the shock absorber to the frame with a cap screw and new lock nut. Tighten to 33 ft-lb. 8. Secure the shock absorber to the lower A-arm with a cap screw and new lock nut. Tighten to 20 ft-lb. 9. Secure the boot guard to the lower A-arm with the two cap screws. Tighten securely. 10. Install the wheel and tighten to 45 ft-lb. 11. Remove the vehicle from the support stand.
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Wheels and Tires
1. Clean the wheels and hubs with parts-cleaning solvent. 2. Clean the tires with soap and water. 3. Inspect each wheel for cracks, dents, or bends. 4. Inspect each tire for cuts, wear, missing lugs, and leaks. INSTALLING
KEY: 1. Machine Screw 2. Brake Disc 3. Wheel Hub 4. Hub Stud 5. Cotter Pin 6. 7. 8. 9. 10. Castle Nut Wheel Mounting Nut Tire - Front Valve Stem 11. 12. 13. 14. Valve Stem Cap Wheel Tire - Rear Wheel Cap (Prowler) 0741-724
1. Install each wheel on its hub and secure with the existing hardware. 2. Tighten to 45 ft-lb. CHECKING/INFLATING 1. Using an air pressure gauge, measure the air pressure in each tire. Adjust the air pressure as necessary to meet the recommended inflation pressure.
TIRE SIZE
! WARNING
Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable vehicle operation.
The UTV models are equipped with low-pressure tubeless tires of the size and type listed in Section 1. Do not under any circumstances substitute tires of a different type or size.
! WARNING
Do not mix tire tread patterns. Use the same pattern type on front and rear. Failure to heed warning could cause poor handling qualities of the vehicle and could cause excessive drive train damage not covered by warranty.
CD005
7
2. Inspect the tires for damage, wear, or punctures.
! WARNING
Do not operate the vehicle if tire damage exists.
TIRE INFLATION PRESSURE Front and rear tire inflation pressure should be 0.70 kg/cm (10 psi). REMOVING 1. Secure the vehicle on a support stand to elevate the wheels.
NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally. NOTE: Be sure all tires are the specified size and have identical tread pattern.
! WARNING
3. Check the front wheel alignment (toe-in and toe-out) and adjust as necessary (see Section 8). 4. Test drive the vehicle on a dry, level surface and note any pulling to the left or right during acceleration, deceleration, and braking.
2. Remove the nuts securing the wheels; then remove the wheels.
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NOTE: Pulling could be caused by uneven tire pressure side-to-side, steering alignment out of adjustment, unequal loading, or improper tire size.
Troubleshooting
Problem: Suspension too soft Condition
1. Spring(s) weak 2. Shock absorber damaged
Remedy
1. Replace spring(s) 2. Replace shock absorber
Problem: Suspension too stiff Condition

