2014 Prowler Service
User Manual: Manual
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Page Count: 218 [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(s)
- Muffler/Spark Arrester
- Engine/Transmission Oil - Filter
- Front Differential - Rear Drive Lubricant
- Driveshaft/Coupling
- Nuts/Bolts/Cap Screws
- Headlight/Taillight-Brakelight
- Shift Lever (XT/XTZ)
- Shift Lever/Shift Cable (XTX)
- Hydraulic Brake System
- Parking Brake (XT/XTZ)
- Burnishing Brake Pads
- Checking/Replacing V-Belt
- Steering/Frame/Controls
- Steering Assembly (XT)
- Electronic Power Steering (EPS) (XTX/XTZ)
- Steering Assembly (XTX/XTZ)
- Steering Wheel
- Upper Steering Shaft
- Lower Steering Shaft Assembly
- Steering Knuckles
- Checking/Adjusting Front Wheel Alignment
- Front Bumper Assembly
- Hood
- Fenders
- Floor
- Belly Panel
- Accelerator Pedal
- Shift Lever (XT/XTZ)
- Shift Lever (XTX)
- LCD Gauge/Indicator Lights
- Exhaust System
- Cargo Box
- Taillight Assembly
- Seats
- Troubleshooting
- Engine/Transmission
- SPECIAL TOOLS
- Troubleshooting
- Prowler XT/XTX (Table of Contents)
- Removing Engine/ Transmission
- 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 Face Radial Runout
- 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
- Right-Side Components
- Removing Right-Side Components
- Servicing Right-Side Components
- Installing Right-Side Components
- Left-Side Components
- Removing Left-Side Components
- Servicing Left-Side Components
- Installing Left-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
- Prowler XTZ (Table of Contents)
- Removing Engine/Transmission
- 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 Face Radial Runout
- 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
- Removing Piston Rings
- Cleaning/Inspecting Piston
- 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
- Measuring Camshaft Runout
- Measuring Camshaft Lobe Height
- Inspecting Camshaft Bearing Journal
- Measuring Camshaft to Cylinder Head Clearance
- Inspecting Camshaft Spring/Drive Pin (Front Camshaft Only)
- 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
- OIL PUMP ASSEMBLY
- Disassembling and Inspecting
- Assembling
- 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) (XTZ)
- Electronic Power Steering (EPS) (XTX)
- 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 Unit (ECM)
- Regulator/Rectifier
- Headlights
- Taillight-Brakelight
- Ignition Timing
- Tilt Sensor
- Throttle Position Sensor (TPS)
- ECM Error Codes (XT/XTZ)
- EFI Diagnostic System (XTX)
- 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)
- Code List
- Troubleshooting
- Drive System
- GENERAL INFORMATION
- SPECIAL TOOLS
- Front Drive Actuator
- Front Differential
- REMOVING
- Disassembling Input Shaft
- Assembling Input Shaft
- Disassembling Differential Assembly
- Disassembling Pinion Gear
- Assembling Pinion Gear
- Shimming Procedure/Shim Selection
- Backlash
- Ring Gear End-Play
- RING GEAR/THRUST BUTTON
- Removing
- Inspecting
- Installing/Shimming
- Assembling Differential Assembly
- Removing/Installing Axle Seal
- INSTALLING DIFFERENTIAL
- Drive Axles
- Rear Gear Case
- Hub
- Hydraulic Brake Caliper
- Universal Joints (XTZ)
- Troubleshooting Drive System
- Troubleshooting Brake System
- Suspension
- BACK COVER