Arctic CatFOR

2009 ARCTIC
Prowler XtCAT
Xtx Service
ATV Manual
DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
Full download: http://manualplace.com/download/arctic-cat-2009-prowler-xt-xtx-service-manual/

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2009 Arctic
Cat UTV (Utility Terrain Vehicle) models (see cover). The complete manual is designed to aid service personnel in ser-
vice-oriented applications.
Arctic Cat offers an additional publication (when it becomes available) to aid in servicing the other UTV model. To ser-
vice the model not included in this manual, please refer to the following publication:
• 2009 UTV Service Manual - Prowler XTZ
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 fol-
low 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. September 2008

www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Back to TOC
This is the cut pages sample. Download all 174 page(s) at: ManualPlace.com
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

TABLE OF CONTENTS

Click on the blue text to go.

Foreword

1. General Information/Specifications 1
2. Periodic Maintenance/Tune-Up 2
3. Engine/Transmission 3
4. Fuel/Lubrication/Cooling 4
5. Electrical System 5
6. Drive System 6
7. Suspension 7
8. Steering/Frame 8

9. Controls/Indicators 9

www.mymowerparts.com
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

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
www.mymowerparts.com
Back to TOC 1-1
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

SUSPENSION COMPONENTS (Front)

General Specifications* Part Part Bolted To
Torque
ft-lb N-m
A-Arm Frame 33 45
CHASSIS Ball Joint Cap Screw Knuckle 35 48
Dry Weight (approx) 526 kg (1160 lb) Shock Absorber (Upper) Frame 33 45
Length (overall) 292 cm (115 in.) Shock Absorber (Lower) Upper A-Arm 33 45
Height (overall) 197 cm (77.5 in.) Knuckle A-Arm 33 45
Width (overall) 156 cm (61.3 in.) SUSPENSION COMPONENTS (Rear)
Suspension Travel (front) 25.4 cm (10 in.) Sway Bar Bracket Frame 33 45
(rear) 25.4 cm (10 in.)
A-Arm Frame 33 45
Brake Type Hydraulic
Wheelbase 190 cm (75 in.)
Shock Absorber (Upper) Frame 33 45
Tire Size (front) 26 x 9-14 Shock Absorber (Lower) Lower A-Arm 20 27
(rear) 26 x 11-14 Knuckle A-Arm 33 45
Tire Inflation Pressure 0.70 kg/cm² (10 psi) Cargo Box Hinge Cargo Box Frame 20 27
MISCELLANY Cargo Box Cargo Box Frame 20 27
Gas Tank Capacity (rated) 31 L (8.2 U.S. gal.)
Latch Pivot Bushing Cargo Box Frame 15 20
Coolant Capacity 2.9 L (3.0 U.S. qt)
Latch Striker Cargo Box Liner 5 7
Differential Capacity 275 ml (9.3 fl oz)**
BRAKE COMPONENTS
Rear Drive Capacity 250 ml (8.5 fl oz)** Brake Disc** Hub 15 20
Engine Oil Capacity 2.5 L (2.6 U.S. qt) - Overhaul
1.9 L (2.0 U.S. qt) - Change
Brake Hose Caliper 20 27
Gasoline (recommended) 87 Octane Regular Unleaded Brake Hose Master Cylinder 20 27
Engine Oil (recommended) Arctic Cat ACX All Weather Syn- Master Cylinder Frame 25 34
thetic Parking Brake Mechanism Frame 20 27
Front Differential Lubricant SAE Approved 80W-90 Hypoid Hydraulic Caliper Holder Knuckle 20 27
Rear Drive Lubricant (Prowler/XT) SAE Approved 80W-90 Hypoid
Rear Driveline Brake Caliper Rear Differential/Gear Case 20 27
Rear Differential Lubricant (XTX) Arctic Cat 80W-90 Hypoid Friction
Modified Driveline Rear Drive Input Flange 12 16
Belt Width 35.0 mm (1.38 in.) Parking Brake Actuator Lever Caliper 35 48
Brake Fluid DOT 4 Parking Brake Caliper Rear Drive Housing 20 27
Assembly
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (2) CHASSIS/CANOPY ASSEMBLY
Starting System Electric Shift Lever* Shift Axle 20 27
Front/Rear Canopy Tube Arm Rest/Steering Post 20 27
* Specifications subject to change without notice. Support
** Visible at plug threads. Top Canopy Support Front/Rear Canopy Tubes 8 11
Rear Canopy Tube Lower Canopy Support 8 11
DRIVE TRAIN COMPONENTS
Torque Specifications Rear Differential/Gear Case Frame 38 48
Drive Coupler Drive Flange 40 54
Front Engine Mounting Mounting Stud 25 34
Bracket
EXHAUST COMPONENTS
Rear Engine Mounting Mounting Stud 25 34
Torque Bracket
Part Part Bolted To
ft-lb N-m Front Differential Frame/Differential Bracket 38 52
Exhaust Pipe Cylinder Head 20 27 Rear Output Flange Rear U-Joint Flange 40 54
Spark Arrester Muffler 48 5 Pinion Housing Differential Housing 23 31
in.-lb
Differential Housing Cover*** Differential Housing 23 31
ELECTRICAL COMPONENTS
Drive Bevel Gear Nut*** Shaft 87 118
Coil* Frame 8 11
Lock Collar Differential Housing 125 170
Ground Wire Engine 8 11
Hub Nut Front/Rear Shaft/Axle (min) 200 272
STEERING COMPONENTS
Oil Drain Plug Front Differential - Rear 45 5
Steering Wheel Shaft** Steering Wheel 25 34 Drive/Differential in.-lb
Steering Wheel Shaft**** Intermediate Shaft (Upper) 36 49 Oil Fill Plug Front Differential - Rear 16 22
Intermediate Shaft (Lower)**** Steering Pinion Shaft 36 49 Drive/Differential
Rack and Pinion Assembly Frame 50 68 Oil Drain Plug Engine 16 22
Tie Rod** Rack 74 100 Wheel Hub 45 61
Tie Rod End** Knuckle 30 41 Front Input Drive Flange Front U-Joint 20 27
Jam Nut Tie Rod End 8 11 * w/Blue Loctite #243 *** w/Green Loctite #609
** w/Red Loctite #271 **** w/Green Loctite #270
www.mymowerparts.com
1-2 Back to TOC Back to Section TOC Next
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

