2006 XT 650 Prowler

User Manual: Manual

Open the PDF directly: View PDF .
Page Count: 190

Download
Open PDF In Browser	View PDF

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2006 Arctic Cat ATV 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 ATV 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 the complete 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 ATV 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 ATV-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the ATV. 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.

October 2005

TABLE OF CONTENTS
Click on the blue text to go.

Foreword
1.

General Information

Periodic Maintenance/Tune-Up

Engine/Transmission

Fuel/Lubrication/Cooling

Electrical System

Drive System

Suspension

Steering/Frame

Controls/Indicators

10. Aids for Maintenance

11. Troubleshooting

SECTION 1 - GENERAL INFORMATION

TABLE OF
CONTENTS
General Specifications ............................................ 1-2
Break-In Procedure ................................................. 1-3
Gasoline - Oil - Lubricant ........................................ 1-3
Genuine Parts ......................................................... 1-4
Preparation For Storage .......................................... 1-4
Preparation After Storage........................................ 1-5

Back to TOC

1-1

General Specifications*
CARBURETOR
Type

CHASSIS

Keihin CVK36

Main Jet

132

Dry Weight (approx)

Slow Jet

Length (overall)

Low Speed Fuel Screw Setting
(turns)

1 1/4

Height (overall)

197 cm (77.5 in.)

Width (overall)

156 cm (61.3 in.)

Jet Needle

NFKS

Suspension Travel (front)

25 cm (10 in.)

Needle Jet

6.0/4.0

Suspension Travel (rear)

20 cm (8 in.)

Idle RPM

1250-1350

Brake Type

Hydraulic

Starter Jet

Wheelbase

190 cm (75 in.)

Float Arm Height

17 mm (0.7 in.)

Tracking

Throttle Cable Free-Play (at lever)

3-6 mm (1/8-1/4 in.)

(front)
(rear)

128.3 cm (50.5 in.)
123.2 cm (48.5 in.)

Tire Size

(front)
(rear)

26 x 9-14
26 x 11-14

ELECTRICAL
Ignition Timing

10° BTDC @ 1500 RPM

Spark Plug Type

Champion R6YCA

Spark Plug Gap

0.7-0.8 mm
(0.028-0.032 in.)

Spark Plug Cap

4000-6000 ohms

Ignition Coil
Resistance

Ignition Coil Peak
Voltage (static)
Magneto Coil
Resistance

(primary) Less than 1 ohm
(terminal to ground)
(secondary) 5200-7800 ohms
(high tension - plug cap
removed - to ground)
(primary/CDI) 132-198 DC volts
(terminal to ground)
(trigger) 160-240 ohms
(green to blue)
(source) Less than 1 ohm
(yellow to white)
(charging) Less than 1 ohm
(black to black)

Magneto Coil
Peak Voltage

Stator Coil Output

Magneto Output (approx)

1-2

(trigger) 4.2-6.3 volts
(green to blue)
(source) 0.40-0.62 volt
(yellow to white)
(no load) 60 AC volts @ 5000 RPM
(black to black #1)
(black to black #2)
325W @ 5000 RPM

Back to TOC

Tire Inflation Pressure

533 kg (1175 lb)
292 cm (115 in.)

0.70 kg/cm² (10 psi)

Turning Radius

3.3 m (10.8 ft)

MISCELLANY
Gas Tank Capacity (rated)

31 L (8.2 U.S. gal.)

Coolant Capacity

2.9 L (3.0 U.S. qt)

Differential Capacity

275 ml (9.3 fl oz)**

Rear Drive Capacity

250 ml (8.5 fl oz)***

Engine Oil Capacity

2.5 L (2.6 U.S. qt)

Gasoline (recommended)

87 Octane Regular
Unleaded

Engine Oil (recommended)

SAE 10W-40

Differential/Rear Drive
Lubricant

SAE Approved
80W-90 Hypoid

Belt Width

35.0 mm (1.38 in.)

Brake Fluid

DOT 4

Taillight/Brakelight

12V/8W/27W

Headlight

12V/27W (2)

Starting System

Electric

* Specifications subject to change without notice.
** At the oil level plug threads.
*** At the filler plug threads.

Back to Section TOC

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.
During the break-in period (or whenever the brake
pads are replaced), the hydraulic brake pads must be
burnished. Slow disc-speed hydraulic brakes must
be properly burnished in order to achieve maximum
stopping power.

! CAUTION
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 BRAKES, USE FOLLOWING PROCEDURE:

• Choose an area sufficiently large to safely accelerate vehicle to 30 mph and to brake to a stop.
• Accelerate to 30 mph; then compress brake
lever to decelerate to 0-5 mph.
• Repeat procedure five times until brakes are burnished.
• This procedure burnishes the brake pads, stabilizes the pad material, and extends the life of the
brake pads.

NOTE: Do not be reluctant to heat up the brake
pads during the burnishing procedure.

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.

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.

! CAUTION
Do not use white gas. Only Arctic Cat approved
gasoline additives should be used.

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, nondetergent, and castor-based oils.

The recommended oil to use is Arctic Cat 4-Cycle
Engine Oil (p/n 0436-005) or an equivalent oil
which is rated SE, SF, or SG under API service classification. These oils meet all of the lubrication
requirements of the Arctic Cat engine. The recommended engine oil viscosity is SAE 10W-40. Ambient temperature should determine the correct weight
of oil. See the following viscosity chart for details.

! WARNING
Do not attempt sudden stops or put the vehicle into
a situation where a sudden stop will be required
until the brake pads are properly burnished.

Back

Back to TOC

Back to Section TOC

1-3Next

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.

! 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.

OILCHARTB

RECOMMENDED FRONT
DIFFERENTIAL/REAR DRIVE
LUBRICANT

Tighten the gas tank cap securely after filling the
tank.

! WARNING
Do not over-fill the gas tank.

The recommended lubricant is Arctic Cat Gear Lube
(p/n 0436-007) 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 differentials and rear drives.

! CAUTION
Any lubricant used in place of the recommended
lubricant could cause serious front differential/rear
drive damage.

FILLING 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
Illustrated Parts Manual for the correct part number,
quantity, and description.

! WARNING

Preparation
For Storage

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.

! CAUTION
Prior to storing the vehicle, it must be properly serviced to prevent rusting and component deterioration.

Arctic Cat recommends the following procedure to
prepare the vehicle for storage.
1. Clean the seat cushion (cover and base) with a
damp cloth and allow it to dry.

ATV0049B

Back1-4

Back to TOC

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.

Back to Section TOC

3. Either drain the gas tank or add Fuel Stabilizer
(p/n 0638-165) to the gas in the gas tank.
Remove the air filter housing cover and air filter. Start the engine and allow it to idle; then
using Arctic Cat Engine Storage Preserver (p/n
0636-177), 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.

4. 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.

! CAUTION
Avoid storing outside in direct sunlight and avoid
using a plastic cover as moisture will collect on the
vehicle causing rusting.

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.
12. Follow the recommendations found in the prestart inspection.

Preparation After
Storage
Taking the vehicle out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. Arctic Cat recommends the
following procedure to prepare the vehicle.
1. Clean the vehicle thoroughly.
2. Clean the engine. Remove the cloth from the
exhaust system.

Back

Back to TOC

Back to Section TOC

1-5

SECTION 2 PERIODIC MAINTENANCE/TUNE-UP

2
TABLE OF
CONTENTS
Periodic Maintenance Chart .................................... 2-2
Lubrication Points.................................................... 2-3
Battery..................................................................... 2-3
Fuses ...................................................................... 2-4
Air Cleaner/Filter ..................................................... 2-4
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 ...................................................... 2-9
Adjusting Throttle Cable .......................................... 2-9
Adjusting Engine RPM (Idle) ................................... 2-9
Engine/Transmission Oil - Filter............................. 2-10
Front Differential/Rear Drive Lubricant .................. 2-11
Tires ...................................................................... 2-12
Steering Components ........................................... 2-12
Driveshaft/Coupling ............................................... 2-12
Suspension/Shock Absorbers/Bushings ............... 2-12
Nuts/Bolts/Cap Screws.......................................... 2-13
Ignition Timing ....................................................... 2-13
Headlight/Taillight-Brakelight ................................. 2-13
Switches ................................................................ 2-14
Low Range/High Range/Neutral/Reverse Lever.... 2-14
Frame/Welds ......................................................... 2-15
Electrical Connections........................................... 2-15
Hydraulic Brake System ........................................ 2-15
Parking Brake ........................................................ 2-17
Burnishing Brake Pads .......................................... 2-19
Coolant .................................................................. 2-19
Checking/Replacing V-Belt .................................... 2-19
2-1

A = Adjust
C = Clean
D = Drain

Periodic Maintenance
Chart

Item

Battery

Initial
Service
After
Break-In
(First Mo or
100 Mi)

Every
Day

Every
Month or
Every 100
Miles

Every 3
Months or
Every 300
Miles

I = Inspect
L = Lubricate
R = Replace

Every 6
Months or
Every 500
Miles

Fuses
I

Valve/Tappet Clearance

R
I

Engine Compression

A
I

Muffler/Spark Arrester

R (4000 Mi
or 18 Mo)
C

Gas/Vent Hoses

Throttle Cable

R
R (2 Yrs)

C-L

Carb Float Chamber
Engine RPM (Idle)

As
Needed

C
I

Air Filter/Drain Tube

Spark Plug

Every Year
or Every
1500 Miles

A-R

D*
I

Engine-Transmission Oil
Level

Engine-Transmission
Oil/Filter

Oil Strainer

Front Differential/Rear Drive
Lubricant

A
R*

R
I

C
R (4 Yrs)

Tires/Air Pressure

Steering Components

V-Belt (Automatic)

Suspension (Ball joint
boots, drive axle boots front
and rear, tie rods, differential and rear drive bellows)

Nuts/Cap Screws/Screws

R
I

R
l

Ignition Timing

A
I

Headlight/TaillightBrakelight

Switches

Gauges/Indicators

Frame/Welds

Shift Lever

A-L
R

Electrical Connections

Complete Brake System
(Hydraulic & Parking)

Brake Pads

Brake Fluid

R (2 Yrs)

Brake Hoses

Coolant/Cooling System

I
I

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

2-2

L-R

R (4 Yrs)
R (2 Yrs)

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

CHARGTIM

D. Shift Linkage
E. Differential Lock Cable End

F. Idle RPM Screw (Carburetor)

Battery

CHARGE

To remove and charge the battery, use the following
procedure.

! WARNING
AF879D

The level of the battery fluid must be kept between
the upper and lower level lines at all times. If the
level drops below the lower level line, add only distilled water until it reaches upper level line.

! WARNING
Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a
battery.

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.

1. Remove the fasteners holding the left-rear
splash panel in place; then remove the battery
access panel.

If the battery is discharged, remove the battery from
the vehicle and charge the battery at the standard
charging rate of 1.5A x 10 hr.

2-3

8. Place the battery into position in the vehicle and
secure with the battery access panel.

! CAUTION
Connecting cables in reverse (positive to negative
and negative to positive) can cause serious damage to the electrical system.

Fuses
PR054A

2. Remove the negative battery cable; then remove
the positive cable and the battery vent tube.
Remove the battery from the vehicle. Care
should be taken not to damage the vent tube.

! WARNING
Avoid spillage and contact with skin, eyes, and
clothing.

! CAUTION

The main fuses are located in a power distribution
module under the operator’s 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

Do not charge the battery while it is in the vehicle
with the battery terminals connected.

3. Remove the vent plugs; then (if necessary) fill
the battery with distilled water to the upper
level indicated on the battery.
4. Trickle charge the battery at 1.5A for 10 hours.
1411-191

! CAUTION
Never exceed the standard charging rate.

! CAUTION

5. After charging, check fluid level and fill with
distilled water as necessary; then install vent
plugs.

Always replace a blown fuse with a fuse of the
same type and rating.

! CAUTION

Air Cleaner/Filter

Before installing the battery, make sure the ignition
switch is in the OFF position.

6. Attach the vent tube and check the vent tube to
make sure it is not crimped or obstructed in any
way and that it is properly routed through and
secured to the frame.
7. Connect cables to the proper terminals: positive
cable to the positive terminal (+) and negative
cable to the negative terminal (-). Connect the
negative cable last.

2-4

The air filter inside the air filter housing must be
kept clean to provide good engine power and gas
mileage. If the vehicle is used under normal conditions, service the filter at the intervals specified. If
operated in dusty, wet, or muddy conditions, inspect
and service the filter more frequently. 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
Failure to inspect the air filter frequently if the vehicle is used in dusty, wet, or muddy conditions can
damage the engine.

! CAUTION

1. Remove the seats; then remove the center console.

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.

2. Unsnap the four fasteners securing the air
cleaner housing cover and remove the cover.

7. Clean any dirt or debris from inside the air
cleaner. Be sure no dirt enters the carburetors.

3. Remove the air filter/filter screen assembly and
separate the foam filter from the screen.

8. Place the filter assembly in the air filter housing
making sure it is properly positioned and properly seated with the filter screen down.

PR101
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.

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 (p/n 0436-194) and
Foam Filter Oil (p/n 0436-195) are available from
Arctic Cat.

5. Dry the filter.

CD670

CHECKING AND CLEANING
DRAINS

1. Inspect one-way drains beneath the main housing for debris and for proper sealing.

2-5

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.

! CAUTION

PR141A

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.

2. Replace any one-way drain that is cracked or
shows any signs of hardening or deterioration.

! CAUTION

VALVE/TAPPET CLEARANCE
Intake

0.1016 mm (0.004 in.)

Exhaust

0.1524 mm (0.006 in.)

The one-way drain to the left is the clean air section
of the filter housing. Any leak of this one-way 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.

Valve/Tappet
Clearance

(Feeler Gauge Procedure)
CC007D

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, and air filter
housing must be removed for this procedure.

4. Install the timing inspection plug.
5. Place the two tappet covers into position making
sure the proper cap screws are with the proper
cover. Tighten the cap screws securely.

Valve/Tappet Clearance
(Valve Adjuster Procedure)

1. Remove the timing inspection plug; then
remove the tappet covers (for more detailed
information, see Section 3 - Servicing Top-Side
Components).

To check and adjust valve/tappet clearance, use the
following procedure.

2. Rotate the crankshaft to the TDC position on the
compression stroke.

NOTE: The engine must be cold for this procedure.

NOTE: At this point, the rocker arms and
adjuster screws must not have pressure on them.

NOTE: The seats, center console, and air filter
housing must be removed for this procedure.

1. Remove the 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.
2-6

NOTE: At this point, the rocker arms and
adjuster screws must not have pressure on them.
NOTE: Use Valve Clearance
0444-078) for this procedure.

Adjuster

(p/n

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.

CF005

9. Install the spark plug; then install the timing
inspection plug.

6. While holding the valve adjuster handle in
place, rotate the valve adjuster dial counterclockwise until proper valve/tappet clearance is
attained.

Testing Engine
Compression

NOTE: Refer to the appropriate specifications in
Feeler Gauge Procedure sub-section for the proper
valve/tappet clearance.

To test engine compression, use the following procedure.

NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.

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.

7. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely
with the valve adjuster handle.

1. Remove the high tension lead from the spark
plug.

8. Place the two tappet covers with O-rings into
position; then tighten the covers securely.

2. Using compressed air, blow any debris from
around the spark plug.

! WARNING
Always wear safety glasses when using compressed air.

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 Gauge (p/n 0444-096).
CF006A

5. While holding the throttle in the full-open position, crank the engine over with the electric
starter until the gauge shows a peak reading
(five to 10 compression strokes).
NOTE: The compression should be within a
range of 63-77 psi in the full-open throttle position.

2-7

6. If compression is abnormally low, inspect the
following items.
A. Verify starter cranks engine over.
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.
ATV0052B

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.
8. If compression is now evident, service the piston
rings (see Section 3).

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.

Muffler/Spark Arrester
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
may need to be adjusted. To maintain a hot, strong
spark, keep the plug free of carbon.

The muffler has a spark arrester which must be periodically cleaned. At the intervals shown in the Periodic Maintenance Chart, clean the spark arrester
using the following procedure.

! WARNING
Wait until the muffler cools to avoid burns.

1. Remove the three cap screws securing the spark
arrester screen assembly to the muffler; then
loosen and remove the spark arrester. Account
for a gasket.

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.
CF105A

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

2-8

CF104

CD560A

2. Using a suitable brush, clean the carbon deposits
from the screen taking care not to damage the
screen.

2. Turn the adjuster until the throttle cable has
proper free-play of 3-6 mm (1/8 - 1/4 in.) at the
pedal.

NOTE: If the screen or gasket is damaged in any
way, it must be replaced.

3. Tighten the jam nut against the throttle cable
adjuster securely; then slide the rubber boot over
the adjuster.

3. Install the spark arrester assembly and gasket
and secure with the three cap screws. Tighten
the cap screws to 0.6 kg-m (4.0 ft-lb).

Adjusting Engine RPM
(Idle)

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.
Make certain that the vent hose is securely connected to the carburetor and the opposite end is
always open.

Adjusting Throttle
Cable

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.

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.

To adjust the throttle cable free-play, locate the
in-line cable adjuster behind the carburetor.
1. Slide the rubber boot (A) away; then loosen the
jam nut (B) from the throttle cable adjuster (C).

2-9

PR081A

! WARNING
Adjust the idle to the correct RPM. Make sure the
engine is at normal operating temperature before
adjusting the idle RPM.

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.

1. Park the vehicle on level ground.

PR078A

4. Using the Oil Filter Wrench (p/n 0444-042) 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.

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 specifications. Pour the specified amount of the recommended oil in the filler hole. Install 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.

2. Remove the oil level stick/filler plug.

8. Turn the engine off and wait approximately one
minute.
9. Unscrew the oil level stick and wipe it with a
clean cloth.
10. Install the oil level stick until the threads touch
engine case.
NOTE: The oil level stick should not be threaded
into the case for checking the oil level.
PR053B

3. Remove the drain plug from the bottom of the
engine and drain the oil into a drain pan.

2-10

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.

PR065A

To change the lubricant, use the following procedure.
1. Place the vehicle on level ground.

2. Remove each oil filler plug.

ATV-0100

12. Inspect the area around the drain plug and oil filter for leaks.

Front Differential/Rear
Drive Lubricant
Check and change the lubricant according to the
Periodic Maintenance Chart. When changing the
lubricant, use approved SAE 80W-90 hypoid gear
lube. To check lubricant, use the following procedure.

PR046A

1. Remove the rear drive filler plug; the lubricant
level should be 1 in. below the threads of the
plug.

PR065A

3. Drain the oil into a drain pan by removing in
turn the drain plug from each.

PR046A

2. If low, add SAE approved 80W-90 hypoid gear
lube as necessary.

2-11

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.

Steering Components
The following steering components should be
inspected periodically to ensure safe and proper
operation.
ATV0082A

Rear Drive

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.

737-651A

G. Cotter pins not damaged or missing.

4. After all the oil has been drained, install the
drain plugs and tighten to specifications.
5. Pour the appropriate amount of recommended
oil into the filler hole.
6. Install the filler plugs.
NOTE: If the differential/rear drive oil is contaminated with water, inspect the drain plug, filler plug,
and/or bladder.

Tires
TIRE SIZES

The Prowler XT is equipped with low-pressure
tubeless tires of the size and type listed (see Section
1). Do not under any circumstances substitute tires
of a different type or size.

! WARNING
Always use the size and type of tires specified.
Always maintain proper tire inflation pressure.

TIRE INFLATION PRESSURE

Front and rear tire inflation pressure should be 0.70
kg-cm² (10 psi).
2-12

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.

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.
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.

