2006 XT 650 Prowler

User Manual: Manual

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FOREWORD

This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2006 Arc-

tic 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 direc-

tive 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 photo-

graphs 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.

®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

TABLE OF CONTENTS

Click on the blue text to go.

Foreword

1. General Information

2. Periodic Maintenance/Tune-Up

3. Engine/Transmission

4. Fuel/Lubrication/Cooling

5. Electrical System

6. Drive System

7. Suspension

8. Steering/Frame

9. Controls/Indicators

10. Aids for Maintenance

11. Troubleshooting

1-1

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

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1-2

General Specifications*

* Specifications subject to change without notice.

** At the oil level plug threads.

*** At the filler plug threads.

CARBURETOR

Type Keih i n C V K3 6

Main Jet 132

Slow Jet 40

Low Speed Fuel Screw Setting

(turns)

1 1/4

Jet Needle NFKS

Needle Jet 6.0/4.0

Idle RPM 1250-1350

Starter Jet 85

Float Arm Height 17 mm (0.7 in.)

Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.)

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

(primary)

(secondary)

Less than 1 ohm

(terminal to ground)

5200-7800 ohms

(high tension - plug cap

removed - to ground)

Ignition Coil Peak

Voltage (static)

(primary/CDI) 132-198 DC volts

(terminal to ground)

Magneto Coil

Resistance

(trigger)

(source)

(charging)

160-240 ohms

(green to blue)

Less than 1 ohm

(yellow to white)

Less than 1 ohm

(black to black)

Magneto Coil

Peak Voltage

(trigger)

(source)

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

CHASSIS

Dry Weight (approx) 533 kg (1175 lb)

Length (overall) 292 cm (115 in.)

Height (overall) 197 cm (77.5 in.)

Width (overall) 156 cm (61.3 in.)

Suspension Travel (front) 25 cm (10 in.)

Suspension Travel (rear) 20 cm (8 in.)

Brake Type Hydraulic

Wheelbase 190 cm (75 in.)

Tracking (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

Tire Inflation Pressure 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

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1-3

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 compo-

nents 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 prop-

erly. 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 throt-

tle is recommended; however, brief full-throttle

accelerations and variations in driving speeds con-

tribute 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.

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 nec-

essary to add a gasoline antifreeze since ethanol will

prevent the accumulation of moisture in the fuel sys-

tem.

RECOMMENDED ENGINE/

TRANSMISSION OIL

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 clas-

sification. These oils meet all of the lubrication

requirements of the Arctic Cat engine. The recom-

mended engine oil viscosity is SAE 10W-40. Ambi-

ent temperature should determine the correct weight

of oil. See the following viscosity chart for details.

! CAUTION

BRAKE PADS MUST BE BURNISHED TO ACHIEVE

FULL BRAKING EFFECTIVENESS. Braking dis-

tance will be extended until brake pads are properly

burnished.

TO PROPERLY BURNISH THE BRAKES, USE FOL-

LOWING PROCEDURE:

• Choose an area sufficiently large to safely accel-

erate 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 bur-

nished.

• This procedure burnishes the brake pads, stabi-

lizes the pad material, and extends the life of the

brake pads.

! 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.

! CAUTION

Do not use white gas. Only Arctic Cat approved

gasoline additives should be used.

! CAUTION

Any oil used in place of the recommended oil could

cause serious engine damage. Do not use oils

which contain graphite or molybdenum additives.

These oils can adversely affect clutch operation.

Also, not recommended are racing, vegetable, non-

detergent, and castor-based oils.

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1-4

OILCHARTB

RECOMMENDED FRONT

DIFFERENTIAL/REAR DRIVE

LUBRICANT

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.

FILLING GAS TANK

ATV0049B

Since gasoline expands as its temperature rises, the

gas tank must be filled to its rated capacity only.

Expansion room must be maintained in the tank par-

ticularly if the tank is filled with cold gasoline and

then moved to a warm area.

Tighten the gas tank cap securely after filling the

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.

Preparation

For Storage

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.

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.

! CAUTION

Any lubricant used in place of the recommended

lubricant could cause serious front differential/rear

drive damage.

! WARNING

Always fill the gas tank in a well-ventilated area.

Never add fuel to the gas tank near any open flames

or with the engine running. DO NOT SMOKE while

filling the gas tank.

! 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.

! WARNING

Do not over-fill the gas tank.

! CAUTION

Prior to storing the vehicle, it must be properly ser-

viced to prevent rusting and component deteriora-

tion.

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1-5

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 fil-

ter. 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 sec-

onds; then stop the engine. Install the air filter

and housing cover.

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.

Preparation After

Storage

Taking the vehicle out of storage and correctly pre-

paring it will assure many miles and hours of trou-

ble-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.

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 bat-

tery cables.

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 neces-

sary.

12. Follow the recommendations found in the pre-

start inspection.

! CAUTION

If the interior of the air filter housing is dirty, clean

the area before starting the engine.

! CAUTION

Avoid storing outside in direct sunlight and avoid

using a plastic cover as moisture will collect on the

vehicle causing rusting.

! 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.

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2-1

SECTION 2 -

PERIODIC MAINTENANCE/TUNE-UP

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

2-2

Periodic Maintenance

Chart

A = Adjust I = Inspect

C = Clean L = Lubricate

D = Drain R = Replace

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

Item

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

Every 6

Months or

Every 500

Miles

Every Year

or Every

1500 Miles

Needed

Battery I I C

Fuses IR

Air Filter/Drain Tube I I C* R

Valve/Tappet Clearance I I A

Engine Compression I

Spark Plug I I R (4000 Mi

or 18 Mo)

Muffler/Spark Arrester C R

Gas/Vent Hoses I I R (2 Yrs)

Throttle Cable I I C-L A-R

Carb Float Chamber D*

Engine RPM (Idle) I I A

Engine-Transmission Oil

Level

I A

Engine-Transmission

Oil/Filter

RR* R

Oil Strainer I I C

Front Differential/Rear Drive

Lubricant

IR (4 Yrs)

Tires/Air Pressure I I R

Steering Components I I I R

V-Belt (Automatic) I l R

Suspension (Ball joint

boots, drive axle boots front

and rear, tie rods, differen-

tial and rear drive bellows)

II R

Nuts/Cap Screws/Screws I I I A

Ignition Timing I

Headlight/Taillight-

Brakelight

II R

Switches I I R

Shift Lever IA-L

Gauges/Indicators I I R

Frame/Welds I I l

Electrical Connections lC

Complete Brake System

(Hydraulic & Parking)

II C L-R

Brake Pads I I* R

Brake Fluid I I R (2 Yrs)

Brake Hoses I I R (4 Yrs)

Coolant/Cooling System I I R (2 Yrs)

2-3

Lubrication Points

It is advisable to lubricate certain components peri-

odically to ensure free movement. Apply light oil to

the components using the following list as reference.

A. Accelerator Pedal Pivot/Cable Ends

B. Brake Pedal Pivot

C. Parking Brake Cable Ends

D. Shift Linkage

E. Differential Lock Cable End

F. Idle RPM Screw (Carburetor)

Battery

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 dis-

tilled water until it reaches upper level line.

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.

CHARGTIM

CHARGE

To remove and charge the battery, use the following

procedure.

1. Remove the fasteners holding the left-rear

splash panel in place; then remove the battery

access panel.

! WARNING

Battery acid is harmful if it contacts eyes, skin, or

clothing. Care must be taken whenever handling a

battery.

! WARNING

Anytime service is performed on a battery, the fol-

lowing must be observed: keep sparks, open flame,

cigarettes, or any other flame away. Always wear

safety glasses. Protect skin and clothing when han-

dling a battery. When servicing battery in enclosed

space, keep the area well-ventilated. Make sure bat-

tery venting is not obstructed.

2-4

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.

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.

5. After charging, check fluid level and fill with

distilled water as necessary; then install vent

plugs.

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.

8. Place the battery into position in the vehicle and

secure with the battery access panel.

Fuses

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.

1411-191

Air Cleaner/Filter

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 condi-

tions, service the filter at the intervals specified. If

operated in dusty, wet, or muddy conditions, inspect

and service the filter more frequently. Use the fol-

lowing procedure to remove the filter and inspect

and/or clean it.

! WARNING

Avoid spillage and contact with skin, eyes, and

clothing.

! CAUTION

Do not charge the battery while it is in the vehicle

with the battery terminals connected.

! CAUTION

Never exceed the standard charging rate.

! CAUTION

Before installing the battery, make sure the ignition

switch is in the OFF position.

! CAUTION

Connecting cables in reverse (positive to negative

and negative to positive) can cause serious dam-

age to the electrical system.

Prowler XT

! CAUTION

Always replace a blown fuse with a fuse of the

same type and rating.

2-5

CLEANING AND INSPECTING

FILTER

1. Remove the seats; then remove the center con-

sole.

2. Unsnap the four fasteners securing the air

cleaner housing cover and remove the cover.

3. Remove the air filter/filter screen assembly and

separate the foam filter from the screen.

PR101

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.

6. Put the filter in a plastic bag; then pour in air fil-

ter oil and work the filter. Reattach the filter to

the filter screen.

7. Clean any dirt or debris from inside the air

cleaner. Be sure no dirt enters the carburetors.

8. Place the filter assembly in the air filter housing

making sure it is properly positioned and prop-

erly seated with the filter screen down.

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.

CD670

CHECKING AND CLEANING

DRAINS

1. Inspect one-way drains beneath the main hous-

ing for debris and for proper sealing.

! CAUTION

Failure to inspect the air filter frequently if the vehi-

cle is used in dusty, wet, or muddy conditions can

damage the engine.

! CAUTION

A torn air filter can cause damage to the vehicle

engine. Dirt and dust may get inside the engine if

the element is torn. Carefully examine the element

for tears before and after cleaning it. Replace the

element with a new one if it is torn.

2-6

PR141A

2. Replace any one-way drain that is cracked or

shows any signs of hardening or deterioration.

3. Wipe any accumulation of oil or gas from the

filter housing and one-way drains.

Valve/Tappet

Clearance

(Feeler Gauge Procedure)

To check and adjust valve/tappet clearance, use the

following procedure.

NOTE: The engine must be cold for this proce-

dure.

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.

NOTE: At this point, the rocker arms and

adjuster screws must not have pressure on them.

3. Using a feeler gauge, check each valve/tappet

clearance. If clearance is not within specifica-

tions, loosen the jam nut and rotate the tappet

adjuster screw until the clearance is within spec-

ifications. Tighten each jam nut securely after

completing the adjustment.

CC007D

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)

To check and adjust valve/tappet clearance, use the

following procedure.

NOTE: The engine must be cold for this proce-

dure.

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.

! CAUTION

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.

! CAUTION

The feeler gauge must be positioned at the same

angle as the valve and valve adjuster for an accu-

rate measurement of clearance. Failure to measure

the valve clearance accurately could cause valve

component damage.

VALVE/TAPPET CLEARANCE

Intake 0.1016 mm (0.004 in.)

Exhaust 0.1524 mm (0.006 in.)

2-7

NOTE: At this point, the rocker arms and

adjuster screws must not have pressure on them.

NOTE: Use Valve Clearance Adjuster (p/n

0444-078) for this procedure.

3. Place the valve adjuster onto the jam nut secur-

ing 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 clock-

wise until friction is felt.

5. Align the valve adjuster handle with one of the

marks on the valve adjuster dial.

6. While holding the valve adjuster handle in

place, rotate the valve adjuster dial counter-

clockwise until proper valve/tappet clearance is

attained.

NOTE: Refer to the appropriate specifications in

Feeler Gauge Procedure sub-section for the proper

valve/tappet clearance.

NOTE: Rotating the valve adjuster dial counter-

clockwise will open the valve/tappet clearance by

0.05 mm (0.002 in.) per mark.

7. While holding the adjuster dial at the proper

clearance setting, tighten the jam nut securely

with the valve adjuster handle.

8. Place the two tappet covers with O-rings into

position; then tighten the covers securely.

CF006A

CF005

9. Install the spark plug; then install the timing

inspection plug.

Testing Engine

Compression

To test engine compression, use the following pro-

cedure.

NOTE: The engine must be warm and the battery

must be fully charged for this test.

NOTE: The seats and center console must be

removed for this procedure.

1. Remove the high tension lead from the spark

plug.

2. Using compressed air, blow any debris from

around the spark plug.

3. Remove the spark plug; then attach the high ten-

sion 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).

5. While holding the throttle in the full-open posi-

tion, 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.

! WARNING

Always wear safety glasses when using com-

pressed air.

2-8

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.

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).

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.

ATV-0051

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

ATV0052B

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

The muffler has a spark arrester which must be peri-

odically cleaned. At the intervals shown in the Peri-

odic Maintenance Chart, clean the spark arrester

using the following procedure.

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.

CF105A

! 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.

! WARNING

Wait until the muffler cools to avoid burns.

2-9

CF104

2. Using a suitable brush, clean the carbon deposits

from the screen taking care not to damage the

screen.

NOTE: If the screen or gasket is damaged in any

way, it must be replaced.

3. Install the spark arrester assembly and gasket

and secure with the three cap screws. Tighten

the cap screws to 0.6 kg-m (4.0 ft-lb).

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 con-

nected to the carburetor and the opposite end is

always open.

Adjusting Throttle

Cable

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).

CD560A

2. Turn the adjuster until the throttle cable has

proper free-play of 3-6 mm (1/8 - 1/4 in.) at the

pedal.

3. Tighten the jam nut against the throttle cable

adjuster securely; then slide the rubber boot over

the adjuster.

Adjusting Engine RPM

(Idle)

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 nor-

mal operating temperature.

2. Turn the idle adjustment screw clockwise one

turn past the recommended RPM setting; then

turn it counterclockwise to 1250-1350 RPM.

2-10

PR081A

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.

2. Remove the oil level stick/filler plug.

PR053B

3. Remove the drain plug from the bottom of the

engine and drain the oil into a drain pan.

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 spec-

ifications. Pour the specified amount of the rec-

ommended 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 min-

utes.

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.

! WARNING

Adjust the idle to the correct RPM. Make sure the

engine is at normal operating temperature before

adjusting the idle RPM.

! CAUTION

Any oil used in place of the recommended oil could

cause serious engine damage. Do not use oils

which contain graphite or molybdenum additives.

These oils can adversely affect clutch operation.

Also, not recommended are racing, vegetable,

non-detergent, and castor-based oils.

2-11

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.

ATV-0100

12. Inspect the area around the drain plug and oil fil-

ter 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 proce-

dure.

1. Remove the rear drive filler plug; the lubricant

level should be 1 in. below the threads of the

plug.

PR046A

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

lube as necessary.

PR065A

To change the lubricant, use the following proce-

dure.

1. Place the vehicle on level ground.

2. Remove each oil filler plug.

PR046A

PR065A

3. Drain the oil into a drain pan by removing in

turn the drain plug from each.

! CAUTION

Do not over-fill the engine with oil. Always make

sure that the oil level is above the “L” m a r k b u t n o t

higher than the “F” mark.

2-12

ATV0082A

737-651A

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 contami-

nated 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.

TIRE INFLATION PRESSURE

Front and rear tire inflation pressure should be 0.70

kg-cm² (10 psi).

A low-pressure gauge is provided in the tool kit to

measure the air pressure in the tires. Check the air

pressure in all tires before each use of the vehicle.

Steering Components

The following steering components should be

inspected periodically to ensure safe and proper

operation.

A. Steering wheel secure.

B. Steering has equal and complete full-left and

full-right capability.

C. Steering sector mounting bolts tight.

D. Ball joints not worn, cracked, or damaged.

E. Tie rods not bent or cracked.

F. Knuckles not worn, cracked, or damaged.

G. Cotter pins not damaged or missing.

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.

! WARNING

Always use the size and type of tires specified.

Always maintain proper tire inflation pressure.

Rear Drive

2-13

E. Shock absorber eyelet bushings worn, deteri-

orated, 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 Sec-

tion 10.

Ignition Timing

The ignition timing cannot be adjusted; however,

verifying ignition timing can aid in troubleshooting

other components. To verify ignition timing, use the

following procedure.

NOTE: To check ignition timing, the seats and

center console must be removed.

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 crank-

case cover.

2. Start the engine and using the RPM function on

the speedometer/tachometer, run at the recom-

mended RPM; ignition timing should be the rec-

ommended degrees BTDC.

3. Install the timing inspection plug.

If ignition timing cannot be verified, the rotor may

be damaged, the key may be sheared, the trigger coil

bracket may be bent or damaged, or the CDI unit

may be faulty.

Headlight/Taillight-

Brakelight

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 frag-

ile. 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.

To replace the headlight bulb, use the following pro-

cedure.

1. Remove the wiring harness connector from the

back of the headlight.

2. Grasp the bulb socket, turn it counterclockwise

and remove, and pull the bulb straight out of the

socket.

3. Install the new bulb into the socket and rotate it

completely clockwise in the housing.

