2014 Prowler HDX Service
User Manual: Manual
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Page Count: 192 [warning: Documents this large are best viewed by clicking the View PDF Link!]
- FRONT COVER
- FOREWORD
- Table of Contents
- General Information
- Periodic Maintenance
- SPECIAL TOOLS
- Periodic Maintenance Chart
- Lubrication Points
- Air Filter
- Valve/Tappet Clearance
- Testing Engine Compression
- Spark Plug
- Muffler/Spark Arrester
- Engine/Transmission Oil - Filter
- Front Differential - Rear Drive Lubricant
- Driveshaft/Coupling
- Nuts/Bolts/Cap Screws
- Headlight/Taillight- Brakelight
- Shift Lever
- Hydraulic Brake System
- Burnishing Brake Pads
- Checking/Replacing V- Belt
- Steering/Frame/Controls
- Electronic Power Steering (EPS)
- Tie Rods
- Steering Assembly
- Steering Wheel
- Upper Steering Shaft
- Intermediate Steering Shaft Assembly
- Steering Knuckles
- Accelerator Pedal
- Shift Lever
- Shift Cable
- LCD Gauge/Indicator Lights
- Checking/Adjusting Front Wheel Alignment
- Front Bumper Assembly
- Hood
- Fenders
- Floor
- Dashboard
- Belly Panel
- Exhaust System
- Cargo Box
- Taillight Assembly
- Seat
- Troubleshooting
- Engine/Transmission
- SPECIAL TOOLS
- Troubleshooting
- Removing Engine/ Transmission
- Servicing Engine (500)
- Top-Side Components
- Removing Top-Side Components
- Servicing Top-Side Components
- VALVE ASSEMBLY
- Cleaning/Inspecting Cylinder Head Cover
- Removing Valves
- Measuring Valve Stem Runout
- Measuring Valve Stem Outside Diameter
- Measuring Valve Face/Seat Width
- Measuring Valve Face Radial Runout
- Measuring Valve Guide (Inside Diameter)
- Servicing Valves/Valve Guides/Valve Seats
- Measuring Rocker Arm (Inside Diameter)
- Measuring Rocker Arm Shaft (Outside Diameter)
- Installing Valves
- PISTON ASSEMBLY
- Cleaning/Inspecting Piston
- Removing Piston Rings
- Cleaning/Inspecting Piston Ring Grooves
- Measuring Piston-Ring End Gap (Installed)
- Measuring Piston Pin, Connecting Rod Small End, and Piston-Pin Bore
- Measuring Piston Skirt/ Cylinder Clearance
- Installing Piston Rings
- CYLINDER/CYLINDER HEAD ASSEMBLY
- Cleaning/Inspecting Cylinder Head
- Measuring Cylinder Head Distortion
- Cleaning/Inspecting Cylinder
- Inspecting Cam Chain Guide
- Honing Cylinder
- Measuring Camshaft Runout
- Measuring Camshaft Lobe Height
- Inspecting Camshaft Bearing Journal
- Measuring Camshaft to Cylinder Head Clearance
- Inspecting Camshaft Spring/Drive Pin
- Installing Top-Side Components
- Left-Side Components
- Removing Left-Side Components
- Servicing Left-Side Components
- Installing Left-Side Components
- Right-Side Components
- Removing Right-Side Components
- Servicing Right-Side Components
- Installing Right-Side Components
- Center Crankcase Components
- Separating Crankcase Halves
- Disassembling Crankcase Half
- Servicing Center Crankcase Components
- SECONDARY GEARS
- Checking Backlash
- Correcting Backlash
- Checking Tooth Contact
- Correcting Tooth Contact
- CRANKSHAFT ASSEMBLY
- Measuring Connecting Rod (Small End Inside Diameter)
- Measuring Connecting Rod (Small End Deflection)
- Measuring Connecting Rod (Big End Side-to-Side)
- Measuring Crankshaft (Runout)
- Measuring Crankshaft (Web-to- Web)
- COUNTERSHAFT
- Disassembling
- ASSEMBLING
- Assembling Crankcase Half
- Joining Crankcase Halves
- Servicing Engine (700)
- Top-Side Components
- Removing Top-Side Components