ENGINE/TRANSMISSION

Part Part Bolted To

Torque Torque Conversions
ft-lb N-m
(ft-lb/N-m)
Clutch Shoe** Crankshaft 221 300
Clutch Cover/Housing Crankcase 8 11
Assembly
Crankcase Half (6 mm) Crankcase Half 10 14 ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
Crankcase Half (8 mm) Crankcase Half 20 27 1 1.4 26 35.4 51 69.4 76 103.4
Cylinder Head (Cap Screw) Crankcase 40 54
2 2.7 27 36.7 52 70.7 77 104.7
Cylinder Head Nut (6 mm) Cylinder 8 11
3 4.1 28 38.1 53 72.1 78 106.1
Cylinder Head Nut (8 mm) Cylinder 18 24
Cylinder Head Cover Cylinder Head 8.5 11.5 4 5.4 29 39.4 54 73.4 79 107.4

1
Driven Pulley Nut Driveshaft 80 109 5 6.8 30 40.8 55 74.8 80 108.8
Movable Drive Face Nut** Driveshaft 165 224 6 8.2 31 42.2 56 76.2 81 110.2
Ground Wire Engine 8 11 7 9.5 32 43.5 57 77.5 82 111.5
Magneto Cover Crankcase 8 11
8 10.9 33 44.9 58 78.9 83 112.9
Tappet Cover Valve Cover 9 12
9 12.2 34 46.2 59 80.2 84 114.2
Crankshaft Spacer Crankshaft 28 38
Oil Pump Drive Gear** Crank Balancer Shaft 62 84 10 13.6 35 47.6 60 81.6 85 115.6
Output Shaft Flange Nut Output Shaft** 62 84 11 15 36 49 61 83 86 117
Outer Magneto Cover Magneto Cover 8 11 12 16.3 37 50.3 62 84.3 87 118.3
Magneto Rotor Nut** Crankshaft 105 143 13 17.7 38 51.7 63 85.7 88 119.7
Cam Sprocket** Camshaft 11 15
14 19 39 53 64 87 89 121
V-Belt Cover Crankcase 8 11
15 20.4 40 54.4 65 88.4 90 122.4
Output Yoke Nut Secondary Driven Output 74 100
Shaft 16 21.8 41 55.8 66 89.8 91 123.8
* w/Blue Loctite #243 17 23.1 42 57.1 67 91.1 92 125.1
** w/Red Loctite #271
18 24.5 43 58.5 68 92.5 93 126.5
*** w/Green Loctite #609
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136

Tightening Torque
(General Bolts)