4. Install the wiring harness connector.

TAILLIGHT-BRAKELIGHT

To replace the taillight-brakelight bulb, use the fol-

lowing 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 assem-

bly and turn clockwise to lock in place.

4. Install the taillight-brakelight assembly on the

canopy support.

IGNITION TIMING

Prowler XT 10° BTDC @ 1500 RPM

! WARNING

Do not attempt to remove the bulb when it is hot.

Severe burns may result.

2-14

CHECKING/ADJUSTING

HEADLIGHT AIM

The headlights can be adjusted vertically. The geo-

metric center of the HIGH beam light zone is to be

used for vertical aiming.

1. Position the vehicle on a level floor so the head-

lights 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 hori-

zontal 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.

0740-647

7. Using the adjuster knob, adjust each headlight

until correct aim is obtained.

CD714A

Switches

Each time the vehicle is used, switches should be

checked for proper operation. Use the following list

for reference.

A. Ignition/start switch — engine will run;

starter will engage.

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

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.

2-15

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.

PR093A

3. Holding the shift lever centered in the neutral

position, move the shifter arm until (N) is indi-

cated 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 replace-

ment or repair constitutes removal, see Section 8.

Electrical Connections

The electrical connections should be checked peri-

odically for proper function. In case of an electrical

failure, check fuses, connections (for tightness, cor-

rosion, damage), and/or bulbs. If an electrical com-

ponent needs to be tested for proper function, see

Section 5.

Hydraulic

Brake System

CHECKING/BLEEDING

The hydraulic brake system has been filled and bled

at the factory. To check and/or bleed a hydraulic

brake system, use the following procedure.

1. With the master cylinder in a level position,

check the fluid level in the reservoir. If the level

in the reservoir is not above the MIN, add DOT

4 brake fluid.

PR095

2. Depress the brake pedal several times to check

for a firm brake. If the brake is not firm, the sys-

tem 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.

2-16

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 proce-

dure until no air bubbles are present.

AF637D

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 main-

tain a sufficient amount of fluid in the reservoir will

result in air in the system.

D. At this point, perform steps B and C on the

other FRONT bleeder screw; then move to

the REAR bleeder screw and follow the same

procedure.

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

firm.

4. Carefully check the entire hydraulic brake sys-

tem that all hose connections are tight, the bleed

screws are tight, the protective caps are

installed, and no leakage is present.

INSPECTING HOSES

Carefully inspect the hydraulic brake hoses for

cracks or other damage. If found, the brake hoses

must be replaced.

CHECKING/REPLACING PADS

The clearance between the brake pads and brake

discs is adjusted automatically as the brake pads

wear. The only maintenance that is required is

replacement of the brake pads when they show

excessive wear. Check the thickness of each of the

brake pads as follows.

1. Remove a front wheel.

2. Measure the thickness of each brake pad.

PR376A

3. If 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.

4. To replace the brake pads, use the following pro-

cedure.

A. Remove the wheel.

B. Remove the cap screws securing the caliper

holder to the knuckle; then remove the pads

from the caliper.

! 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.

2-17

PR237

C. Install the new brake pads.

D. Secure the caliper holder to the knuckle with

the cap screws. Tighten to specifications.

PR377B

E. Install the wheel. Tighten to specifications.

5. Burnish the brake pads (see Burnishing Brake

Pads in this section).

Parking Brake

CHECKING

Although the parking brake has been adjusted at the

factory, the brake should be checked for proper

operation. The brake must be maintained to be fully

functional.

1. With the engine off, transmission in neutral, and

the parking brake set, attempt to move the vehi-

cle.

2. If the rear wheels are locked, it is adjusted prop-

erly.

3. If the rear wheels are not locked, it must be

adjusted (set up).

ADJUSTING

To adjust (set up) the parking brake, use the follow-

ing procedure.

NOTE: Remove the four rear body screws secur-

ing the belly panel to the frame and allow it to drop

down for better access to the parking brake actua-

tor.

PR096

1. Remove the parking brake cable from the actua-

tor lever; then remove the actuator nut and actu-

ator lever. Note the position of the lever before

removing.

PR098

2. Rotate the actuator clockwise (hand tight) until

it contacts the back of the piston; then rotate

counterclockwise approximately one spline.

PR089A

2-18

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).

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.

PR097A

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 sup-

port and allow the cargo box to tilt all the way

back.

PR099

3. Remove the two cap screws securing the brake

caliper to the rear drive housing and remove the

caliper.

PR080B

4. Push in on the caliper holder and remove the

outer brake pad; then remove the inner pad.

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 fac-

ing 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 specifi-

cations.

! CAUTION

If after adjusting the parking brake cable the park-

ing brake will not hold the vehicle, the brake pads

must be replaced.

2-19

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).

Burnishing Brake Pads

Brake pads must be burnished to achieve full brak-

ing effectiveness. Braking distance will be extended

until brake pads are properly burnished. To properly

burnish the brake pads, use the following procedure.

1. Choose an area large enough to safely accelerate

the vehicle to 30 mph and to brake to a stop.

2. Accelerate to 30 mph; then depress the brake

pedal to decelerate to 0-5 mph.

3. Repeat procedure five times until brake pads are

burnished.

4. Adjust the parking brake (if necessary).

5. Verify that the brakelight illuminates when the

brake pedal is depressed.

Coolant

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 Arc-

tic 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 cool-

ing system to the bottom of the stand pipe in the

radiator neck.

AN604D

Checking/Replacing

V-Belt

REMOVING

1. Remove the seats and center console; then

remove the left-side seat-base.

PR104

2. Remove the cap screws securing the V-belt

cover noting the location of the differ-

ent-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.

! 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.

! CAUTION

After operating the vehicle for the initial 5-10 min-

utes, stop the engine, allow the engine to cool

down, and check the coolant level. Add coolant as

necessary.

2-20

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.

PR110

PR108

4. Remove the V-belt.

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 sepa-

rated, 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 pul-

ley and over the front shaft.

PR109

NOTE: The arrow on the V-belt should point rear-

ward.

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.

-AIN(ARNESS

'ROUND

%NGINE

'ROUND

! CAUTION

Make sure the drive belt does not prevent the mov-

able face from contacting the spacer when tighten-

ing the nut or false torque readings could occur.

The assembly could loosen after starting the

engine causing damage to the shaft and pulley.

2-21

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 pul-

ley.

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.

NOTE: Make sure the main harness and engine

ground wires are installed and secured in the

proper location with the unpainted cap screw.

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.

3-1

SECTION 3 - ENGINE/TRANSMISSION

TABLE OF

CONTENTS

Engine/Transmission ............................................... 3-2

Specifications .......................................................... 3-3

Prowler XT (Table of Contents) ............................... 3-4

3-2

Engine/Transmission

This section has been organized into sub-sections

which show a progression for the complete servic-

ing of the Arctic Cat Prowler XT engine/transmis-

sion.

To service the center crankcase halves, the

engine/transmission must be removed from the

frame.

To service top-side, left-side, and right-side compo-

nents, 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.

3-3

Specifications*

* Specifications subject to change without notice.

VALVES AND GUIDES

Valve Face Diameter (intake)

(exhaust)

31.6 mm (1.24 in.)

27.9 mm (1.10 in.)

Valve/Tappet Clearance

(cold engine)

(intake)

(exhaust)

0.1016 mm (0.004 in.)

0.1524 mm (0.006 in.)

Valve Guide/Stem

Clearance

(intake)

(exhaust)

0.013 mm

(0.0005 in.)

0.013 mm

(0.0005 in.)

Valve Guide/Valve

Stem Deflection

(wobble method)

(max) 0.35 mm (0.014 in.)

Valve Guide Inside

Diameter

5.000-5.012 mm

(0.1969-0.1973 in.)

Valve Stem Outside

Diameter

(intake)

(exhaust)

4.972-4.987 mm

(0.1957-0.1963 in.)

4.972-4.987 mm

(0.1957-0.1963 in.)

Valve Stem Runout (max) 0.1 mm (0.0039 in.)

Valve Head Thickness (min) 2.3 mm (0.0906 in.)

Valve Stem End Length (min) 3.97 mm (0.156 in.)

Valve Face/Seat Width (intake)

(exhaust)

2.25 mm (0.0886 in.)

2.60 mm (0.1024 in.)

Valve Seat Angle (intake)

(exhaust)

45° 15’-45° 30’

Valve Face Radial Runout (max) 0.2 mm (0.0079 in.)

Valve Spring Free Length (min) 38.7 mm (1.524 in.)

Valve Spring Tension

@ 31.5 mm (1.24 in.)

(outer) 19.0 kg (42 lb)

CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min) (intake)

(exhaust)

13.97 mm (0.55 in.)

Camshaft Journal Oil

Clearance

(max) 0.04 mm (0.0016 in.)

Camshaft Journal Holder

Inside Diameter

(right & center)

(left)

21.98-22.04 mm

(0.8654-0.8677 in.)

17.48-17.53 mm

(0.6882-0.6902 in.)

Camshaft Journal

Outside Diameter

(right & center)

(left)

21.96-21.98 mm

(0.8646-0.8654 in.)

17.47-17.48 mm

(0.6878-0.6882 in.)

Camshaft Runout (max) 0.05 mm (0.002 in.)

Rocker Arm Inside

Diameter

12.000-12.018 mm

(0.4724-0.4731 in.)

Rocker Arm Shaft

Outside Diameter

11.97-11.98 mm

(0.4713-0.4717 in.)

Cylinder Head Distortion (max) 0.05 mm (0.002 in.)

Cylinder Head Cover

Distortion

(max) 0.05 mm (0.002 in.)

CYLINDER, PISTON, AND RINGS

Piston Skirt/Cylinder

Clearance

0.045 mm (0.0018 in.)

Cylinder Bore 98 mm (3.858 in.)

Piston Diameter

15 mm (0.6 in.) from Skirt

End

97.948-97.962 mm

(3.856-3.857 in.)

Piston Ring

Free End Gap

(1st Ring)

(2nd Ring)

12.5 mm (0.492 in.)

Bore x Stroke 97.9 x 85 mm

(3.86 x 3.35 in.)

Cylinder Trueness (max) 0.01 mm (0.004 in.)

Piston Ring End Gap

- Installed

0.36 mm (0.014 in.)

Piston Ring to Groove

Clearance (max)

(1st)

(2nd)

0.03 mm

(0.0012 in.)

0.03 mm

(0.0012 in.)

Piston Ring Groove Width (1st)

(2nd)

(Oil)

1.202-1.204 mm

(0.0473-0.0474 in.)

1.202-1.204 mm

(0.0473-0.0474 in.)

2.01-2.03 mm

(0.0791-0.0799 in.)

Piston Ring Thickness (1st)

(2nd)

1.970-1.990 mm

(0.0776-0.0783 in.)

1.970-1.990 mm

(0.0776-0.0783 in.)

Piston Pin Bore (max) 23.0 mm (0.9055 in.)

Piston Pin Outside Diame-

ter

(min) 22.99 mm (0.9051 in.)

CRANKSHAFT

Connecting Rod

(small end inside diameter)

(max)

23.021 mm

(0.9063 in.)

Connecting Rod

(big end side-to-side) 0.6 mm (0.024 in.)

Connecting Rod (big end

width)

25 mm (0.9843 in.)

Connecting Rod @ 150 mm

(5.9 in.)

(small end deflection)

(max) 0.3 mm (0.0118 in.)

Crankshaft (web-to-web) 71 mm (2.79 in.)

Crankshaft Runout(max) 0.03 mm (0.0012 in.)

Oil Pressure @2500 RPM

(Cooling Fan Cycling)

1.40-2.11 kg/cm²

(20-30 psi)

Cooling Fan

Thermo-Switch

Operating Temperature

(offJon)

(onJoff)

90°C (194°F) ±10%

75°C (167°F) ±10%

Engine Coolant

Thermo-Switch

Operating Temperature

107°-113°C

(225°-235°F)

3-4

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

Removing Engine/

Transmission

Many service procedures can be performed without

removing the engine/transmission from the frame.

Closely observe the note introducing each sub-sec-

tion for this important information.

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.

1. Remove the seats and center console; then

remove the left-side and right-side seat-bases.

2. Remove the center belly panel; then drain the oil

and coolant.

NOTE: Use a small funnel between the frame and

coolant drain plug to prevent coolant from drain-

ing on the frame and splashing.

PR122A

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.

PR130A

 AT THIS POINT

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.

! WARNING

Make sure the vehicle is solidly supported on the

support stands to avoid injury.

3-5

PR155A

PR157A

5. From the left-side, disconnect the starter wire,

alternator connector, CDI connector, shift posi-

tion switch connector, and electric choke con-

nector; then remove the cap screw securing the

main harness and the engine ground wires to the

V-belt housing.

PR145A

PR128A

PR111A

6. Remove the E-clip from the shift arm; then dis-

connect the shifter linkage. Account for three

spacer washers.

PR138A

7. Remove four machine screws securing the

shifter mount to the frame; then remove the

shifter assembly.

PR123A

8. Loosen the clamp securing the air intake boot to

the carburetor and the clamp securing the air fil-

ter housing to the inlet housing boot; then

remove the crankcase breather hose from the

crankcase.

3-6

PR127A

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.

PR140A

10. Remove the throttle arm cover from the carbure-

tor; then disconnect and remove the throttle

cable and the carburetor.

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 com-

partment.

PR150A

12. Remove the exhaust duct from the V-belt hous-

ing; then remove the inlet boot connecting the

inlet duct to the V-belt housing.

PR144B

3-7

PR153B

13. Remove the muffler; then remove the exhaust

pipe.

14. Set the parking brake; then from the underside

of the vehicle, mark the flanges of the drive-line

couplers for assembling and remove the cap

screws (three on the front drive coupler and

three on the rear drive coupler) securing the

driveshafts to the drive couplers.

NOTE: Remove the front driveshaft first or the

parking brake will not hold the coupler stationary

and cap screw removing will be more difficult.

PR152A

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 drive-

shaft.

PR148A

16. Remove two flange nuts from the underside of

the rear engine mounts.

PR153A

17. Remove two flange nuts securing the engine

mounting bracket to the front engine mounts.

PR147

18. Attach suitable lifting chains to the engine/trans-

mission; then using an engine hoist, lift the

assembly out of the engine compartment.

3-8

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.

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: The engine/transmission does not have

to removed from the frame for this procedure.

Removing Top-Side

Components

A. Valve Cover

B. Cylinder Head

NOTE: Remove the spark plug and timing

inspection plug; then using the recoil starter,

rotate the crankshaft to top-dead-center of the

compression stroke.

1. Remove the two tappet covers.

CC001D

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.

CD205

 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.

3-9

CD206

CD211A

3. Loosen the cap screw on the end of the ten-

sioner; then remove the two machine screws

securing the tensioner adjuster assembly and

remove the assembly. Account for a gasket.

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.

CC012D

5. Bend the washer tabs down and remove the two

cap screws securing the sprocket to the cam-

shaft; then drop the sprocket off the camshaft.

CC013D

6. Remove the cap screw securing the chain ten-

sioner (account for a washer); then remove the

tensioner.

CC014D

7. While holding the chain, slide the sprocket and

camshaft out of the cylinder head.

3-10

CC266D

NOTE: Loop the chain over the cylinder and

secure it to keep it from falling into the crankcase.

8. Remove the five nuts securing the cylinder head

to the cylinder; then remove the four cylinder

head cap screws with copper washers.

CC017D

CC018D

CC016D

9. Remove the cylinder head from the cylinder,

remove the gasket, and account for two align-

ment pins; then remove the cam chain guide.

CC020D

CC022D

 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.

3-11

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.

CC023D

12. Lift the cylinder off the crankcase taking care

not to allow the piston to drop against the crank-

case. Account for the gasket and two alignment

pins.

CC024D

CC025D

CC026D

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

CC032D

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

remove the piston pin. Account for the oppo-

site-side circlip. Remove the piston.

NOTE: It is advisable to remove the oppo-

site-side circlip prior to using the puller.

CC033D

 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 pis-

ton.

3-12

NOTE: Support the connecting rod with rubber

bands to avoid damaging the rod or install the

Connecting Rod Holder (p/n 0444-006).

NOTE: If the existing rings will not be replaced

with new rings, note the location of each ring for

proper installation. When replacing with new rings,

replace as a complete set only. If the piston rings

must be removed, remove them in this sequence.

A. Starting with the top ring, slide one end of the

ring out of the ring-groove.

B. Remove each ring by working it toward the

dome of the piston while rotating it out of the

groove.

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.

NOTE: The engine/transmission does not have

to be removed from the frame for this procedure.

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.

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.

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.

! CAUTION

Do not allow the connecting rod to go down inside

the crankcase. If the rod is down inside the crank-

case and the crankshaft is rotated, severe damage

will result.

 AT THIS POINT

To service piston, see Servicing Top-Side

Components sub-section.

 AT THIS POINT

To service center crankcase components only,

proceed to Removing Right-Side Components.

 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.