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. For proper torque values, see Section 10.

Ignition Timing

Headlight/TaillightBrakelight
Each time the vehicle is used, lights should be
checked for proper function. With the ignition
switch in the ON position, select the high and/or low
beam on the light switch; the headlights and taillight
should illuminate. Test the brakelight by depressing
the brake pedal. The brakelight should illuminate.
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.

! WARNING
Do not attempt to remove the bulb when it is hot.
Severe burns may result.

The ignition timing cannot be adjusted; however,
verifying ignition timing can aid in troubleshooting
other components. To verify ignition timing, use the
following procedure.

To replace the headlight bulb, use the following procedure.

NOTE: To check ignition timing, the seats and
center console must be removed.

1. Remove the wiring harness connector from the
back of the headlight.

1. Attach the Timing Light (p/n 0644-197) to the
spark plug high tension lead; then remove the
timing inspection plug from the left-side crankcase cover.

2. Grasp the bulb socket, turn it counterclockwise
and remove, and pull the bulb straight out of the
socket.

2. Start the engine and using the RPM function on
the speedometer/tachometer, run at the recommended RPM; ignition timing should be the recommended degrees BTDC.
IGNITION TIMING
Prowler XT

10° BTDC @ 1500 RPM

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
may be faulty.

3. Install the new bulb into the socket and rotate it
completely clockwise in the housing.
4. Install the wiring harness connector.
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.

2-13

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).
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.

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.
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.

Low Range/High Range/
Neutral/Reverse Lever
0740-647

7. Using the adjuster knob, adjust each headlight
until correct aim is obtained.

2-14

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.

Electrical Connections
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.
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 two torx-head screws and nuts on the
linkage.

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.

PR093A

3. Holding the shift lever centered in the neutral
position, move the shifter arm until (N) is indicated on the LCD.
4. Tighten the torx-head screws securely; then
recheck the adjustment by selecting each gear
position and checking for the correct indication
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.

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 (p/n 1639-799).
B. Install and secure the cover; then slowly
depress the brake pedal several times.

2-15

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.

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

AF637D

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.

PR377A

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.

PR376A

3. If thickness of either brake pad is less than 3.2
mm (0.125 in.), the brake pads must be replaced.

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.

NOTE: The brake pads should be replaced as a
set.

E. Repeat steps B and C until the brake pedal is
firm.

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.

2-16

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.

PR237

C. Install the new brake pads.
D. Secure the caliper holder to the knuckle with
the cap screws. Tighten to specifications.

2
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 specifications.
5. Burnish the brake pads (see Burnishing Brake
Pads in this section).

Parking Brake
PR098

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.

2. Rotate the actuator clockwise (hand tight) until
it contacts the back of the piston; then rotate
counterclockwise approximately one spline.

1. With the engine off, transmission in neutral, and
the parking brake set, attempt to move the vehicle.
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).
PR089A

2-17

3. Install the actuator lever in the position noted in
step 1; then install the actuator nut and tighten to
4.8 kg-m (35 ft-lb).

PR099

3. Remove the two cap screws securing the brake
caliper to the rear drive housing and remove the
caliper.
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.

PR080B

4. Push in on the caliper holder and remove the
outer brake pad; then remove the inner pad.
PR097A

! CAUTION
If after adjusting the parking brake cable the parking brake will not hold the vehicle, the brake pads
must be replaced.

MEASURING/REPLACING BRAKE
PADS
Removing

1. Remove the parking brake cable (see Adjusting
in this sub-section).
2. Lift the cargo box; then disconnect the lift support and allow the cargo box to tilt all the way
back.

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.
4. If the thickness of either brake pad is less than
3.2 mm (0.125 in.), the brake pads must be
replaced.
NOTE: The brake pads should be replaced as a
set.

Installing

1. Place the brake pads into the caliper.
NOTE: The metal backing of the pad will be facing the actuator when installed properly.

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 specifications.
2-18

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).

AN604D

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.

! 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.

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.

! 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.

Checking/Replacing
V-Belt
REMOVING

1. Remove the seats and center console; then
remove the left-side seat-base.

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
PR104

The cooling system should be inspected daily for
leakage and damage. Also, the coolant level should
be checked periodically.
When filling the cooling system, use premixed Arctic Cat Antifreeze (p/n 0638-395). 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.

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.
NOTE: Note the location of the main harness and
engine ground wires for installing purposes.

2-19

%NGINE
'ROUND

-AIN (ARNESS
'ROUND

PR111A

3. Remove the nut securing the movable drive
face; then remove the face. Account for the
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.

PR109

INSTALLING

1. Spread the faces of the driven pulley by pushing
the inner face toward the engine while turning it
counterclockwise; then when the faces are separated, insert a wedge (approximately 3/8 in.
thick) between the faces. Release the inner face.
2. Place the V-belt into position on the driven pulley and over the front shaft.

PR110

PR109

NOTE: The arrow on the V-belt should point rearward.

3. 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 nut.
Tighten the nut to specifications.
PR108

4. Remove the V-belt.

2-20

! 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.

NOTE: Make sure the main harness and engine
ground wires are installed and secured in the
proper location with the unpainted cap screw.

PR108

NOTE: At this point, the wedge can be removed
from between the driven pulley faces.

4. Rotate the V-belt and driven pulley/clutch until
the V-belt is flush with the top of the driven pulley.
5. 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 specifications.

PR111B

6. Secure the seat-base with the four cap screws.
Tighten securely.
7. Install the seats and center console making sure
the seats lock securely.

2-21

SECTION 3 - ENGINE/TRANSMISSION

TABLE OF
CONTENTS
Engine/Transmission ............................................... 3-2
Specifications .......................................................... 3-3
Prowler XT (Table of Contents) ............................... 3-4

3-1

Engine/Transmission
This section has been organized into sub-sections
which show a progression for the complete servicing of the Arctic Cat Prowler XT 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.

3-2

Specifications*
VALVES AND GUIDES
Valve Face Diameter
Valve/Tappet Clearance
(cold engine)
Valve Guide/Stem
Clearance
Valve Guide/Valve
Stem Deflection
(wobble method)
Valve Guide Inside
Diameter
Valve Stem Outside
Diameter
Valve Stem Runout
Valve Head Thickness
Valve Stem End Length
Valve Face/Seat Width
Valve Seat Angle
Valve Face Radial Runout
Valve Spring Free Length
Valve Spring Tension
@ 31.5 mm (1.24 in.)

(intake) 31.6 mm (1.24 in.)
(exhaust) 27.9 mm (1.10 in.)
(intake) 0.1016 mm (0.004 in.)
(exhaust) 0.1524 mm (0.006 in.)
(intake) 0.013 mm
(0.0005 in.)
(exhaust) 0.013 mm
(0.0005 in.)
(max) 0.35 mm (0.014 in.)
5.000-5.012 mm
(0.1969-0.1973 in.)
(intake) 4.972-4.987 mm
(0.1957-0.1963 in.)
(exhaust) 4.972-4.987 mm
(0.1957-0.1963 in.)
(max) 0.1 mm (0.0039 in.)
(min) 2.3 mm (0.0906 in.)
(min) 3.97 mm (0.156 in.)
(intake) 2.25 mm (0.0886 in.)
(exhaust) 2.60 mm (0.1024 in.)
(intake) 45° 15’-45° 30’
(exhaust) 45° 15’-45° 30’
(max) 0.2 mm (0.0079 in.)
(min) 38.7 mm (1.524 in.)
(outer) 19.0 kg (42 lb)

(intake) 13.97 mm (0.55 in.)
(exhaust) 13.97 mm (0.55 in.)
(max) 0.04 mm (0.0016 in.)

Camshaft Journal Oil
Clearance
Camshaft Journal Holder (right & center) 21.98-22.04 mm
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
12.000-12.018 mm
Diameter
(0.4724-0.4731 in.)
Rocker Arm Shaft
11.97-11.98 mm
Outside Diameter
(0.4713-0.4717 in.)
Cylinder Head Distortion
(max) 0.05 mm (0.002 in.)
Cylinder Head Cover
(max) 0.05 mm (0.002 in.)
Distortion

0.045 mm (0.0018 in.)
98 mm (3.858 in.)
97.948-97.962 mm
(3.856-3.857 in.)
(1st Ring) 12.5 mm (0.492 in.)
(2nd Ring) 12.5 mm (0.492 in.)
97.9 x 85 mm
(3.86 x 3.35 in.)
(max) 0.01 mm (0.004 in.)
0.36 mm (0.014 in.)

Bore x Stroke

CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min)

CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder
Clearance
Cylinder Bore
Piston Diameter
15 mm (0.6 in.) from Skirt
End
Piston Ring
Free End Gap

Cylinder Trueness
Piston Ring End Gap
- Installed
Piston Ring to Groove
Clearance (max)
Piston Ring Groove Width

Piston Ring Thickness

Piston Pin Bore
Piston Pin Outside Diameter

(1st) 0.03 mm
(0.0012 in.)
(2nd) 0.03 mm
(0.0012 in.)
(1st) 1.202-1.204 mm
(0.0473-0.0474 in.)
(2nd) 1.202-1.204 mm
(0.0473-0.0474 in.)
(Oil) 2.01-2.03 mm
(0.0791-0.0799 in.)
(1st) 1.970-1.990 mm
(0.0776-0.0783 in.)
(2nd) 1.970-1.990 mm
(0.0776-0.0783 in.)
(max) 23.0 mm (0.9055 in.)
(min) 22.99 mm (0.9051 in.)

CRANKSHAFT
Connecting Rod
(small end inside diameter)
(max)
Connecting Rod
(big end side-to-side)
Connecting Rod (big end
width)
Connecting Rod @ 150 mm
(5.9 in.)
(small end deflection)
Crankshaft (web-to-web)
Crankshaft Runout(max)
Oil Pressure @2500 RPM
(Cooling Fan Cycling)
Cooling Fan
Thermo-Switch
Operating Temperature
Engine Coolant
Thermo-Switch
Operating Temperature

23.021 mm
(0.9063 in.)
0.6 mm (0.024 in.)
25 mm (0.9843 in.)
(max) 0.3 mm (0.0118 in.)
71 mm (2.79 in.)
0.03 mm (0.0012 in.)
1.40-2.11 kg/cm²
(20-30 psi)
(offJon) 90°C (194°F) ±10%
(onJoff) 75°C (167°F) ±10%
107°-113°C
(225°-235°F)

* Specifications subject to change without notice.

3-3

Prowler XT

(Table of Contents)
Removing Engine/Transmission ............................. 3-4
Top-Side Components............................................. 3-8
Removing Top-Side Components ........................... 3-8
Right-Side Components ........................................ 3-12
Removing Right-Side Components....................... 3-12
Left-Side Components .......................................... 3-14
Removing Left-Side Components ......................... 3-15
Center Crankcase Components ........................... 3-18
Separating Crankcase Halves............................... 3-18
Disassembling Crankcase Half ............................. 3-19
Servicing Components.......................................... 3-21
Assembling Crankcase Half .................................. 3-39
Joining Crankcase Halves..................................... 3-42
Installing Left-Side Components ........................... 3-43
Installing Right-Side Components......................... 3-45
Installing Top-Side Components ........................... 3-47
Installing Engine/Transmission.............................. 3-54

NOTE: Use a small funnel between the frame and
coolant drain plug to prevent coolant from draining on the frame and splashing.

PR122A

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

PR156A

3. Remove the negative cable from the battery;
then remove the positive cable.
4. From the right-side, remove the spark plug cap;
then disconnect the temperature sensor lead,
speed sensor connector, fuel quantity sender
lead, and reverse override switch connector.

If the technician's objective is to service/replace
left-side cover oil seals (3), front output joint oil
seal (1), rear output joint oil seal (1), 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.

! 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.
3-4

PR130A

PR155A

PR111A

6. Remove the E-clip from the shift arm; then disconnect the shifter linkage. Account for three
spacer washers.

3
PR157A

5. From the left-side, disconnect the starter wire,
alternator connector, CDI connector, shift position switch connector, and electric choke connector; then remove the cap screw securing the
main harness and the engine ground wires to the
V-belt housing.

PR138A

7. Remove four machine screws securing the
shifter mount to the frame; then remove the
shifter assembly.

PR145A

PR123A

8. Loosen the clamp securing the air intake boot to
the carburetor and the clamp securing the air filter housing to the inlet housing boot; then
remove the crankcase breather hose from the
crankcase.

PR128A

3-5

PR127A

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.

PR118

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.
PR150A

12. Remove the exhaust duct from the V-belt housing; then remove the inlet boot connecting the
inlet duct to the V-belt housing.

PR140A

10. Remove the throttle arm cover from the carburetor; then disconnect and remove the throttle
cable and the carburetor.
PR144B

3-6

PR153B

PR148A

13. Remove the muffler; then remove the exhaust
pipe.

16. Remove two flange nuts from the underside of
the rear engine mounts.

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.

PR153A

17. Remove two flange nuts securing the engine
mounting bracket to the front engine mounts.

PR152A

PR147

18. Attach suitable lifting chains to the engine/transmission; then using an engine hoist, lift the
assembly out of the engine compartment.

PR120A

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.

3-7

Removing Top-Side
Components
A. Valve Cover
B. Cylinder Head

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.

NOTE: Remove the spark plug and timing
inspection plug; then using the recoil starter,
rotate the crankshaft to top-dead-center of the
compression stroke.

1. Remove the two tappet covers.

CC001D

PR146

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.

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 twelve 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.

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.
NOTE: The engine/transmission does not have
to removed from the frame for this procedure.
CD205

3-8

CD206

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.

3
CD211A

3. Loosen the cap screw on the end of the tensioner; then remove the two machine screws
securing the tensioner adjuster assembly and
remove the assembly. Account for a gasket.

CC013D

6. Remove the cap screw securing the chain tensioner (account for a washer); then remove the
tensioner.

CC009D

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.

CC014D

7. While holding the chain, slide the sprocket and
camshaft out of the cylinder head.

3-9

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 copper washers.

CC020D

CC017D

AT THIS POINT

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

3-10

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

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.

13. Using an awl, remove one piston-pin circlip.

CC032D

CC024D

14. Using the Piston-Pin Puller (p/n 0644-328),
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

3-11

NOTE: Support the connecting rod with rubber
bands to avoid damaging the rod or install the
Connecting Rod Holder (p/n 0444-006).

! 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.

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.

Removing Right-Side
Components
A. Water Pump
B. Side Cover
C. Rotor/Flywheel

1. Remove the four cap screws securing the dust
cover to the right-side cover; then remove the
cover.
2. Remove the flange nut securing the starter cup
to the crankshaft; then remove the starter cup.
Account for the O-ring inside the cup.

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
Components sub-section.

Servicing

Top-Side

AT THIS POINT

To service center crankcase components only,
proceed to Removing Right-Side Components.

Right-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.

CD925A

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.
4. Remove the two machine screws securing the
speed sensor housing; then remove the housing.
Account for the gasket and two seal washers.

AT THIS POINT

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.

3-12

NOTE: Inspect the inside of the left-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.

CC620

6. Remove the two machine screws securing the
water pump to the engine; then remove the
water pump.
CD942A

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.

CC623

10. Using Magneto Rotor Remover Set (p/n
0444-075), remove the rotor/flywheel assembly
from the crankshaft. Account for the key; then
remove the starter clutch gear assembly and
washer.

AT THIS POINT

To service the water pump, see Section 4.

7. Remove the twelve machine screws securing the
right-side cover to the crankcase noting the location of the different-sized machine screws for
installing purposes.

CD939A

CC626

8. Using Side Case Puller (p/n 0644-262), remove
the side cover. Account for a gasket and two
alignment pins.

3-13

CD940A

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.

CD949

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.

13. 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.

CD140

CD952A

Left-Side Components

CD138

12. 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.

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

3-14

4. Remove the nut securing the fixed driven
assembly; then remove the assembly.

Removing Left-Side
Components
A. V-Belt Cover
B. Driven Pulley
C. Clutch Cover

1. Remove the machine screws securing the V-belt
cover noting the location of the different-lengthed machine screws for installing purposes; then using a rubber mallet, gently tap on
the cover tabs to loosen the cover.
CD968

5. Remove the fixed drive face.
6. Remove the machine screws securing the air
intake plate; then remove the plate/cushion
assembly.

CD961A

2. Remove the nut securing the movable drive
face; then remove the face. Account for a spacer.

CD970

CD962

CD972

7. Remove the machine screws securing the clutch
cover. Note the location of the different-lengthed machine screws for installing purposes. Using a rubber mallet, carefully remove
the cover. Account for two alignment pins.

CD964

3. Remove the V-belt.
3-15

CD973A

! CAUTION

CC600A

NOTE: For steps 8-14, refer to illustration
CC829A.

Care must be taken when removing the cover so
the cover gasket is not damaged.

KEY
A.
B.
C.
D.

Oil Pump Driven Gear
Oil Pump Drive Gear
Clutch Shoe Assembly
One-Way Clutch
(Green Dot MUST Show)
E. Final Drive Carrier Bearing Housing
F. Input Shaft

CC829A

NOTE: To aid in installing, it is recommended
that the assemblies are kept together and IN
ORDER.

8. Remove the one-way clutch (D) from the clutch
housing. Note the location of the green alignment dot (or the word OUTSIDE) for installing
purposes.
9. 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.
CF085A

3-16

CC596

NOTE: Account for and inspect the clutch housing seal.

CD996

11. Remove the nut (left-hand threads) securing the
clutch shoe assembly (C).
12. Remove the cap screw securing the oil pump
drive gear (B). Account for a cap screw, washer,
pin, and spacer.

CF088A

10. Remove the two machine screws securing the
shift indicator sending unit; then remove the
unit. Account for two neutral contact pins and
two springs.

CC606

13. Remove the machine screws securing the final
drive carrier bearing housing (E); then remove
the housing and account for two alignment pins.
14. 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.
15. Remove the three machine screws securing the
oil pump; then remove the pump.

CD994

CD988

3-17

2. Remove the right-side machine screws securing
the crankcase halves. Note the location of the
different-lengthed machine screws.

Center Crankcase
Components
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.

CC663

Separating Crankcase
Halves
1. Remove the left-side machine screws securing
the crankcase halves. Note the location of the
different-lengthed machine screws.

3. Using the Crankcase Separator/Crankshaft
Remover (p/n 0444-009) 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.

CC665
CC664

3-18

Disassembling
Crankcase Half
NOTE: For steps 1-7, refer to illustration CC821B.
KEY
A.
B.
C.
D.
E.
F.
G.
H.

Secondary Driven Shaft Assembly
Crank Balancer Assembly
Crankshaft
Countershaft Assembly
Driveshaft
Reverse Idler Gear Assembly
Gear Shift Shaft
Shift Shaft with 2 Forks

3
CC821B

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.

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 four washers and a needle bearing.
CD267

2. Remove the reverse idler gear assembly (F).
Account for all washers, shaft, bushing, and the
gear.

3-19

CC675
PR380A

7. Note the alignment dots on the crank balancer
assembly (B) gear and crankshaft (C) gear for
assembling purposes; then slide the crank balancer gear off the crank balancer. Account for
the key in the keyway.

PR381A

5. Remove the countershaft assembly (D). Account
for a washer on each end of the countershaft.
CD826

8. Remove the crank balancer.
NOTE: There is a flat spot on the crank balancer
bearing flange to allow clearance past the crankshaft.

CC674

NOTE: Do not disassemble the countershaft
assembly unless necessary. If necessary, see Servicing Center Crankcase Components sub-section.

