Arctic Cat 2013 Prowler XT Service Manual
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Arctic Cat 2013 Prowler XT Service Manual

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Prowler XT/XTX/XTZ

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Summary of Contents for Arctic Cat 2013 Prowler XT

  • Page 1 Prowler XT/XTX/XTZ...
  • Page 2 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to fol- low the directive because it deals with the possibility of serious personal injury or even death.
  • Page 4 TABLE OF CONTENTS General Information/Specifications Periodic Maintenance/Tune-Up Engine/Transmission Fuel/Lubrication/Cooling Electrical System Drive System Suspension Steering/Frame/Controls...

  • Page 6: Table Of Contents

    SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications ..........1-2 Torque Specifications ..........1-3 Torque Conversions (ft-lb/N-m) ....... 1-4 Break-In Procedure ..........1-4 Gasoline - Oil - Lubricant ........1-5 Genuine Parts ............1-5 Preparation For Storage.......... 1-6 Preparation After Storage........

  • Page 7: General Specifications

    Gasoline (recommended) 87 Octane Regular Cylinder Head/Cover Distortion (max) 0.05 mm Unleaded CYLINDER, PISTON, AND RINGS - XT/XTX Engine Oil (recommended) Arctic Cat ACX All Weather Piston Skirt/Cylinder Clearance 0.06 mm Synthetic Cylinder Bore (550 cc) 91.995-92.005 mm Front Differential/Rear Drive Lubricant...

  • Page 8: Torque Specifications

    STEERING COMPONENTS CRANKSHAFT - XTZ Torque Connecting Rod (max) 20.021 mm Part Part Bolted To ft-lb N-m (small end inside diameter) Steering Wheel** Steering Wheel Shaft Connecting Rod (big end side-to-side) 0.95 mm Steering Wheel Shaft*** Intermediate Shaft (Upper) 36 Connecting Rod (max) 0.3 mm...

  • Page 9: Torque Conversions (Ft-Lb/N-M)

    ENGINE/TRANSMISSION - H2 Torque Conversions Torque Part Part Bolted To (ft-lb/N-m) ft-lb N-m Clutch Shoe** Crankshaft 221 300 Clutch Cover/Housing Crankcase Assembly Lower Crankcase Cover Crankcase ft-lb ft-lb ft-lb ft-lb (6 mm) Lower Crankcase Cover Crankcase 35.4 69.4 103.4 (8 mm) 36.7 70.7 104.7...

  • Page 10: Gasoline - Oil - Lubricant

    When using ethanol blended gasoline, it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system. CAUTION Do not use white gas. Only Arctic Cat approved gaso- line additives should be used. RECOMMENDED ENGINE/ TRANSMISSION OIL...

  • Page 11: Preparation For Storage

    Start the engine and allow it to coolant as necessary. idle. Using Arctic Cat Engine Storage Preserver, rap- 6. Charge the battery; then install. Connect the battery idly inject the preserver into the air filter opening for cables.
  • Page 12 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart ........2-2 Periodic Maintenance..........2-3 Lubrication Points............ 2-3 Air Filter ..............2-3 Valve/Tappet Clearance........... 2-4 Testing Engine Compression........2-5 Spark Plug(s) ............2-5 Muffler/Spark Arrester ..........2-6 Engine/Transmission Oil - Filter....... 2-6 Front Differential - Rear Drive Lubricant....

  • Page 13: Periodic Maintenance Chart

    * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 0W-40 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change and strainer inspection interval can be increased to every 1,000 miles or every year.

  • Page 14: Periodic Maintenance

    Arctic Cat ROV. 1. Remove the seats; then remove the center console.  NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal 2. Unsnap the four fasteners securing the air cleaner components when servicing the engine/transmission.

  • Page 15: Valve/Tappet Clearance

    2. Replace any one-way drain that is cracked or shows VALVE/TAPPET CLEARANCE any signs of hardening or deterioration. Intake 0.1016 mm (0.004 in.) Exhaust 0.1524 mm (0.006 in.) CAUTION The one-way drain to the left is the clean air section of the filter housing.

  • Page 16: Testing Engine Compression

    F. On the XTZ, rotate the engine 270° to the TDC 6. If compression is abnormally low, verify the position of the rear cylinder; then repeat steps following items. A-E for the rear cylinder. A. Starter cranks engine over. 3. Install the spark plug(s) and timing inspection plug; then on the XTZ remove the cap screw and install the B.