3-13

CC620

6. Remove the two machine screws securing the

water pump to the engine; then remove the

water pump.

CC623

7. Remove the twelve machine screws securing the

right-side cover to the crankcase noting the loca-

tion of the different-sized machine screws for

installing purposes.

CC626

8. Using Side Case Puller (p/n 0644-262), remove

the side cover. Account for a gasket and two

alignment pins.

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.

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.

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.

CD939A

 AT THIS POINT

To service the water pump, see Section 4.

3-14

CD940A

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.

CD140

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.

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.

CD952A

Left-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: The engine/transmission does not have

to be removed from the frame for this procedure.

 AT THIS POINT

To service the magneto assembly, see Section 5.

 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.

3-15

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 differ-

ent-lengthed machine screws for installing pur-

poses; then using a rubber mallet, gently tap on

the cover tabs to loosen the cover.

CD961A

2. Remove the nut securing the movable drive

face; then remove the face. Account for a spacer.

CD962

CD964

3. Remove the V-belt.

4. Remove the nut securing the fixed driven

assembly; then remove the assembly.

CD968

5. Remove the fixed drive face.

6. Remove the machine screws securing the air

intake plate; then remove the plate/cushion

assembly.

CD970

CD972

7. Remove the machine screws securing the clutch

cover. Note the location of the differ-

ent-lengthed machine screws for installing pur-

poses. Using a rubber mallet, carefully remove

the cover. Account for two alignment pins.

3-16

CD973A CC600A

NOTE: For steps 8-14, refer to illustration

CC829A.

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 align-

ment dot (or the word OUTSIDE) for installing

purposes.

9. Using a hydraulic press, remove the clutch hous-

ing assembly from the clutch cover. Account for

the left fixed drive spacer and an O-ring inside

the fixed drive spacer. CF085A

! CAUTION

Care must be taken when removing the cover so

the cover gasket is not damaged.

KEY

A. Oil Pump Driven Gear

B. Oil Pump Drive Gear

C. Clutch Shoe Assembly

D. One-Way Clutch

(Green Dot MUST Show)

E. Final Drive Carrier Bearing Housing

F. Input Shaft

3-17

CC596

NOTE: Account for and inspect the clutch hous-

ing seal.

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.

CD994

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.

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.

CD988

3-18

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.

Separating Crankcase

Halves

1. Remove the left-side machine screws securing

the crankcase halves. Note the location of the

different-lengthed machine screws.

CC664

2. Remove the right-side machine screws securing

the crankcase halves. Note the location of the

different-lengthed machine screws.

CC663

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

3-19

Disassembling

Crankcase Half

NOTE: For steps 1-7, refer to illustration CC821B.

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.

CD267

2. Remove the reverse idler gear assembly (F).

Account for all washers, shaft, bushing, and the

gear.

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 loca-

tion of the two holes on the end of the shaft.

Account for four washers and a needle bearing.

KEY

A. Secondary Driven Shaft Assembly

B. Crank Balancer Assembly

C. Crankshaft

D. Countershaft Assembly

E. Driveshaft

F. Reverse Idler Gear Assembly

G. Gear Shift Shaft

H. Shift Shaft with 2 Forks

3-20

PR380A

PR381A

5. Remove the countershaft assembly (D). Account

for a washer on each end of the countershaft.

CC674

NOTE: Do not disassemble the countershaft

assembly unless necessary. If necessary, see Ser-

vicing Center Crankcase Components sub-sec-

tion.

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

remove the driveshaft.

CC675

7. Note the alignment dots on the crank balancer

assembly (B) gear and crankshaft (C) gear for

assembling purposes; then slide the crank bal-

ancer gear off the crank balancer. Account for

the key in the keyway.

CD826

8. Remove the crank balancer.

NOTE: There is a flat spot on the crank balancer

bearing flange to allow clearance past the crank-

shaft.

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 dam-

age to the crankshaft threads.

3-21

CC680

11. Remove the machine screws securing the oil

strainer cap; then remove the cap. Account for

the cap O-ring.

CC681

12. Remove the two machine screws securing the

oil strainer; then remove the strainer.

CC682

13. To remove the assembly, remove the nut secur-

ing the secondary drive gear and secondary

driven gear; then from the inside of the crank-

case using a rubber mallet, remove the output

shaft assembly. Account for the output shaft,

two gears, a shim, a washer, and the nut.

CC686

Table of Contents

(Servicing Components)

NOTE: Critical engine/transmission specifica-

tions are located at the beginning of this section.

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.

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 cyl-

inder head assembly must be replaced.

! 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.

3-22

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 seal-

ing surface for any indication of high spots. A

high spot can be noted by a bright metallic fin-

ish. Correct any high spots before assembly by

continuing to move the valve cover in a figure

eight motion until a uniform bright metallic fin-

ish is attained.

CC130D

Removing Valves

NOTE: Keep all valves and valve components as

a set. Note the original location of each valve set

for use during installation. Return each valve set to

its original location during installation.

1. Using a valve spring compressor, compress the

valve springs and remove the valve cotters.

Account for an upper spring retainer.

CC132D

2. Remove the valve seal and the lower remaining

spring seat. Discard the valve seal.

CC136D

NOTE: The valve seals must be replaced.

3. Remove the valve springs; then invert the cylin-

der 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.

ATV-1082

2. Maximum runout must not exceed specifica-

tions.

! 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.

! CAUTION

Water or parts-cleaning solvent must be used in

conjunction with the wet-or-dry sandpaper or dam-

age to the sealing surface may result.

3-23

Measuring Valve Stem

Outside Diameter

1. Using a micrometer, measure the valve stem

outside diameter.

2. Acceptable diameter range (intake valve) must

be within specifications.

3. Acceptable diameter range (exhaust valve) must

be within specifications.

Measuring Valve Face/Seat Width

1. Using a micrometer, measure the width of the

valve face.

ATV-1004

2. Acceptable width range must be within specifi-

cations.

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.

ATV1082A

3. Rotate the valve in the V blocks.

4. Maximum runout must not exceed specifica-

tions.

Measuring Valve Guide/Valve Stem

Deflection (Wobble Method)

1. Mount a dial indicator and base on the surface

plate; then place the cylinder head on the surface

plate.

2. Install the valve into the cylinder head; then

position the dial indicator contact point against

the outside edge of the valve face. Zero the indi-

cator.

CC131D

3. Push the valve from side to side; then from top

to bottom.

4. Maximum “wobble” deflection must not exceed

specifications.

Measuring Valve Guide

(Inside Diameter)

1. Insert a snap gauge 1/2 way down into each

valve guide bore; then remove the gauge and

measure it with a micrometer.

2. Acceptable inside diameter range must be

within specifications.

3. If a valve guide is out of tolerance, it must be

replaced.

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.

3-24

CC137D

2. Using the Standard Valve Guide Reamer (p/n

0444-017), remove any burrs or tight areas from

the valve guide journals.

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 cyl-

inder head.

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.

CC138D

Valve Seat/Guide Servicing Flow

Chart

ATV-0107

Grinding Valve Seats

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.

3-25

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.

NOTE: Repeat procedure on the remaining

intake valve seat.

CC140D

Lapping Valves

NOTE: Do not grind the valves. If a valve is dam-

aged, 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 com-

pound to the entire seating face of each valve.

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.

Measuring Rocker Arm

(Inside Diameter)

1. Using a dial calipers, measure the inside diame-

ter of the rocker arm.

2. Acceptable inside diameter range must be

within specifications.

Measuring Rocker Arm Shaft

(Outside Diameter)

1. Using a micrometer, measure the outside diame-

ter of the rocker arm shaft.

2. Acceptable outside diameter range must be

within specifications.

Installing Valves

1. Apply grease to the inside surface of the valve

seals; then place a lower spring seat and valve

guide seal over each valve guide.

CC144D

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.

ATV-1011A

3-26

4. Place a spring retainer over the valve springs;

then using the valve spring compressor, com-

press the valve springs and install the valve cot-

ters.

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” indi-

cates worn piston rings or an out-of-round cylin-

der.

Removing Piston Rings

1. Starting with the top ring, slide one end of the

ring out of the ring-groove.

CC400D

2. Remove each ring by working it toward the

dome of the piston while rotating it out of the

groove.

NOTE: If the existing rings will not be replaced

with new ones, note the location of each ring for

proper installation. When installing new rings,

install as a complete set only.

Cleaning/Inspecting Piston Rings

1. Take an old piston ring and snap it into two

pieces; then grind the end of the old ring to a 45°

angle and to a sharp edge.

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.

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.

! 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.

3-27

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.

ATV-1070

2. Insert an inside dial indicator into the piston-pin

bore. The diameter must not exceed specifica-

tions. Take two measurements to ensure accu-

racy.

ATV-1069

Measuring Piston Skirt/

Cylinder Clearance

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

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 speci-

fications.

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 illustra-

tion.

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.

3-28

ATV-1024A

CYLINDER/CYLINDER HEAD

ASSEMBLY

NOTE: If the cylinder/cylinder head assembly

cannot be trued, they must be replaced.

Cleaning/Inspecting Cylinder Head

1. Using a non-metallic carbon removal tool,

remove any carbon buildup from the combus-

tion chamber being careful not to nick, scrape,

or damage the combustion chamber or the seal-

ing 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 cov-

ered with #400 grit wet-or-dry sandpaper. Using

light pressure, move the cylinder head in a fig-

ure 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.

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 specifica-

tions.

CC141D

Cleaning/Inspecting Cylinder

1. Wash the cylinder in parts-cleaning solvent.

2. Inspect the cylinder for pitting, scoring, scuff-

ing, warpage, and corrosion. If marks are found,

repair the surface using a cylinder hone (see

Honing Cylinder in this sub-section).

! CAUTION

Incorrect installation of the piston rings will result

in engine damage.

! CAUTION

The cylinder head studs must be removed for this

procedure.

! CAUTION

Water or parts-cleaning solvent must be used in

conjunction with the wet-or-dry sandpaper or dam-

age to the sealing surface may result.

3-29

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 indi-

cation 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 cyl-

inder in a figure eight motion until a uniform

bright metallic finish is attained.

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 mea-

surements for a total of six measurements. The

trueness (out-of-roundness) is the difference

between the highest and lowest reading. Maxi-

mum trueness (out-of-roundness) must not

exceed specifications.

CC127D

2. Wash the cylinder in parts-cleaning solvent.

3. Inspect the cylinder for pitting, scoring, scuff-

ing, 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 avail-

able, use a lightweight petroleum-based oil. Thor-

oughly clean cylinder after honing using soap and

hot water. Dry with compressed air; then immedi-

ately apply oil to the cylinder bore. If the bore is

severely damaged or gouged, replace the cylinder.

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.

! CAUTION

Water or parts-cleaning solvent must be used in

conjunction with the wet-or-dry sandpaper or dam-

age to the sealing surface may result.

3-30

CC283D

2. Rotate the camshaft and note runout; maximum

tolerance must not exceed specifications.

Measuring Camshaft Lobe Height

1. Using a calipers, measure each cam lobe height.

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.

Measuring Camshaft to

Cylinder Head Clearance

1. Remove the adjuster screws and jam nuts.

CC005D

2. Place a strip of plasti-gauge in each of the cam-

shaft lands in the cylinder head.

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 measur-

ing clearance.

4. Remove the cap screws securing the valve cover

to the cylinder; then remove the valve cover and

camshaft.

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.

CC145D

6. If clearance is excessive, measure the journals of

the camshaft.

3-31

CC287D

NOTE: If the journals are worn, replace the cam-

shaft; then measure the clearance again. If it is still

out of tolerance, replace the cylinder head.

Inspecting Camshaft Spring/Drive

1. Inspect the spring and drive pin for damage.

CF061A

CF060A

2. If damaged, the camshaft must be replaced.

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

1. Inspect the shoe for uneven wear, chips, cracks,

or discoloration. If any shoe is damaged, the

complete set must be replaced.

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.

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 hous-

ing 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.

! CAUTION

Always replace centrifugal clutch shoes as a com-

plete set or severe imbalance of the clutch assem-

bly could occur.

3-32

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.

CC446D

DRIVEN PULLEY ASSEMBLY

Disassembling

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.

CD047

2. Place the driven pulley assembly onto the com-

pressor tool base engaging the dowel pins into

appropriate holes in the fixed face of the assem-

bly.

CD048

3. Install the pilot bushing with the machined end

directed down; then fit the bushing into the pul-

ley hub.

CD067

4. Using a suitable marking pen, make alignment

marks on the fixed face spring holder and both

pulley faces.

CD049

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.

! WARNING

This procedure involves relaxing a compressed

spring assembly. DO NOT attempt disassembling

without the proper tools.

3-33

CD050

6. Using a spanner and suitable breaker bar, loosen

the notched-ring nut; then spin the nut free of

the hub.

CD051

7. Firmly hold the handle and slowly turn the wing

nut counterclockwise to relax the spring.

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.

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.

CD054

11. Remove the four pins and spacers from the cam

slots in the movable face; then remove the mov-

able face.

CF091

! WARNING

The spring assembly is under pressure. Extreme

care must be taken when relaxing the spring.

Always wear safety glasses. Use proper tools only.

3-34

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.

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.

NOTE: Make sure the spacer is on the base or

damage to the fixed face will occur when the

spring is compressed.

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.

CD061

4. Install the spring over the hub and movable face

sleeve.

3-35

CF089

5. Place the spring holder on the spring.

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.

CD052

7. Compress the spring until the spring holder

nears the threads on the fixed face hub.

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.

CD066

10. Remove the wing nut, washer, and holding han-

dle; then remove the driven pulley from the pul-

ley compressor.

3-36

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: Always start with the original shims on

the rear shaft.

1. Place the left-side crankcase cover onto the

left-side crankcase half to prevent runout of the

secondary transmission output shaft.

2. Install the secondary driven output shaft assem-

bly onto the crankcase.

3. Mount the dial indicator so the tip is contacting

a tooth on the secondary driven bevel gear.

4. While rocking the driven bevel gear back and

forth, note the maximum backlash reading on

the gauge.

5. Acceptable backlash range is 0.05-0.33 mm

(0.002-0.013 in.).

Correcting Backlash

NOTE: If backlash measurement is within the

acceptable range, no correction is necessary.

1. If backlash measurement is less than specified,

remove an existing shim, measure it, and install

a new thinner shim.

2. If backlash measurement is more than specified,

remove an existing shim, measure it, and install

a thicker shim.

NOTE: Continue to remove, measure, and install

until backlash measurement is within tolerance.

Note the following chart.

Checking Tooth Contact

NOTE: After correcting backlash of the second-

ary 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.

3. Apply a thin, even coat of a machinist-layout

dye to several teeth of the gear.

4. Install the secondary driven output shaft assem-

bly.

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.

ATV-0103

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

3-37

ATV-0105

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.

NOTE: To correct tooth contact, steps 1 and 2

(with NOTE) of “Correcting Backlash” must be fol-

lowed and the above “Tooth Contact/Shim Correc-

tion” chart must be consulted.

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.

CC290D

2. Maximum diameter must not exceed specifica-

tions.

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 jour-

nal.

2. Zero the indicator and push the small end of the

connecting rod away from the dial indicator.

3. Maximum deflection must not exceed specifica-

tions.

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.

Tooth Contact Shim Correction

Contacts at Top Decrease Shim Thickness

Contacts at Root Increase Shim Thickness

! CAUTION

After correcting tooth contact, backlash must again

be checked and corrected (if necessary). Continue

the correcting backlash/correcting tooth contact

procedures until they are both within tolerance val-

ues.

3-38

CC289D

3. Acceptable gap range must be within specifica-

tions.

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 specifi-

cations.

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-1074

3. Zero the indicator and rotate the crankshaft

slowly.

4. Maximum runout must not exceed specifica-

tions.

NOTE: Proceed to check runout on the other end

of the crankshaft by positioning the indicator con-

tact at point 2 and following steps 2-4.

Measuring Crankshaft

(Web-to-Web)

1. Using a calipers, measure the distance from the

outside edge of one web to the outside edge of

the other web.

ATV-1017

2. Acceptable width range must be within specifi-

cations.

COUNTERSHAFT

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.

4. Remove the low driven gear washer and lock

washers; then remove the low driven gear.

Account for the bushing and bearing.

5. Remove the washer; then remove the sliding

dog.

6. Remove the high driven gear. Account for the

washer, bushing, and bearing.

! CAUTION

Care should be taken to support the connecting rod

when rotating the crankshaft.

! CAUTION

When disassembling the countershaft, care must

be taken to note the direction each major compo-

nent (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.

3-39

Assembling

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 prop-

erly positioned; then place the lock washers and

washer onto the shaft.

4. Place the reverse driven gear onto the counter-

shaft 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 assem-

bly, account for the washer on each end of the

shaft.

Assembling Crankcase

Half

1. Install the output shaft assembly into the crank-

case making sure the two gears, shim, washer,

and nut are properly sequenced.

CC686

NOTE: The beveled side of the secondary drive

gear must face upward.