1. A-arm-related bushings worn
Remedy
1. Replace bushing
Problem: Suspension noisy Condition

1. Cap screws (suspension system) loose 2. A-arm-related bushings worn
Remedy
1. Tighten cap screws 2. Replace bushings
Back7-8
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SECTION 8 - STEERING/FRAME
TABLE OF CONTENTS
Steering/Frame........................................................ 8-2 Steering Assembly .................................................. 8-2 Steering Wheel........................................................ 8-4 Steering Wheel Shaft .............................................. 8-5 Steering Shaft Assembly ......................................... 8-7 Steering Knuckles ................................................... 8-9 Checking/Adjusting Front Wheel Alignment .......... 8-11 Front Bumper Assembly (XT/XTX) ........................ 8-12 Hood...................................................................... 8-12 Fenders ................................................................. 8-13 Floor ...................................................................... 8-13 Belly Panel ............................................................ 8-14 Exhaust System .................................................... 8-14 Cargo Box ............................................................. 8-14 Taillight Assembly.................................................. 8-15 Seats ..................................................................... 8-16 Troubleshooting ..................................................... 8-17
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8-1
Steering/Frame
NOTE: Critical torque specifications are located in Section 1.
4. Remove the cap screw securing the lower steering shaft joint to the pinion shaft; then slide the joint free of the pinion.
Steering Assembly
REMOVING 1. Secure the vehicle on a support stand to elevate the front wheels; then remove the front wheels.
PR302
! WARNING
5. Remove two cap screws securing the rack and pinion assembly to the frame. Account for two nuts and two washers.
2. Remove the cotter pins and nuts securing the tie rod ends to the knuckles; then remove the tie rod ends from the knuckles.
PR303A
6. Remove the rack and pinion assembly from the right-side.
PR301
3. Make matching alignment marks on the pinion shaft and lower steering shaft joint.
PR305
INSPECTING
PR333A
NOTE: Any time steering components are disassembled, all connecting components should be marked for proper alignment during assembling.
1. Inspect the tie rod ends for damaged threads, torn boots, or excessive wear. 2. Inspect the tie rods for bends or deformation.
8-2
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3. Inspect the rack and pinion-to-tie rod boots for tears or deterioration.
PR526A
PR307
4. Check boot clamps for security. 5. Check that the rack and pinion assembly operates smoothly with no binding from full-left to full-right position. 6. Inspect for grease seepage from the rack and pinion assembly.
NOTE: The steering assembly (rack and pinion) is not repairable and must be replaced as an assembly; however, the tie rods and boots are replacable.
4. Coat the thread with red Loctite #271; then install the tire rod into the rack and using an appropriate crow-foot, tighten to 74 ft-lb.
REPLACING TIE RODS/BOOTS 1. Secure the rack and pinion assembly in a vise or other suitable holding fixture; then remove the tie rod end, jam nut, and rack boot. 2. Slide the steering stopper (A) away from the inner tie rod end (B); then hold the rack (C) with a pipe wrench and remove the inner tie rod end from the rack.
PR527
8
PR519
NOTE: Always attach the crow-foot to the torque wrench with the open end 90 to the torque wrench handle to ensure accurate torque application.
PR523A
3. Clean all Loctite from the threads in the rack and if the tie rod is to be reused, clean the tie rod threads also.
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8-3 Next
PR528A
PR309
5. Install the rack boot and secure with the clamps; then loosely install the jam nut and outer tie rod end.
3. Apply green Loctite #270 to the cap screw; then secure the lower steering shaft joint to the pinion shaft making sure the shaft does not protrude into the joint beyond the clamping surface.
PR520
INSTALLING 1. Place the rack and pinion assembly into position from the right-side of the vehicle; then secure with the two cap screws, washers, and nuts. Tighten to 50 ft-lb.
PR309A
! WARNING
Allowing the lower steering shaft joint to extend too far onto the pinion shaft could cause binding or lock-up of the steering joint resulting in loss of steering control.
4. Tighten the cap screw to 36 ft-lb; then check that the steering wheel turns freely. 5. Install the tie rod ends into the steering knuckles; then secure with the castle nuts (coated with red Loctite #271) tightened to 30 ft-lb. 6. Install the cotter pins and spread to secure. 7. Install the wheels and tighten to 45 ft-lb. Check the steering system for full and free travel; then check and adjust the front wheel alignment (see Checking/Adjusting Front Wheel Alignment in this section).
PR305
2. With the rack and the steering wheel centered, slide the lower steering shaft joint onto the pinion shaft aligning the match marks.
Steering Wheel
REMOVING
Back8-4
1. Remove the steering wheel cover; then match mark the steering shaft and steering wheel.
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Steering Wheel Shaft