6. Using a rubber mallet, tap on the crankcase to
remove the driveshaft.

CD832B

9. Remove the snap ring securing the water pump
driven gear shaft.
10. Using a hydraulic press, remove the crankshaft
assembly.
NOTE: Use a protective end cap to prevent damage to the crankshaft threads.

3-20

CC680

11. Remove the machine screws securing the oil
strainer cap; then remove the cap. Account for
the cap O-ring.

CC686

Table of Contents
(Servicing Components)

NOTE: Critical engine/transmission specifications are located at the beginning of this section.

CC681

12. Remove the two machine screws securing the
oil strainer; then remove the strainer.

Servicing Top-Side Components .......................... 3-21
Valve Assembly ................................................ 3-21
Piston Assembly ............................................... 3-26
Cylinder/Cylinder Head Assembly ..................... 3-28
Servicing Left-Side Components .......................... 3-31
Inspecting Centrifugal Clutch Shoe ................... 3-31
Inspecting Clutch Housing ................................ 3-31
Inspecting Primary One-Way Drive .................. 3-31
Inspecting Oil Pump ......................................... 3-32
Driven Pulley Assembly..................................... 3-32
Servicing Center Crankcase Components ........... 3-36
Secondary Gears ............................................. 3-36
Crankshaft Assembly ........................................ 3-37
Countershaft ..................................................... 3-38

Servicing Top-Side
Components
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.
CC682

! 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.

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.

Cleaning/Inspecting Valve Cover
NOTE: If the valve cover cannot be trued, the cylinder head assembly must be replaced.
3-21

1. Wash the valve cover in parts-cleaning solvent.
2. Place the valve cover on the Surface Plate (p/n
0644-016) 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.
CC132D

! 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.

2. Remove the valve seal and the lower remaining
spring seat. Discard the valve seal.

CC136D

NOTE: The valve seals must be replaced.
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.

Removing Valves

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
(p/n 0644-022); then check the valve stem
runout using a dial indicator.

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.

1. Using a valve spring compressor, compress the
valve springs and remove the valve cotters.
Account for an upper spring retainer.

ATV-1082

2. Maximum runout must not exceed specifications.

3-22

Measuring Valve Stem
Outside Diameter

Measuring Valve Guide/Valve Stem
Deflection (Wobble Method)

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.

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.

Measuring Valve Face/Seat Width

1. Using a micrometer, measure the width of the
valve face.

3
CC131D

3. Push the valve from side to side; then from top
to bottom.
ATV-1004

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.

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.
Replacing Valve Guide
NOTE: If a valve guide is worn or damaged, it
must be replaced.

1. If a valve guide needs replacing, insert a valve
guide remover into the valve seat side of the
valve guide. Using a hammer, gently drive the
valve guide out of the cylinder head.

ATV1082A

3. Rotate the valve in the V blocks.
4. Maximum runout must not exceed specifications.
3-23

CC137D

2. Using the Standard Valve Guide Reamer (p/n
0444-017), remove any burrs or tight areas from
the valve guide journals.

CC138D

Valve Seat/Guide Servicing Flow
Chart

CC142D

3. To install a valve guide, use a valve guide
installer and gently drive a valve guide with a
retaining clip into the bore from the valve spring
side until the retaining clip just contacts the cylinder head.

ATV-0107

Grinding Valve Seats
CC143D

4. After installing the guide, use the standard valve
guide reamer to remove all burrs and tight areas
that may remain in each valve guide.

NOTE: If the valve seat is beyond servicing, the
cylinder head must be replaced.

1. Insert an exhaust valve seat pilot shaft into an
exhaust valve guide. Slide an exhaust valve seat
grinding tool onto the pilot shaft; then using
light pressure on a driver handle and a deep
socket, grind the exhaust valve seat until within
specifications.
NOTE: Repeat procedure on the remaining
exhaust valve seat.

3-24

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)
CC139D

2. Insert an intake valve seat pilot shaft into one of
the intake valve guides. Slide the intake valve
seat grinding tool onto the pilot shaft; then using
light pressure on a driver handle and a deep
socket, grind the intake valve seat until within
specifications.

1. Using a micrometer, measure the outside diameter of the rocker arm shaft.
2. Acceptable outside diameter range must be
within specifications.
Installing Valves

NOTE: Repeat procedure on the remaining
intake valve seat.

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.

CC140D

CC144D

Lapping Valves
NOTE: Do not grind the valves. If a valve is damaged, it must be replaced.

1. Remove all carbon from the valves.
2. Lubricate each valve stem with light oil; then
apply a small amount of valve lapping compound to the entire seating face of each valve.

2. Insert each valve into its original valve location.
3. Install the valve springs with the painted end of
the spring facing away from the cylinder head.
NOTE: If the painted end is not visible, install the
ends of the springs with the closest coils toward
the head.

3. Attach the suction cup of a valve lapping tool to
the head of the valve.
4. Rotate the valve until the valve and seat are
evenly polished.
5. Clean all compound residue from the valve and
seat.
ATV-1011A

3-25

4. Place a spring retainer over the valve springs;
then using the valve spring compressor, compress the valve springs and install the valve cotters.

CC400D

2. Remove each ring by working it toward the
dome of the piston while rotating it out of the
groove.
CC132D

PISTON ASSEMBLY
NOTE: Whenever a piston, rings, or pin are out
of tolerance, they must be replaced.

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.

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.

3-26

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.
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.

! 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.

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.

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.

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.
ATV-1085B

NOTE: Note the direction of the exhaust side of
the piston (5) for correct ring end gap orientation.

2. Install the compression ring with the orientation
mark (MTOP) in the 2nd (middle) ring groove
and the ring with the orientation mark (M) in the
1st (top) ring groove.

ATV-1069

Measuring Piston Skirt/
Cylinder Clearance

1. Measure the cylinder front to back in six places.

3-27

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.

Cleaning/Inspecting Cylinder Head

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.

! 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
Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result.

3-28

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.

! 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.

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.
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.

CC129D

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.

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.

1. Place the camshaft on a set of V blocks; then
position the dial indicator contact point against
the shaft and zero the indicator.

3-29

CC283D

CC005D

2. Rotate the camshaft and note runout; maximum
tolerance must not exceed specifications.

2. Place a strip of plasti-gauge in each of the camshaft lands in the cylinder head.

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.

ATV1013A

2. The lobe heights must not be less than minimum
specifications.
Inspecting Camshaft Bearing
Journal

1. Inspect the bearing journal for scoring, seizure
marks, or pitting.
2. If excessive scoring, seizure marks, or pitting is
found, the cylinder head assembly must be
replaced.

CC003D

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.

Measuring Camshaft to
Cylinder Head Clearance

1. Remove the adjuster screws and jam nuts.

CC145D

6. If clearance is excessive, measure the journals of
the camshaft.
3-30

Servicing Left-Side
Components
NOTE: Whenever a part is worn excessively,
cracked, damaged in any way, or out of tolerance,
replacement is necessary.

INSPECTING CENTRIFUGAL
CLUTCH SHOE
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.

1. Inspect the shoe for uneven wear, chips, cracks,
or discoloration. If any shoe is damaged, the
complete set must be replaced.

Inspecting Camshaft Spring/Drive
Pin

2. Inspect the shoe for wear or damage. If any
shoe is worn to the bottom of the groove, the
complete set must be replaced.

1. Inspect the spring and drive pin for damage.

! CAUTION

Always replace centrifugal clutch shoes as a complete set or severe imbalance of the clutch assembly could occur.

CF061A

ATV1014

INSPECTING CLUTCH HOUSING

1. Inspect the housing for discoloration, marks,
scuffs, cracks, scratches, or uneven wear.
2. If the housing is damaged in any way, the housing must be replaced.
CF060A

2. If damaged, the camshaft 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.

3-31

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.

CD048

3. Install the pilot bushing with the machined end
directed down; then fit the bushing into the pulley hub.

CC446D

DRIVEN PULLEY ASSEMBLY
Disassembling

! WARNING
This procedure involves relaxing a compressed
spring assembly. DO NOT attempt disassembling
without the proper tools.

1. Secure Driven Pulley Compressor (p/n
0444-121) in a suitable holding fixture such as a
bench vise; then remove the wing nut, holding
handle, flat washer, and pilot bushing leaving
the large spacer on the compressor tool base.

CD067

4. Using a suitable marking pen, make alignment
marks on the fixed face spring holder and both
pulley faces.

CD049

CD047

2. Place the driven pulley assembly onto the compressor tool base engaging the dowel pins into
appropriate holes in the fixed face of the assembly.

3-32

5. Place the holding handle on the spring holder
fitting the two dowel pins into the spring holder
face; then install a flat washer and the wing nut.
Turn the wing nut down until resistance is felt.
NOTE: Do not use the wing nut to compress the
spring further.

CD050

! WARNING
The spring assembly is under pressure. Extreme
care must be taken when relaxing the spring.
Always wear safety glasses. Use proper tools only.

CD053A

10. Using a thin pry-bar or screwdriver, work the
movable face sleeve upward and free of the
O-rings; then remove the sleeve.

6. Using a spanner and suitable breaker bar, loosen
the notched-ring nut; then spin the nut free of
the hub.

CD054

11. Remove the four pins and spacers from the cam
slots in the movable face; then remove the movable face.
CD051

7. Firmly hold the handle and slowly turn the wing
nut counterclockwise to relax the spring.

CF091

CD052

8. Continue to relax the spring until the wing nut is
flush with the end of the threads.
9. Firmly holding the spring and spring holder,
remove the wing nut; then remove the spring.

3-33

NOTE: Make sure the spacer is on the base or
damage to the fixed face will occur when the
spring is compressed.

CD056

Inspecting

1. Inspect the pulley faces for wear, galling, or
grooving.
2. Inspect the O-rings on the movable face for
nicks, tears, or swelling.

CF092A

3. Inspect two grease seals in the movable face for
nicks, cuts, or damage.

CD048

2. Apply multi-purpose grease to the O-rings and
grease seals on the movable face; then install on
the fixed face making sure the alignment marks
are properly aligned.

CD060

3. Install the four pins and spacers into the fixed
face hub; then pack the cam slots in the movable
face with multi-purpose grease.

CF095A

4. Inspect the pins and bushings for wear, flat
spots, looseness, or cracking.
Assembling

1. Place the fixed face of the driven pulley on the
pulley compressor base making sure the dowel
pins are engaged in the appropriate holes in the
pulley face.
3-34

CD061

4. Install the spring over the hub and movable face
sleeve.

CF089

5. Place the spring holder on the spring.

CD052

8. Continue compressing the spring while guiding
the spring holder onto the hub. When a slight
resistance is felt, stop turning the wing nut.
9. Install the nut (threads coated with red Loctite
#271); then tighten the nut to specification using
the spanner and a torque wrench.

CF087B

6. Assemble the notched-ring nut, spring holding
handle, one flat washer, and the wing nut in
order on the pulley compressor bolt; then thread
the wing nut onto the bolt.
CD066

10. Remove the wing nut, washer, and holding handle; then remove the driven pulley from the pulley compressor.

CD052

7. Compress the spring until the spring holder
nears the threads on the fixed face hub.

3-35

Servicing Center
Crankcase Components
NOTE: Whenever a part is worn excessively,
cracked, damaged in any way, or out of tolerance,
replacement is necessary.

SECONDARY GEARS
NOTE: All references to front or rear and left-side
or right-side are based on the orientation of the
engine/transmission as installed in this vehicle.
NOTE: When checking and correcting secondary
gear backlash and tooth contact, the universal
joint must be secured to the rear shaft or false
measurements will occur.

Checking Backlash

NOTE: Continue to remove, measure, and install
until backlash measurement is within tolerance.
Note the following chart.
Backlash Measurement

Shim Correction

Under 0.05 mm (0.002 in.)

Decrease Shim
Thickness

At 0.05-0.33 mm
(0.002-0.013 in.)

No Correction Required

Over 0.33 mm (0.013 in.)

Increase Shim
Thickness

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

1. Remove the secondary driven output shaft
assembly from the left-side crankcase half.
2. Clean the secondary driven bevel gear teeth of
old oil and grease residue.

NOTE: Always start with the original shims on
the rear shaft.

3. Apply a thin, even coat of a machinist-layout
dye to several teeth of the gear.

1. Place the left-side crankcase cover onto the
left-side crankcase half to prevent runout of the
secondary transmission output shaft.

4. Install the secondary driven output shaft assembly.

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.

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.

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.

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.

3-36

ATV-0103

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.

ATV-0105

CC290D

2. Maximum diameter must not exceed specifications.
ATV-0104

Correcting Tooth Contact
NOTE: If tooth contact pattern is comparable to
the correct pattern illustration, no correction is
necessary.

1. If tooth contact pattern is comparable to an
incorrect pattern, correct tooth contact according
to the following chart.
Tooth Contact

Shim Correction

Contacts at Top

Decrease Shim Thickness

Contacts at Root

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

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.
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.

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.

3-37

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.

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.

ATV-1017

2. Acceptable width range must be within specifications.
COUNTERSHAFT

! 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.

Disassembling

1. Remove drive gear #2; then remove the circlip
securing the reverse gear dog.
2. Remove the reverse gear dog; then remove the
circlip securing the reverse driven gear.
3. Remove the reverse driven gear and account for
the washer, bushing, and bearing.
3. Zero the indicator and rotate the crankshaft
slowly.

4. Remove the low driven gear washer and lock
washers; then remove the low driven gear.
Account for the bushing and bearing.

! CAUTION

5. Remove the washer; then remove the sliding
dog.

ATV-1074

Care should be taken to support the connecting rod
when rotating the crankshaft.

4. Maximum runout must not exceed specifications.
NOTE: Proceed to check runout on the other end
of the crankshaft by positioning the indicator contact at point 2 and following steps 2-4.

3-38

6. Remove the high driven gear. Account for the
washer, bushing, and bearing.

Assembling
KEY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

Washer - Drive Gear (R)
Drive Gear #2
Circlip
Reverse Gear Dog
Spacer
Washer
Bushing
Bearing
Reverse Driven Gear
Lock Washer
Countershaft
Lock Washer
Low Driven Gear
Driven Gear Washer
Sliding Dog
High Driven Gear
Washer - Drive Gear (L)

738-929A

1. Place the high driven gear onto the countershaft
making sure the bearing, bushing, and washer
are properly positioned.
2. Place the sliding dog onto the countershaft.
3. Place the low driven gear onto the countershaft
making sure the bearing and bushing are properly positioned; then place the lock washers and
washer onto the shaft.
4. Place the reverse driven gear onto the countershaft making sure the bearing, bushing, and
washer are properly positioned; then secure with
the circlip.
5. Place the reverse gear dog onto the countershaft;
then secure with the circlip.
6. Place drive gear #2 onto the countershaft.
NOTE: When installing the countershaft assembly, account for the washer on each end of the
shaft.

CC686

NOTE: The beveled side of the secondary drive
gear must face upward.

2. Apply red Loctite #271 to the threads of the output shaft; then secure with the nut. Tighten nut
to specifications; then using a punch, peen the
nut.

Assembling Crankcase
Half
1. Install the output shaft assembly into the crankcase making sure the two gears, shim, washer,
and nut are properly sequenced.
CC687

3-39

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.

CD832

CC688

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.

CC689

NOTE: If heating the bearing is not possible, the
crankshaft can be installed using a crankshaft
installing tool.

CD826A

6. Place a washer on each end of the countershaft
assembly; then install the assembly.

CC690

4. Install the crank balancer.

CC674

7. Install the driveshaft.

3-40

8. Install the thrust bearing assembly (flat washer,
needle bearing, flat washer) on the shift shaft;
then install the shaft assembly making sure the
two holes on the end of the shaft are positioned
vertically.

11. Install the front and rear secondary driven shaft
assemblies into the right side of the crankcase
making sure the bearing locating pins are facing
upward and the bearing C-ring is fully seated in
the crankcase.

PR382A

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.

12. Place the oil strainer into position; then secure
with the two machine screws.

NOTE: Make sure the shift fork tabs face upward
and that they are properly seated into the shift
cams.

CC682

13. Place the oil strainer cap into position making
sure the O-ring is in position; then secure the
cap with machine screws. Tighten securely.
CC669

10. Install the reverse idler gear assembly noting the
positioning of the two washers, gear, bushing,
and shaft.

CC681

CC668

3-41

Joining Crankcase
Halves
1. Apply High-Temp Sealant (p/n 0636-069) to the
left-side mating surface.

CC695

4. Using a plastic mallet, lightly tap the case halves
together until machine screws can be installed.
5. From the left side, install the 8 mm cap screws;
then tighten only until snug.
NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.
CC693

2. Lightly oil all bearings and grease all shafts in
the left-side crankcase.

6. From the right side, install the remaining 8 mm
machine screws (one inside the case); then
tighten only until snug.
NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

7. From the right side, install the eight case half 6
mm machine screws; then tighten only until
snug.
NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

8. From the left side, install the 6 mm machine
screws; then tighten only until snug.
CC694

NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

9. In a crisscross/case-to-case pattern, tighten the 8
mm machine screws (from steps 5-6) until the
halves are correctly joined; then tighten to specifications.

CC696

3. Using a propane torch, heat the left-side crankshaft bearing until the oil begins to smoke; then
join the two crankcase halves.

CC697

3-42

NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

10. In a crisscross/case-to-case pattern, tighten the 6
mm machine screws (from steps 7-8) to specifications.

3. Install the timing chain on the crankshaft; then
install the oil pump onto the engine. Tighten the
machine screws securely.

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 Right-Side Components, to
Installing Left-Side Components, and to Installing Top-Side Components.
CC613

Installing Left-Side
Components
1. Install the shift indicator sending unit making
sure the two neutral contact pins and the two
springs are properly positioned. Tighten the
machine screws securely.

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 specifications.

CC712

CC602

2. Install the secondary shaft bearing housing making sure the two alignment pins are properly
positioned. 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.

CC609
CC711

NOTE: When installed correctly, the sides of the
drive and driven gears will be flush with each
other.
3-43

6. Install the clutch shoe assembly and secure with
the nut (threads coated with red Loctite #271).
Tighten to specifications.

10. Install the one-way clutch into the clutch housing assembly.

! CAUTION
Note that the nut has left-hand threads.

CF084

! CAUTION
CD979

7. 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.
8. Install the clutch cover alignment pins into the
crankcase, apply oil to the cover gasket, and
install the gasket onto the crankcase.

When installed correctly, the green alignment dot
(or the word OUTSIDE) on the one-way clutch DOES
NOT SHOW.

11. Place the clutch cover/clutch housing assembly
into position on the crankcase; then secure with
the machine screws making sure the different-lengthed machine screws are in their proper
location. Tighten to specifications.

9. Lightly grease the clutch housing seal; then
insert the left fixed drive spacer.

12. Place the air intake plate into position; then
tighten the machine screws (threads treated with
a small amount of red Loctite #271) securely.

CF088A

CD970

13. Place the driven pulley assembly into position
and secure with the nut. Tighten to specifications.

CF086

3-44

CC726

14. Slide the fixed drive face onto the shaft.
15. Spread the faces of the driven pulley by pushing
the inner face toward the engine while turning it
counterclockwise; then when the faces are separated, insert a wedge (approximately 3/8 in.
thick) between the faces. Release the inner face.

CC552

NOTE: At this point, the wedge can be removed
from between the driven pulley faces.

18. Rotate the V-belt and drive/driven assemblies
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 machine
screws making sure the different-lengthed
machine screws are in their proper location.
Tighten the machine screws to specifications.

CC549

16. Place the V-belt into position on the driven pulley and over the front shaft.

CD083

Installing Right-Side
Components

CC550

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
shaft. Secure the drive face with a nut (threads
coated with red Loctite #271). Tighten the nut to
specifications.