2. Apply red Loctite #271 to the threads of the out-

put shaft; then secure with the nut. Tighten nut

to specifications; then using a punch, peen the

nut.

CC687

KEY

1. Washer - Drive Gear (R)

2. Drive Gear #2

3. Circlip

4. Reverse Gear Dog

5. Spacer

6. Washer

7. Bushing

8. Bearing

9. Reverse Driven Gear

10. Lock Washer

11. Countershaft

12. Lock Washer

13. Low Driven Gear

14. Driven Gear Washer

15. Sliding Dog

16. High Driven Gear

17. Washer - Drive Gear (L)

3-40

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.

CC688

CC689

NOTE: If heating the bearing is not possible, the

crankshaft can be installed using a crankshaft

installing tool.

CC690

4. Install the crank balancer.

CD832

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.

CD826A

6. Place a washer on each end of the countershaft

assembly; then install the assembly.

CC674

7. Install the driveshaft.

3-41

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.

PR382A

9. Insert the two shift forks into the sliding dogs

noting the direction of the tabs from disassem-

bling; then install the shift fork shaft.

NOTE: Make sure the shift fork tabs face upward

and that they are properly seated into the shift

cams.

CC669

10. Install the reverse idler gear assembly noting the

positioning of the two washers, gear, bushing,

and shaft.

CC668

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.

CD268A

12. Place the oil strainer into position; then secure

with the two machine screws.

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.

CC681

3-42

Joining Crankcase

Halves

1. Apply High-Temp Sealant (p/n 0636-069) to the

left-side mating surface.

CC693

2. Lightly oil all bearings and grease all shafts in

the left-side crankcase.

CC694

CC696

3. Using a propane torch, heat the left-side crank-

shaft bearing until the oil begins to smoke; then

join the two crankcase halves.

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.

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.

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 spec-

ifications.

CC697

3-43

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 specifi-

cations.

NOTE: Rotate the shafts back and forth to

ensure no binding or sticking occurs.

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.

CC602

2. Install the secondary shaft bearing housing mak-

ing sure the two alignment pins are properly

positioned. Tighten the cap screws securely.

CC711

3. Install the timing chain on the crankshaft; then

install the oil pump onto the engine. Tighten the

machine screws securely.

CC613

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

5. Grease the driven gear pin and insert it into the

oil pump shaft; then install the driven gear (not-

ing the direction of the sides of the gear from

removing). Secure with a snap ring.

CC609

NOTE: When installed correctly, the sides of the

drive and driven gears will be flush with each

other.

 AT THIS POINT

After completing center crankcase components,

proceed to Installing Right-Side Components, to

Installing Left-Side Components, and to In-

stalling Top-Side Components.

3-44

6. Install the clutch shoe assembly and secure with

the nut (threads coated with red Loctite #271).

Tighten to specifications.

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.

9. Lightly grease the clutch housing seal; then

insert the left fixed drive spacer.

CF088A

CF086

10. Install the one-way clutch into the clutch hous-

ing assembly.

CF084

11. Place the clutch cover/clutch housing assembly

into position on the crankcase; then secure with

the machine screws making sure the differ-

ent-lengthed machine screws are in their proper

location. Tighten to specifications.

12. Place the air intake plate into position; then

tighten the machine screws (threads treated with

a small amount of red Loctite #271) securely.

CD970

13. Place the driven pulley assembly into position

and secure with the nut. Tighten to specifica-

tions.

! CAUTION

Note that the nut has left-hand threads.

! CAUTION

When installed correctly, the green alignment dot

(or the word OUTSIDE) on the one-way clutch DOES

NOT SHOW.

3-45

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 sepa-

rated, insert a wedge (approximately 3/8 in.

thick) between the faces. Release the inner face.

CC549

16. Place the V-belt into position on the driven pul-

ley and over the front shaft.

CC550

NOTE: The arrows on the V-belt should point for-

ward.

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.

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.

CD083

Installing Right-Side

Components

NOTE: Plug the oil passage in the crankcase

housing prior to installing the drive gear/driven

gear assembly to prevent loss of an alignment pin.

1. Install the water pump 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.

3-46

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.

CC845

NOTE: The sharp side of the snap ring should be

facing outward.

NOTE: Once the gears are secured, remove the

oil passage plug from the crankcase.

3. Install the two starter gear shafts; then install the

two starter gears (with the beveled side of the

intermediate gear facing inward as noted in

removing).

CC636

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 mak-

ing sure the washers are properly positioned.

CD954A

6. Lubricate the magneto cover gasket with fresh

engine oil; then place it into position on the two

dowel pins.

CC629

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 crank-

shaft making sure a new, lubricated O-ring is

inside the cup. Tighten the flange nut to specifi-

cations.

CC710

3-47

9. Tighten the cap screws (from step 6) to specifi-

cations.

10. Place the speed sensor housing and gasket into

position and secure with the two cap screws.

Tighten securely.

CD069

11. Place the water pump into position and secure

with two machine screws. Tighten securely.

CC623

12. Install the crossover tube on the water pump and

cylinder head making sure the O-ring is properly

positioned.

CC619

CC620

13. Install the shift arm on the shift arm shaft mak-

ing sure the scribed marks (from removing) are

aligned. Tighten securely.

14. Place the recoil starter assembly into position on

the left-side cover; then tighten four machine

screws to specifications.

Installing Top-Side

Components

A. Piston

B. Cylinder

0732-301

NOTE: If the piston rings were removed, install

them in this sequence.

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.

KEY

1. Cylinder

2. Stud Bolt

3. Nut

4. Cylinder Gasket

5. Pin

6. Water Hose Union

7. Cap Screw

8. O-Ring

3-48

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 orienta-

tion mark (MTOP) in the 2nd (middle) ring

groove and the ring with the orientation mark

(M) in the 1st (top) ring groove.

ATV-1024A

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.

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

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 crank-

case.

CC024D

! CAUTION

Incorrect installation of the piston rings will result

in engine damage.

! CAUTION

The cylinder should slide on easily. Do not force the

cylinder or damage to the piston, rings, cylinder, or

crankshaft assembly may occur.

3-49

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

0741-101

NOTE: Steps 1-5 in the preceding sub-section

must precede this procedure.

6. Place the chain guide into the cylinder.

CC022D

7. Place the head gasket into position on the cylin-

der. Place the alignment pins into position; then

place the head assembly into position on the cyl-

inder.

KEY

1. Cylinder Head Assy

2. Valve Guide

3. Sleeve

4. Cap Screw

5. Cap Screw

6. Cylinder Head Gasket

7. Pin

8. Cap Screw

9. Stud Bolt

10. Stud Bolt

11. Stud Bolt

12. Cap Screw

13. Cap Screw

14. Nut

15. Nut

16. Gasket

17. Crush Washer

18. Spark Plug

19. Inspection Cap

20. O-Ring

21. Cap Screw

22. Cylinder Head Plug

23. Intake Pipe Assy

24. O-Ring

25. Machine Screw

26. Clamp

27. Temperature Switch

Assy

28. Thermostat Cover

29. Thermostat

! CAUTION

Care should be taken that the bottom of the chain

guide is secured in the crankcase boss.

3-50

CC020D

CF057A

8. Install the four cylinder head cap screws with

copper washers. Tighten only until snug.

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.

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.

732-307B

NOTE: At this point, oil the camshaft bearings,

cam lobes, and the three seating journals on the

cylinder.

13. While holding the cam chain sprocket to the

side, install the rear cam chain tensioner guide

into the cylinder head. Install the pivot cap

screw and washer.

CD461

14. With the cam lobes directed down (toward the

piston), maneuver the camshaft/sprocket assem-

bly 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.

3-51

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 cylin-

der head ensuring the following.

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 align-

ment hole (smallest) are aligned.

16. Place the tab-washer onto the sprocket making

sure it covers the pin in the alignment hole.

ATV1027

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.

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.

CD465

! CAUTION

If any of the above factors are not as stated, go

back to step 11 and carefully proceed.

! 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.

3-52

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.

CD466

20. Place the C-ring into position in its groove in the

cylinder head.

CC012D

21. Install the cylinder head plug in the cylinder

head with the open end facing downward and

toward the inside.

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.

CD501

NOTE: The adjuster shaft will be drawn into the

tensioner as the adjuster screw is rotated clock-

wise. 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.

CD469

24. Using a flat-blade screwdriver, rotate the

adjuster screw inside the tensioner counter-

clockwise until all tension is released; then

install the cap screw into the end of the chain

tensioner.

CD470

! CAUTION

The open end of the plug must be positioned down-

ward.

3-53

CD471

25. Loosen the four adjuster screw jam nuts; then

loosen the four adjuster screws on the rocker

arms in the valve cover.

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.

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.

CC003D

29. In a crisscross pattern starting from the center

and working outward, tighten the cap screws

securely.

30. Adjust valve/tappet clearance using the follow-

ing procedure.

NOTE: Use Valve Clearance Adjuster (p/n

0444-078) for this procedure.

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.

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 counter-

clockwise until specified valve/tappet clear-

ance is attained.

NOTE: Rotating the valve adjuster dial counter-

clockwise will open the valve/tappet clearance by

0.05 mm (0.002 in.) per mark.

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.

3-54

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/trans-

mission; then using an engine hoist, lower the

assembly into the engine compartment.

PR114

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.

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.

PR153A

PR147

4. Apply multi-purpose grease to the driveshaft

splines; then align the flange marks and slide the

splines into the slip-joints.

! 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 brack-

ets. Pinching or breaking of lines or shorting of

wiring could occur.

3-55

PR148

PR151A

5. Install the cap screws securing the drive-line

couplers to the drive flanges and tighten to spec-

ifications.

PR120A

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 specifica-

tions.

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.

PR153B

PR144B

8. Connect the lower coolant hose to the water

pump housing; then connect the upper coolant

hose to the thermostat housing. Tighten the

hose clamps securely.

9. Install the starter wire on the starter and tighten

the nut securely; then connect the CDI connec-

tor, alternator connector, shift position switch

connector, and electric choke connector.

PR145A

! CAUTION

The drive-line yokes must be aligned (timed) or

damage will occur to the universal joints and gears.

3-56

PR128A

10. From the right-side, connect the speed sensor

connector, fuel quantity sender lead, and tem-

perature sensor lead; then install the spark plug

cap.

PR155A

PR130A

11. Install the carburetor and tighten the intake boot

clamp securely; then connect the gas line, vac-

uum line, and throttle cable.

PR117

PR140B

PR154

12. Place the air filter assembly into position and

secure with the self-tapping screws; then con-

nect the intake boot to the carburetor and the

inlet housing boot to the air filter housing.

Tighten the clamps securely.

PR127A

3-57

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 plac-

ing 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 tem-

perature. Check for fluid leaks; then shut off

engine and check oil and coolant levels (see

Section 2).

4-1

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

4-2

Carburetor

Specifications

Carburetor Schematic

0741-115

PROWLER XT

Ty p e Ke i h i n C V K3 6

Main Jet 132

Slow Jet 40

Pilot Screw Setting (turns) 1 1/4

Needle Jet 6.0/4.0

Jet Needle NFKS

Idle RPM 1250-1350

Starter Jet 85

Float Arm Height 17 mm

(0.7 in.)

Throttle Cable Free-Play

(at accelerator pedal)

3-6 mm

(1/8-1/4 in.)

KEY

1. Cover

2. Screw

3. Spring

4. Vacuum Piston

5. Spring Seat

6. Jet Needle

7. Needle Jet

8. Jet Holder

9. Main Jet

10. Slow Jet

11. Starter Jet

12. Float Valve

13. Clip

14. Float Set

15. Float Pin

16. Pilot Screw

17. Spring

18. Washer

19. O-Ring

20. Idle Adjust Screw

21. Washer

22. Spring

23. Plate

24. Screw

25. Electric Choke

26. Choke Cover

27. Float Chamber

Assy

28. Screw

29. Spring

30. Diaphragm Assy

31. Pump Housing

32. U-Ring

33. Screw

34. Screw

35. Cover

36. Screw

37. Vent Hose

4-3

Carburetor

REMOVING

1. Remove the seats and center console; then

remove the left-side seat-base.

2. Loosen the clamps on the inlet boot; then

remove the boot from the left-side.

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 cham-

ber vent hose.

5. Remove the throttle arm cover; then loosen the

outer jam nut on the throttle cable and discon-

nect the throttle cable from the carburetor.

PR154A

PR162A

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.

CH015D

2. Remove the vacuum piston assembly from the

carburetor body. Account for a spring, spring

seat, and the jet needle.

CC746

3. Remove the three screws securing the primer

housing. Account for the diaphragm assembly,

spring, and U-ring (in the housing).

! WARNING

Whenever any maintenance or inspection is per-

formed on the fuel system during which there may

be fuel leakage, there should be no welding, smok-

ing, open flames, etc., in the area.

4-4

CC748

4. Remove the Phillips-head screws securing the

float chamber; then remove the chamber.

Account for the O-ring.

CC749

CC750

5. Remove the float pin.

CC752

6. Lift the float assembly from the carburetor.

Account for the float needle valve.

CC753

NOTE: Note the locations of the jets, pilot screw,

and holder for disassembling procedures.

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.

CC758

10. Unscrew and remove the idle speed adjuster

assembly. Account for the spring and washer.

4-5

ASSEMBLING

1. Screw the idle speed adjuster into the carburetor

making sure the washer and spring are properly

positioned.

2. Install the pilot screw with the spring, the

washer, and the O-ring in this order.

CC758

NOTE: Turn the pilot screw clockwise until it is

lightly seated; then turn it counterclockwise the

recommended number of turns as an initial set-

ting.

NOTE: Note the locations of the jets and holder

during assembling procedures.

CC759A

CC761A

3. Install the slow jet. Tighten securely.

4. Install the main jet into the needle jet holder and

tighten securely; then install the needle jet

holder assembly into the carburetor and tighten

securely.

5. Place the float assembly (with float needle

valve) into position and secure to the carburetor

with the float pin.

CC753

NOTE: Check float arm height by placing the car-

buretor on its side w/float contacting the needle;

then measure with a caliper the height when the

float arm is in contact with the needle valve. Float

arm height should be 17 mm (0.7 in.).

6. Place the float chamber into position making

sure the O-ring is properly positioned; then

secure with the Phillips-head screws.

CC750

CC749

4-6

7. Place the U-ring into the primer housing. Posi-

tion 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.

CC748

8. Place the jet needle, spring seat, and spring into

the vacuum piston; then place the assembly

down into the carburetor.

CC746

9. Place the top cover into position; then secure

with the Phillips-head screws. Tighten securely.

CH015D

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 carbure-

tor 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 hous-

ing and the carburetor; then tighten the clamps

securely.

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.

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.

! CAUTION

It is important to press down on the primer housing

until it contacts the carburetor to make sure the dia-

phragm lip is properly seated in the groove in the

carburetor. If the diaphragm is not properly seated,

leakage will occur.

! 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 deterio-

ration will result.

4-7

6. Inspect the vacuum piston/diaphragm for cracks,

imperfections in the casting, or cracks and tears

in the rubber.

7. Inspect float for damage.

8. Inspect gasket and O-rings for distortion, tears,

or noticeable damage.

9. Inspect tips of the jet needle, pilot screw, and the

inlet needle valve for wear, damage, or distor-

tion.

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 oper-

ation.

11. Inspect the plunger assembly/starter valve and

seat for wear or damage.

12. Inspect the carburetor mounting flange for dam-

age and tightness.

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.

CD560A

Engine RPM (Idle)

To properly adjust the idle RPM, a tachometer is nec-

essary.

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.

PR081A

Gas Tank

REMOVING

1. Remove the seats and center console; then

remove the left-side and right-side seat-bases.

2. Remove twelve cap screws and two self-tapping

screws securing the floorboard to the frame.

! WARNING

Adjust the idle to the correct RPM. Make sure the

engine is fully warm before adjusting the idle RPM.

! 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.

4-8

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.

PR163

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.

PR165

5. Disconnect the vent hose, gas hose, and fuel

level sensor connector; then cap the vent fitting

and gas hose fitting.

PR166B

6. Remove the outer cap screw securing the front

tank hold-down; then swing the hold-down to

the left.

PR167A

PR170

7. Remove four press-nuts securing the gas cap

inset; then remove the gas cap and inset. Install

the gas cap.

4-9

PR168

8. Remove the joining cap screw and nut from the

rear gas tank hold-down strap; then remove the

inside hold-down strap.

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-clean-

ing solvent.

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 opera-

tion.

INSTALLING

1. Place the gas tank into position in the vehicle;

then install the inside rear hold-down strap.

PR173

PR172A

2. Swing the front hold-down to the right into posi-

tion and install the cap screw and nut. Do not

tighten at this time.

PR171

3. Install the rear hold-down strap joining cap

screw and nut. Do not tighten at this time.

! 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.

4-10

PR166A

4. Place the gas cap filler panel into position; then

if necessary, position the gas tank so the filler

panel and filler neck are not binding or rubbing.