REMOVING 1. Remove the steering wheel (see Steering Wheel in this section). 2. Remove the six screws securing the dash panel to the frame and one cap screw and nut from the center support.
PR324A
2. Remove the nut securing the steering wheel and remove the steering wheel. Account for the flat thrust-washer and two wave washers.
PR181A
PR226
INSPECTING 1. Inspect the steering wheel for cracks, missing padding, or broken spokes. 2. Inspect the splines for wear. 3. Check that the steering wheel is not bent. INSTALLING 1. Place the flat thrust-washer and then the two wave washers onto the steering shaft. 2. Install the steering wheel aligning the two match marks; then apply a drop of red Loctite #271 to the threads of the nut and secure the steering wheel. Tighten to 25 ft-lb.
NOTE: If a new steering wheel is being installed, mark the wheel as close as possible to the old wheel mark; then check for proper positioning with the front wheels straight forward.
PR475A
3. Slide the dash panel rearward to access the upper steering shaft joint; then remove the cap screw securing the upper shaft joint to the steering wheel shaft.
3. Install the steering wheel cover and secure with the existing hardware. Do not over-tighten.
PR313A
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4. Match mark the upper steering shaft joint and the steering wheel shaft; then remove the steering wheel shaft. Account for the lower thrust-washer.
INSPECTING 1. Inspect the steering wheel shaft for excessive wear. 2. Check for worn splines, cracks, or damaged threads. 3. Roll the steering wheel shaft on a flat surface to check for bends. 4. Inspect the nylon bushings in the steering shaft housing for cracking or excessive wear. INSTALLING 1. Slide the steering wheel shaft into the steering housing; then with the lower thrust-washer in position, align the match marks and slide the upper steering shaft joint onto the steering wheel shaft.
PR324A
4. Hold rearward pressure on the steering wheel and tighten the cap screw (from step 2) to 36 ft-lb. 5. Remove the steering wheel nut. Apply one drop of red Loctite #271 to the threads and install the nut. Tighten to 25 ft-lb. 6. Check for freedom of movement of the steering system; then install the steering wheel cover. 7. Move the dash panel into position and secure to the frame and center support with the existing hardware.
PR313A
PR475A
2. Apply green Loctite #270 to the cap screw; then install the cap screw in the upper steering shaft joint. Install the nut and finger-tighten. 3. Align the match marks on the steering wheel shaft and the steering wheel and slide the steering wheel onto the splines; then install the nut and finger-tighten.
PR181A
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Steering Shaft Assembly

REMOVING 1. Remove the steering wheel (see Steering Wheel in this section). 2. Remove the six screws securing the dash panel to the frame and one cap screw and nut from the center support.
PR313A
5. Remove the cap screw securing the lower steering shaft joint to the pinion shaft; then slide the steering shaft assembly free and remove through the opening in the splash panel.
PR181A
PR304
PR475A
3. Slide the dash panel rearward to access the steering shaft joints; then match mark all connecting components for reassembling.
NOTE: Any time steering components are disassembled, all connecting components should be marked for proper alignment during reassembling.
8
PR314B
INSPECTING
NOTE: The steering shaft assembly is not repairable or rebuildable. If any damage or excessive wear is detected, the assembly must be replaced.
4. Remove the cap screw securing the upper steering shaft joint to the steering wheel shaft; then slide the steering wheel shaft free of the upper steering shaft joint. Account for one flat thrust washer.
1. Inspect the joints for excessive wear or looseness. 2. Inspect welds and slip-joints for cracks. 3. Check for excessive wobble in the slip-joint. INSTALLING
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1. Place the steering shaft assembly into position through the opening in the splash panel.
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PR314A
PR313A
2. Align the match marks on the pinion shaft and the lower steering shaft joint; then slide the steering shaft joint onto the pinion shaft.
5. Apply green Loctite #270 to the cap screw; then install the cap screw in the upper steering shaft joint and finger-tighten.
PR333A
PR310
3. Apply green Loctite #270 to the cap screw; then secure the lower steering shaft joint to the pinion shaft making sure the pinion shaft does not protrude into the joint beyond the clamping surface. Tighten to 25 ft-lb.
6. Install the flat thrust-washer and two wave washers on the steering wheel shaft; then align the match marks on the steering wheel shaft and the steering wheel. Loosely install the nut.
PR226 PR309A
! WARNING
Allowing the lower steering shaft joint to extend too far onto the pinion shaft could cause binding or lock-up of the steering joint resulting in loss of steering control.
7. Hold rearward pressure on the steering wheel and tighten the cap screw (from step 5) to 25 ft-lb. 8. Remove the steering wheel nut and apply one drop of red Loctite #271 to the threads. Install the nut and tighten to 25 ft-lb. 9. Check that the steering wheel turns freely from full-right to full-left; then install the steering wheel cover.
4. Align the match mark on the upper steering shaft joint with the mark on the steering wheel shaft; then install the flat thrust washer and the steering shaft joint onto the steering wheel shaft.
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NOTE: If the steering is stiff or the steering wheel is difficult to turn, loosen and then tighten the cap screw on the upper steering shaft joint. Check the steering wheel nut for specified torque value.
7. Remove the two cap screws securing the ball joints in the knuckle.
10. Place the dash panel into position and secure to the frame and center support with the six screws and the cap screw and nut.
PR193
8. Tap the ball joint end out of the knuckle; then remove the knuckle. 9. Remove the snap ring securing the bearing in the knuckle; then press the bearing out of the knuckle.
PR181A
PR289 PR475A
Steering Knuckles
REMOVING AND DISASSEMBLING 1. Secure the vehicle on a support stand to elevate the wheel; then remove the wheel.
1. Clean all knuckle components. 2. Inspect the bearing for pits, scoring, rusting, or premature wear. 3. Inspect the knuckle for cracks, breaks, or galling of the bearing surface. ASSEMBLING AND INSTALLING 1. Using a suitable press and driver, press the bearing into the knuckle until firmly seated; then install the snap ring.
! WARNING
2. Remove the cotter pin from the axle. 3. Remove the nut securing the hub. 4. Remove the brake caliper. 5. Remove the hub assembly. 6. Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle.
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8-9 Next