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 drive gear alignment pin
and the drive gear (with the flat side of the gear
facing outward as noted in removing); then
secure with the snap ring.

3-45

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 specifications.
5. Install the shift shaft with the two washers making sure the washers are properly positioned.

CC641

NOTE: The sharp side of the snap ring should be
facing outward.

2. 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.

CD954A

6. Lubricate the magneto cover gasket with fresh
engine oil; then place it into position on the two
dowel pins.

CC845

NOTE: The sharp side of the snap ring should be
facing outward.
CC629

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).

7. Lubricate the two magneto cover oil seals; then
install the magneto cover and secure with the
cap screws. Tighten only until snug.
8. Place the starter cup into position on the crankshaft making sure a new, lubricated O-ring is
inside the cup. Tighten the flange nut to specifications.

CC636
CC710

3-46

9. Tighten the cap screws (from step 6) to specifications.
10. Place the speed sensor housing and gasket into
position and secure with the two cap screws.
Tighten securely.

CC620

13. Install the shift arm on the shift arm shaft making sure the scribed marks (from removing) are
aligned. Tighten securely.

CD069

11. Place the water pump into position and secure
with two machine screws. Tighten securely.

14. Place the recoil starter assembly into position on
the left-side cover; then tighten four machine
screws to specifications.

3
Installing Top-Side
Components
A. Piston
B. Cylinder

CC623

12. Install the crossover tube on the water pump and
cylinder head making sure the O-ring is properly
positioned.

KEY
1.
2.
3.
4.
5.
6.
7.
8.

Cylinder
Stud Bolt
Nut
Cylinder Gasket
Pin
Water Hose Union
Cap Screw
O-Ring

0732-301

NOTE: If the piston rings were removed, install
them in this sequence.

CC619

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.

3-47

ATV-1085B

NOTE: Note the direction of the exhaust side of
the piston (5) for correct ring end gap orientation.

B. Install the compression ring with the orientation mark (MTOP) in the 2nd (middle) ring
groove and the ring with the orientation mark
(M) in the 1st (top) ring groove.

CC032D

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

ATV-1024A

! 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.

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.

! CAUTION
The cylinder should slide on easily. Do not force the
cylinder or damage to the piston, rings, cylinder, or
crankshaft assembly may occur.

CC024D

3-48

4. Loosely install the two nuts which secure the
cylinder to the crankcase.
NOTE: The two cylinder-to-crankcase nuts will
be tightened in step 10.

CC023D

5. Install the coolant hose onto the crankcase union
and tighten the clamp.
C. Cylinder Head
D. Valve Cover
KEY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Cylinder Head Assy
Valve Guide
Sleeve
Cap Screw
Cap Screw
Cylinder Head Gasket
Pin
Cap Screw
Stud Bolt
Stud Bolt
Stud Bolt
Cap Screw
Cap Screw
Nut
Nut

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.

Gasket
Crush Washer
Spark Plug
Inspection Cap
O-Ring
Cap Screw
Cylinder Head Plug
Intake Pipe Assy
O-Ring
Machine Screw
Clamp
Temperature Switch
Assy
28. Thermostat Cover
29. Thermostat

0741-101

NOTE: Steps 1-5 in the preceding sub-section
must precede this procedure.

6. Place the chain guide into the cylinder.

! CAUTION
Care should be taken that the bottom of the chain
guide is secured in the crankcase boss.

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.

3-49

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.

CC020D

732-307B

NOTE: At this point, oil the camshaft bearings,
cam lobes, and the three seating journals on the
cylinder.

CF057A

8. Install the four cylinder head cap screws with
copper washers. Tighten only until snug.

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.

CD461
CC272D

9. Loosely install the five cylinder head nuts.
10. In a crisscross pattern, tighten the four cylinder
head cap screws (from step 8) to 5.5 kg-m (40
ft-lb); then tighten the 8 mm nut (from step 9) to
2.5 kg-m (18 ft-lb). Using a crisscross pattern,
tighten the 6 mm nuts (from step 9) to 1.1 kg-m
(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.

3-50

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.

CD463

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 head ensuring the following.

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.

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.

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.

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
specifications. Bend the tab to secure the cap
screw.

! CAUTION
If any of the above factors are not as stated, go
back to step 11 and carefully proceed.

16. Place the tab-washer onto the sprocket making
sure it covers the pin in the alignment hole.

CD465

3-51

19. Rotate the crankshaft until the first cap screw
(from step 17) can be addressed; then tighten to
specifications. Bend the tab to secure the cap
screw.

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.

23. Place the chain tensioner adjuster assembly and
gasket into position on the cylinder and secure
with the two machine screws.

CC012D

21. Install the cylinder head plug in the cylinder
head with the open end facing downward and
toward the inside.

! CAUTION
The open end of the plug must be positioned downward.

CD469

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.

CD470
CD468

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.
3-52

CD471

CC003D

25. Loosen the four adjuster screw jam nuts; then
loosen the four adjuster screws on the rocker
arms in the valve cover.

29. In a crisscross pattern starting from the center
and working outward, tighten the cap screws
securely.
30. Adjust valve/tappet clearance using the following procedure.
NOTE: Use Valve Clearance
0444-078) for this procedure.

Adjuster

(p/n

A. Turn the engine over until the piston reaches
top dead center on the compression stroke.
B. 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.
CC528D

26. Apply a thin coat of Three Bond Sealant (p/n
0636-070) to the mating surfaces of the cylinder
head and valve cover.

C. 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.
D. Align the valve adjuster handle with one of
the marks on the valve adjuster dial.
E. While holding the valve adjuster handle in
place, rotate the valve adjuster dial counterclockwise until specified valve/tappet clearance is attained.
NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.

CC275D

27. Place the valve cover into position.
NOTE: At this point, the rocker arms and
adjuster screws must not have pressure on them.

28. Install the four top side cap screws with rubber
washers; then install the remaining cap screws.
Tighten only until snug.

F. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely
with the valve adjuster handle.
31. Place the two tappet covers into position making
sure the proper cap screws are with the proper
cover. Tighten the cap screws securely.

3-53

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.

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.

CC001D

32. If removed, install the spark plug. Tighten to
specifications.

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.

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
specifications.

! WARNING
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.
PR153A

PR114

PR147

4. Apply multi-purpose grease to the driveshaft
splines; then align the flange marks and slide the
splines into the slip-joints.
3-54

PR148

PR153B

3
PR151A

! CAUTION
The drive-line yokes must be aligned (timed) or
damage will occur to the universal joints and gears.

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.

5. Install the cap screws securing the drive-line
couplers to the drive flanges and tighten to specifications.

9. Install the starter wire on the starter and tighten
the nut securely; then connect the CDI connector, alternator connector, shift position switch
connector, and electric choke connector.

PR120A

PR145A

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 specifications.
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.
3-55

PR128A

PR117

10. From the right-side, connect the speed sensor
connector, fuel quantity sender lead, and temperature sensor lead; then install the spark plug
cap.

PR140B

PR155A

PR154

PR130A

11. Install the carburetor and tighten the intake boot
clamp securely; then connect the gas line, vacuum line, and throttle cable.

12. Place the air filter assembly into position and
secure with the self-tapping screws; then connect the intake boot to the carburetor and the
inlet housing boot to the air filter housing.
Tighten the clamps securely.

PR127A

3-56

13. Place the shifter assembly into position and
secure with the four machine screws. Tighten
securely.
14. Connect the shifter linkage to the shift arm placing the spacer washers in appropriate locations;
then secure with the E-clip.
NOTE: Before operating vehicle, check and
adjust shifter linkage as required (see Section 2).

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).

3-57

SECTION 4 FUEL/LUBRICATION/COOLING

TABLE OF
CONTENTS
Carburetor Specifications ........................................ 4-2
Carburetor Schematic ............................................. 4-2
Carburetor ............................................................... 4-3
Cleaning and Inspecting Carburetor........................ 4-6
Throttle Cable Free-Play ......................................... 4-7
Engine RPM (Idle) ................................................... 4-7
Gas Tank ................................................................. 4-7
Gas/Vent Hoses ................................................... 4-10
Vacuum Pulse Fuel Pump ..................................... 4-10
Oil Flow Chart ....................................................... 4-11
Oil Filter/Oil Pump ................................................. 4-11
Oil Cooler .............................................................. 4-12
Liquid Cooling System........................................... 4-14
Radiator/Oil Cooler................................................ 4-15
Thermostat ............................................................ 4-17
Fan ........................................................................ 4-17
Water Pump .......................................................... 4-18
Testing Vacuum Pulse Fuel Pump......................... 4-19

4-1

Carburetor
Specifications
PROWLER XT
Type

Keihin CVK36

Main Jet

132

Slow Jet

Pilot Screw Setting (turns)

1 1/4

Needle Jet

6.0/4.0

Jet Needle

NFKS

Idle RPM

1250-1350

Starter Jet

Float Arm Height

17 mm
(0.7 in.)

Throttle Cable Free-Play
(at accelerator pedal)

3-6 mm
(1/8-1/4 in.)

Carburetor Schematic
KEY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

Cover
Screw
Spring
Vacuum Piston
Spring Seat
Jet Needle
Needle Jet
Jet Holder
Main Jet
Slow Jet
Starter Jet
Float Valve
Clip
Float Set
Float Pin
Pilot Screw
Spring
Washer
O-Ring
Idle Adjust Screw
Washer
Spring

23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.

Plate
Screw
Electric Choke
Choke Cover
Float Chamber
Assy
Screw
Spring
Diaphragm Assy
Pump Housing
U-Ring
Screw
Screw
Cover
Screw
Vent Hose

0741-115

4-2

Carburetor
! 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

PR162A

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.

6. Disconnect the electric choke connector; then
remove the carburetor from the vehicle.
DISASSEMBLING

1. Remove the four Phillips-head screws securing
the top cover; then remove the cover.

PR160A

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.

CH015D

2. Remove the vacuum piston assembly from the
carburetor body. Account for a spring, spring
seat, and the jet needle.

5. Remove the throttle arm cover; then loosen the
outer jam nut on the throttle cable and disconnect the throttle cable from the carburetor.

CC746

3. Remove the three screws securing the primer
housing. Account for the diaphragm assembly,
spring, and U-ring (in the housing).
PR154A

4-3

6. Lift the float assembly from the carburetor.
Account for the float needle valve.

CC748

4. Remove the Phillips-head screws securing the
float chamber; then remove the chamber.
Account for the O-ring.

CC753

NOTE: Note the locations of the jets, pilot screw,
and holder for disassembling procedures.

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
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 speed adjuster
assembly. Account for the spring and washer.
CC752

4-4

ASSEMBLING

1. Screw the idle speed adjuster into the carburetor
making sure the washer and spring are properly
positioned.

4. Install the main jet into the needle jet holder and
tighten securely; then install the needle jet
holder assembly into the carburetor and tighten
securely.

2. Install the pilot screw with the spring, the
washer, and the O-ring in this order.

5. Place the float assembly (with float needle
valve) into position and secure to the carburetor
with the float pin.

CC758

CC753

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: 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.).

NOTE: Note the locations of the jets and holder
during assembling procedures.

6. Place the float chamber into position making
sure the O-ring is properly positioned; then
secure with the Phillips-head screws.

CC759A
CC750

CC761A

3. Install the slow jet. Tighten securely.
CC749

4-5

7. Place the U-ring into the primer housing. Position the spring and diaphragm assembly (lip
toward the carburetor) onto the carburetor; then
secure the assembly with the primer 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 primer 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.

8. Place the jet needle, spring seat, and spring into
the vacuum piston; then place the assembly
down into the carburetor.

6. Install the left-side seat-base; then install the
center console and the seats making sure the
seats lock securely.

Cleaning and Inspecting
Carburetor
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

! 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.
CC746

9. Place the top cover into position; then secure
with the Phillips-head screws. Tighten securely.

1. Place all metallic components in a wire basket
and submerge in carburetor cleaner.
2. Soak for 30 minutes; then rinse with fresh
parts-cleaning solvent.
3. Wash all non-metallic components with soap
and water. Rinse thoroughly.
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.

CH015D

4-6

6. Inspect the vacuum piston/diaphragm for cracks,
imperfections in the casting, or cracks and tears
in the rubber.

Engine RPM (Idle)

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
inlet needle valve 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.

11. Inspect the plunger assembly/starter valve and
seat for wear or damage.
12. Inspect the carburetor mounting flange for damage and tightness.

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. Start the engine and warm it up to operating
temperature.

2. Rotate the idle adjustment screw clockwise or
counterclockwise until the engine idles at
1250-1350 RPM.

! WARNING
Adjust the idle to the correct RPM. Make sure the
engine is fully warm before adjusting the idle RPM.

Throttle Cable
Free-Play
1. Check throttle cable free-play at the accelerator
pedal; free-play should be as specified.
2. To adjust, slide the rubber boot (A) away from
the adjuster located near the carburetor. Loosen
the jam nut (B) and rotate the adjuster (C) in the
appropriate direction until proper free-play is
attained. Tighten the jam nut against the
adjuster; then slide the rubber boot over the
adjuster.

PR081A

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.

REMOVING
CD560A

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.

4-7

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.

PR166B

6. Remove the outer cap screw securing the front
tank hold-down; then swing the hold-down to
the left.
PR163

PR167A
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.

PR170

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, gas hose, and fuel
level sensor connector; then cap the vent fitting
and gas hose fitting.

4-8

INSTALLING

! 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.

1. Place the gas tank into position in the vehicle;
then install the inside rear hold-down strap.
PR168

8. Remove the joining cap screw and nut from the
rear gas tank hold-down strap; then remove the
inside hold-down strap.

PR173

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
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Clean all gas tank components with parts-cleaning solvent.

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.

2. Inspect all hoses for cracks or leaks.
3. Inspect gas tank cap and tank for leaks, holes,
and damaged threads.
4. Inspect the fuel level sensor for proper operation.

PR171

3. Install the rear hold-down strap joining cap
screw and nut. Do not tighten at this time.

4-9

PR166A

PR167A

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.

6. Connect the gas hose and gas tank vent hose to
the proper fittings; then connect the fuel level
sensor wire connector to the main harness.

PR176

PR166B

5. Secure the filler panel with four press-nuts; then
tighten the hardware securing the hold-down
straps (from steps 2-3) securely.

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.

Vacuum Pulse Fuel
Pump
The vacuum pulse fuel pump is a nonserviceable
assembly. If the pump fails, it must be replaced.

4-10

Oil Flow Chart

4
ATV-1102

TESTING OIL PUMP PRESSURE

Oil Filter/Oil Pump

NOTE: The engine must be warmed up to the
specified temperature for this test.

NOTE: Whenever internal engine components
wear excessively or break and whenever oil is contaminated, the oil pump should be disassembled,
cleaned and inspected, and serviced as necessary.

1. Remove the seats and center console; then
remove the left-side seat-base.
2. Tilt the cargo box back.
3. Loosen the clamps securing the V-belt housing
exhaust duct; then remove the duct and set
aside.

KEY
1.
2.
3.
4.
5.
6.
7.
8.

Oil Pump
Driven Gear
Pin
Washer
Circlip
Cap Screw
Strainer
Cap Screw

9.
10.
11.
12.
13.
14.
15.
16.

Cap
O-Ring
Cap Screw
Filter
Drain Plug
Gasket
Oil Relief Valve Assy
Oil Filter Union
0738-289

PR266A

4. Disconnect the upper oil cooler hose; then using
a T-fitting and appropriate adapter, connect the
Oil/Fuel Pressure Gauge (p/n 0644-375) into the
oil cooler circuit.
4-11

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
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.
PR265A

NOTE: Some oil seepage may occur when
installing the oil pressure gauge. Wipe up oil residue with a cloth.

5. Set the parking brake and start the engine.
Allow the engine to warm up to operating temperature (with cooling fan cycling).
6. Set the speedometer/tachometer to RPM. With
the engine running at 2500 RPM, the pressure
gauge must show as specified.
OIL PRESSURE @ 2500 RPM
1.40-2.11 kg/cm²
(20-30 psi)
Operating Temperature (Cooling Fan Cycling)

7. Reconnect the oil cooler hose and tighten the
hose clamp securely; then install the V-belt
exhaust duct and tighten the clamps securely.
8. 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, defective
oil pump, or plugged oil cooler (see Checking Oil
Cooler Restriction in the Oil Cooler sub-section).
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.

REMOVING/DISASSEMBLING
NOTE: Prior to removing the oil pump due to a
low oil pressure reading, check for oil cooler
restrictions (see Checking Oil Cooler Restriction in
the Oil Cooler sub-section).

1. Remove the oil pump from the engine (see
Right-Side Components in Section 3).

4-12

1. Clean all oil-pump components.
2. Inspect the rotors for scoring and gouges.
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).

Oil Cooler
CHECKING OIL COOLER
RESTRICTION

1. Remove the seats, center console, and left-side
seat-base; then remove the V-belt exhaust duct.
Tilt the cargo box back.
2. Disconnect the lower oil cooler hose; then using
a T-fitting and appropriate adapter, connect the
Oil/Fuel Pressure Gauge (p/n 0644-375) into the
oil cooler circuit.

PR267A

PR275A

3. Set the parking brake and start the engine.
Allow the engine to warm up to operating temperature (with cooling fan cycling).
4. Set the speedometer/tachometer to RPM. With
the engine running at 2500 RPM, the pressure
gauge must show 4.2-5.6 kg/cm2 (60-80 psi).
NOTE: If the gauge readings are normal but low
oil pressure was noted while testing the oil pump
pressure, the oil cooler is plugged and must be
replaced.
PR268A

REMOVING OIL COOLER
NOTE: The oil cooler is attached to the rear of
the radiator and must be removed as an assembly
(see Radiator/Oil Cooler sub-section).

3. Remove four machine screws securing the oil
cooler to the fan shroud and remove the oil
cooler.

1. Disconnect the two-wire connector on the cooling fan harness; then remove the machine screw
and wire clamp securing the cooling fan switch
wires.

PR273A

INSTALLING OIL COOLER

PR271A

2. Remove four machine screws (two on each side)
securing the fan shroud to the radiator noting
orientation of the fan and oil cooler for assembling.

1. Place the oil cooler on a clean flat surface; then
position the fan shroud over the oil cooler making sure the fan wires are directed toward the top
of the shroud and the oil cooler connections are
directed toward the bottom of the shroud.
Secure with four machine screws.

4-13

PR273A

2. Place the radiator on a flat surface (front side
down); then position the oil cooler/cooling fan
assembly onto the radiator with the oil cooler
connections directed toward the bottom of the
radiator. Secure with four machine screws making sure to install the radiator overflow hose
hold-down clip on the upper-right machine
screw.

3. Connect the cooling fan harness to the cooling
fan connector; then secure the cooling fan harness wire clamp with the machine screw.

Liquid Cooling System
KEY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

Radiator Assy
Radiator
Radiator Screen
Radiator Cap
Grommet
Vent Hose
Thumb Screw
Fan Shroud
Fan
Machine Screw
Clamp
Clamp
Temperature Sender
O-Ring
Shoulder Screw
Nut w/Washer
Stem Bushing
Coolant Hose
Coolant Hose
Coolant Hose
Hose Clamp
Cable Tie
Hose Clamp

0739-654

The cooling system should be inspected daily for
leakage and damage. Also, the coolant level should
be checked periodically.

4-14

When filling the cooling system, use premixed Arctic Cat Antifreeze (p/n 0638-395). 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.

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.

! 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.

Radiator/Oil Cooler
REMOVING

PR186

4. Drain the coolant into a suitable container; then
disconnect the cooling fan wire connector from
the main harness.

1. Remove six torx-head screws securing the dash
assembly to the frame; then remove the parking
brake release handle and jam nut. Slide the dash
rearward approximately four inches.