- Servicing Top-Side Components
- VALVE ASSEMBLY
- Cleaning/Inspecting Valve Cover
- Removing Valves
- Measuring Valve Stem Runout
- Measuring Valve Stem Outside Diameter
- Measuring Valve Face/Seat Width
- Measuring Valve Guide/Valve Stem Deflection (Wobble Method)
- Measuring Valve Guide (Inside Diameter)
- Servicing Valves/Valve Guides/Valve Seats
- Measuring Rocker Arm (Inside Diameter)
- Measuring Rocker Arm Shaft (Outside Diameter)
- Installing Valves
- PISTON ASSEMBLY
- Cleaning/Inspecting Piston
- Removing Piston Rings
- Cleaning/Inspecting Piston Rings
- Measuring Piston-Ring End Gap (Installed)
- Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore
- Measuring Piston Skirt/Cylinder Clearance
- Installing Piston Rings
- CYLINDER/CYLINDER HEAD ASSEMBLY
- Cleaning/Inspecting Cylinder Head
- Measuring Cylinder Head Distortion
- Cleaning/Inspecting Cylinder
- Inspecting Cam Chain Guide
- Inspecting Cylinder
- Measuring Camshaft Runout
- Measuring Camshaft Lobe Height
- Inspecting Camshaft Bearing Journal
- Measuring Camshaft to Cylinder Head Clearance
- Inspecting Camshaft Spring/Drive Pin
- Installing Top-Side Components
- Left-Side Components
- Removing Left-Side Components
- Servicing Left-Side Components
- Installing Left-Side Components
- Right-Side Components
- Removing Right-Side Components
- Servicing Right-Side Components
- Installing Right-Side Components
- Center Crankcase Components
- Separating Crankcase Halves
- Disassembling Crankcase Half
- Servicing Center Crankcase Components
- SECONDARY OUTPUT DRIVE GEARS
- Initial Set-Up
- Checking Backlash
- Correcting Backlash
- CRANKSHAFT ASSEMBLY
- Measuring Connecting Rod (Small End Inside Diameter)
- Measuring Connecting Rod (Small End Deflection)
- Measuring Connecting Rod (Big End Side-to-Side)
- Measuring Crankshaft (Runout)
- Measuring Crankshaft (Web-to- Web)
- COUNTERSHAFT
- Disassembling
- Assembling
- Assembling Crankcase Half
- Joining Crankcase Halves
- Installing Engine/ Transmission
- Fuel/Lubrication/Cooling
- Electrical System
- SPECIAL TOOLS
- TESTING ELECTRICAL COMPONENTS
- ELECTRICAL CONNECTIONS
- Battery
- RPM Limiter
- Switches
- Accessory Receptacle/ Connector
- Brakelight Switch
- Engine Coolant Temperature (ECT) Sensor
- Fan Motor
- Power Distribution Module (PDM)
- Ignition Coil
- EFI Sensors/Components
- Speed Sensor
- Electronic Power Steering (EPS)
- Ignition Switch
- Headlight Switch
- Drive Select Switch
- Reverse Override Switch
- Front Drive Actuator
- Stator Coil/Crankshaft Position (CKP) Sensor
- Starter Motor
- Starter Relay
- Electronic Control Module (ECM)
- Regulator/Rectifier
- Headlights
- Taillight-Brakelight
- Ignition Timing
- EFI Diagnostic System
- DIGITAL GAUGE
- Coolant (COOL) Diagnostic Mode
- Fuel Sensor (FUEL) Diagnostic Mode
- Tachometer (tACH) Diagnostic Mode
- Speed (SPd) Diagnostic Mode
- TPS (tPS) Diagnostic Mode
- MAP (bArO) Diagnostic Mode
- Inlet Air Temperature (AIr) Diagnostic Mode
- Battery (bAtt) Diagnostic Mode
- DIAGNOSTIC TROUBLE CODES (DTC)
- If an EFI or related chassis component fails or an out-of- tolerance signal is detected by the ECM, a diagnostic trouble code (DTC) will be generated in the ECM and displayed on the LCD. The DTC will be displayed alternately with a wrench icon or mal...
- Code List
- Tilt Sensor
- Throttle Position Sensor (TPS)
- Troubleshooting
- Drive System
- Suspension
- BACK COVER