Thread
Tightening
Type of Bolt Diameter A
Torque
(mm)
(Conventional or 4 Marked Bolt) 5 12-36 in.-lb
6 36-60 in.-lb
8 7-11 ft-lb
10 16-25 ft-lb
(7 Marked Bolt) 5 24-48 in.-lb
6 6-8 ft-lb
8 13-20 ft-lb
10 29-43 ft-lb

www.mymowerparts.com
Back Back to TOC Back to Section TOC 1-3Next
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
RECOMMENDED ENGINE/
TRANSMISSION OIL
Break-In Procedure
! CAUTION
Any oil used in place of the recommended oil could
A new vehicle and an overhauled engine require a
cause serious engine damage. Do not use oils which
“break-in” period. The first 10 hours (or 200 miles) are
most critical to the life of this vehicle. Proper opera- contain graphite or molybdenum additives. These
tion during this break-in period will help assure maxi- oils can adversely affect clutch operation. Also, not
mum life and performance from the vehicle. recommended are racing, vegetable, non-detergent,
and castor-based oils.
During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the engine The recommended oil to use is Arctic Cat ACX All
RPM during the break-in period allows the compo- Weather synthetic engine oil, which has been specifi-
nents to “load” (aiding the mating process) and then cally formulated for use in this Arctic Cat engine.
“unload” (allowing components to cool). Although it Although Arctic Cat ACX All-Weather synthetic
is essential to place some stress on the engine compo- engine oil is the only oil recommended for use in this
nents during break-in, care should be taken not to engine, use of any API certified SM 5W-50 oil is
overload the engine too often. Do not pull a trailer or acceptable.
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 accelera-
tions 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 pre-
scribed adjustments and tightening of all fasteners. OILCHARTI

RECOMMENDED FRONT
DIFFERENTIAL/REAR DRIVE
Gasoline - Oil - LUBRICANT (Prowler/XT)
Lubricant
The recommended lubricant is Arctic Cat Gear Lube
or an equivalent gear lube which is SAE approved
RECOMMENDED GASOLINE 80W-90 hypoid. This lubricant meets all of the lubrica-
tion requirements of the Arctic Cat vehicle front differ-
ential and rear drive.
The recommended gasoline to use is 87 minimum
octane regular unleaded. In many areas, oxygenates
(either ethanol or MTBE) are added to the gasoline. ! CAUTION
Oxygenated gasolines containing up to 10% ethanol, Any lubricant used in place of the recommended
5% methane, or 5% MTBE are acceptable gasolines. lubricant could cause serious front differential/rear
When using ethanol blended gasoline, it is not neces- drive damage.
sary to add a gasoline antifreeze since ethanol will pre-
vent the accumulation of moisture in the fuel system. RECOMMENDED DIFFERENTIAL
LUBRICANT (Prowler XTX)
! CAUTION „NOTE: Arctic Cat recommends the use of genu-
Do not use white gas. Only Arctic Cat approved gas- ine Arctic Cat lubricants.
oline 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.

www.mymowerparts.com
Back1-4 Back to TOC Back to Section TOC Next
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
The recommended lubricant for the rear differential is
Arctic Cat 80W-90 Hypoid Friction Modified. This
lubricant meets all of the rear differential lubrication Preparation For Storage
requirements of this vehicle.

! CAUTION ! CAUTION
Any lubricant used in place of the recommended
Prior to storing the vehicle, it must be properly ser-
lubricant could cause serious differential damage.
viced to prevent rusting and component deteriora-
tion.
FILLING GAS TANK
1. Clean the seat cushion (cover and base) with a
! WARNING damp cloth and allow it to dry.

1
Always fill the gas tank in a well-ventilated area.
2. Clean the vehicle thoroughly by washing dirt, oil,
Never add fuel to the gas tank near any open flames grass, and other foreign matter from the entire
or with the engine running. DO NOT SMOKE while vehicle. Allow it to dry thoroughly. DO NOT get
filling the gas tank. 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 hous-
ing cover and air filter. Start the engine and allow
it to idle. Using Arctic Cat Engine Storage Pre-
server, 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
4. On the carbureted model, drain the carburetor float
chamber.
Since gasoline expands as its temperature rises, the gas
tank must be filled to its rated capacity only. Expan- 5. Plug the exhaust hole in the exhaust system with a
sion room must be maintained in the tank particularly clean cloth.
if the tank is filled with cold gasoline and then moved
to a warm area. 6. Apply light oil to the plungers of the shock absorb-
ers.
! WARNING 7. Tighten all nuts, bolts, cap screws, and screws.
Do not overflow gasoline when filling the gas tank. A Make sure rivets holding components together are
fire hazard could materialize. Always allow the tight. Replace all loose rivets. Care must be taken
engine to cool before filling the gas tank. that all calibrated nuts, cap screws, and bolts are
tightened to specifications.
Tighten the gas tank cap securely after filling the tank.
8. Fill the cooling system to the bottom of the stand
pipe in the radiator neck with properly mixed cool-
! WARNING ant.
Do not over-fill the gas tank.
9. Disconnect the battery cables; then remove the
battery, clean the battery posts and cables, and
store in a clean, dry area.
Genuine Parts 10. Store the vehicle indoors in a level position.