NOTE: During assembling, new cotter pins should be installed.
4. Apply a small amount of grease to the hub splines.
PR292A
PR290A
5. Install the hub assembly onto the splines of the shaft.
PR289
2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Tighten to 33 ft-lb.
CD009
6. Secure the hub assembly with the nut. Tighten to 200 ft-lb.
PR202
PR256
7. Install a new cotter pin and secure by spreading as shown.
PR203
Back8-10
3. Install the tie rod end and secure with the nut (coated with red Loctite #271). Tighten to 30 ft-lb; then install a new cotter pin and spread the pin.
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PR260
PR087A
NOTE: If the hole in the axle shaft does not align with the slots in the castle nut, tighten the nut until the hole and slots align.
To adjust the wheel alignment, use the following procedure. 1. Center the steering wheel; then using an open-end wrench to hold the tie rod ends, loosen the right-side and left-side jam nuts.
8. Secure the brake caliper to the knuckle with the two cap screws. Tighten to 20 ft-lb.
PR084A PR377B
9. Install the wheel; then using a crisscross pattern, tighten to 45 ft-lb. 10. Remove the vehicle from the support stand.
Checking/Adjusting Front Wheel Alignment

NOTE: All measurements and adjustments must be made with the vehicle unloaded.
8
PR085A
Mark the center-line of the front tires at the front and rear of the tire; then using a tape measure, measure and record the distance between the marks at the front and rear. The front measurement should be 6-12 mm (1/4-1/2 in.) greater than the rear measurement (toe-out).
! CAUTION
Always use a wrench to hold the tie rod ends when loosening or tightening the jam nuts or damage to the boots could occur.
2. Turn the left-side and right-side tie rods in equal increments to achieve the proper toe-out; then tighten the jam nuts securely.
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Hood
REMOVING 1. Open the hood; then disconnect the four headlight connectors and remove two nylon ties.
PR086
Front Bumper Assembly

(XT/XTX)
REMOVING Remove four cap screws and nuts. Account for four lock washers and eight flat washers.
PR328A
2. Loosen but do not remove the four cap screws and flange nuts securing the hood hinge to the frame; then lower the hood.
PR327A