PR183A

5. Remove the two shoulder bolts and nuts securing the radiator to the frame; then disconnect the
upper and lower coolant hoses.
PR181A

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. Place a shallow container under the right-side
oil cooler hose; then remove the hose from the
oil cooler.

PR182A

4-15

PR185

PR183A

7. Allow the oil cooler to drain; then remove the
left-side oil cooler hose.

3. Pour the recommended coolant into the radiator
and secure the radiator cap.

8. Lift the radiator/oil cooler assembly from the
vehicle. Account for two upper and two lower
rubber mounting grommets.

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.

CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Flush the radiator with water to remove any contaminants.
2. Inspect the radiator for leaks and damage.
3. Inspect all hoses for cracks and deterioration.
4. Inspect all fasteners and grommets for damage
or wear.
INSTALLING

1. Place the radiator/oil cooler 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 while guiding the parking brake release rod through the
hole; then secure the dash with the appropriate
hardware.
6. Install the jam-nut and parking brake release
handle; then tighten the jam-nut so the handle is
correctly oriented.
7. Set the parking brake; then start the engine and
let idle for approximately one minute to fill the
oil cooler. Shut the engine off and add oil to the
crankcase as required to the specified level (see
Section 2).

PR184A

2. Connect the upper and lower radiator hoses and
the left and right oil cooler hoses to the radiator/oil cooler and secure with the appropriate
hose clamps; then connect the cooling fan connector to the main harness.
4-16

INSTALLING

1. Place the thermostat 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.
PR053B

8. 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 required.

Thermostat
REMOVING
PR281A

1. Drain approximately one quart of coolant from
the cooling system.

2. Fill the cooling system with the recommended
amount of antifreeze. Check for leakage.

2. Remove the two cap screws securing the thermostat housing to the cylinder head. Account for
a thermostat with seal.

Fan

INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Inspect the thermostat for corrosion, wear, or
spring damage.
2. Using the following procedure, inspect the thermostat for proper operation.

REMOVING

1. Remove the radiator (see Radiator/Oil Cooler in
this section).
2. Remove the fan assembly from the radiator.
INSTALLING

A. Suspend the thermostat in a container filled
with water.

1. Position the fan assembly on the radiator; then
secure with existing hardware.

B. Heat the water and monitor the temperature
with a thermometer.

NOTE: The fan wiring must be in the upper-right
position.

C. The thermostat should start to open at
73.5-76.5°C (164-170°F).

2. Install the radiator (see Radiator/Oil Cooler in
this section).

D. If the thermostat does not open, it must be
replaced.
3. Inspect all coolant hoses, connections, and
clamps for deterioration, cracks, and wear.
NOTE: All coolant hoses and clamps should be
replaced every four years or 4000 miles.
4-17

4. Loosen the coolant hose clamps and slide the
clamps away from the hose ends approximately
51 mm (2 in.); then remove both hoses from the
water pump.

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.

PR132

5. Remove the two cap screws securing the water
pump to the engine; then remove the water
pump.

KEY
1.
2.
3.
4.
5.
6.

Water Pump Assy
Screw
Driven Gear
Shaft
Pin
Circlip

7.
8.
9.
10.
11.

Bearing
Circlip
Drive Gear
Pin
Circlip
0739-945

REMOVING

CC786A

1. Remove the radiator cap; then remove the water
pump coolant drain plug and drain the coolant.

INSTALLING

1. Secure the water pump to the engine with the
two cap screws tightened securely; then tighten
the two Phillips-head cap screws securely.

PR122A

2. Drain the oil from the engine/transmission.
3. Remove the seats and center console; then
remove the right-side seat-base.

4-18

CC786A

Testing Vacuum Pulse
Fuel Pump

AT THIS POINT

Prior to removing the vacuum pulse fuel pump,
the following check should be performed to
determine that removal is necessary.
CC785A

2. Connect the two coolant hoses to the water
pump and secure with the clamps; then install
the water pump coolant drain plug.

! 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.

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.

4
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.

5. Check the entire cooling system for leakage.

! CAUTION

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.

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.

6. Install the right-side seat-base; then install the
center console and seats making sure the seats
lock securely.

PR280A

4-19

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.

4-20

SECTION 5 ELECTRICAL SYSTEM

TABLE OF
CONTENTS

Specifications .......................................................... 5-2
Battery..................................................................... 5-3
RPM Limiter............................................................. 5-3
Testing Electrical Components ................................ 5-3
Accessory Receptacle/Connector ........................... 5-4
Brakelight Switch..................................................... 5-4
Coolant Temperature and Cooling Fan Switches .... 5-4
Fan Motor ................................................................ 5-5
Power Distribution Module....................................... 5-6
Fuses ...................................................................... 5-6
Ignition Coil ............................................................. 5-6
Speed Sensor ......................................................... 5-7
Ignition Switch ......................................................... 5-8
Dash Switches ........................................................ 5-8
Center Console Switch............................................ 5-9
Front Drive Selector Actuator .................................. 5-9
Differential Lock Switch ......................................... 5-10
Magneto Coils ....................................................... 5-10
Starter Motor ......................................................... 5-12
Starter Relay ......................................................... 5-12
CDI Unit................................................................. 5-13
Regulator/Rectifier................................................. 5-13
Neutral Start/Start-in-Gear/2WD Relays ............... 5-13
Headlights ............................................................. 5-14
Taillight-Brakelight ................................................. 5-14
Ignition Timing ....................................................... 5-14

5-1

Specifications
Prowler XT
IGNITION
Ignition Timing

10° BTDC @ 1500 RPM

Spark Plug Type

Champion R6YCA

Spark Plug Gap

0.7-0.8 mm
(0.028-0.032 in.)

Spark Plug Cap
Ignition Coil
Resistance

4000-6000 ohms
(primary)
(secondary)

Ignition Coil Peak
Voltage (static)

(primary/CDI)

Less than 1 ohm
(terminal to ground)
5200-7800 ohms
(high tension - plug cap
removed - to ground)
132-198 DC volts
(terminal to ground)

MAGNETO
Magneto Coil
Resistance

(trigger)
(source)
(charging)

Magneto Coil
Peak Voltage

(trigger)
(source)

160-240 ohms
(green to blue)
Less than 1 ohm
(yellow to white)
Less than 1 ohm
(black to black)
4.2-6.3 volts
(green to blue)
0.40-0.62 volt
(yellow to white)

Stator Coil Output

(no load)

60 AC volts @ 5000
RPM
(black to black #1)
(black to black #2)

Magneto Output

(approx)

325W @ 5000 RPM

5-2

Battery

7. Connect cables to the proper terminals: positive
cable to the positive terminal (+) and negative
cable to the negative terminal (-). Connect the
negative cable last.

! WARNING

! CAUTION

Connecting cables in reverse (positive to negative
and negative to positive) can cause serious damage to the electrical system.

1. Remove the battery from the vehicle.

8. Check the vent tube to make sure it is not
pinched or obstructed in any way and that it is
properly routed down through the frame.

RPM Limiter

! WARNING
Remove the negative cable first; then remove the
positive cable.

! CAUTION
Do not charge the battery while it is in the vehicle
with the battery terminals connected.

2. Remove the vent plugs; then fill the battery with
electrolyte to the UPPER level indicated on the
battery.
NOTE: Electrolyte should be at room temperature before filling. Do not use water or any other
liquid to activate a battery.

NOTE: The Prowler XT is equipped with a CDI
unit that retards ignition timing when maximum
RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed
misfire.

Testing Electrical
Components

3. Allow the battery to stand for 15-30 minutes
after filling. Electrolyte level may fall during
this time. Refill with electrolyte to UPPER level
line.

All of the electrical tests should be made using the
Fluke Model 73 Multimeter (p/n 0644-191) and
when testing peak voltage, the Peak Voltage Reading Adapter (p/n 0644-307) 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.

4. Trickle-charge the battery at 1.5A for 8-10
hours.

NOTE: For absolute accuracy, all tests should be
made at room temperature of 68° F.

! WARNING
Electrolyte is a sulfuric acid solution. Avoid spillage
and contact with skin, eyes, and clothing.

5. After charging, check electrolyte level and fill
with DISTILLED WATER as necessary; then
install the vent plugs. Wash off acid spillage
with water and dry the battery.

! CAUTION
Before installing the battery, make sure the ignition
switch is in the OFF position.

6. Place the battery into position in the vehicle and
secure; then connect the vent hose to the battery.

5-3

Accessory
Receptacle/Connector
NOTE: This test procedure is for either the
receptacles or the connectors.

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.

RESISTANCE
(Switch Connector)

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.

! CAUTION
Always disconnect the battery when performing
resistance tests to avoid damaging the multimeter.

NOTE: The brake pedal must be depressed for
this test.

1. Set the meter selector to the OHMS position.

NOTE: If the meter shows no battery voltage,
troubleshoot the battery, fuse, receptacle, connector, or the main wiring harness.

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.
NOTE: The ignition switch must be in the ON
position.

VOLTAGE
(Wiring Harness Connector)

AR621D

1. Set the meter selector to the DC Voltage position.

3. When the lever is depressed, the meter must
show less than 1 ohm.

2. Connect the red tester lead to the orange wire;
then connect the black tester lead to ground.

NOTE: If the meter shows more than 1 ohm of
resistance, replace the switch.

Coolant Temperature
and Cooling Fan
Switches
1. Connect the meter leads (selector in the OHMS
position) to the switch contacts.

PR276A

3. The meter must show battery voltage.

5-4

2. Suspend the switch and a thermometer in a container of water; then heat the water.

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.

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.

RESISTANCE
(Fan Motor Connector)
733-554E

! CAUTION

3. On the coolant temperature switch when the
water temperature reaches 112-118° C
(234-244° F), the meter should show a closed
circuit.

Always disconnect the battery when performing
resistance tests to avoid damaging the multimeter.

4. On the coolant temperature switch, allow the
water 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.

2. Connect the red tester lead to the red wire; then
connect the black tester lead to the black wire.

1. Set the meter selector to the OHMS position.

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 water 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.
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.

Fan Motor
NOTE: The ignition switch must be in the ON
position.

VOLTAGE
(Main Harness Connector to Fan
Motor)

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.
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.

! CAUTION
Care should be taken to keep clear of the fan
blades.

1. Set the meter selector to the DC Voltage position.

5-5

Power Distribution
Module
The fuses are located in a power distribution module
under the driver’s seat.
If there is any type of electrical system failure,
always check the fuses first.

Fuses
! CAUTION
Always disconnect the battery when performing
resistance tests to avoid damaging the multimeter.

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.

Prowler XT

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.
1411-191

1. Remove all fuses from the power distribution
module.
2. Set the meter selector to the DC Voltage position.

Ignition Coil

3. Connect the black tester lead to ground.

The ignition coil is mounted on the fuel pump
mounting plate adjacent to the fuel pump.

4. Using the red tester lead, contact each end of the
fuse holder connector terminals individually.

VOLTAGE (Primary Side)

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.

5-6

See PEAK VOLTAGE Primary/CDI this sub-section.
RESISTANCE

! CAUTION
Always disconnect the battery when performing
resistance tests to avoid damaging the multimeter.

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/CDI
NOTE: The CDI is located beneath the driver’s
seat above the battery.

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.
PR278A

2. The meter reading must be within specification.
Secondary Winding

! WARNING
Do not touch the primary wire with the ignition
switch turned on or severe electrical shock will
occur.

1. Connect the red tester lead to the high tension
lead (with the plug cap removed); then connect
the black tester lead to ground.

3. Turn the ignition switch to the ON position.

2. The meter reading must be within specification.

5. With the test leads still connected, crank the
engine with the electric starter.

NOTE: If the meter does not show as specified,
replace ignition coil.

4. The meter must show 132-198 DC volts.

6. The meter must show 300-450 DC volts.

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.

Speed Sensor

NOTE: Prior to testing the speed sensor, inspect
the three-wire connector on the speed sensor for
contamination, broken pins, and/or corrosion.

AR603D

2. The meter reading must be within specification.
NOTE: If the meter does not show as specified,
replace the spark plug cap.

PEAK VOLTAGE
NOTE: All of the peak voltage tests should be
made using the Fluke Model 73 Multimeter (p/n
0644-191) with Peak Voltage Reading Adapter (p/n
0644-307). 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.

PR279A

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).
3. Turn the ignition switch to the ON position.
4. The meter must show approximately 6 DC volts.
5-7

5. Leave the black tester lead connected; then connect the red tester lead to the signal lead (S) pin.
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.

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.

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.
CD070

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.

NOTE: When the starter is engaged, battery voltage will be approximately 10.5 DC volts.

Dash Switches
VOLTAGE (Headlight Switch)

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.

CD071

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.

5-8

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.
NOTE: The battery voltage will show lower in
steps 3 and 4 due to electrical loading of the headlights.

VOLTAGE
(2WD/4WD Selector Switch)

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.

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.

Center Console Switch

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.

Front Drive Selector
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 (p/n
0744-041).

VOLTAGE (Reverse Override
Switch)
NOTE: To perform the following tests, the ignition switch must be in the ON position and the
transmission shifted into reverse gear.

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.

PR293

2. Connect the black lead to the black wire using a
MaxiClip (p/n 0744-041); then select 2WD on
the 2WD/4WD selector switch.

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.

5-9

PR295

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 fuse on the power distribution module, the ignition switch, or the main
wiring harness.

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.

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.

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: The 4WD and LOCK icons in the
upper-left corner of the LCD should illuminate.

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).
CF094C

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.

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.

Magneto Coils
VOLTAGE (Charging Coil - 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.

5-10

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.

VOLTAGE
(Stator Coil - No Load)

The connector is the black and white one on the
right side of the engine just above the brake cable
adjuster.
NOTE: Test the connector that comes from the
engine.

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.

! CAUTION
Do not run the engine at high RPM for more than 10
seconds.

NOTE: If both charging coil tests failed, check all
connections, etc., and test again. If no voltage is
present, replace the stator assembly.

RESISTANCE (Charging Coil)

! CAUTION
Always disconnect the battery when performing
resistance tests to avoid damaging the multimeter.

1. Set the meter selector to 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.
RESISTANCE
(Source Coil)

1. Set the meter selector to the OHMS position.
2. Connect the red tester lead to the yellow wire;
then connect the black tester lead to the white
wire.
3. The meter reading must be within specification.
NOTE: If the meter shows other than specified in
any resistance test, replace the stator assembly.

Magneto Coil (Trigger)

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.
Magneto Coil (Source)

1. Set the meter selector to the DC Voltage position.

2. Test between the three black wires for a total of
three tests.

2. Connect the red tester lead to the yellow wire;
then connect the black tester lead to the white
wire.

3. The meter reading must be within specification.

3. Crank the engine over using the electric starter.

RESISTANCE (Trigger Coil)

4. The meter reading must be within specification.

! CAUTION
Always disconnect the battery when performing
resistance tests to avoid damaging the multimeter.

1. Set the meter selector to the OHMS position.
5-11

Starter Motor
NOTE: The starter motor is not a serviceable
component. If the motor is defective, it must be
replaced.

REMOVING

1. Disconnect the battery.

! CAUTION
Always disconnect the negative battery cable from
the battery first; then disconnect the positive cable.

2. Remove the nut securing the positive cable to
the starter; then remove the cable from the
starter.
3. Remove the two machine screws securing the
starter 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

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.

Starter Relay
1. Remove the operator’s 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.

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 (on automatic transmission models) in the NEUTRAL position.

1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the starter terminal; then connect the black tester lead to ground.
3. With the starter button depressed, the meter
must show battery voltage and the starter motor
should operate.

PR296

NOTE: Make sure that the ignition switch is in
the ON position, transmission in neutral, and parking brake set.

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.
5-12

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.

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.

Regulator/Rectifier
The regulator/rectifier is located under the driver’s
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.
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.

CDI Unit
The CDI is located beneath the operator’s seat near the
battery.
NOTE: The CDI unit is not a serviceable component. If the unit is defective, it must be replaced.

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.

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 (Charging Coil - No
Load) in this section. If charging coil voltage is
normal, replace the regulator/rectifier.

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.

5-13

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. 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 (p/n
0744-041).
3. Connect the red tester lead to the yellow wire
(high beam) or white wire (low beam) using a
MaxiClip (p/n 0744-041). 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.

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.
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.

5-14

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.

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 fuse, brakelight switch, wiring
harness, or connectors.

Ignition Timing
The ignition timing cannot be adjusted; however,
verifying ignition timing can aid in troubleshooting
other components. To verify engine timing, use the
following procedure.
1. Attach the engine Timing Light (p/n 0644-197)
to the spark plug high tension lead; then remove
the timing inspection plug from the right-side
crankcase cover.
2. With the Arctic Cat Engine Tachometer (p/n
0644-275) connected, start the engine and run at
the specified RPM.
3. Ignition timing should be 10° BTDC.
4. 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
may be faulty.

SECTION 6 - DRIVE SYSTEM

TABLE OF
CONTENTS
Drive System ........................................................... 6-2
General Information................................................. 6-2
Front Drive Actuator ................................................ 6-3
Front Differential ...................................................... 6-4
Drive Axles ............................................................ 6-17
Rear Gear Case .................................................... 6-22
Hub........................................................................ 6-23
Hydraulic Brake Caliper......................................... 6-25
Universal Joints ..................................................... 6-27
6-1

TROUBLESHOOTING

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.

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

New Housing

Reassembled
Housing

M6
(Torx T-30 Recess)

1.1-1.3 kg-m
(8-9.5 ft-lb)

0.9-1.2 kg-m
(6.5-9 ft-lb)

M8
(Torx T-40 Recess)

3.5-4.3 kg-m
(25-31 ft-lb)

2.9-3.5 kg-m
(21-25 ft-lb)

SPECIFICATIONS

Specific specifications regarding the gear cases
(capacities, lubricant type, etc.) can be found in Section 1 of this manual.
Ring Gear Backlash

0.28-0.38 mm (0.011-0.015 in.)

Ring Gear End Play

0.1-0.2 mm (0.004-0.008 in.)

SPECIAL TOOLS

A number of special tools must be available to the
technician when servicing the gear case.
Description

p/n

Boot Clamp Pliers

0444-120

Pinion Gear/Shaft Removal Tool

0444-127

Slide Hammer w/CV Joint Attachment

0444-123

CV Joint Attachment (Only)

0444-119

Internal Hex Socket (48 mm)

0444-104

NOTE: Special tools are available from the Arctic
Cat Service Parts Department.

6-2

If a noise is heard from the gear case area, it can be
difficult to locate and/or diagnose. If the noise is
related to wheel speed, but not to engine RPM, the
problem is probably in the final drive or
engine/transmission bevel gear set. When a problem
is localized, a number of inspections must be made
to pinpoint that problem. The most obvious of the
inspections include CV boots, wheel and hub nut
tightness, wheel bearing damage, gear case lubricant
contamination, low lubricant level, seal leakage, CV
joints, or selector arm.
NOTE: Small metallic particles will collect on the
magnetic drain plug as a normal part of break-in
and will also give a metallic cast to drained lubricant. Contamination would include large particles
or water which gives a “milky” look to the lubricant.
NOTE: Lubricant on a new pinion housing
assembly could be grease. If the front of the gear
case is leaking at the rear drive boot, wipe excess
lubricant from the bottom of the pinion housing;
then operate the vehicle for a period of time.
Inspect the pinion housing area for any signs of
leakage. If lubricant is again on the bottom of the
pinion housing, the seal must be replaced.