PR176

5. Secure the filler panel with four press-nuts; then

tighten the hardware securing the hold-down

straps (from steps 2-3) securely.

PR166A

PR167A

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.

PR166B

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.

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 con-

nected to the carburetor and the opposite end is

always open.

Vacuum Pulse Fuel

Pump

The vacuum pulse fuel pump is a nonserviceable

assembly. If the pump fails, it must be replaced.

4-11

Oil Flow Chart

ATV-1102

Oil Filter/Oil Pump

NOTE: Whenever internal engine components

wear excessively or break and whenever oil is con-

taminated, the oil pump should be disassembled,

cleaned and inspected, and serviced as necessary.

0738-289

TESTING OIL PUMP PRESSURE

NOTE: The engine must be warmed up to the

specified temperature for this test.

1. Remove the seats and center console; then

remove the left-side seat-base.

2. Tilt the cargo box back.

3. Loosen the clamps securing the V-belt housing

exhaust duct; then remove the duct and set

aside.

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.

KEY

1. Oil Pump

2. Driven Gear

3. Pin

4. Washer

5. Circlip

6. Cap Screw

7. Strainer

8. Cap Screw

9. Cap

10. O-Ring

11. Cap Screw

12. Filter

13. Drain Plug

14. Gasket

15. Oil Relief Valve Assy

16. Oil Filter Union

4-12

PR265A

NOTE: Some oil seepage may occur when

installing the oil pressure gauge. Wipe up oil resi-

due with a cloth.

5. Set the parking brake and start the engine.

Allow the engine to warm up to operating tem-

perature (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.

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 speci-

fied, 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).

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.

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.

OIL PRESSURE @ 2500 RPM

1.40-2.11 kg/cm²

(20-30 psi)

Operating Temperature (Cooling Fan Cycling)

4-13

PR267A

3. Set the parking brake and start the engine.

Allow the engine to warm up to operating tem-

perature (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.

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).

1. Disconnect the two-wire connector on the cool-

ing fan harness; then remove the machine screw

and wire clamp securing the cooling fan switch

wires.

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 assem-

bling.

PR275A

PR268A

3. Remove four machine screws securing the oil

cooler to the fan shroud and remove the oil

cooler.

PR273A

INSTALLING OIL COOLER

1. Place the oil cooler on a clean flat surface; then

position the fan shroud over the oil cooler mak-

ing 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.

4-14

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 mak-

ing sure to install the radiator overflow hose

hold-down clip on the upper-right machine

screw.

PR273A

3. Connect the cooling fan harness to the cooling

fan connector; then secure the cooling fan har-

ness wire clamp with the machine screw.

Liquid Cooling System

0739-654

The cooling system should be inspected daily for

leakage and damage. Also, the coolant level should

be checked periodically.

KEY

1. Radiator Assy

2. Radiator

3. Radiator Screen

4. Radiator Cap

5. Grommet

6. Vent Hose

7. Thumb Screw

8. Fan Shroud

9. Fan

10. Machine Screw

11. Clamp

12. Clamp

13. Temperature Sender

14. O-Ring

15. Shoulder Screw

16. Nut w/Washer

17. Stem Bushing

18. Coolant Hose

19. Coolant Hose

20. Coolant Hose

21. Hose Clamp

22. Cable Tie

23. Hose Clamp

4-15

When filling the cooling system, use premixed Arc-

tic 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 cool-

ing system to the bottom of the stand pipe in the

radiator neck.

Radiator/Oil Cooler

REMOVING

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.

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.

PR182A

3. While lifting up on the front of the storage box,

pry the rear center clear of the center dash

mount and remove the storage box.

PR186

4. Drain the coolant into a suitable container; then

disconnect the cooling fan wire connector from

the main harness.

PR183A

5. Remove the two shoulder bolts and nuts secur-

ing the radiator to the frame; then disconnect the

upper and lower coolant hoses.

PR184A

6. Place a shallow container under the right-side

oil cooler hose; then remove the hose from the

oil cooler.

! CAUTION

After operating the vehicle for the initial 5-10 min-

utes, stop the engine, allow the engine to cool

down, and check the coolant level. Add coolant as

necessary.

4-16

PR185

7. Allow the oil cooler to drain; then remove the

left-side oil cooler hose.

8. Lift the radiator/oil cooler assembly from the

vehicle. Account for two upper and two lower

rubber mounting grommets.

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 con-

taminants.

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 mak-

ing sure the grommets are correctly installed;

then secure to the mounts with the two shoulder

bolts and nuts. Tighten securely.

PR184A

2. Connect the upper and lower radiator hoses and

the left and right oil cooler hoses to the radia-

tor/oil cooler and secure with the appropriate

hose clamps; then connect the cooling fan con-

nector to the main harness.

PR183A

3. Pour the recommended coolant into the radiator

and secure the radiator cap.

4. Place the storage box into position and using a

smooth, flat pry-bar, pry the center of the box

past the dash mount; then secure with the appro-

priate fasteners.

PR187

5. Slide the dash forward into position while guid-

ing 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).

4-17

PR053B

8. Start the engine and warm up to operating tem-

perature; then check that the coolant level is at

the specified level (see Section 2). Add coolant

as required.

Thermostat

REMOVING

1. Drain approximately one quart of coolant from

the cooling system.

2. Remove the two cap screws securing the ther-

mostat housing to the cylinder head. Account for

a thermostat with seal.

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 ther-

mostat for proper operation.

A. Suspend the thermostat in a container filled

with water.

B. Heat the water and monitor the temperature

with a thermometer.

C. The thermostat should start to open at

73.5-76.5°C (164-170°F).

D. If the thermostat does not open, it must be

replaced.

3. Inspect all coolant hoses, connections, and

clamps for deterioration, cracks, and wear.

NOTE: All coolant hoses and clamps should be

replaced every four years or 4000 miles.

INSTALLING

1. Place the thermostat into the thermostat hous-

ing; then secure the thermostat housing to the

cylinder head with the two cap screws.

PR281A

2. Fill the cooling system with the recommended

amount of antifreeze. Check for leakage.

Fan

REMOVING

1. Remove the radiator (see Radiator/Oil Cooler in

this section).

2. Remove the fan assembly from the radiator.

INSTALLING

1. Position the fan assembly on the radiator; then

secure with existing hardware.

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

position.

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

this section).

! 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.

4-18

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.

0739-945

REMOVING

1. Remove the radiator cap; then remove the water

pump coolant drain plug and drain the coolant.

PR122A

2. Drain the oil from the engine/transmission.

3. Remove the seats and center console; then

remove the right-side seat-base.

4. Loosen the coolant hose clamps and slide the

clamps away from the hose ends approximately

51 mm (2 in.); then remove both hoses from the

water pump.

PR132

5. Remove the two cap screws securing the water

pump to the engine; then remove the water

pump.

CC786A

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.

CC786A

KEY

1. Water Pump Assy

2. Screw

3. Driven Gear

4. Shaft

5. Pin

6. Circlip

7. Bearing

8. Circlip

9. Drive Gear

10. Pin

11. Circlip

4-19

CC785A

2. Connect the two coolant hoses to the water

pump and secure with the clamps; then install

the water pump coolant drain plug.

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.

6. Install the right-side seat-base; then install the

center console and seats making sure the seats

lock securely.

Testing Vacuum Pulse

Fuel Pump

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.

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 vac-

uum hose and disconnect the hoses.

PR280A

! CAUTION

After operating the vehicle for the initial 5-10 min-

utes, stop the engine, allow the engine to cool

down, and check the coolant level. Add coolant as

necessary.

 AT THIS POINT

Prior to removing the vacuum pulse fuel pump,

the following check should be performed to

determine that removal is necessary.

! 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.

4-20

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 electri-

cal 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.

5-1

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

5-2

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 4000-6000 ohms

Ignition Coil

Resistance

(primary)

(secondary)

Less than 1 ohm

(terminal to ground)

5200-7800 ohms

(high tension - plug cap

removed - to ground)

Ignition Coil Peak

Voltage (static)

(primary/CDI) 132-198 DC volts

(terminal to ground)

MAGNETO

Magneto Coil

Resistance

(trigger)

(source)

(charging)

160-240 ohms

(green to blue)

Less than 1 ohm

(yellow to white)

Less than 1 ohm

(black to black)

Magneto Coil

Peak Voltage

(trigger)

(source)

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

5-3

Battery

1. Remove the battery from the vehicle.

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 tempera-

ture before filling. Do not use water or any other

liquid to activate a battery.

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.

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

hours.

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.

6. Place the battery into position in the vehicle and

secure; then connect the vent hose to the 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.

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

NOTE: The Prowler XT is equipped with a CDI

unit that retards ignition timing when maximum

RPM is approached. When the RPM limiter is acti-

vated, it could be misinterpreted as a high-speed

misfire.

Testing Electrical

Components

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 Read-

ing 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 spe-

cific component, always verify first that the fuse(s)

are good, that the bulb(s) are good, that the connec-

tions are clean and tight, that the battery is fully

charged, and that all appropriate switches are acti-

vated.

NOTE: For absolute accuracy, all tests should be

made at room temperature of 68° F.

! WARNING

Anytime service is performed on a battery, the fol-

lowing must be observed: keep sparks, open flame,

cigarettes, or any other flame away. Always wear

safety glasses. Protect skin and clothing when han-

dling a battery. When servicing battery in enclosed

space, keep the area well-ventilated. Make sure

venting tube of battery is always open once battery

is filled with electrolyte.

! 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.

! WARNING

Electrolyte is a sulfuric acid solution. Avoid spillage

and contact with skin, eyes, and clothing.

! CAUTION

Before installing the battery, make sure the ignition

switch is in the OFF position.

! CAUTION

Connecting cables in reverse (positive to negative

and negative to positive) can cause serious dam-

age to the electrical system.

5-4

Accessory

Receptacle/Connector

NOTE: This test procedure is for either the

receptacles or the connectors.

VOLTAGE

1. Turn the ignition switch to the ON position; then

set the meter selector to the DC Voltage posi-

tion.

2. Connect the red tester lead to the red/white wire

or the positive connector; then connect the black

tester lead to ground.

3. The meter must show battery voltage.

NOTE: If the meter shows no battery voltage,

troubleshoot the battery, fuse, receptacle, connec-

tor, or the main wiring harness.

Brakelight Switch

The switch connector is the two-prong black con-

nector below the master cylinder.

NOTE: The ignition switch must be in the ON

position.

VOLTAGE

(Wiring Harness Connector)

1. Set the meter selector to the DC Voltage posi-

tion.

2. Connect the red tester lead to the orange wire;

then connect the black tester lead to ground.

PR276A

3. The meter must show battery voltage.

NOTE: If the meter shows no battery voltage,

troubleshoot the battery, fuse, switch, or the main

wiring harness.

NOTE: If the meter shows battery voltage, the

main wiring harness is good; proceed to test the

switch/component, the connector, and the switch

wiring harness for resistance.

RESISTANCE

(Switch Connector)

NOTE: The brake pedal must be depressed for

this test.

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to one black wire;

then connect the black tester lead to the other

black wire.

AR621D

3. When the lever is depressed, the meter must

show less than 1 ohm.

NOTE: If the meter shows more than 1 ohm of

resistance, replace the switch.

Coolant Temperature

and Cooling Fan

Switches

1. Connect the meter leads (selector in the OHMS

position) to the switch contacts.

2. Suspend the switch and a thermometer in a con-

tainer of water; then heat the water.

! CAUTION

Always disconnect the battery when performing

resistance tests to avoid damaging the multimeter.

5-5

NOTE: Neither the switch nor the thermometer

should be allowed to touch the bottom of the con-

tainer or inaccurate readings will occur. Use wire

holders to suspend switch and thermometer.

733-554E

3. On the coolant temperature switch when the

water temperature reaches 112-118° C

(234-244° F), the meter should show a closed

circuit.

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.

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 tem-

perature 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)

1. Set the meter selector to the DC Voltage posi-

tion.

2. Connect the red tester lead to the black/red wire

(the black 2-prong at the fan motor); then con-

nect 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)

1. Set the meter selector to the OHMS position.

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

connect the black tester lead to the black wire.

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

Always disconnect the battery when performing

resistance tests to avoid damaging the multimeter.

! CAUTION

Care should be taken to keep clear of the fan

blades.

5-6

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.

1411-191

1. Remove all fuses from the power distribution

module.

2. Set the meter selector to the DC Voltage posi-

tion.

3. Connect the black tester lead to ground.

4. Using the red tester lead, contact each end of the

fuse holder connector terminals individually.

5. The meter must show battery voltage from one

side of the connector terminal ends.

NOTE: Battery voltage will be indicated from

only one side of the fuse holder connector termi-

nal; the other side will show no voltage.

NOTE: When testing the HI fuse holder, the head-

light 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 distribu-

tion module, or the main wiring harness.

Fuses

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.

3. The meter must show less than 1 ohm resis-

tance. 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.

Ignition Coil

The ignition coil is mounted on the fuel pump

mounting plate adjacent to the fuel pump.

VOLTAGE (Primary Side)

See PEAK VOLTAGE Primary/CDI this sub-sec-

tion.

RESISTANCE

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.

Prowler XT

! CAUTION

Always disconnect the battery when performing

resistance tests to avoid damaging the multimeter.

! CAUTION

Always disconnect the battery when performing

resistance tests to avoid damaging the multimeter.

5-7

PR278A

2. The meter reading must be within specification.

Secondary Winding

1. Connect the red tester lead to the high tension

lead (with the plug cap removed); then connect

the black tester lead to ground.

2. The meter reading must be within specification.

NOTE: If the meter does not show as specified,

replace ignition coil.

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.

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, read-

ings may vary due to internal circuitry.

NOTE: The battery must be at full charge for

these tests.

Primary/CDI

NOTE: The CDI is located beneath the driver’s

seat above the battery.

1. Set the meter selector to the DC Voltage posi-

tion; 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.

3. Turn the ignition switch to the ON position.

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

5. With the test leads still connected, crank the

engine with the electric starter.

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

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.

PR279A

1. Set the meter selector to the DC Voltage posi-

tion.

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.

! WARNING

Do not touch the primary wire with the ignition

switch turned on or severe electrical shock will

occur.

5-8

5. Leave the black tester lead connected; then con-

nect 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 specifica-

tions, the speedometer must be replaced. See Sec-

tion 9.

To replace a speed sensor, use the following proce-

dure.

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.

CD070

3. Install the new speed sensor into the housing

with new O-ring lightly coated with multi-pur-

pose grease; then secure the sensor with the

Allen-head cap screw (threads coated with blue

Loctite #242). Tighten securely.

CD071

Ignition Switch

To access the ignition switch, dash switches, front

accessory connectors, and front switched accessory

connector, the dash must be unfastened and slid to the

rear.

VOLTAGE

1. Set the meter selector to the DC Voltage posi-

tion.

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 igni-

tion switch to the ON position. The meter must

show battery voltage.

5. Connect the red meter lead to the yellow/green

wire; then with the black lead grounded, turn the

ignition switch to the START position. The

starter should engage and the meter must show

battery voltage.

NOTE: When the starter is engaged, battery volt-

age 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.

NOTE: If the meter does not show battery volt-

age, 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 head-

light switch. The meter must show battery volt-

age.

5-9

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 head-

lights.

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 volt-

age, 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

VOLTAGE (Reverse Override

Switch)

NOTE: To perform the following tests, the igni-

tion 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 approxi-

mately 1.5 DC volts.

2. Depress the reverse override switch. The meter

showing should not change from step 1.

3. Select 4WD on the 2WD/4WD selector switch.

The meter must show approximately 5 DC volts.

4. Depress the reverse override switch. The meter

must show approximately 1.5 DC volts.

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 test-

ing 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).

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.

5-10

PR295

NOTE: The black tester lead can remain con-

nected 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, trouble-

shoot the 10 amp IGNITION fuse on the power dis-

tribution 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.

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).

Differential Lock

Switch

VOLTAGE

1. Select DC Voltage on the multimeter; then con-

nect the red tester lead to the switch terminal

(leaving the wire connected) and the black tester

lead to ground.

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.

CF094C

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 posi-

tion.

2. Connect the red tester lead to the positive bat-

tery post; then connect the black tester lead to

the negative battery post.

5-11

3. With the engine running at a constant 5000 RPM

(with the headlights on), the meter must show

14-15.5 DC volts.

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 posi-

tion.

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.

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)

1. Set the meter selector to OHMS position.

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

three tests.

3. The meter reading must be within specification.

RESISTANCE (Trigger Coil)

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to the green wire;

then connect the black tester lead to the blue

wire. The meter reading must be within specifi-

cation.

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.

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, read-

ings may vary due to internal circuitry.

NOTE: The battery must be at full charge for

these tests.

Magneto Coil (Trigger)

1. Set the meter selector to the DC Voltage posi-

tion.

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 posi-

tion.

2. Connect the red tester lead to the yellow wire;

then connect the black tester lead to the white

wire.