PR332A
3. Finish removing the cap screws and flange nuts (from step 2); then remove the hood assembly. CLEANING AND INSPECTING
1. Clean all bumper components with hot, soapy water. 2. Inspect all welds for cracking or bending. INSTALLING Place the bumper assembly into position on the frame; then secure with the four cap screws and nuts making sure the flat washers and lock washers are properly positioned. Tighten securely.
1. Clean all hood components with soap and water. 2. Inspect the hood for cracks and/or loose fasteners. 3. Inspect for any missing decals. INSTALLING 1. Place the hood into position on the vehicle; then install the two outside cap screws and flange nuts. Finger-tighten only at this time.
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2. Open the hood; then install the remaining two cap screws and flange nuts. Tighten all four securely. INSTALLING Place the appropriate fender into position and secure with existing hardware.
Floor
REMOVING 1. Remove the seats and center console. 2. Remove twelve cap screws and two self-tapping screws securing the floor to the frame.
PR332
3. Connect the four headlight connectors; then secure the wires with two new nylon ties.
3. While pulling forward on the upper-rear of the floor, lift the rear part of the floor above the seat lock stud.
NOTE: To aid in removing, insert a small wood block to hold in position.
PR332B
Fenders
REMOVING Remove three torx-head screws securing each fender to the frame. Account for a stiffener bracket on the front fenders.
PR163
PR164
4. From the opposite side of the vehicle repeat step 3; then lift the rear of the floor up and lift the floor out of the vehicle.
PR311A
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Exhaust System
REMOVING MUFFLER 1. Remove the two exhaust springs at the muffler/exhaust pipe juncture.
PR165

1. Clean the floor with soap and water. 2. Inspect the floor for cracks or holes. INSTALLING 1. Place the front of the floor into position in the vehicle first; then lower the rear and push past the seat lock studs. 2. Secure the floor with twelve cap screws and two self-tappings screws. 3. Install the center console and seats making sure the seats lock securely into position. INSPECTING MUFFLER
PR131
2. Slide the muffler assembly clear of the holder pins.
1. Inspect muffler externally for cracks, holes, and dents. 2. Inspect the muffler internally by shaking the muffler back and forth and listening for rattles or loose debris inside the muffler.
NOTE: For additional details on cleaning the muffler/spark arrester, see Section 2.
Belly Panel
REMOVING 1. Remove the body screws securing the belly panel to the underside of the frame. 2. Remove the belly panel. INSTALLING 1. Place the belly panel into position on the underside of the frame. 2. Install the body screws. Tighten securely.
INSTALLING MUFFLER 1. Place the muffler onto the holder pins and slide into position. 2. Secure the muffler to the exhaust pipe with the two exhaust springs.
Cargo Box
REMOVING 1. Raise the cargo box; then remove the cap screw and nut securing the lower lift support to the frame. Account for the washer. The cargo box will tilt fully rearward.
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2. Align the holes in the upper pivot housings with the holes in the cargo box; then install the lower pivot housings and secure with the four shoulder cap screws. Tighten to 20 ft-lb. 3. Raise the cargo box; then connect the lift support to the frame, install the cap screw and nut, and tighten the nut securely. 4. Lower the cargo box and lock into position.
Taillight Assembly
PR473A
2. Loosen but do not remove the four shoulder cap screws securing the pivot housings to the cargo box.
REMOVING 1. Remove two torx-head screws securing the taillight assembly to the rear canopy tube; then rotate the taillight assembly left or right to allow the connector to clear the access opening.
PR335
3. Lower the cargo box; then remove the four cap screws (from step 2). 4. With the help of an assistant or an adequate lift, remove the cargo box from the vehicle. Account for four pivot housings. CLEANING AND INSPECTING
PR056
2. Disconnect the three-prong connector from the bulb socket and remove the taillight assembly. INSPECTING
1. Clean all cargo box components with soap and water. 2. Inspect the cargo box for cracks, tears, and loose hardware. 3. Inspect the welds of the cargo box frame for cracking or bending. 4. Inspect the cargo box gate latches for smooth operation. INSTALLING 1. With the help of an assistant or an adequate lift, set the cargo box into position on the frame; then position the two upper pivot housings between the cargo box and frame. Lightly grease the pivot housings.
1. Inspect wiring harness, three-prong connector, lens, base, cap screws, and socket for damage. 2. Inspect all wires for corroding, pinching, and cracking. 3. Inspect the bulb for wattage, voltage, and proper operation. INSTALLING 1. Connect the three-prong connector to the bulb socket; then place the taillight assembly into position on the rear canopy tube. 2. Install the two torx-head screws and tighten securely.
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Seats
REMOVING/INSTALLING 1. To remove a seat, pull the seat lock lever up. Raise the front of the seat and slide it forward.
2. To install a seat, slide the rear of the seat into the seat retainers and push down firmly on the front of seat. The seat should automatically lock into position.
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Troubleshooting
Problem: Handling too heavy or stiff Condition
1. Front wheel alignment incorrect 2. Lubrication inadequate 3. Tire inflation pressure incorrect 4. Tie rod ends seizing 5. Linkage connections seizing
Remedy
1. Adjust alignment 2. Lubricate appropriate components 3. Adjust pressure 4. Replace tie rod ends 5. Repair - replace connections
Remedy
Problem: Steering oscillation Condition