Additional troubleshooting could include the following.
• Binding/abrupt motion: CV boot torn (grease loss,
foreign object damage, broken cage); gear lubricant loss or not filled (bearing seizure, broken gear
teeth, seal leakage, bladder or hose leakage,
missing filler/drain plug).
• Noise from drive system: wheel or gear case bearing damage, improper gear backlash, improper
assembly, low or no gear case lubricant.
• Lockup: gear case lubricant loss or not filled, water
contamination causing bearing seizure.

Front Drive Actuator

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.

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.

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

AG928

INSTALLING

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.

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.

PR189A

3. Remove the mounting cap screw from above the
actuator on the suspension side.

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.

PR190A

6-3

NOTE: The jack stands should be placed under
the main frame to avoid contact with front suspension components.

! 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 reinstall the plug.
AG928

4. Loosen the front cap screw; then tighten the cap
screw on the driveshaft side.

PR022

3. Remove the front wheels.

AG926

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.

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.

7. Remove the two brake calipers. Account for the
four cap screws; then remove the hubs.

7. Secure the wiring harness to the frame with a
nylon cable tie; then install the inner fender
panel.

Front Differential
REMOVING DIFFERENTIAL

1. Remove the belly panel; then place the vehicle
on jack stands adjusted high enough to allow
working from the underside of the vehicle.

6-4

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.

PR191

PR193

9. Remove two cap screws securing the differential
lock cable support; then disconnect the differential lock cable at the differential.

11. Pull the steering knuckle away from the axle
taking care not to damage the seals with the axle
end.

PR194A

PR222

12. Support the axle to not allow it to drop or hang.

! CAUTION
The axle must be supported. If the axle is allowed
to drop or hang, damage to the inner CV joint
may occur.

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.
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.

PR200

14. Scribe match marks on the front input drive
flange and the front drive yoke flange; then
remove three cap screws securing the yoke and
flange. Separate the flanges but do not remove
the driveshaft.
6-5

PR198A

CD016

15. Using Slide Hammer w/CV Joint Attachment
(p/n 0444-123), remove the front axles.

18. Free the differential assembly from the frame
mountings; then lower the differential through
the frame.
Disassembling Input Shaft

1. Using a T-40 torx wrench, remove the cap
screws securing the pinion housing.

PR199

16. Remove the lower differential mounting cap
screw. Account for a lock nut and four washers.
Note the position of the washers for assembling.
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.

PR205A

17. Remove the upper differential mounting cap
screw. Account for a lock nut and two washers.

CD103

6-6

CD106

AF983

3. Remove the input shaft from the pinion housing.

AF984
CD107

4. Using a seal removal tool, remove the input
shaft seal. Account for a spacer.

KX219

Assembling Input Shaft
AF982

5. Remove the snap ring securing the input shaft
bearing; then place the pinion housing in a press
and remove the bearing.

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.

6-7

AF993

KX222

4. Install the input shaft into the pinion housing;
then secure in the bearing with a circlip.

AF994

2. Install the input shaft seal making sure it is flush
with the edge of the housing.
KX210A

3. Lubricate the input shaft splines with High-Performance Grease (p/n 0436-501).

5. Place the pinion housing with new gasket onto
the gear case housing; then secure with existing
cap screws. Tighten to specifications.

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 3.5-4.3 kg-m
(25-31 ft-lb).

KX221

KX209

6-8

PR261A

KX174

NOTE: If the cover is difficult to remove, pry on
the cover in more than one recessed location.

Disassembling Pinion Gear
NOTE: This procedure can be performed on a
rear gear case.

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

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.

5. Make match marks on the left bearing housing
and differential housing; then remove the plate
and account for a shim. Mark the shim as
left-side.

KX176
KX173

3. Using a plastic mallet, tap lightly to remove the
differential cover. Account for an O-ring.

6-9

KX177

CC875

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 (p/n
0444-127) 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, a bearing, and a shim.

KX181

7. Using the 48 mm Internal Hex Socket (p/n
0444-104), remove the lock collar securing the
pinion gear assembly.
6-10

CC879

CC891

NOTE: Do not stake the lock collar until proper
backlash has been verified.

C. Cover Side - add the value (B) on the gear
case housing to the value (C) on the gear case
cover; then add 1.5 mm (0.060 in.). This will
give you the proper shim thickness.

CC880

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.

D. Gear Case Side - install a 1.3-1.4 mm
(0.050-0.055 in.) shim and tighten the bolts to
3.5-4.3 kg-m (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.

NOTE: If the gear case housing is being
replaced, proceed to the following Shimming Procedure/Shim Selection sub-section.

Shimming Procedure/Shim
Selection

1. Press bearings into bores by outer ring to hard
contact with seat.

738-268A

2. Note the following shim selections (shims are
nominally 1.5 mm/0.060 in. thick):

3. Prior to final assembling, apply molybdenum
disulfide grease to all oil seal lips.

A. Pinion Gear Sub-Assembly - add the value
(A) on the gear case housing with 1.5 mm
(0.060 in.); then subtract the value on the
10-tooth pinion gear. This will give you the
proper shim thickness.

4. Prior to final assembling, prelubricate journal on
pinion assembly with SAE 80W-90 hypoid gear
lubricant prior to pressing assembly into gear
case housing.

B. Install the lock collar and tighten to specifications; then on final assembling, stake the lock
collar edge approximately 1.5 mm (0.060 in.)
into the lower oil channel.

Assembling Pinion Gear

1. Place the shim (with the chamfer side toward the
inside) onto the pinion shaft; then install the
bearing onto the pinion shaft. Install the pinion
shaft collar.

6-11

3. Install the pinion gear assembly into the housing. Using the 48 mm Internal Hex Socket
(p/n 0444-104), secure the pinion gear assembly
with the existing lock collar. Tighten to specifications.
NOTE: On a front differential, the lock collar has
right-hand threads. On a rear gear case, the lock
collar has left-hand threads.

CC881

CC890

CC882

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.

CC883

2. Place the pinion assembly in a bearing puller;
then install the bearing using a press.

CC891

5. Install the shift fork shaft w/spring into the gear
housing making sure the shaft O-ring is positioned to the inside.

CC884

CC892

6-12

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.

KX178

9. Install the left bearing housing aligning the
match mark to the mark on the differential housing.
CC893

7. Place the input shaft assembly onto the gear
housing; then secure with the existing cap
screws. Tighten to specifications.
NOTE: If a new gear housing is being installed,
tighten the cap screws to 3.5-4.3 kg-m (25-31 ft-lb).

KX177

10. Install the differential lock assembly into the
bearing housing; then place the O-ring on the
gear case housing.

CD103

KX175

CD110

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.
6-13

KX174

CC886

11. Making sure the O-ring is properly positioned
on the gear case housing, install the housing
with existing hardware. Account for the ID tag.
Tighten the cap screws to specifications.

3. Using a flat-nosed punch, drive the bearing out
of the housing.

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 3.5-4.3 kg-m
(25-31 ft-lb).

Removing Needle Bearing
NOTE: Removing the needle bearing is rarely
necessary. Avoid removing the needle bearing
unless the bearing is clearly damaged.
NOTE: This procedure can be performed on a
rear gear case.

1. Place a 6.35 mm (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.

CC887

Installing Needle Bearing

1. Apply red Loctite #271 to the outside of a new
bearing; then place the new bearing into the
housing.

CC888

CC885

2. Using a propane torch, heat the area surrounding
the needle bearing to soften the Loctite.

6-14

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.

CC889

3. Install the pinion shaft and secure with the existing 48 mm lock collar. Tighten to specifications.

CC899

2. Using a press, remove the bearing.

CC900
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.

3. Using a press, install the new bearing into the
housing.

CC901

CC891

5. Install the pinion housing.
Removing/Installing Axle Seal

NOTE: Prior to installing the seal, apply grease
to the seal outside diameter.

4. Install the seal into the housing pressing evenly
on the outside edge until the seal is seated.

NOTE: This procedure can be performed on a
rear gear case.

1. Remove the seal using a seal removal tool.

6-15

CD018

5. Repeat steps 1-4 for the opposite side.

PR198A

6. Install the front axles (see Drive Axles in this
section).

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.

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 specifications.

2. Install the lower front mounting through-bolt,
washers, spacers, and lock nut. Note the correct
location for the spacer washers.

PR201

PR205A

3. Tighten the nuts to specifications.
4. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid
lubricant into the differential and install the
filler plug. Tighten to specifications.
5. Align the scribed match marks on the front input
drive flange and the front drive yoke flange;
then secure with the three cap screws tightened
to specifications.

6-16

PR193

8. Secure the lower shock eyelets with cap screws
and lock nuts. Tighten to specifications.

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 cap
screws tightened to specifications.
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 to specifications.

! 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.

PR194

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.

KX041

4. Slide the hub out of the knuckle and set aside.

12. Apply a light coat of multi-purpose grease to the
hub splines; then install the hubs and nuts.
Tighten to specifications; then install new cotter
pins.

PR221

5. Remove the cap screw and lock nut securing the
knuckle to the upper A-arm. Discard the lock
nut.

AF894D

13. Install the wheels and tighten to specifications.
14. Remove the vehicle from the support stand.
6-17

CLEANING AND INSPECTING
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

1. Using a side-cutters (or suitable substitute),
remove the large clamp from the boot.

PR218

7. Place a drain pan under the vehicle to contain
any oil leakage; then using a slide hammer,
remove the drive axle.

CD020

2. Wipe away excess grease to access the retaining
ring. Using an awl or circlip pliers, remove the
circlip.

AF935

REMOVING FRONT DRIVE AXLE
NOTE: For removing a front drive axle, see Front
Differential in this section.

6-18

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

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.

6
CD751

8. Apply 40 grams (1/3 of contents) of grease from
the Grease Pack (p/n 0441-173) into the knuckles and the new outside boot.

CD022

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.

ATV-1052

6-19

NOTE: Grease Pack (p/n 0441-173) 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

ASSEMBLING AXLES

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.

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 pliers, secure the small
clamp of the inner boot.

CD754

10. Using Boot Clamp Pliers (p/n 0444-120), secure
both outside boot clamps.

! CAUTION
It is important that the clamps are positioned correctly or they may loosen when in motion.

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.

CD024

6-20

7. Slide the boot over the housing; then using the
boot clamp pliers, secure the boot with the
clamp.

CD022

! 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.

5. Secure the bearing ring with the circlip making
sure the sharp side of the circlip faces away
from the boot.

CD024

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.

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 specifications.

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 circlip.
NOTE: Pull the bearing ring out of the housing
until it contacts the circlip; then slide the ring in
half way. This will purge air from the housing and
ensure the bearing is packed properly.

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 specifications; then install and spread a new cotter pin
making sure each side of the pin is flush to the
hub nut.

CD027

5. Install the wheel. Tighten to specifications.
CD021

6. Remove the vehicle from the support stand and
release the parking brake.
6-21

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 specifications.
2. Secure the lower shock eyelet to the A-arm with
a cap screw and a new lock nut. Tighten to specifications.
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 specifications.
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 specifications; then install and spread a new cotter pin
making sure each side of the pin is flush to the
hub nut.

PR046A

Rear Gear Case
REMOVING
NOTE: Release the cargo box latch and allow the
cargo box to tilt back; then remove the cargo box
lift support by disengaging the ball sockets from
the ball studs and tilt the cargo box all the way
back.

1. Remove both of the rear drive axles (see Drive
Axles in this section).
2. Scribe a match mark on the rear input drive
flange and the rear input yoke flange; then
remove three cap screws securing the flanges
together.

CD027

7. Install the wheel and tighten to specifications.
8. Remove the vehicle from the support stand.
9. Check the front differential oil level and add oil
as necessary.
PR211A

3. Remove the drive-line brake caliper.
4. Remove the two cap screws and lock nuts securing the rear gear case to the frame; then remove
the gear case through the upper left-side of the
frame and lift out the top.

6-22

Hub
REMOVING

1. Secure the vehicle on a support stand to elevate
the wheel; then remove the wheel.

PR207

AT THIS POINT

For servicing the input shaft, pinion gear, needle
bearing, and axle seal, see Front Differential in
this section.

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.

! WARNING
Make sure the vehicle is solidly supported on the
support stand to avoid injury.

INSTALLING

1. Slide the gear case into position down through
the upper-left side of the frame; then secure it to
the frame with cap screws and lock nuts.
Tighten to specifications.

2. Remove the cotter pin from the axle.
NOTE: During assembly, new cotter pins should
be installed.

NOTE: If a new gear case is being installed,
tighten the cap screws to 5.1-6.3 kg-m (37-45.5
ft-lb).

2. Align the scribed match marks on the rear input
drive coupler flange and the rear input yoke
flange; then install three cap screws and tighten
to specifications.

PR257

3. Remove the flange nut securing the hub.
4. Remove the brake caliper (front only).

PR211A

3. Install the rear drive axles (see Drive Axles in
this section).
4. Install the drive-line brake caliper and tighten
the mounting cap screws to specifications; then
adjust the parking brake (see Parking Brake in
Section 2).
PR243A

5. Remove the hub assembly.
6-23

6. Remove the four cap screws securing the brake
disc (front hub only).

PR252A

INSTALLING
PR254A

CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Secure the brake disc (if applicable) to the hub
with the four cap screws coated with red Loctite
#271. Tighten to specifications.
2. Apply grease to the splines in the hub.

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

To replace wheel studs, use the following procedure.
1. Secure the hub in a suitable holding fixture and
remove the brake disc (if applicable).

PR254B

3. Install the hub assembly onto the axle; then set
the parking brake.

2. Drive the damaged stud out of the hub; then
place the new stud into the hub and thread on an
appropriate flange nut.

PR221

4. Secure the hub assembly with the nut. Tighten to
specifications; then secure with a new cotter pin.
PR250

3. Using a socket and ratchet handle, tighten the
nut until the stud is fully drawn into the hub.

6-24

PR258

5. For front hubs, secure the brake calipers to the
knuckle with two cap screws tightened to specifications.

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.

PR377B

6. Install the wheel and tighten to specifications.

7. Remove the vehicle from the support stand.

Hydraulic
Brake Caliper
PR237

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.

! WARNING
Make sure the vehicle is solidly supported on the
support stand to avoid injury.
PR238

2. Drain the brake fluid from the caliper, hose, and
master cylinder.

5. Remove the caliper holder from the caliper and
account for the brake caliper O-ring. Do not
remove the piston from the caliper.

6-25

2. Compress the caliper holder toward the caliper
and install the inner brake pad; then install the
outer pad.

PR239B

6. Plug the fluid port with a suitable plug to prevent contamination during cleaning.
PR238

PR240A
PR239

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

1. Install the caliper onto the caliper holder making
sure the caliper is correctly oriented on the
holder.

PR239C

6-26

3. Place the brake caliper assembly into position
and secure with the cap screws. Tighten the caliper to specifications.
4. Place a new crush washer on each side of the
brake hose fitting and install it on the caliper.
Tighten to specifications.
5. Fill the reservoir; then bleed the brake system
(see Section 2).
6. Install the wheel. Tighten to specifications.
7. Remove the vehicle from the support stand and
verify brake operation.

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.

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.

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.

PR121

4. Install U-Joint Separator Tool (p/n 0444-128) on
the universal joint fixed yoke; then remove the
bearing cup retainers.

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.

PR120A
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.

6-27

PR375

INSPECTING

PR367C

INSTALLING

1. Inspect the yoke bores for damage or signs of
bearing cup looseness. If bearing cups are loose,
the yoke must be replaced.

1. Remove the bearing cups from the universal
cross; then insert the cross into the yoke and
install one bearing cup on the cross.

! 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.

PR367B

2. Check that yoke legs are parallel.

PR368

2. Secure U-Joint Separator Tool (p/n 0444-128) in
a vise; then place the yoke, cross, and bearing
cup into position and press the cup into the
yoke.

PR367A

3. Check splines and flanges for excessive wear,
thread damage, or warpage.

PR374

3. Install the retainer in the bearing cup; then
remove the yoke from the separator tool.
6-28

NOTE: Repeat steps 2-3 for the opposite-side
bearing cup.

4. Remove the separator tool from the vise and
install the universal joint cross, bearing cups,
and movable yoke into the fixed yoke using the
same procedure as steps 2-3 except the vise cannot be used.

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

PR355

6-29

SECTION 7 - SUSPENSION

TABLE OF
CONTENTS
Shock Absorbers ..................................................... 7-2
Front A-Arms ........................................................... 7-3
Rear A-Arms ........................................................... 7-5
Wheels and Tires .................................................... 7-7

7-1

Shock Absorbers
REMOVING

1. Secure the vehicle on a support stand to elevate
the wheels and to release load on the suspension.

! WARNING
Make sure the vehicle is solidly supported on the
support stand to avoid injury.

2. Remove the two cap screws and nuts securing
each front shock absorber to the frame. Account
for bushings and sleeves from each.

AF730D

CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Clean all shock absorber components in
parts-cleaning solvent.
2. Inspect each shock rod for nicks, pits, rust,
bends, and oily residue.
3. Inspect all springs, spring retainers, shock rods,
dampers, bushings, shock bodies, and eyelets for
cracks, leaks, and bends.
INSTALLING
AF605D

! CAUTION
On the FIS style rear suspension, 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 rear
suspension. Account for bushings and sleeves
from each.

1. Place the shock absorber spring over the shock
absorber, compress the spring, and install the
retainer.
2. Place bushings and sleeves (where appropriate)
into shock eyelet; then install shock with two
cap screws and nuts. Tighten all nuts to specifications.

! CAUTION
Do not tighten the nuts beyond the 4.8 kg-m (35
ft-lb) specification or the shock eyelet or mount
WILL be damaged.

NOTE: The rear shock absorber-to-lower A-arm
torque factor is 2.8 kg-m (20 ft-lb).

3. Remove the vehicle from the support stand.

AF626D

4. Compress the shock absorber spring, remove the
retainer, and remove the spring.
7-2

Front A-Arms
REMOVING

1. Secure the vehicle on a support stand to elevate
the front wheels; then remove the wheels.

! WARNING
Make sure the vehicle is solidly supported on the
support stand to avoid injury.

2. Remove the cotter pin from the nut. Discard the
cotter pin.

AF618D

7. Remove the cap screws securing the ball joints
to the knuckle.

! CAUTION
Support the knuckle when removing the cap screws
or damage to the threads will occur.

PR257

3. Remove the nut securing the hub.
4. Remove the brake caliper. Account for two cap
screws.

PR193

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.

CD007

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.

AF626D

10. Remove the cap screws securing the A-arms to
the frame.

7-3

AF610D

AF616D

11. Remove the circlip from the ball joint; then
remove the ball joint from the A-arm.

2. Install the A-arm assemblies into the frame
mounts and secure with the cap screws. Only
finger-tighten at this time.

AF616D
AF610D

CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

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.

7-4

AF627D

4. Secure the lower eyelet of the shock absorber to
the upper A-arm. Tighten nut to specifications.
5. Secure the A-arm assemblies to the frame
mounts (from step 2). Tighten the cap screws to
specifications.

! CAUTION
Do not tighten the nut beyond the 4.8 kg-m (35 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 specifications.

PR377B

11. Secure the hub nut (from step 9) to the
shaft/axle. Tighten to specifications.
AF628D

7. Install the tie rod end and secure with the nut.
Tighten to specifications; then install a new cotter pin and spread the pin to secure the nut.

12. Install a new cotter pin and spread the pin to
secure the nut.

NOTE: During assembly, new cotter pins should
be installed.

PR260

13. Install the wheel and tighten to specifications.
14. Remove the vehicle from the support stand.

AF618D

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
Make sure the vehicle is solidly supported on the
support stand to avoid injury.