3. Crank the engine over using the electric starter.

4. The meter reading must be within specification.

! CAUTION

Do not run the engine at high RPM for more than 10

seconds.

! CAUTION

Do not run the engine at high RPM for more than 10

seconds.

! CAUTION

Always disconnect the battery when performing

resistance tests to avoid damaging the multimeter.

! CAUTION

Always disconnect the battery when performing

resistance tests to avoid damaging the multimeter.

5-12

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.

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

Perform this test on the starter motor positive termi-

nal. To access the terminal, slide the boot away.

NOTE: The ignition switch must be in the ON

position, and the shift lever (on automatic trans-

mission models) in the NEUTRAL position.

1. Set the meter selector to the DC Voltage posi-

tion.

2. Connect the red tester lead to the starter termi-

nal; 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.

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 mul-

timeter set to the DC Voltage position, check the

relay as follows.

2. Connect the red tester lead to the positive bat-

tery terminal; then connect the black tester lead

to the starter cable connection on the starter

relay. The meter must show battery voltage.

PR296

NOTE: Make sure that the ignition switch is in

the ON position, transmission in neutral, and park-

ing 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.

! CAUTION

Always disconnect the negative battery cable from

the battery first; then disconnect the positive cable.

5-13

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 con-

tinues to indicate battery voltage, proceed to step

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.

PR297A

5. Depress the starter button and observe the multi-

meter.

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 compo-

nent. 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 wir-

ing harness from the CDI connector to the CDI

unit.

Regulator/Rectifier

The regulator/rectifier is located under the driver’s

seat next to the battery. Try to verify all other charg-

ing 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 fol-

lows.

2. Connect the red tester lead to the positive bat-

tery post and the black tester lead to the negative

battery post.

3. Slowly increase RPM. The voltage should

increase with the engine RPM to a maximum of

15.5 DC volts.

NOTE: If voltage rises above 15.5 DC volts, the

regulator is faulty or a battery connection is loose

or corroded. Clean and tighten battery connec-

tions 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.

5-14

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 con-

nect 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 posi-

tion.

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 posi-

tion.

2. Connect the black tester lead to the black wire;

then connect the red tester lead to the white

wire. The meter should show battery voltage.

3. With the ignition key in the LIGHTS position,

the meter must show battery voltage.

NOTE: If battery voltage is not shown and the

headlights are illuminated, inspect the three-wire

connector in the left-rear canopy tube at the junc-

ture 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 posi-

tion.

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.

6-1

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

6-2

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 assem-

bled with thread-rolling screws (trilobular). When

assembling with these screws, start the screws care-

fully into the housing; then use the following torque

values.

SPECIFICATIONS

Specific specifications regarding the gear cases

(capacities, lubricant type, etc.) can be found in Sec-

tion 1 of this manual.

SPECIAL TOOLS

A number of special tools must be available to the

technician when servicing the gear case.

NOTE: Special tools are available from the Arctic

Cat Service Parts Department.

TROUBLESHOOTING

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 lubri-

cant. Contamination would include large particles

or water which gives a “milky” look to the lubri-

cant.

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 fol-

lowing.

• Binding/abrupt motion: CV boot torn (grease loss,

foreign object damage, broken cage); gear lubri-

cant 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 bear-

ing 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.

Size New Housing Reassembled

Housing

(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)

(Torx T-40 Recess)

3.5-4.3 kg-m

(25-31 ft-lb)

2.9-3.5 kg-m

(21-25 ft-lb)

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.)

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

6-3

Front Drive Actuator

NOTE: The actuator is not a serviceable compo-

nent. 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

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 actua-

tor.

PR189A

3. Remove the mounting cap screw from above the

actuator on the suspension side.

PR190A

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.

AG928

INSTALLING

1. Lubricate the O-ring on the actuator; then ensure

that all mounting surfaces are clean and free of

debris.

2. Align the actuator with the selector shaft and

slide it forward onto the shaft taking care to

engage the cap screw in the slot of the front

mounting tab.

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.

6-4

AG928

4. Loosen the front cap screw; then tighten the cap

screw on the driveshaft side.

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.

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.

NOTE: The jack stands should be placed under

the main frame to avoid contact with front suspen-

sion components.

2. Remove the drain plug and drain the gear lubri-

cant into a drain pan; then reinstall the plug.

PR022

3. Remove the front wheels.

4. Set the parking brake; then turn the ignition

switch to the ON position and select 4WD on

the 2WD/4WD selector switch.

5. Remove the cotter pin securing the hex nut; then

remove the hex nut.

6. Release the parking brake.

NOTE: It is not necessary to remove the brake

hoses from the calipers for this procedure.

7. Remove the two brake calipers. Account for the

four cap screws; then remove the hubs.

AF894D

8. Disconnect the front drive actuator power con-

nector from the main harness; then disconnect

the differential lock indicator connector from

the differential lock switch located on the

right-side of the differential.

! WARNING

Make sure the vehicle is solidly supported on the

jack stands to avoid injury.

6-5

PR191

9. Remove two cap screws securing the differential

lock cable support; then disconnect the differen-

tial lock cable at the differential.

PR194A

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.

PR193

11. Pull the steering knuckle away from the axle

taking care not to damage the seals with the axle

end.

PR222

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

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.

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.

! CAUTION

The axle must be supported. If the axle is allowed

to drop or hang, damage to the inner CV joint

may occur.

6-6

PR198A

15. Using Slide Hammer w/CV Joint Attachment

(p/n 0444-123), remove the front axles.

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.

PR205A

17. Remove the upper differential mounting cap

screw. Account for a lock nut and two washers.

CD016

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.

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 compo-

nents for assembling purposes.

CD103

6-7

CD106

3. Remove the input shaft from the pinion housing.

CD107

4. Using a seal removal tool, remove the input

shaft seal. Account for a spacer.

AF982

5. Remove the snap ring securing the input shaft

bearing; then place the pinion housing in a press

and remove the bearing.

AF983

AF984

KX219

Assembling Input Shaft

1. Place the pinion housing in a press and install

the input shaft bearing. Secure the bearing with

the existing snap ring making sure the sharp

edge of the snap ring faces to the outside.

6-8

AF993

AF994

2. Install the input shaft seal making sure it is flush

with the edge of the housing.

3. Lubricate the input shaft splines with High-Per-

formance Grease (p/n 0436-501).

NOTE: Any time drive splines are separated,

clean all splines with parts-cleaning solvent and

dry with compressed air; then lubricate with rec-

ommended grease.

KX221

KX222

4. Install the input shaft into the pinion housing;

then secure in the bearing with a circlip.

KX210A

5. Place the pinion housing with new gasket onto

the gear case housing; then secure with existing

cap screws. Tighten to specifications.

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).

KX209

6-9

PR261A

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.

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 assem-

bling purposes.

KX173

3. Using a plastic mallet, tap lightly to remove the

differential cover. Account for an O-ring.

KX174

NOTE: If the cover is difficult to remove, pry on

the cover in more than one recessed location.

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

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

6-10

KX177

KX178

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.

KX179

KX181

7. Using the 48 mm Internal Hex Socket (p/n

0444-104), remove the lock collar securing the

pinion gear assembly.

CC875

CC876

8. Using the Pinion Gear/Shaft Removal Tool (p/n

0444-127) and a hammer, remove the pinion

gear from the gear case housing.

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.

6-11

CC879

CC880

NOTE: If gears are being replaced, use the exist-

ing shims. The numbers are scribed onto the

gears: the ring gear has the number on the oppo-

site 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 con-

sidered as being in the 0 category.

NOTE: If the gear case housing is being

replaced, proceed to the following Shimming Pro-

cedure/Shim Selection sub-section.

Shimming Procedure/Shim

Selection

1. Press bearings into bores by outer ring to hard

contact with seat.

2. Note the following shim selections (shims are

nominally 1.5 mm/0.060 in. thick):

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.

B. Install the lock collar and tighten to specifica-

tions; then on final assembling, stake the lock

collar edge approximately 1.5 mm (0.060 in.)

into the lower oil channel.

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.

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 ver-

ified.

738-268A

3. Prior to final assembling, apply molybdenum

disulfide grease to all oil seal lips.

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.

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.

6-12

CC881

CC882

CC883

2. Place the pinion assembly in a bearing puller;

then install the bearing using a press.

CC884

3. Install the pinion gear assembly into the hous-

ing. Using the 48 mm Internal Hex Socket

(p/n 0444-104), secure the pinion gear assembly

with the existing lock collar. Tighten to specifi-

cations.

NOTE: On a front differential, the lock collar has

right-hand threads. On a rear gear case, the lock

collar has left-hand threads.

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.

CC891

5. Install the shift fork shaft w/spring into the gear

housing making sure the shaft O-ring is posi-

tioned to the inside.

CC892

6-13

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.

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).

CD103

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.

KX178

9. Install the left bearing housing aligning the

match mark to the mark on the differential hous-

ing.

KX177

10. Install the differential lock assembly into the

bearing housing; then place the O-ring on the

gear case housing.

KX175

6-14

KX174

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.

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.

CC885

2. Using a propane torch, heat the area surrounding

the needle bearing to soften the Loctite.

CC886

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

of the 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

2. Using a suitable driver, install the needle bear-

ing into the gear case housing making sure the

bearing is seated.

NOTE: Do not push the bearing too far into the

housing.

6-15

CC889

3. Install the pinion shaft and secure with the exist-

ing 48 mm lock collar. Tighten to specifications.

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.

CC891

5. Install the pinion housing.

Removing/Installing Axle Seal

NOTE: This procedure can be performed on a

rear gear case.

1. Remove the seal using a seal removal tool.

CC899

2. Using a press, remove the bearing.

CC900

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

housing.

CC901

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.

6-16

CD018

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

INSTALLING DIFFERENTIAL

1. Place the differential assembly into position in

the frame; then install the top mounting

through-bolt, two washers, and lock nut. Do not

tighten at this time.

2. Install the lower front mounting through-bolt,

washers, spacers, and lock nut. Note the correct

location for the spacer washers.

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.

PR198A

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

section).

7. Install the knuckle assemblies onto the axles and

ball joints; then secure with four cap screws tak-

ing care not to damage the threads when install-

ing. Tighten to specifications.

PR201

PR193

8. Secure the lower shock eyelets with cap screws

and lock nuts. Tighten to specifications.

6-17

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.

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.

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.

AF894D

13. Install the wheels and tighten to specifications.

14. Remove the vehicle from the support stand.

15. Install the belly panel.

Drive Axles

REMOVING REAR DRIVE AXLE

1. Secure the vehicle on a support stand to elevate

the wheels.

2. Set the parking brake; then remove the wheels.

3. Remove the cotter pins securing the hex nuts;

then remove the hex nuts.

KX041

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

PR221

5. Remove the cap screw and lock nut securing the

knuckle to the upper A-arm. Discard the lock

nut.

! WARNING

Make sure the vehicle is solidly supported on the

support stand to avoid injury.

6-18

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.

PR218

7. Place a drain pan under the vehicle to contain

any oil leakage; then using a slide hammer,

remove the drive axle.

AF935

REMOVING FRONT DRIVE AXLE

NOTE: For removing a front drive axle, see Front

Differential in this section.

CLEANING AND INSPECTING

NOTE: Always clean and inspect the drive axle

components to determine if any service or replace-

ment is necessary.

1. Using a clean towel, wipe away any oil or

grease from the axle components.

CD019

2. Inspect boots for any tears, cracks, or deteriora-

tion.

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.

CD020

2. Wipe away excess grease to access the retaining

ring. Using an awl or circlip pliers, remove the

circlip.

6-19

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 pur-

poses.

CD023

4. Note the difference inside each bearing ring end

for assembling purposes; then remove the bear-

ing ring.

NOTE: The recess of the bearing must face

toward the housing.

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.

6. Using a side-cutters (or suitable substitute),

remove the small clamp from the shaft.

CD752

NOTE: At this point if the outside boot is dam-

aged, 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.

CD751

8. Apply 40 grams (1/3 of contents) of grease from

the Grease Pack (p/n 0441-173) into the knuck-

les and the new outside boot.

ATV-1052

6-20

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 out-

side boots.

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

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

both outside boot clamps.

CD024

ASSEMBLING AXLES

1. Install the inner boot with the small clamp mak-

ing 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.

CD754

2. Using the boot clamp pliers, secure the small

clamp of the inner boot.

ATV-1048

3. Apply 80 grams (2/3 of contents) of grease from

the pack into the bearing housing.

4. Install the bearing onto the shaft making sure the

recess of the bearing is facing the housing.

! CAUTION

Do no over-fill the joint as boot damage may occur

resulting in joint failure.

! CAUTION

It is important that the clamps are positioned cor-

rectly or they may loosen when in motion.

6-21

CD022

5. Secure the bearing ring with the circlip making

sure the sharp side of the circlip faces away

from the boot.

CD023

6. Making sure the marks made during disassem-

bling 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.

CD021

7. Slide the boot over the housing; then using the

boot clamp pliers, secure the boot with the

clamp.

CD024

8. Inspect the axle components for correct posi-

tioning 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 speci-

fications.

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 specifi-

cations; 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.

6. Remove the vehicle from the support stand and

release the parking brake.

! 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.

6-22

INSTALLING FRONT DRIVE AXLE

1. Position the drive axle in the gear case and steer-

ing knuckle; then insert the ball joints into the

steering knuckles. Secure with cap screws tight-

ened to specifications.

2. Secure the lower shock eyelet to the A-arm with

a cap screw and a new lock nut. Tighten to spec-

ifications.

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 specifi-

cations; then install and spread a new cotter pin

making sure each side of the pin is flush to the

hub nut.

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.

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.

PR211A

3. Remove the drive-line brake caliper.

4. Remove the two cap screws and lock nuts secur-

ing 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.

6-23

PR207

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.

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.

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).

Hub

REMOVING

1. Secure the vehicle on a support stand to elevate

the wheel; then remove the wheel.

NOTE: Removing or tightening of the hub nuts

requires that the axles be locked. To lock the rear

axle, set the parking brake. To lock the front axle,

turn the ignition switch to ON, select 4WD on the

2WD/4WD drive selector switch, and engage the

differential lock; then set the parking brake and

turn the ignition switch to OFF.

2. Remove the cotter pin from the axle.

NOTE: During assembly, new cotter pins should

be installed.

PR257

3. Remove the flange nut securing the hub.

4. Remove the brake caliper (front only).

PR243A

5. Remove the hub assembly.

 AT THIS POINT

For servicing the input shaft, pinion gear, needle

bearing, and axle seal, see Front Differential in

this section. ! WARNING

Make sure the vehicle is solidly supported on the

support stand to avoid injury.

6-24

6. Remove the four cap screws securing the brake

disc (front hub only).

PR254A

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is

necessary.

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).

2. Drive the damaged stud out of the hub; then

place the new stud into the hub and thread on an

appropriate flange nut.

PR250

3. Using a socket and ratchet handle, tighten the

nut until the stud is fully drawn into the hub.

PR252A

INSTALLING

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.

PR254B

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

the parking brake.

PR221

4. Secure the hub assembly with the nut. Tighten to

specifications; then secure with a new cotter pin.

6-25

PR258

5. For front hubs, secure the brake calipers to the

knuckle with two cap screws tightened to speci-

fications.

PR377B

6. Install the wheel and tighten to specifications.

7. Remove the vehicle from the support stand.

Hydraulic

Brake Caliper

NOTE: The brake caliper is a non-serviceable

component; it must be replaced as an assembly.

REMOVING/DISASSEMBLING

1. Secure the vehicle on a support stand to elevate

the wheel; then remove the wheel.

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

master cylinder.

PR235

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.

PR237

PR238

5. Remove the caliper holder from the caliper and

account for the brake caliper O-ring. Do not

remove the piston from the caliper.

! WARNING

Make sure the vehicle is solidly supported on the

support stand to avoid injury.

! CAUTION

Brake fluid is highly corrosive. Do not spill brake

fluid on any surface of the vehicle and do not reuse

brake fluid.

6-26

PR239B

6. Plug the fluid port with a suitable plug to pre-

vent contamination during cleaning.

PR240A

CLEANING AND INSPECTING

1. Clean all caliper components (except the brake

pads) with parts-cleaning solvent.

2. Inspect the brake pads for damage and excessive

wear.

NOTE: For measuring brake pads, see Section 2.

ASSEMBLING/INSTALLING

1. Install the caliper onto the caliper holder making

sure the caliper is correctly oriented on the

holder.

PR239C

2. Compress the caliper holder toward the caliper

and install the inner brake pad; then install the

outer pad.

PR238

PR239

3. Place the brake caliper assembly into position

and secure with the cap screws. Tighten the cali-

per 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.

6-27

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 ele-

vated high enough to allow working from the

underside of the vehicle.

2. To aid in installing, match mark drive-line com-

ponents prior to removing.

PR152A

3. Remove the cap screws securing the propeller

shaft flange to the yoke flange on the appropri-

ate drive-line; then remove the propeller shaft.