1. Tires inflated unequally 2. Wheel(s) wobbly 3. Wheel hub cap screw(s) loose - missing 4. Wheel hub bearing worn - damaged 5. Tie rod ends worn - loose 6. Tires defective - incorrect 7. A-arm bushings damaged 8. Bolts - nuts (frame) loose 1. Adjust pressure 2. Replace wheel(s) 3. Tighten - replace cap screws 4. Replace bearing 5. Replace - tighten tie rod ends 6. Replace tires 7. Replace bushings 8. Tighten bolts - nuts
Problem: Steering pulling to one side Condition

1. Tires inflated unequally 2. Front wheel alignment incorrect 3. Wheel hub bearings worn - broken 4. Frame distorted 5. Shock absorber defective
Remedy
1. Adjust pressure 2. Adjust alignment 3. Replace bearings 4. Repair - replace frame 5. Replace shock absorber
Problem: Steering impaired Condition

1. Tire pressure too high 2. Steering linkage connections worn 3. Cap screws (suspension system) loose
Remedy
1. Adjust pressure 2. Replace connections 3. Tighten cap screws
Problem: Tire wear rapid or uneven Condition

1. Wheel hub bearings worn - loose 2. Front wheel alignment incorrect
Remedy
1. Replace bearings 2. Adjust alignment
Problem: Steering noise Condition

1. Caps screws - nuts loose 2. Wheel hub bearings broken - damaged 3. Lubrication inadequate
Remedy
1. Tighten cap screws - nuts 2. Replace bearings 3. Lubricate appropriate components
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8-17 Next

Problem: Rear wheel oscillation Condition
1. Rear wheel hub bearings worn - loose 2. Tires defective - incorrect 3. Wheel rim distorted 4. Wheel hub cap screws loose 5. Parking brake adjusted incorrectly 6. Rear suspension arm-related bushing worn 7. Rear shock absorber damaged 8. Rear suspension arm nut loose
Remedy
1. Replace bearings 2. Replace tires 3. Replace rim 4. Tighten cap screws 5. Adjust parking brake 6. Replace bushing 7. Replace shock absorber 8. Tighten nut
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SECTION 9 - CONTROLS/INDICATORS
9
TABLE OF CONTENTS
Master Cylinder Assembly....................................... 9-2 Accelerator Pedal .................................................... 9-2 Front Differential Lock ............................................. 9-3 Shift Lever ............................................................... 9-3 Speedometer/Tachometer/LCD/ Indicator Lights..................................................... 9-4
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9-1
Master Cylinder Assembly