2. Set the parking brake.
CD009

9. Secure the hub assembly with the nut. Tighten
only until snug.
10. Secure the brake caliper to the knuckle with the
two cap screws. Tighten to specifications.

3. Remove the wheel.
4. Remove the cotter pin securing the hex nut; then
remove the hex nut.

7-5

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.

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 specifications.
3. Tighten the hardware securing the A-arms to the
frame mounts (from step 1) to specifications.
4. Apply grease on the drive axle splines; then
install the hub assembly onto the drive axle.

AF934

7. Slide the axle out of the knuckle and set aside.
8. Remove the cap screws and lock nuts securing
the knuckle to the A-arms. Discard the lock
nuts.

PR221

5. Secure the hub assembly with the nut. Tighten to
specifications.
6. Install a new cotter pin and spread the pin to
secure the nut.
PR220A

NOTE: Never reuse a lock nut. Once a lock nut
has been removed, it must be replaced with a new
lock nut.

9. Remove the cap screws and lock nuts securing
the A-arms to the frame; then remove the
A-arms.
CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Clean all A-arm components in parts-cleaning
solvent.
2. Inspect the A-arm for bends, cracks, and worn
bushings.

7-6

PR196

7. Secure the shock absorber to the frame with a
cap screw and new lock nut. Tighten to specifications.
8. Secure the shock absorber to the lower A-arm
with a cap screw and new lock nut. Tighten to
specifications.

9. Secure the boot guard to the lower A-arm with
the two cap screws. Tighten securely.

10. Install the wheel and tighten to specifications.
11. Remove the vehicle from the support stand.

Wheels and Tires
KEY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Machine Screw
Brake Disc
Wheel Hub - Front
Hub Stud
Cotter Pin
Hex Nut
Wheel
Mounting Nut
Tire - Front
Valve Stem
Valve Stem Cap
Wheel Hub - Rear
Wheel
Tire - Rear

0739-534

TIRE SIZE

REMOVING

! WARNING
Use only Arctic Cat approved tires when replacing
tires. Failure to do so could result in unstable vehicle operation.

The Prowler XT is equipped with low-pressure
tubeless tires of the size and type listed (see Section
1). Do not under any circumstances substitute tires
of a different type or size.

1. Secure the vehicle on a support stand to elevate
the wheels.

! WARNING
Make sure the vehicle is solidly supported on the
support stand to avoid injury.

2. Remove the wheels.

! 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.

TIRE INFLATION PRESSURE

Front and rear tire inflation pressure should be 0.70
kg/cm² (10 psi).
CD006

7-7

CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

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

CD005

2. Inspect the tires for damage, wear, or punctures.

! WARNING

1. Install each wheel on its hub.

Do not operate the vehicle if tire damage exists.

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.

3. Check the front wheel 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.
CD006

2. Tighten to specifications.
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.

7-8

NOTE: Pulling could be caused by uneven tire
pressure side-to-side, steering alignment out of
adjustment, unequal loading, or improper tire size.

SECTION 8 - STEERING/FRAME

TABLE OF
CONTENTS
Steering Assembly .................................................. 8-2
Steering Wheel........................................................ 8-4
Steering Wheel Shaft .............................................. 8-4
Steering Shaft Assembly ......................................... 8-5
Steering Knuckles ................................................... 8-7
Checking/Adjusting Front Wheel Alignment ............ 8-9
Front Bumper Assembly ........................................ 8-10
Hood...................................................................... 8-10
Fenders ................................................................. 8-11
Floor ...................................................................... 8-12
Belly Panel ............................................................ 8-12
Exhaust System .................................................... 8-12
Cargo Box ............................................................. 8-13
Adjusting Headlights ............................................. 8-14
Taillight Assembly.................................................. 8-14
Seat ....................................................................... 8-15

8-1

Steering Assembly
REMOVING

1. Secure the vehicle on a support stand to elevate
the front wheels; then remove the front wheels.

! WARNING
Make sure the vehicle is solidly supported on the
support stand to avoid injury.

2. Remove the cotter pins and nuts securing the tie
rod ends to the knuckles; then remove the tie rod
ends from the knuckles.

PR302

5. Remove two cap screws securing the rack and
pinion assembly to the frame. Account for two
nuts and two washers.

PR303A
PR301

3. Make matching alignment marks on the pinion
shaft and lower steering shaft joint.

6. Remove the rack and pinion assembly from the
right-side.

PR305
PR333A

NOTE: Any time steering components are disassembled, all connecting components should be
marked for proper alignment during assembling.

4. Remove the cap screw securing the lower steering shaft joint to the pinion shaft; then slide the
joint free of the pinion.

INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Inspect the tie rod ends for damaged threads,
torn boots, or excessive wear.
2. Inspect the tie rods for bends or deformation.
3. Inspect the rack and pinion-to-tie rod boots for
tears or deterioration.

8-2

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.

PR309

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.

6. Inspect for grease seepage from the rack and
pinion assembly.
NOTE: The steering assembly is not repairable.
If any of the above items fail inspection, the steering assembly must be replaced.

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 specifications.

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 specifications; then
check that the steering wheel turns freely.

PR305

2. With the rack and the steering wheel centered,
slide the lower steering shaft joint onto the pinion shaft aligning the match marks.

5. Install the tie rod ends into the steering knuckles; then secure with the castle nuts tightened to
specifications.
6. Install the cotter pins and spread to secure.
NOTE: If the holes in the tie rod ends don’t align
with the slots in the castle nuts, tighten the nuts
sufficiently to install the cotter pins.

7. Install the wheels and check the steering system
for full and free travel; then remove the vehicle
from the supports.

8-3

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 specifications.

Steering Wheel
REMOVING

1. Remove the steering wheel cover; then match
mark the steering shaft and steering wheel.
NOTE: Any time steering components are disassembled, all connecting components should be
marked for proper alignment during assembling.

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.

3. Install the steering wheel cover and secure with
the existing hardware. Do not over-tighten.

Steering Wheel Shaft
REMOVING

2. Remove the nut securing the steering wheel and
remove the steering wheel. Account for the flat
thrust-washer and two wave washers.

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.

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.

PR313A

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.
NOTE: Any time steering components are disassembled, all connecting components should be
marked for proper alignment during assembling.

INSPECTING

1. Inspect the steering wheel shaft for excessive
wear.
2. Check for worn splines, cracks, or damaged
threads.

8-4

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.

7. Move the dash panel into position and secure
with the existing hardware.

Steering Shaft
Assembly
REMOVING

1. Remove the steering wheel (see Steering Wheel
in this section).
2. Remove the six torx-head screws securing the
dash panel to the frame; then remove the parking brake release handle and the jam nut.
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.

PR313A

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.

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.

8
PR313A

PR324A

4. Hold rearward pressure on the steering wheel
and tighten the cap screw (from step 2) to specifications.

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.

5. Remove the steering wheel nut. Apply one drop
of red Loctite #271 to the threads and install the
nut. Tighten to specifications.
6. Check for freedom of movement of the steering
system; then install the steering wheel cover.

8-5

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.

PR304

PR333A

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 specifications.

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.

1. Inspect the joints for excessive wear or looseness.
PR309A

2. Inspect welds and slip-joints for cracks.
3. Check for excessive wobble in the slip-joint.
INSTALLING

1. Place the steering shaft assembly into position
through the opening in the splash panel.

! 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. 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.

PR314A

8-6

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.

10. Place the dash panel into position and secure
with the six torx-head screws.

Steering Knuckles
PR313A

5. Apply green Loctite #270 to the cap screw; then
install the cap screw in the upper steering shaft
joint and finger-tighten.

REMOVING AND DISASSEMBLING

1. Secure the vehicle on a support stand to elevate
the wheel; then remove the wheel.

! WARNING
Make sure the vehicle is solidly supported on the
support stand to avoid injury.

2. Remove the cotter pin from the axle.
3. Remove the nut securing the hub.
4. Remove the brake caliper.
PR310

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.

5. Remove the hub assembly.
6. Remove the cotter pin from the tie rod end and
remove the tie rod end from the knuckle.
7. Remove the two cap screws securing the ball
joints in the knuckle.

PR226

7. Hold rearward pressure on the steering wheel
and tighten the cap screw (from step 5) to specifications.
8. Remove the steering wheel nut and apply one
drop of red Loctite #271 to the threads. Install
the nut and tighten to specifications.

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.

9. Check that the steering wheel turns freely from
full-right to full-left; then install the steering
wheel cover.
8-7

2. Install the knuckle to the upper and lower ball
joints and secure with the two cap screws.
Tighten to specifications.

PR289

CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

PR202

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.

PR203

3. Install the tie rod end and secure with the nut.
Tighten to specifications; then install a new cotter pin and spread the pin.
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

8-8

CD009

PR377B

6. Secure the hub assembly with the nut. Tighten to
specifications.

9. Install the wheel; then using a crisscross pattern,
tighten to specifications.
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.

PR256

7. Install a new cotter pin and secure by spreading
as shown.

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).

8
PR260

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.

8. Secure the brake caliper to the knuckle with the
two cap screws. Tighten to specifications.

PR087A

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.

8-9

Front Bumper
Assembly
REMOVING

To remove the front bumper assembly, remove four
cap screws and nuts. Account for four lock washers
and eight flat washers.
PR084A

PR327A
PR085A

! 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.

CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Clean all bumper components with parts-cleaning solvent.
2. Inspect all welds for cracking or bending.
INSTALLING

To install the front bumper assembly, 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.

Hood
PR086

REMOVING

1. Open the hood; then disconnect the four headlight connectors and remove two nylon ties.

8-10

PR328A

PR332

2. Loosen but do not remove the four cap screws
and flange nuts securing the hood hinge to the
frame; then lower the hood.

3. Connect the four headlight connectors; then
secure the wires with two new nylon ties.

PR332B
PR332A

3. Finish removing the cap screws and flange nuts
(from step 2); then remove the hood assembly.

Fenders

CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Clean all hood components with parts-cleaning
solvent and soap and water.

REMOVING

To remove the fenders, remove three torx-head
screws securing each fender to the frame. Account
for a stiffener bracket on the front fenders.

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.
2. Open the hood; then install the remaining two
cap screws and flange nuts. Tighten all four
securely.

PR311A

INSTALLING

To install the fenders, place the appropriate fender
into position and secure with existing hardware.
8-11

CLEANING AND INSPECTING

Floor

NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

REMOVING

1. Clean the floor with soap and water.

1. Remove the seats and center console.

2. Inspect the floor for cracks or holes.

2. Remove twelve cap screws and two self-tapping
screws securing the floor to the frame.
3. While pulling forward on the upper-rear of the
floor, lift the rear part of the floor above the seat
lock stud; then insert a small wood block to hold
in position.

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.

Belly Panel
REMOVING
PR163

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.

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.

Exhaust System
REMOVING MUFFLER

1. Remove the two exhaust springs at the muffler/exhaust pipe juncture.

PR165

8-12

PR131

PR102

2. Slide the muffler assembly rearward and clear of
the holder pins.

2. Loosen but do not remove the four shoulder cap
screws securing the pivot housings to the cargo
box.

INSPECTING MUFFLER
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

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.

INSTALLING MUFFLER

1. Place the muffler onto the holder pins and slide
forward into position.
2. Secure the muffler to the exhaust pipe with the
two exhaust springs.

Cargo Box
REMOVING

1. Raise the cargo box; then disengage the lift support socket from the ball. The cargo box will tilt
fully rearward.

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
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

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.

8-13

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.
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 specifications.
3. Raise the cargo box; then connect the lift support to the ball.
4. Lower the cargo box and lock into position.

0740-647

7. Turn the adjustment knob counterclockwise to
lower the beam and clockwise to raise the beam.

Adjusting Headlights
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).
NOTE: There should be an average operating
load on the vehicle when adjusting the headlight
aim.

8-14

CD714A

! WARNING
Do not operate the vehicle unless the headlight
beam is adjusted properly. An incorrectly adjusted
beam will not provide the operator the optimum
amount of light.

Taillight Assembly
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.

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.
PR056

2. Disconnect the three-prong connector from the
bulb socket and remove the taillight assembly.
INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Inspect wiring harness, three-prong connector,
lens, base, cap screws, and socket for damage.
2. Inspect all wires for corroding, pinching, and
cracking.

Seat
REMOVING/INSTALLING

1. To remove the seat, pull the seat lock lever up.
Raise the front of the seat and slide it forward.
2. To install the 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.

8-15

SECTION 9 - CONTROLS/INDICATORS

9
TABLE OF
CONTENTS
Master Cylinder Assembly....................................... 9-2
Accelerator Pedal .................................................... 9-3
2WD/4WD Selector ................................................. 9-3
Front Differential Lock ............................................. 9-3
Low Range/High Range/Neutral/Reverse Lever...... 9-4
Speedometer/Tachometer/LCD............................... 9-4

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
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

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.

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.
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
specifications.

PR338

2. Secure the master cylinder assembly to the
frame with two cap screws and two flange nuts.
Tighten to specifications.
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).

9-2

Accelerator Pedal

2WD/4WD Selector

REMOVING

To remove the accelerator pedal, 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.

The automatic drive selector allows the operator to
operate in either 2-wheel drive (rear wheels) or
4-wheel drive (all wheels). For normal riding on
flat, dry, hard surfaces, 2-wheel drive should be sufficient. In situations of aggressive trail conditions,
4-wheel drive would be the desired choice.
To either engage or disengage the front wheels,
move the switch to the 4WD position or to the 2WD
position.

PR342B

PR083

! CAUTION
Do not attempt to engage or disengage the front differential while the vehicle is moving.

Front Differential Lock
PR342C

INSTALLING

To install the accelerator pedal, 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.

The front differential lock allows the operator to
mechanically lock the differential to apply equal
power to both front wheels. To engage the front differential lock, pull the DIFF LOCK toggle out; to
disengage the front differential lock, push the DIFF
LOCK toggle in.

ADJUSTING

To adjust the throttle cable, see Section 2.

PR083

9-3

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 6.35 mm (0.250
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.
CD560A

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.

2. Install the shoulder screw and secure with the
flange nut. Tighten to specifications.

Speedometer/
Tachometer/LCD

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.
4. Turn the ignition switch to the OFF position.
Tighten the jam nut securely; then install the
protector sleeve on the adjuster assembly.

Low Range/
High Range/Neutral/
Reverse Lever
REMOVING

1. Remove the seats and center console.
2. Remove the flange nut and shoulder screw from
the shift lever pivot; then remove the shift lever.
Account for the shifter spring.

CF094B

1. Clock/Engine Hour Meter - The clock function
indicates time in the 12 hour mode; the hour
meter indicates the total time the vehicle has run
and cannot be reset to zero. To set the clock, use
the following procedure.
A. With the ignition switch in the ON position,
press and release the Mode Button (3) until
the Clock/Engine Hour Meter (1) is displayed; then (if necessary) press and release
the Set/Reset Button (4) to the clock display.
B. Press and hold the Set/Reset Button (4) until
the minutes stop scrolling and the hour display starts to scroll. Momentarily release
when the correct hour is displayed; then
repeatedly press and release the Set/Reset
Button (4) until the correct minutes are displayed.

9-4

NOTE: Approximately two seconds after releasing either Button, the LCD will return to normal
operation.

8. Speed Function Display - Displays which speed
function (MPH, TACH, K/PH) is being indicated by the Speed/Tach indicator.

NOTE: Clock memory power is supplied through
the 15-amp accessory fuse and verified during
gauge “power-up” and reset. In the event of clock
memory power failure (blown fuse, etc.), the gauge
will “power-up,” reset, and shut down repeatedly
until clock memory power is restored. Always
check the 15-amp accessory fuse if this gauge
condition is noted.

NOTE: The speed and tach functions may be
switched by pressing the Set/Reset Button.

NOTE: The engine hour meter will not activate
until engine speed exceeds 500 RPM.

9. Differential Lock Indicator - Displays LOCK
when the differential lock has been engaged.
10. Drive Select Indicator - Displays 4WD when
selected by the 2WD/4WD selector switch or
when the differential lock is engaged.
11. High Beam Indicator - The High Beam icon will
appear only when the lights are on high beam.

2. Fuel Level Indicator - Indicates approximate
amount of gasoline in the gas tank.
NOTE: When the bottom segment flashes,
approximately 3.8 L (1.0 U.S. gal.) of gasoline
remains in the tank.

3. Mode Button - Shifts the digital gauge through
three modes: speed/tachometer, distance, and
time.
NOTE: The Mode Button must be pressed and
released to shift modes. Approximately two seconds after the Mode Button is released, the digital
gauge will return to full display.

4. Set/Reset Button - In conjunction with the Mode
Button, sets and resets various displays on the
digital gauge. Also used to switch from speedometer function to tachometer function on the
speedometer/tachometer gauge.

CF101A

12. Battery Condition Indicator - The word VOLT
will flash on the LCD whenever a low voltage
(< 9 DC volts) or high voltage (>16 DC volts) is
detected.

5. Odometer/Trip Meter (#1 and #2) - Odometer
registers the total distance the vehicle has traveled. Trip meters can register two distances (for
instance, #1 could register trip distance and #2
could register distance between stops). The trip
meters can be reset while the odometer only registers accumulated miles/kilometers.
NOTE: To select the odometer (ODO), trip #1
(T1), or trip #2 (T2), press the Mode Button (3) to
select the distance mode; then press the Set/Reset
Button (4) to select the desired display. Hold the
Set/Reset button down to reset trip meters.

6. Gear Position Indicator - Indicates which gearshift position is selected.
7. Speed/Tach Indicator - Indicates approximate
vehicle speed in mph or k/ph when speedometer
function is selected or rpm when tachometer
function is selected.

9
CF098A

13. Temperature Indicator - The high temperature
icon will flash and the speed/tach needle will
sweep full scale if the engine overheats. After 30
seconds, the speed/tach needle will return to
normal, but the temperature icon will continue
to flash. The icon should not be visible during
normal operation.

9-5

CF099A

! CAUTION
Continued operation of the vehicle with high engine
temperature may result in engine damage or premature wear.

PR181A

3. Remove two nuts securing the gauge assembly
to the dash; then unplug the multi-pin connector
and remove the gauge from the vehicle.

REPLACING
SPEEDOMETER/TACHOMETER/LCD

To replace the speedometer, use the following procedure.
1. Remove the six torx-head 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.

PR284A

4. Place the new gauge into the dash panel opening; then place the gauge holder over the mounting screws and secure with the two 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 torx-head screws.
7. Install the parking brake handle and jam nut.