PR120A

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 bear-

ing cup.

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.

6-28

PR375

INSPECTING

1. Inspect the yoke bores for damage or signs of

bearing cup looseness. If bearing cups are loose,

the yoke must be replaced.

PR367B

2. Check that yoke legs are parallel.

PR367A

3. Check splines and flanges for excessive wear,

thread damage, or warpage.

PR367C

INSTALLING

1. Remove the bearing cups from the universal

cross; then insert the cross into the yoke and

install one bearing cup on the cross.

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.

PR374

3. Install the retainer in the bearing cup; then

remove the yoke from the separator tool.

! 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.

6-29

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 can-

not be used.

PR355

5. Check that the universal joint can be flexed

freely without binding; then apply multi-pur-

pose grease to the splines and install the propel-

ler shaft noting the match marks made prior to

removing.

PR152A

7-1

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

7-2

Shock Absorbers

REMOVING

1. Secure the vehicle on a support stand to elevate

the wheels and to release load on the suspen-

sion.

2. Remove the two cap screws and nuts securing

each front shock absorber to the frame. Account

for bushings and sleeves from each.

AF605D

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.

AF626D

4. Compress the shock absorber spring, remove the

retainer, and remove the spring.

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

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 specifi-

cations.

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.

! WARNING

Make sure the vehicle is solidly supported on the

support stand to avoid injury.

! CAUTION

On the FIS style rear suspension, additional sup-

port stands are necessary to support the rear axle

when the shock absorbers are removed or damage

may occur.

! 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.

7-3

Front A-Arms

REMOVING

1. Secure the vehicle on a support stand to elevate

the front wheels; then remove the wheels.

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

cotter pin.

PR257

3. Remove the nut securing the hub.

4. Remove the brake caliper. Account for two cap

screws.

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.

AF618D

7. Remove the cap screws securing the ball joints

to the knuckle.

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.

AF626D

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

the frame.

! WARNING

Make sure the vehicle is solidly supported on the

support stand to avoid injury.

! CAUTION

Support the knuckle when removing the cap screws

or damage to the threads will occur.

7-4

AF610D

11. Remove the circlip from the ball joint; then

remove the ball joint from the A-arm.

AF616D

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. Clean the ball joint mounting hole of all residual

Loctite, grease, oil, or dirt for installing pur-

poses.

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.

AF616D

2. Install the A-arm assemblies into the frame

mounts and secure with the cap screws. Only

finger-tighten at this time.

AF610D

3. Route the brake hose through the upper A-arm

shock absorber mount.

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.

7-5

6. Install the knuckle assembly onto the ball joints

and secure with cap screws. Tighten to specifi-

cations.

AF628D

7. Install the tie rod end and secure with the nut.

Tighten to specifications; then install a new cot-

ter pin and spread the pin to secure the nut.

NOTE: During assembly, new cotter pins should

be installed.

AF618D

8. Apply grease to the hub and drive axle splines;

then install the hub assembly onto the drive

axle.

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.

PR377B

11. Secure the hub nut (from step 9) to the

shaft/axle. Tighten to specifications.

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

secure the nut.

PR260

13. Install the wheel and tighten to specifications.

14. Remove the vehicle from the support stand.

Rear A-Arms

REMOVING

1. Secure the vehicle on a support stand to elevate

the wheels.

2. Set the parking brake.

3. Remove the wheel.

4. Remove the cotter pin securing the hex nut; then

remove the hex nut.

! WARNING

Make sure the vehicle is solidly supported on the

support stand to avoid injury.

7-6

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.

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.

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.

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.

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.

PR196

7. Secure the shock absorber to the frame with a

cap screw and new lock nut. Tighten to specifi-

cations.

8. Secure the shock absorber to the lower A-arm

with a cap screw and new lock nut. Tighten to

specifications.

7-7

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

0739-534

TIRE SIZE

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.

TIRE INFLATION PRESSURE

Front and rear tire inflation pressure should be 0.70

kg/cm² (10 psi).

REMOVING

1. Secure the vehicle on a support stand to elevate

the wheels.

2. Remove the wheels.

CD006

KEY

1. Machine Screw

2. Brake Disc

3. Wheel Hub - Front

4. Hub Stud

5. Cotter Pin

6. Hex Nut

7. Wheel

8. Mounting Nut

9. Tire - Front

10. Valve Stem

11. Valve Stem Cap

12. Wheel Hub - Rear

13. Wheel

14. Tire - Rear

! WARNING

Use only Arctic Cat approved tires when replacing

tires. Failure to do so could result in unstable vehi-

cle operation.

! 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.

! WARNING

Make sure the vehicle is solidly supported on the

support stand to avoid injury.

7-8

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

1. Install each wheel on its hub.

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.

CD005

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

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 accel-

eration, deceleration, and braking.

NOTE: Pulling could be caused by uneven tire

pressure side-to-side, steering alignment out of

adjustment, unequal loading, or improper tire size.

! WARNING

Do not operate the vehicle if tire damage exists.

8-1

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

8-2

Steering Assembly

REMOVING

1. Secure the vehicle on a support stand to elevate

the front wheels; then remove the front wheels.

2. Remove the cotter pins and nuts securing the tie

rod ends to the knuckles; then remove the tie rod

ends from the knuckles.

PR301

3. Make matching alignment marks on the pinion

shaft and lower steering shaft joint.

PR333A

NOTE: Any time steering components are disas-

sembled, all connecting components should be

marked for proper alignment during assembling.

4. Remove the cap screw securing the lower steer-

ing shaft joint to the pinion shaft; then slide the

joint free of the pinion.

PR302

5. Remove two cap screws securing the rack and

pinion assembly to the frame. Account for two

nuts and two washers.

PR303A

6. Remove the rack and pinion assembly from the

right-side.

PR305

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.

! WARNING

Make sure the vehicle is solidly supported on the

support stand to avoid injury.

8-3

PR307

4. Check boot clamps for security.

5. Check that the rack and pinion assembly oper-

ates smoothly with no binding from full-left to

full-right position.

6. Inspect for grease seepage from the rack and

pinion assembly.

NOTE: The steering assembly is not repairable.

If any of the above items fail inspection, the steer-

ing 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.

PR305

2. With the rack and the steering wheel centered,

slide the lower steering shaft joint onto the pin-

ion shaft aligning the match marks.

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.

PR309A

4. Tighten the cap screw to specifications; then

check that the steering wheel turns freely.

5. Install the tie rod ends into the steering knuck-

les; 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.

! 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.

8-4

Steering Wheel

REMOVING

1. Remove the steering wheel cover; then match

mark the steering shaft and steering wheel.

NOTE: Any time steering components are disas-

sembled, all connecting components should be

marked for proper alignment during assembling.

PR324A

2. Remove the nut securing the steering wheel and

remove the steering wheel. Account for the flat

thrust-washer and two wave washers.

PR226

INSPECTING

1. Inspect the steering wheel for cracks, missing

padding, or broken spokes.

2. Inspect the splines for wear.

3. Check that the steering wheel is not bent.

INSTALLING

1. Place the flat thrust-washer and then the two

wave washers onto the steering shaft.

2. Install the steering wheel aligning the two match

marks; then apply a drop of red Loctite #271 to

the threads of the nut and secure the steering

wheel. Tighten to specifications.

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

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 park-

ing brake release handle and jam nut.

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 steer-

ing wheel shaft.

PR313A

4. Match mark the upper steering shaft joint and

the steering wheel shaft; then remove the steer-

ing wheel shaft. Account for the lower

thrust-washer.

NOTE: Any time steering components are disas-

sembled, 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.

8-5

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.

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 steer-

ing wheel onto the splines; then install the nut

and finger-tighten.

PR324A

4. Hold rearward pressure on the steering wheel

and tighten the cap screw (from step 2) to speci-

fications.

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.

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 park-

ing brake release handle and the jam nut.

3. Slide the dash panel rearward to access the

steering shaft joints; then match mark all con-

necting components for reassembling.

NOTE: Any time steering components are disas-

sembled, all connecting components should be

marked for proper alignment during reassembling.

4. Remove the cap screw securing the upper steer-

ing 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.

PR313A

5. Remove the cap screw securing the lower steer-

ing shaft joint to the pinion shaft; then slide the

steering shaft assembly free and remove through

the opening in the splash panel.

8-6

PR304

PR314B

INSPECTING

NOTE: The steering shaft assembly is not repair-

able or rebuildable. If any damage or excessive

wear is detected, the assembly must be replaced.

1. Inspect the joints for excessive wear or loose-

ness.

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.

PR314A

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.

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 pro-

trude into the joint beyond the clamping surface.

Tighten to specifications.

PR309A

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.

! 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.

8-7

PR313A

5. Apply green Loctite #270 to the cap screw; then

install the cap screw in the upper steering shaft

joint and finger-tighten.

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.

PR226

7. Hold rearward pressure on the steering wheel

and tighten the cap screw (from step 5) to speci-

fications.

8. Remove the steering wheel nut and apply one

drop of red Loctite #271 to the threads. Install

the nut and tighten to specifications.

9. Check that the steering wheel turns freely from

full-right to full-left; then install the steering

wheel cover.

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

REMOVING AND DISASSEMBLING

1. Secure the vehicle on a support stand to elevate

the wheel; then remove the wheel.

2. Remove the cotter pin from the axle.

3. Remove the nut securing the hub.

4. Remove the brake caliper.

5. Remove the hub assembly.

6. Remove the cotter pin from the tie rod end and

remove the tie rod end from the knuckle.

7. Remove the two cap screws securing the ball

joints in the knuckle.

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.

! WARNING

Make sure the vehicle is solidly supported on the

support stand to avoid injury.

8-8

PR289

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is

necessary.

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 bear-

ing into the knuckle until firmly seated; then

install the snap ring.

PR292A

PR289

2. Install the knuckle to the upper and lower ball

joints and secure with the two cap screws.

Tighten to specifications.

PR202

PR203

3. Install the tie rod end and secure with the nut.

Tighten to specifications; then install a new cot-

ter 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.

PR290A

5. Install the hub assembly onto the splines of the

shaft.

8-9

CD009

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

specifications.

PR256

7. Install a new cotter pin and secure by spreading

as shown.

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.

PR377B

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.

Mark the center-line of the front tires at the front

and rear of the tire; then using a tape measure, mea-

sure 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 measure-

ment (toe-out).

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.

8-10

PR084A

PR085A

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.

PR086

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.

PR327A

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-clean-

ing 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

REMOVING

1. Open the hood; then disconnect the four head-

light connectors and remove two nylon ties.

! 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.

8-11

PR328A

2. Loosen but do not remove the four cap screws

and flange nuts securing the hood hinge to the

frame; then lower the hood.

PR332A

3. Finish removing the cap screws and flange nuts

(from step 2); then remove the hood assembly.

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.

2. Inspect the hood for cracks and/or loose fasten-

ers.

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.

PR332

3. Connect the four headlight connectors; then

secure the wires with two new nylon ties.

PR332B

Fenders

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.

PR311A

INSTALLING

To install the fenders, place the appropriate fender

into position and secure with existing hardware.

8-12

Floor

REMOVING

1. Remove the seats and center console.

2. Remove twelve cap screws and two self-tapping

screws securing the floor to the frame.

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.

PR163

PR164

4. From the opposite side of the vehicle repeat step

3; then lift the rear of the floor up and lift the

floor out of the vehicle.

PR165

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is

necessary.

1. Clean the floor with soap and water.

2. Inspect the floor for cracks or holes.

INSTALLING

1. Place the front of the floor into position in the

vehicle first; then lower the rear and push past

the seat lock studs.

2. Secure the floor with twelve cap screws and two

self-tappings screws.

3. Install the center console and seats making sure

the seats lock securely into position.

Belly Panel

REMOVING

1. Remove the body screws securing the belly

panel to the underside of the frame.

2. Remove the belly panel.

INSTALLING

1. Place the belly panel into position on the under-

side of the frame.

2. Install the body screws. Tighten securely.

Exhaust System

REMOVING MUFFLER

1. Remove the two exhaust springs at the muf-

fler/exhaust pipe juncture.

8-13

PR131

2. Slide the muffler assembly rearward and clear of

the holder pins.

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 sup-

port socket from the ball. The cargo box will tilt

fully rearward.

PR102

2. Loosen but do not remove the four shoulder cap

screws securing the pivot housings to the cargo

box.

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.

8-14

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 sup-

port to the ball.

4. Lower the cargo box and lock into position.

Adjusting Headlights

The headlights can be adjusted vertically. The geo-

metric center of the HIGH beam light zone is to be

used for vertical aiming.

1. Position the vehicle on a level floor so the head-

lights 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 hori-

zontal 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.

0740-647

7. Turn the adjustment knob counterclockwise to

lower the beam and clockwise to raise the beam.

CD714A

Taillight Assembly

REMOVING

1. Remove two torx-head screws securing the tail-

light assembly to the rear canopy tube; then

rotate the taillight assembly left or right to allow

the connector to clear the access opening.

! 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.

8-15

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.

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.

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.

9-1

SECTION 9 - CONTROLS/INDICATORS

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

9-2

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.

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.

PR338

PR336

3. Remove the oil bolt securing the banjo fittings

to the master cylinder; then remove the master

cylinder. Discard the three crush washers.

INSPECTING

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is

necessary.

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 deteriora-

tion.

3. Inspect the reservoir for cracks and leakage.

4. Inspect the brake hose for cracks and deteriora-

tion 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.

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 sys-

tem (see Section 2).

! CAUTION

Brake fluid is highly corrosive. Do not spill brake

fluid on any surface of the vehicle.

9-3

Accelerator Pedal

REMOVING

To remove the accelerator pedal, dislodge the throt-

tle 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.

PR342B

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.

ADJUSTING

To adjust the throttle cable, see Section 2.

2WD/4WD Selector

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 suf-

ficient. 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.

PR083

Front Differential Lock

The front differential lock allows the operator to

mechanically lock the differential to apply equal

power to both front wheels. To engage the front dif-

ferential lock, pull the DIFF LOCK toggle out; to

disengage the front differential lock, push the DIFF

LOCK toggle in.

PR083

! CAUTION

Do not attempt to engage or disengage the front dif-

ferential while the vehicle is moving.

9-4

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.

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.

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.

PR340

INSTALLING

1. With the shifter spring in place on the shift lever,

install the shift lever onto the shifter axle.

2. Install the shoulder screw and secure with the

flange nut. Tighten to specifications.

Speedometer/

Tachometer/LCD

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 dis-

played; 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 dis-

play 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 dis-

played.

9-5

NOTE: Approximately two seconds after releas-

ing either Button, the LCD will return to normal

operation.

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 engine hour meter will not activate

until engine speed exceeds 500 RPM.

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 sec-

onds 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 speed-

ometer function to tachometer function on the

speedometer/tachometer gauge.

5. Odometer/Trip Meter (#1 and #2) - Odometer

registers the total distance the vehicle has trav-

eled. 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 reg-

isters 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 gear-

shift 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.

8. Speed Function Display - Displays which speed

function (MPH, TACH, K/PH) is being indi-

cated by the Speed/Tach indicator.

NOTE: The speed and tach functions may be

switched by pressing the Set/Reset Button.

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.

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.

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.

9-6

CF099A

REPLACING

SPEEDOMETER/TACHOMETER/LCD

To replace the speedometer, use the following pro-

cedure.

1. Remove the six torx-head screws securing the

dash panel to the frame; then remove the park-

ing brake handle and jam nut.

2. Slide the dash panel to the rear sufficiently to

access the components.

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.

PR284A

4. Place the new gauge into the dash panel open-

ing; then place the gauge holder over the mount-

ing 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.

! CAUTION

Continued operation of the vehicle with high engine

temperature may result in engine damage or prema-

ture wear.