NOTE: The master cylinder is a non-serviceable component; it must be replaced as an assembly.
REMOVING 1. Slide a piece of flexible tubing over one of the wheel bleeder valves and direct the other end into a container. Remove the reservoir cover; then open the bleeder valve. Allow the brake fluid to drain until the reservoir is empty.
PR336
3. Remove the oil bolt securing the banjo-fittings to the master cylinder; then remove the master cylinder. Discard the three crush washers.
! CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the vehicle.
INSPECTING 1. Inspect the master cylinder push rod and clevis for wear, bending, or elongation of clevis holes. 2. Inspect the push rod boot for tears or deterioration. 3. Inspect the reservoir for cracks and leakage.
AF637D
2. Remove the cotter pin and pivot pin from the yoke; then remove two cap screws and flange nuts securing the master cylinder assembly to the frame.
4. Inspect the brake hose for cracks and deterioration and the condition of the banjo-fittings. INSTALLING 1. Place the master cylinder into position; then using three new crush washers, secure the two banjo-fittings to the master cylinder. Tighten to 20 ft-lb. 2. Secure the master cylinder assembly to the frame with two cap screws and two flange nuts. Tighten to 25 ft-lb. 3. Install the pivot pin and secure with a new cotter pin. 4. Fill the master cylinder and bleed the brake system (see Section 2).
PR338
Accelerator Pedal
REMOVING Dislodge the throttle cable holding grommet from the actuator arm; then remove two torx-head screws and nuts securing the accelerator pedal assembly to the splash panel and remove the accelerator pedal.
9-2
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2. Select the 2WD position on the 2WD/4WD selector switch; then turn the ignition switch to the ON position and select the LOCK position on the toggle. The front drive actuator should operate engaging four-wheel drive.
NOTE: It may be necessary to turn the steering wheel or to rock the vehicle forward and backward to align the differential lock splines and allow engagement.
3. Return the toggle to the pushed-in position and listen for the front drive actuator to operate.
PR342B
4. Turn the ignition switch to the OFF position. Tighten the jam nut securely; then install the protector sleeve on the adjuster assembly.
Shift Lever
REMOVING 1. Remove the seats and center console.
PR342C
INSTALLING Align the mounting holes with the holes in the splash panel and secure with the two torx-head screws and nuts; then snap the throttle cable holding grommet into the actuator arm.
2. Remove the flange nut and shoulder screw from the shift lever pivot; then remove the shift lever. Account for the shifter spring.
Front Differential Lock

ADJUSTING CABLE 1. With the toggle in the pushed-in position, slide the rubber protector sleeve (A) off the cable near the toggle; then loosen the jam nut (B) and turn the cable adjuster (C) to achieve 3-4 mm (0.12-0.16 in.) free-travel measured at the toggle.
PR340
INSTALLING 1. With the shifter spring in place on the shift lever, install the shift lever onto the shifter axle. 2. Install the shoulder screw and secure with the flange nut. Tighten to 20 ft-lb.
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CD560B
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9-3 Next
Speedometer/ Tachometer/LCD/ Indicator Lights

REPLACING 1. Remove the six screws securing the dash panel to the frame; then remove the parking brake handle and jam nut. 2. Slide the dash panel to the rear sufficiently to access the components.
3. Remove the nuts securing the gauge assembly to the dash; then unplug the multi-pin connector and remove the gauge from the vehicle.
PR284A
4. Place the new gauge into the dash panel opening; then place the gauge holder over the mounting screws and secure with the nuts. 5. Plug the multi-pin connector into the gauge; then turn the ignition switch to the ON position and check gauge functions. 6. Slide the dash into position and secure with the six screws. 7. Install the parking brake handle and jam nut.
PR181A
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What are the main sections covered in the manual?

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What safety symbols are used in the manual and what do they signify?

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

Prowler PRowler 1 Prowler XT 2 PROWLER XTX 3 4 5 6 7 8 9

UTV Service Manual

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

SECTION 1 - GENERAL INFORMATION

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

Torque ft-lb N-m

* Specifications subject to change without notice. ** Visible at plug threads.

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

Torque ft-lb N-m

SUSPENSION COMPONENTS (Rear)

Thread Diameter A (mm)

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

RECOMMENDED ENGINE/ TRANSMISSION OIL

Gasoline - Oil Lubricant

RECOMMENDED DIFFERENTIAL LUBRICANT (Prowler XTX)

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

Preparation For Storage

FILLING GAS TANK

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

Preparation After Storage

6. Charge the battery; then install. Connect the battery cables.

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

SECTION 2 PERIODIC MAINTENANCE/TUNE-UP

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

Periodic Maintenance Chart

A = Adjust C = Clean D = Drain T = Tighten

I = Inspect L = Lubricate R = Replace

R (4000 Mi or 18 Mo) R R (2 Yrs) A-R

I I* I I I T R R (2 Yrs) R (4 Yrs) R (2 Yrs)

* Service/Inspect more frequently when operating in adverse conditions.

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

Charge Time Required (at 1.5-2.0 Amps)

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

5. Dry the filter.

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

0.1016 mm (0.004 in.) 0.1524 mm (0.006 in.)

(Feeler Gauge Procedure)

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

Testing Engine Compression

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.).