9-6

SECTION 10 - AIDS FOR MAINTENANCE

10
TABLE OF
CONTENTS
Torque Specifications ............................................ 10-2
Torque Conversions .............................................. 10-3
Tightening Torque (General Bolts) ........................ 10-3

10-1

SUSPENSION COMPONENTS (Front)
Torque
Part
Part Bolted To
kg-m
ft-lb

Torque Specifications
DRIVE TRAIN COMPONENTS
Part

Torque
kg-m
ft-lb

Part Bolted To

Engine Cradle

Engine

5.5

Engine Cradle

Rubber Mount

3.5

Front Differential*

Frame/Diff Bracket

6.2

Rear Output Joint
Assy

Engine

2.8

Input Housing

Diff Housing

2.9-3.5

21-25

Diff Housing Cover***

Diff Housing

2.9-3.5

21-25

Drive Bevel Gear
Nut***

Shaft

11-13

79.5-94

Differential Gear
Case***

Hub

2.3-3

16.5-22

A-Arm (All)

Frame

4.8

Ball Joint Cap Screw

Knuckle

4.8

35
35

Shock Absorber

Frame

4.8

Shock Absorber

Upper A-Arm

4.8

Knuckle

A-Arm

4.8

SUSPENSION COMPONENTS (Rear)
Axle Retainer Assy

Axle Housing

5.5

Sway Bar Bracket

Frame

4.8

A-Arms

Frame

4.8

Shock Absorber
(Upper)

Axle Housing/Frame

4.8

Shock Absorber
(Lower)

A-Arm

2.8

Knuckle

A-Arm

4.8

Cargo Box Hinge

Cargo Box Frame

2.8

Lock Collar

Diff Housing

17.3

125

Cargo Box

Cargo Box Frame

2.8

Hub Nut

Front/Rear
Shaft/Axle (min)

27.6

200

Latch Pivot Housing

Cargo Box Frame

2.1

Cargo Box Liner

1.1

Oil Drain Plug

Front Diff/Rear Dr

0.5

3.5

Latch Striker

CANOPY ASSEMBLY

Oil Fill Plug

Front Diff/Rear Dr

2.2

Arm Rest/Steering Post Support

Engine

Front/Rear Canopy
Tube

2.8

Oil Drain Plug
Inspection Plug

Rear Drive

0.5

3.5

Top Canopy Support

Hub

5.5-6.2

40-45

Front/Rear Canopy Tubes

1.1

Wheel
Front/Rear Shaft
Flange

Front/Rear U-Joint

5.5

Rear Canopy Tube

Lower Canopy
Support

1.1

ENGINE/TRANSMISSION

EXHAUST COMPONENTS
Exhaust Pipe

Engine

2.8

ELECTRICAL COMPONENTS

Clutch Shoe**

Crankshaft

31.8

230

Clutch Cover/ Housing
Assy

Crankcase

1.1

Coil*

Isolator Plate

1.1

Crankcase Half (6 mm)

Crankcase Half

0.9-1.3

6.5-9.5

Isolator Plate

Frame

1.1

Crankcase Half (8 mm)

Crankcase Half

2.8

Ground Wire

Engine

1.1

Cylinder Head (Cap
Screws)

Crankcase

5.5

Cylinder Head (6 mm)

Cylinder

1.1

Cylinder Head (8 mm)

Cylinder

2.5

Cylinder Head Cover

Cylinder Head

1.15

8.5

Driven Pulley Nut

Fixed Face

13.5

97.5

Fixed Driven

Clutch Shaft

13.5

97.5

STEERING COMPONENTS
Steering Wheel
Shaft**

Steering Wheel

3.5

Steering Wheel Shaft

Intermediate Shaft
(Upper)

3.5

Intermediate Shaft
(Lower)

Steering Pinion
Shaft

3.5

Rack and Pinion

Frame

6.9

Ground Wire

Engine

1.1

Tie Rod End

Knuckle

4.2

Magneto Cover

Crankcase

1.1

Jam Nut

Tie Rod End

1.1

Mechanical Water
Pump Impeller

Pump Shaft

1.05

7.5

Movable Drive Face

Driveshaft

10.4-11.8

75-85

Oil Pump Drive Gear

Crank Balancer
Shaft

8.5

61.5

BRAKE COMPONENTS
Brake Disc*

Hub

2.1

Brake Hose

Caliper

2.8

Brake Hose

Master Cylinder

2.8

Output Shaft Gear

Output Shaft

8.5

61.5

Master Cylinder

Frame

3.5

Recoil Cover

Right-Side Cover

0.8

Parking Brake
Mechanism

Frame

2.8

Rotor/Flywheel Nut

Crankshaft

14.5

105

Hydraulic Caliper

Knuckle

2.8

Cam Sprocket**

Camshaft

1.35

9.8

Rear Caliper

Rear Drive
Gear Case

2.8

Starter Cup

Crankshaft

3.8

27.5

V-Belt Cover

Crankcase

1.1

Plenum***

Engine

1.1

Spark Plug

Engine

1.7

Drive-line Brake

Rear Drive Input
Flange

1.7

CHASSIS COMPONENTS
Shift Lever*

Shift Axle Bracket

2.8

Shift Link Adjuster

1.1

10-2

* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609

Torque Conversions
ft-lb

kg-m

ft-lb

kg-m

ft-lb

kg-m

ft-lb

kg-m

ft-lb

kg-m

0.1

2.9

5.7

8.4

11.2

0.3

3.0

5.8

8.6

11.3

0.4

3.2

5.8

8.7

11.5

0.6

3.3

6.1

8.9

11.6

0.7

3.5

6.2

9.0

11.8

0.8

3.6

6.4

9.1

11.9

1.0

3.7

6.5

9.3

12.0

1.1

3.9

6.6

9.4

12.2

1.2

4.0

6.8

9.5

12.3

1.4

4.2

6.9

9.7

12.5

1.5

4.3

7.1

9.8

12.6

1.7

4.4

7.2

10.0

12.8

1.8

4.6

7.3

10.1

12.9

1.9

4.7

7.5

10.2

13.0

2.1

4.8

7.6

10.4

13.1

2.2

5.0

7.7

10.5

13.3

2.4

5.1

7.9

10.7

13.4

2.5

5.3

8.0

10.8

13.6

2.6

5.4

8.2

10.9

13.7

2.8

5.5

8.3

11.1

100

13.8

Tightening Torque
(General Bolts)

Type of Bolt
(Conventional or
4 Marked Bolt)

(7 Marked Bolt)

Thread
Diameter
A (mm)

Tightening Torque
kg-m

ft-lb

0.2-0.4

1.5-3.0

0.4-0.7

3.0-5.0

1.0-1.6

7.0-11.5

2.2-3.5

16.0-25.5

0.3-0.6

2.0-4.5

0.8-1.2

6.0-8.5

1.8-2.8

13.0-20.0

4.0-6.0

29.0-43.5

10-3

SECTION 11 - TROUBLESHOOTING

TABLE OF
CONTENTS

Engine ................................................................... 11-2
Drive ...................................................................... 11-5
Fuel System .......................................................... 11-6
Electrical................................................................ 11-7
Steering/Suspension ............................................. 11-9
Brakes ................................................................. 11-10

11-1

Engine
Problem: Engine will not start or is hard to start (Compression too low)
Condition
Remedy
1. Valve clearance out of adjustment
1. Adjust clearance
2. Valve guides worn - seated poorly
2. Repair - replace guides
3. Valves mistimed
3. Replace camshaft
4. Piston rings worn - broken
4. Replace rings
5. Cylinder bore worn
5. Replace - rebore cylinder
6. Starter motor cranks too slowly - does not
6. See Electrical in this section
turn
Problem: Engine will not start or is hard to start (No spark)
Condition
Remedy
1. Spark plug fouled
1. Clean - replace plug
2. Spark plug wet
2. Clean - dry plug
3. Magneto defective
3. Replace magneto
4. CDI unit defective
4. Replace CDI unit
5. Ignition coil defective
5. Replace ignition coil
6. High-tension lead open - shorted
6. Replace high tension lead
Problem: Engine will not start or is hard to start (No fuel reaching the carburetor)
Condition
1. Gas tank vent hose obstructed
2. Carburetor inlet needle defective
3. Fuel hose obstructed
4. Fuel screens obstructed
5. Fuel pump defective
Problem: Engine stalls easily

Remedy
1. Clean vent hose
2. Replace needle
3. Clean - replace hose
4. Clean - replace inlet screen - valve screen
5. Replace fuel pump

Condition
Remedy
1. Spark plug fouled
1. Clean - replace plug
2. Magneto defective
2. Replace magneto
3. CDI unit defective
3. Replace CDI unit
4. Carburetor jets obstructed
4. Clean jets
5. Valve clearance out of adjustment
5. Adjust clearance
Problem: Engine noisy (Excessive valve chatter)
Condition
Remedy
1. Valve clearance excessive
1. Adjust clearance
2. Valve spring(s) weak - broken
2. Replace spring(s)
3. Rocker arm - rocker arm shaft worn
3. Replace arm - shaft
4. Camshaft worn
4. Replace camshaft
Problem: Engine noisy (Noise seems to come from piston)
Condition
1. Piston - cylinder worn
2. Combustion chamber carbon buildup
3. Piston pin - piston pin bore worn
4. Piston rings - ring groove(s) worn

11-2

Remedy
1. Replace - service piston - cylinder
2. Clean chamber
3. Replace - service pin - bore
4. Replace rings - piston

Problem: Engine noisy (Noise seems to come from timing chain)
Condition
Remedy
1. Chain stretched
1. Replace chain
2. Sprockets worn
2. Replace sprockets
3. Tension adjuster malfunctioning
3. Repair - replace adjuster
Problem: Engine noisy (Noise seems to come from crankshaft)
Condition
Remedy
1. Bearing worn - burned
1. Replace bearing
2. Lower rod-end bearing worn - burned
2. Replace bearing
3. Connecting rod side clearance too large
3. Replace thrust washer(s)
4. Centrifugal clutch loose
4. Tighten - replace clutch
5. Rotor/flywheel loose
5. Tighten - replace flywheel - crankshaft
Problem: Engine noisy (Noise seems to come from transmission)
Condition
Remedy
1. Gears worn - rubbing
1. Replace gears
2. Splines worn
2. Replace shaft(s)
3. Primary gears worn - rubbing
3. Replace gears
4. Bearings worn
4. Replace bearings
5. Bushing worn
5. Replace bushing
Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)
Condition
Remedy
1. Drive - driven bevel gears damaged - worn
1. Replace gears
2. Backlash excessive
2. Adjust backlash
3. Tooth contact improper
3. Adjust contact
4. Bearing damaged
4. Replace bearing
5. Gears worn - rubbing
5. Replace gears
6. Splines worn
6. Replace shaft(s)
7. Final driven shaft thrust clearance too large 7. Replace thrust washer(s)
Problem: Engine idles poorly
Condition
1. Valve clearance out of adjustment
2. Valve seating poor
3. Valve guides defective
4. Rocker arms - arm shaft worn
5. Magneto defective
6. CDI unit defective
7. Spark plug fouled - gap too wide
8. Ignition coil defective
9. Float out of adjustment
10. Jets obstructed
11. Pilot screw setting improper

Remedy
1. Adjust clearance
2. Replace - service seats - valves
3. Replace guides
4. Replace arms - shafts
5. Replace magneto
6. Replace CDI unit
7. Adjust gap - replace plug
8. Replace ignition coil
9. Adjust float height
10. Clean jets
11. Adjust pilot screw

11-3

Problem: Engine runs poorly at high speed
Condition
1. High RPM “cut out” against RPM limiter
2. Valve springs weak
3. Valve timing out of adjustment
4. Cams - rocker arms worn
5. Spark plug gap too narrow
6. Ignition coil defective
7. Float level too low
8. Air cleaner element obstructed
9. Fuel hose obstructed
Problem: Exhaust smoke dirty or heavy

Remedy
1. Shift into higher gear - decrease speed
2. Replace springs
3. Adjust timing
4. Replace cams - arms
5. Adjust gap
6. Replace ignition oil
7. Adjust float height
8. Clean element
9. Clean - prime hose

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

Remedy
1. Drain excess oil - replace oil
2. Replace - service rings - cylinder
3. Replace guides
4. Replace cylinder
5. Replace valves
6. Replace seals

Condition
1. Valve clearance incorrect
2. Valve springs weak
3. Valve timing out of adjustment
4. Piston ring(s) - cylinder worn
5. Valve seating poor
6. Spark plug fouled
7. Rocker arms - shafts worn
8. Spark plug gap incorrect
9. Carburetor jets obstructed
10. Float level out of adjustment
11. Air cleaner element obstructed
12. Oil (in the engine) overfilled - contaminated
13. Intake manifold leaking air
14. Cam chain worn
Problem: Engine overheats

Remedy
1. Adjust clearance
2. Replace springs
3. Time camshaft
4. Replace - service rings - cylinder
5. Repair seats
6. Clean - replace plug
7. Replace arms - shafts
8. Adjust gap - replace plug
9. Clean jets
10. Adjust float height
11. Clean element
12. Drain excess oil - change oil
13. Tighten - replace manifold
14. Replace cam chain - sprockets

Condition
1. Carbon deposit (piston crown) excessive
2. Oil low
3. Octane low - gasoline poor
4. Oil pump defective
5. Oil circuit obstructed
6. Gasoline level (in float chamber) too low
7. Intake manifold leaking air
8. Coolant level low
9. Fan malfunctioning
10. Fan switch malfunctioning
11. Thermostat stuck - closed
12. Radiator hoses - cap damaged - obstructed

Remedy
1. Clean piston
2. Add oil
3. Drain - replace gasoline
4. Replace pump
5. Clean circuit
6. Adjust float height
7. Tighten - replace manifold
8. Fill - examine system for leaks
9. Check fan fuse - replace fan
10. Replace fan switch
11. Replace thermostat
12. Clear obstruction - replace hoses

11-4

Drive
Problem: Power not transmitted from engine to wheels
Condition
Remedy
1. Rear axle shaft serration worn - broken
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

11-5

Fuel System
Problem: Starting impaired
Condition
1. Starter jet obstructed
2. Starter jet passage obstructed
3. Starter body - carburetor leaking air
4. Starter valve not operating properly
Problem: Idling or low speed impaired

Remedy
1. Clean jet
2. Clean passage
3. Tighten - adjust - replace gasket
4. Check - adjust valve

Condition
1. Slow jet obstructed - loose
2. Slow jet outlet obstructed
3. Pilot screw setting incorrect
4. Starter valve not fully closed
5. Float height incorrect
Problem: Medium or high speed impaired

Remedy
1. Clean - tighten jet
2. Clean outlet
3. Adjust screw
4. Adjust valve
5. Adjust float height

Condition
1. High RPM “cut out” against RPM limiter
2. Main jet obstructed
3. Needle jet obstructed
4. Throttle vacuum piston not operating
properly
5. Filter obstructed
6. Float height incorrect
7. Starter valve not fully closed
Problem: Overflow and fuel level fluctuations

Remedy
1. Shift into higher gear - decrease RPM speed
2. Clean main jet
3. Clean needle jet
4. Check piston operation

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. Replace valve
2. Replace spring
3. Adjust float height - replace float
4. Clean valve
5. Adjust float height

11-6

5. Clean filter
6. Adjust float height
7. Adjust valve

Electrical
Problem: Spark absent or weak
Condition
1. Ignition coil defective
2. Spark plug defective
3. Magneto defective
4. CDI unit defective
5. Pick-up coil defective
Problem: Spark plug fouled with carbon

Remedy
1. Replace ignition coil
2. Replace plug
3. Replace magneto
4. Replace CDI unit
5. Replace pick-up coil

Condition
Remedy
1. Mixture too rich
1. Adjust carburetor
2. Idling RPM too high
2. Adjust carburetor
3. Gasoline incorrect
3. Change to correct gasoline
4. Air cleaner element dirty
4. Clean element
5. Spark plug incorrect (too cold)
5. Replace plug
6. Valve seals cracked - missing
6. Replace seals
7. Oil rings worn - broken
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
Problem: Battery does not charge

Remedy
1. Replace plug
2. Service cooling system
3. Tighten plug
4. Adjust carburetor

Condition
Remedy
1. Lead wires/connections shorted - loose 1. Repair - replace - tighten lead wires
open
2. Magneto coils shorted - grounded - open
2. Replace magneto coils
3. Regulator/rectifier shorted - punctured
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

11-7

Problem: Magneto overcharges
Condition
1. Internal battery short circuited
2. Regulator/rectifier resistor damaged defective
3. Regulator/rectifier poorly grounded
Problem: Charging unstable

Remedy
1. Replace battery
2. Replace resistor

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

Remedy
1. Replace lead wire
2. Replace magneto
3. Replace regulator/rectifier

3. Clean - tighten ground connection

Condition
Remedy
1. Battery charge low
1. Recharge - replace battery
2. Switch contacts defective
2. Replace switch
3. Starter motor brushes not seating
3. Repair - replace brushes
4. Starter relay defective
4. Replace relay
5. Emergency stop - ignition switch off
5. Turn on switches
6. Wiring connections loose - disconnected
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
Problem: Battery discharges too rapidly

Remedy
1. Replace battery
2. Keep electrolyte to prescribed level
3. Charge battery - add distilled water
4. Replace battery
5. Recharge - replace battery

Condition
1. Electrolyte contaminated
2. Specific gravity too high
3. Charging system (charging operation) not
set properly

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

4. Cell plates overcharged - damaged
5. Battery short-circuited
6. Specific gravity too low
Problem: Battery polarity reversed
Condition
1. Battery incorrectly connected

11-8

Remedy
1. Reverse connections - replace battery

Steering/Suspension
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
Problem: Steering oscillation

Remedy
1. Adjust alignment
2. Lubricate appropriate components
3. Adjust pressure
4. Replace tie rod ends
5. Repair - replace connections

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
Problem: Steering pulling to one side

Remedy
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

Condition
1. Tires inflated unequally
2. Front wheel alignment incorrect
3. Wheel hub bearings worn - broken
4. Frame distorted
5. Shock absorber defective
Problem: Steering impaired

Remedy
1. Adjust pressure
2. Adjust alignment
3. Replace bearings
4. Repair - replace frame
5. Replace shock absorber

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

Remedy
1. Adjust pressure
2. Replace connections
3. Tighten cap screws

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

Remedy
1. Replace bearings
2. Adjust alignment

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

11-9

Problem: Suspension too soft
Condition
1. Spring(s) weak
2. Shock absorber damaged
Problem: Suspension too stiff

Remedy
1. Replace spring(s)
2. Replace shock absorber

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

Remedy
1. Replace bushing

Condition
1. Cap screws (suspension system) loose
2. A-arm-related bushings worn
Problem: Rear wheel oscillation

Remedy
1. Tighten cap screws
2. Replace bushings

Condition
Remedy
1. Rear wheel hub bearings worn - loose
1. Replace bearings
2. Tires defective - incorrect
2. Replace tires
3. Wheel rim distorted
3. Replace rim
4. Wheel hub cap screws loose
4. Tighten cap screws
5. Parking brake adjusted incorrectly
5. Adjust parking brake
6. Rear suspension arm-related bushing worn 6. Replace bushing
7. Rear shock absorber damaged
7. Replace shock absorber
8. Rear suspension arm nut loose
8. Tighten nut

Brakes
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
Problem: Brake pedal travel excessive

Remedy
1. Replace pads
2. Adjust free-play
3. Repair - replace hydraulic system
4. Bleed hydraulic system
5. Replace seal(s)

Condition
1. Hydraulic system entrapped air
2. Brake fluid low
3. Brake fluid incorrect
4. Piston seal - cup worn
Problem: Brake fluid leaking

Remedy
1. Bleed hydraulic system
2. Add fluid to proper level
3. Replace with correct fluid
4. Replace seal - cup

Condition
1. Connection joints loose
2. Hose cracked
3. Piston seal worn

Remedy
1. Tighten joint
2. Replace hose
3. Replace seal

11-10

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.3
Linearized                      : No
XMP Toolkit                     : 3.1-702
Producer                        : Acrobat Distiller 7.0 (Windows)
Modify Date                     : 2009:01:05 09:41:11-06:00
Create Date                     : 2005:12:27 09:23:15-06:00
Metadata Date                   : 2009:01:05 09:41:11-06:00
Format                          : application/pdf
Title                           : untitled
Document ID                     : uuid:c0ad1676-3b2e-4f1d-89f9-59752961abee
Instance ID                     : uuid:fcdea6cf-acf2-4c3c-ac0c-89fd0b0c4475
Has XFA                         : No
Page Count                      : 190
Page Layout                     : SinglePage

EXIF Metadata provided by EXIF.tools

2006 XT 650 Prowler

Navigation menu

Versions of this User Manual:

Views

Navigation