10-1

SECTION 10 - AIDS FOR MAINTENANCE

TABLE OF

CONTENTS

Torque Specifications ............................................ 10-2

Torque Conversions .............................................. 10-3

Tightening Torque (General Bolts) ........................ 10-3

10-2

Torque Specifications

* w/Blue Loctite #243

** w/Red Loctite #271

*** w/Green Loctite #609

DRIVE TRAIN COMPONENTS

Part Part Bolted To Torque

kg-m ft-lb

Engine Cradle Engine 5.5 40

Engine Cradle Rubber Mount 3.5 25

Front Differential* Frame/Diff Bracket 6.2 45

Rear Output Joint

Assy

Engine 2.8 20

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

Lock Collar Diff Housing 17.3 125

Hub Nut Front/Rear

Shaft/Axle (min)

27.6 200

Oil Drain Plug Front Diff/Rear Dr 0.5 3.5

Oil Fill Plug Front Diff/Rear Dr 2.2 16

Oil Drain Plug Engine 2.2 16

Inspection Plug Rear Drive 0.5 3.5

Wheel Hub 5.5-6.2 40-45

Front/Rear Shaft

Flange

Front/Rear U-Joint 5.5 40

EXHAUST COMPONENTS

Exhaust Pipe Engine 2.8 20

ELECTRICAL COMPONENTS

Coil* Isolator Plate 1.1 8

Isolator Plate Frame 1.1 8

Ground Wire Engine 1.1 8

STEERING COMPONENTS

Steering Wheel

Shaft**

Steering Wheel 3.5 25

Steering Wheel Shaft Intermediate Shaft

(Upper)

3.5 25

Intermediate Shaft

(Lower)

Steering Pinion

Shaft

3.5 25

Rack and Pinion Frame 6.9 50

Tie Rod End Knuckle 4.2 30

Jam Nut Tie Rod End 1.1 8

BRAKE COMPONENTS

Brake Disc* Hub 2.1 15

Brake Hose Caliper 2.8 20

Brake Hose Master Cylinder 2.8 20

Master Cylinder Frame 3.5 25

Parking Brake

Mechanism

Frame 2.8 20

Hydraulic Caliper Knuckle 2.8 20

Rear Caliper Rear Drive

Gear Case

2.8 20

Drive-line Brake Rear Drive Input

Flange

1.7 12

CHASSIS COMPONENTS

Shift Lever* Shift Axle Bracket 2.8 20

Shift Link Adjuster Shift Link Adjuster 1.1 8

SUSPENSION COMPONENTS (Front)

Part Part Bolted To Torque

kg-m ft-lb

A-Arm (All) Frame 4.8 35

Ball Joint Cap Screw Knuckle 4.8 35

Shock Absorber Frame 4.8 35

Shock Absorber Upper A-Arm 4.8 35

Knuckle A-Arm 4.8 35

SUSPENSION COMPONENTS (Rear)

Axle Retainer Assy Axle Housing 5.5 40

Sway Bar Bracket Frame 4.8 35

A-Arms Frame 4.8 35

Shock Absorber

(Upper)

Axle Hous-

ing/Frame

4.8 35

Shock Absorber

(Lower)

A-Arm 2.8 20

Knuckle A-Arm 4.8 35

Cargo Box Hinge Cargo Box Frame 2.8 20

Cargo Box Cargo Box Frame 2.8 20

Latch Pivot Housing Cargo Box Frame 2.1 15

Latch Striker Cargo Box Liner 1.1 8

CANOPY ASSEMBLY

Front/Rear Canopy

Tu b e

Arm Rest/Steer-

ing Post Support

2.8 20

Top Canopy Support Front/Rear Can-

opy Tubes

1.1 8

Rear Canopy Tube Lower Canopy

Support

1.1 8

ENGINE/TRANSMISSION

Clutch Shoe** Crankshaft 31.8 230

Clutch Cover/ Housing

Assy

Crankcase 1.1 8

Crankcase Half (6 mm) Crankcase Half 0.9-1.3 6.5-9.5

Crankcase Half (8 mm) Crankcase Half 2.8 20

Cylinder Head (Cap

Screws)

Crankcase 5.5 40

Cylinder Head (6 mm) Cylinder 1.1 8

Cylinder Head (8 mm) Cylinder 2.5 18

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

Ground Wire Engine 1.1 8

Magneto Cover Crankcase 1.1 8

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

Output Shaft Gear Output Shaft 8.5 61.5

Recoil Cover Right-Side Cover 0.8 6

Rotor/Flywheel Nut Crankshaft 14.5 105

Cam Sprocket** Camshaft 1.35 9.8

Starter Cup Crankshaft 3.8 27.5

V-Belt Cover Crankcase 1.1 8

Plenum*** Engine 1.1 8

Spark Plug Engine 1.7 12

10-3

Torque Conversions

Tightening Torque

(General Bolts)

ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m

10.1212.941 5.7 61 8.4 81 11.2

20.3223.042 5.8 62 8.6 82 11.3

30.4233.243 5.8 63 8.7 83 11.5

40.6243.344 6.1 64 8.9 84 11.6

50.7253.545 6.2 65 9.0 85 11.8

60.8263.646 6.4 66 9.1 86 11.9

71.0273.747 6.5 67 9.3 87 12.0

81.1283.948 6.6 68 9.4 88 12.2

91.2294.049 6.8 69 9.5 89 12.3

10 1.4304.250 6.9 70 9.7 90 12.5

11 1.5314.351 7.1 71 9.8 91 12.6

12 1.7324.452 7.2 72 10.0 92 12.8

13 1.8334.653 7.3 73 10.1 93 12.9

14 1.9344.754 7.5 74 10.2 94 13.0

15 2.1354.855 7.6 75 10.4 95 13.1

16 2.2365.056 7.7 76 10.5 96 13.3

17 2.4375.157 7.9 77 10.7 97 13.4

18 2.5385.358 8.0 78 10.8 98 13.6

19 2.6395.459 8.2 79 10.9 99 13.7

20 2.8405.560 8.3 80 11.1 100 13.8

Type of Bolt

Thread

Diameter

A (mm)

Tightening Torque

kg-m ft-lb

(Conventional or

4 Marked Bolt)

5 0.2-0.4 1.5-3.0

6 0.4-0.7 3.0-5.0

8 1.0-1.6 7.0-11.5

10 2.2-3.5 16.0-25.5

(7 Marked Bolt) 5 0.3-0.6 2.0-4.5

6 0.8-1.2 6.0-8.5

8 1.8-2.8 13.0-20.0

10 4.0-6.0 29.0-43.5

11-1

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

11-2

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

turn

6. See Electrical in this section

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 Remedy

1. Gas tank vent hose obstructed 1. Clean vent hose

2. Carburetor inlet needle defective 2. Replace needle

3. Fuel hose obstructed 3. Clean - replace hose

4. Fuel screens obstructed 4. Clean - replace inlet screen - valve screen

5. Fuel pump defective 5. Replace fuel pump

Problem: Engine stalls easily

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 Remedy

1. Piston - cylinder worn 1. Replace - service piston - cylinder

2. Combustion chamber carbon buildup 2. Clean chamber

3. Piston pin - piston pin bore worn 3. Replace - service pin - bore

4. Piston rings - ring groove(s) worn 4. Replace rings - piston

11-3

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 Remedy

1. Valve clearance out of adjustment 1. Adjust clearance

2. Valve seating poor 2. Replace - service seats - valves

3. Valve guides defective 3. Replace guides

4. Rocker arms - arm shaft worn 4. Replace arms - shafts

5. Magneto defective 5. Replace magneto

6. CDI unit defective 6. Replace CDI unit

7. Spark plug fouled - gap too wide 7. Adjust gap - replace plug

8. Ignition coil defective 8. Replace ignition coil

9. Float out of adjustment 9. Adjust float height

10. Jets obstructed 10. Clean jets

11. Pilot screw setting improper 11. Adjust pilot screw

11-4

Problem: Engine runs poorly at high speed

Condition Remedy

1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease speed

2. Valve springs weak 2. Replace springs

3. Valve timing out of adjustment 3. Adjust timing

4. Cams - rocker arms worn 4. Replace cams - arms

5. Spark plug gap too narrow 5. Adjust gap

6. Ignition coil defective 6. Replace ignition oil

7. Float level too low 7. Adjust float height

8. Air cleaner element obstructed 8. Clean element

9. Fuel hose obstructed 9. Clean - prime hose

Problem: Exhaust smoke dirty or heavy

Condition Remedy

1. Oil (in the engine) overfilled - contaminated 1. Drain excess oil - replace oil

2. Piston rings - cylinder worn 2. Replace - service rings - cylinder

3. Valve guides worn 3. Replace guides

4. Cylinder wall scored - scuffed 4. Replace cylinder

5. Valve stems worn 5. Replace valves

6. Stem seals defective 6. Replace seals

Problem: Engine lacks power

Condition Remedy

1. Valve clearance incorrect 1. Adjust clearance

2. Valve springs weak 2. Replace springs

3. Valve timing out of adjustment 3. Time camshaft

4. Piston ring(s) - cylinder worn 4. Replace - service rings - cylinder

5. Valve seating poor 5. Repair seats

6. Spark plug fouled 6. Clean - replace plug

7. Rocker arms - shafts worn 7. Replace arms - shafts

8. Spark plug gap incorrect 8. Adjust gap - replace plug

9. Carburetor jets obstructed 9. Clean jets

10. Float level out of adjustment 10. Adjust float height

11. Air cleaner element obstructed 11. Clean element

12. Oil (in the engine) overfilled - contaminated 12. Drain excess oil - change oil

13. Intake manifold leaking air 13. Tighten - replace manifold

14. Cam chain worn 14. Replace cam chain - sprockets

Problem: Engine overheats

Condition Remedy

1. Carbon deposit (piston crown) excessive 1. Clean piston

2. Oil low 2. Add oil

3. Octane low - gasoline poor 3. Drain - replace gasoline

4. Oil pump defective 4. Replace pump

5. Oil circuit obstructed 5. Clean circuit

6. Gasoline level (in float chamber) too low 6. Adjust float height

7. Intake manifold leaking air 7. Tighten - replace manifold

8. Coolant level low 8. Fill - examine system for leaks

9. Fan malfunctioning 9. Check fan fuse - replace fan

10. Fan switch malfunctioning 10. Replace fan switch

11. Thermostat stuck - closed 11. Replace thermostat

12. Radiator hoses - cap damaged - obstructed 12. Clear obstruction - replace hoses

11-5

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 Remedy

1. Secondary drive - driven gear teeth broken 1. Replace gear(s)

2. Propeller shaft serration worn - broken 2. Replace shaft

3. Coupling damaged 3. Replace coupling

4. Coupling joint serration worn - damaged 4. Replace joint

5. Front drive - driven bevel gears broken -

damaged

5. Replace gear(s)

6. Front differential gears/pinions broken -

damaged

6. Replace gears - pinions

7. Front drive actuator not operating 7. Replace fuse - 2WD/4WD switch - front drive

actuator

11-6

Fuel System

Problem: Starting impaired

Condition Remedy

1. Starter jet obstructed 1. Clean jet

2. Starter jet passage obstructed 2. Clean passage

3. Starter body - carburetor leaking air 3. Tighten - adjust - replace gasket

4. Starter valve not operating properly 4. Check - adjust valve

Problem: Idling or low speed impaired

Condition Remedy

1. Slow jet obstructed - loose 1. Clean - tighten jet

2. Slow jet outlet obstructed 2. Clean outlet

3. Pilot screw setting incorrect 3. Adjust screw

4. Starter valve not fully closed 4. Adjust valve

5. Float height incorrect 5. Adjust float height

Problem: Medium or high speed impaired

Condition Remedy

1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease RPM speed

2. Main jet obstructed 2. Clean main jet

3. Needle jet obstructed 3. Clean needle jet

4. Throttle vacuum piston not operating

properly

4. Check piston operation

5. Filter obstructed 5. Clean filter

6. Float height incorrect 6. Adjust float height

7. Starter valve not fully closed 7. Adjust valve

Problem: Overflow and fuel level fluctuations

Condition Remedy

1. Float valve worn - damaged 1. Replace valve

2. Float valve spring broken 2. Replace spring

3. Float not working properly 3. Adjust float height - replace float

4. Float valve dirty 4. Clean valve

5. Float height too high - too low 5. Adjust float height

11-7

Electrical

Problem: Spark absent or weak

Condition Remedy

1. Ignition coil defective 1. Replace ignition coil

2. Spark plug defective 2. Replace plug

3. Magneto defective 3. Replace magneto

4. CDI unit defective 4. Replace CDI unit

5. Pick-up coil defective 5. Replace pick-up coil

Problem: Spark plug fouled with carbon

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 Remedy

1. Spark plug incorrect (too hot) 1. Replace plug

2. Engine overheats 2. Service cooling system

3. Spark plug loose 3. Tighten plug

4. Mixture too lean 4. Adjust carburetor

Problem: Battery does not charge

Condition Remedy

1. Lead wires/connections shorted - loose -

open

1. Repair - replace - tighten lead wires

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 Remedy

1. Lead wires shorted - open - loose (at

terminals)

1. Repair - tighten lead wires

2. Stator coils (magneto) grounded - open 2. Replace stator coils

3. Regulator/rectifier defective 3. Replace regulator/rectifier

4. Electrolyte low 4. Add distilled water

5. Cell plates (battery) defective 5. Replace battery

11-8

Problem: Magneto overcharges

Condition Remedy

1. Internal battery short circuited 1. Replace battery

2. Regulator/rectifier resistor damaged -

defective

2. Replace resistor

3. Regulator/rectifier poorly grounded 3. Clean - tighten ground connection

Problem: Charging unstable

Condition Remedy

1. Lead wire intermittently shorting 1. Replace lead wire

2. Magneto internally shorted 2. Replace magneto

3. Regulator/rectifier defective 3. Replace regulator/rectifier

Problem: Starter button not effective

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 Remedy

1. Charging rate too low - too high 1. Replace battery

2. Battery electrolyte excessive - insufficient 2. Keep electrolyte to prescribed level

3. Specific gravity too high - too low 3. Charge battery - add distilled water

4. Battery run-down - damaged 4. Replace battery

5. Electrolyte contaminated 5. Recharge - replace battery

Problem: Battery discharges too rapidly

Condition Remedy

1. Electrolyte contaminated 1. Replace battery

2. Specific gravity too high 2. Charge battery - add distilled water

3. Charging system (charging operation) not

set properly

3. Check magneto - regulator/rectifier - circuit

connections - adjust for specified charging

operation

4. Cell plates overcharged - damaged 4. Replace battery - correct charging system

5. Battery short-circuited 5. Replace battery

6. Specific gravity too low 6. Recharge battery

Problem: Battery polarity reversed

Condition Remedy

1. Battery incorrectly connected 1. Reverse connections - replace battery

11-9

Steering/Suspension

Problem: Handling too heavy or stiff

Condition Remedy

1. Front wheel alignment incorrect 1. Adjust alignment

2. Lubrication inadequate 2. Lubricate appropriate components

3. Tire inflation pressure incorrect 3. Adjust pressure

4. Tie rod ends seizing 4. Replace tie rod ends

5. Linkage connections seizing 5. Repair - replace connections

Problem: Steering oscillation

Condition Remedy

1. Tires inflated unequally 1. Adjust pressure

2. Wheel(s) wobbly 2. Replace wheel(s)

3. Wheel hub cap screw(s) loose - missing 3. Tighten - replace cap screws

4. Wheel hub bearing worn - damaged 4. Replace bearing

5. Tie rod ends worn - loose 5. Replace - tighten tie rod ends

6. Tires defective - incorrect 6. Replace tires

7. A-arm bushings damaged 7. Replace bushings

8. Bolts - nuts (frame) loose 8. Tighten bolts - nuts

Problem: Steering pulling to one side

Condition Remedy

1. Tires inflated unequally 1. Adjust pressure

2. Front wheel alignment incorrect 2. Adjust alignment

3. Wheel hub bearings worn - broken 3. Replace bearings

4. Frame distorted 4. Repair - replace frame

5. Shock absorber defective 5. Replace shock absorber

Problem: Steering impaired

Condition Remedy

1. Tire pressure too high 1. Adjust pressure

2. Steering linkage connections worn 2. Replace connections

3. Cap screws (suspension system) loose 3. Tighten cap screws

Problem: Tire wear rapid or uneven

Condition Remedy

1. Wheel hub bearings worn - loose 1. Replace bearings

2. Front wheel alignment incorrect 2. Adjust alignment

Problem: Steering noise

Condition Remedy

1. Caps screws - nuts loose 1. Tighten cap screws - nuts

2. Wheel hub bearings broken - damaged 2. Replace bearings

3. Lubrication inadequate 3. Lubricate appropriate components

11-10

Brakes

Problem: Suspension too soft

Condition Remedy

1. Spring(s) weak 1. Replace spring(s)

2. Shock absorber damaged 2. Replace shock absorber

Problem: Suspension too stiff

Condition Remedy

1. A-arm-related bushings worn 1. Replace bushing

Problem: Suspension noisy

Condition Remedy

1. Cap screws (suspension system) loose 1. Tighten cap screws

2. A-arm-related bushings worn 2. Replace bushings

Problem: Rear wheel oscillation

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

Problem: Braking poor

Condition Remedy

1. Pad worn 1. Replace pads

2. Pedal free-play excessive 2. Adjust free-play

3. Brake fluid leaking 3. Repair - replace hydraulic system

4. Hydraulic system leaking air 4. Bleed hydraulic system

5. Master cylinder/brake cylinder seal worn 5. Replace seal(s)

Problem: Brake pedal travel excessive

Condition Remedy

1. Hydraulic system entrapped air 1. Bleed hydraulic system

2. Brake fluid low 2. Add fluid to proper level

3. Brake fluid incorrect 3. Replace with correct fluid

4. Piston seal - cup worn 4. Replace seal - cup

Problem: Brake fluid leaking

Condition Remedy

1. Connection joints loose 1. Tighten joint

2. Hose cracked 2. Replace hose

3. Piston seal worn 3. Replace seal

2006 XT 650 Prowler

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