When replacement of parts is necessary, use only gen- ! CAUTION

uine Arctic Cat parts. They are precision-made to Avoid storing outside in direct sunlight and avoid
ensure high quality and correct fit. Refer to the appro- using a plastic cover as moisture will collect on the
priate Illustrated Parts Manual for the correct part vehicle causing rusting.
number, quantity, and description.

www.mymowerparts.com
Back Back to TOC Back to Section TOC 1-5Next
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
6. Charge the battery; then install. Connect the bat-
tery cables.
Preparation After
Storage ! CAUTION
The ignition switch must be in the OFF position prior
to installing the battery or damage may occur to the
Taking the vehicle out of storage and correctly prepar- ignition system.
ing it will assure many miles and hours of trouble-free
riding. ! CAUTION
1. Clean the vehicle thoroughly. Connect the positive battery cable first; then the
negative.
2. Clean the engine. Remove the cloth from the
exhaust system. 7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight,
3. Check all control wires and cables for signs of and headlight aim; adjust or replace as necessary.
wear or fraying. Replace if necessary.
8. Tighten all nuts, bolts, cap screws, and screws
4. Change the engine/transmission oil and filter. making sure all calibrated nuts, cap screws, and
bolts are tightened to specifications.
5. Check the coolant level and add properly mixed
coolant as necessary. 9. Check tire pressure. Inflate to recommended pres-
sure as necessary.
10. Make sure the steering moves freely and does not
bind.
11. Check the spark plug. Clean or replace as neces-
sary.

www.mymowerparts.com
Back1-6 Back to TOC Back to Section TOC
 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP

TABLE OF
CONTENTS

Periodic Maintenance Chart .................................... 2-2

Periodic Maintenance.............................................. 2-3
Lubrication Points.................................................... 2-3
Air Filter ................................................................... 2-3
Valve/Tappet Clearance
(Feeler Gauge Procedure) ................................... 2-4
Valve/Tappet Clearance
(Valve Adjuster Procedure) .................................. 2-4
Testing Engine Compression................................... 2-5
Spark Plug............................................................... 2-6
Muffler/Spark Arrester ............................................. 2-6
Engine/Transmission Oil - Filter............................... 2-6
Front Differential - Rear Drive/
Differential Lubricant ............................................ 2-7
Driveshaft/Coupling ................................................. 2-8
Nuts/Bolts/Cap Screws............................................ 2-8
Headlight/Taillight-Brakelight ................................... 2-8
Shift Lever (Prowler/XTX)........................................ 2-9
Shift Lever (XT) ..................................................... 2-10
Hydraulic Brake System ........................................ 2-10
Parking Brake ........................................................ 2-12
Burnishing Brake Pads .......................................... 2-14
Checking/Replacing V-Belt .................................... 2-14
Troubleshooting Brake System.............................. 2-16
www.mymowerparts.com
Back to TOC 2-1
Arctic CatFOR
2009 ARCTIC
Prowler XtCAT
Xtx Service
ATV Manual
DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
Full download: http://manualplace.com/download/arctic-cat-2009-prowler-xt-xtx-service-manual/
A = Adjust I = Inspect
C = Clean L = Lubricate
Periodic Maintenance D = Drain R = Replace
Chart T = Tighten

Initial
Every Month Every 3 Every 6
Service After Every Year
Every or Months or Months or As
Item Break-In or Every
Day Every 100 Every 300 Every 500 Needed
(First Mo or 1500 Miles
Miles Miles Miles
100 Mi)
Battery I I C
Fuses I R
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Engine Compression I
Spark Plug I I I R (4000 Mi
or 18 Mo)
Muffler/Spark Arrester C R
Gas/Vent Hoses I I R (2 Yrs)
Throttle Cable Ends/Accelerator Pedal I I C-L A-R
Pivot
Float Chamber (650 cc) D*
Engine RPM (Idle) (650 cc) I I A
Engine-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R*/R**/R*** R
Oil Strainer I I C
Front Differential - Rear Drive/Differ- I I R (4 Yrs)
ential Lubricant
Tires/Air Pressure I I R
Steering Components I I I R
V-Belt I l R
Suspension (Ball joint boots, drive I I R
axle boots front and rear, tie rods, dif-
ferential and rear drive bellows)
Nuts/Bolts/Cap Screws T T A
Ignition Timing I
Headlight/Taillight-Brakelight I I R
Switches I I R
Shift Lever I A-L
Gauges/Indicators I I R
Frame/Welds I I l
Electrical Connections l C
Complete Brake System I I
(Hydraulic & Parking)
Brake Pads I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Coolant/Cooling System I I R (2 Yrs)
Wheel Lug Nuts T T
* Service/Inspect more frequently when operating in adverse conditions.
** When using an API certified SM 5W-50 oil.
*** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year.
www.mymowerparts.com
2-2 Back to TOC
This is the cut pages sample. Download all 174 page(s) at: ManualPlace.com
Back to Section TOC Next