  • Page 17: Muffler/Spark Arrester

    Engine/Transmission Oil - Filter OIL - FILTER Change the engine oil and oil filter at the scheduled inter- vals. 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.

  • Page 18: Front Differential - Rear Drive Lubricant

    4. Using the Oil Filter Wrench 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;...

  • Page 19: Driveshaft/Coupling

    3. Install the bulb and socket into the light assembly and turn clockwise to lock in place. Driveshaft/Coupling 4. Install the taillight-brakelight assembly on the can- opy support. CHECKING/ADJUSTING The following drive system components should be inspected periodically to ensure proper operation. HEADLIGHT AIM A.

  • Page 20: Shift Lever (Xt/Xtz)

    Shift Lever (XT/XTZ) CHECKING SHIFT CABLE 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) indica- tion, and reverse for the (R) indication.

  • Page 21: Hydraulic Brake System

    HDX199 PR095 If either park or low range cannot be reached, the shift 2. Depress the brake pedal several times to check for a cable must be adjusted. firm brake. If the brake is not firm, the system must be bled. ADJUSTING 3.

  • Page 22: Parking Brake (Xt/Xtz)

     NOTE: During the bleeding procedure, watch the reservoir very closely to make sure there is always a sufficient amount of brake fluid. When the level falls below MIN, refill the reservoir before the bleeding procedure is continued. Failure to maintain a suffi- cient amount of fluid in the reservoir will result in air in the system.
  • Page 23 ADJUSTING MEASURING/REPLACING BRAKE PADS (XT) 1. Remove the seats and center console. Removing 2. With the parking brake lever released, loosen the adjuster nut (A); then turn the jam nut (B) clockwise 1. Remove the parking brake cable (see Adjusting in several turns.
  • Page 24 2. Slide brake caliper assembly over the brake disc and into position on the rear drive housing; then secure the caliper with new “patch-lock” cap screws tight- ened to 20 ft-lb. 3. Connect the parking brake cable (see Adjusting in this sub-section).

  • Page 25: Burnishing Brake Pads

    Burnishing Brake Pads Brake pads must be burnished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure. ! WARNING Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss.
  • Page 26 INSTALLING 1. Place the V-belt into position on the driven pulley and over the front shaft. CD963 GZ085  NOTE: The arrows on the V-belt should point in the direction of engine rotation. 2. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the driveshaft.

  • Page 27: Troubleshooting Brake System

    Troubleshooting Brake System Problem: Braking poor Condition Remedy 1. Pad worn 1. Replace pads 2. Brake fluid leaking 2. Repair leak(s) 3. Master cylinder/brake cylinder seal worn 3. Replace seal(s) Problem: Brake pedal travel excessive Condition Remedy 1. Brake fluid low 1.
  • Page 28 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Troubleshooting ............3-3 Prowler XT/XTX (Table of Contents) ....... 3-5 Prowler XTZ (Table of Contents) ......3-51...
  • Page 29 0444-152 the frame. Magneto Rotor Remover Set 0444-254 Piston Pin Puller 0644-328  NOTE: Arctic Cat recommends the use of new gas- Secondary Drive Gear Holder 0444-253 kets, lock nuts, and seals and lubricating all internal Spanner Wrench 0544-005 components when servicing the engine/transmis-...
  • Page 30 Troubleshooting 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 2. Repair - replace guides 3. Valves mistimed 3. Retime engine 4.
  • Page 31 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.
  • Page 32  NOTE: Use a small funnel between the frame and coolant drain plug to prevent coolant from draining Prowler XT/XTX on the frame and splashing. (Table of Contents) Removing Engine/ Transmission......3-5 Top-Side Components..........3-8 Removing Top-Side Components ......3-8 Servicing Top-Side Components......
  • Page 33 PR155A PR474B 6. Remove the E-clip from the transmission shift arm; then disconnect the cable. Remove the gear position switch connector (XTZ). PR157A 5. From the left-side, disconnect the starter wire, alter- nator connector, and gear position switch connector (XT); then remove the cap screw securing the main PR567A harness ground and the battery ground wires to the starter.
  • Page 34 PR598A PR154A 8. Loosen the clamp (A) securing the air intake boot to 11. Remove the coolant hoses from the water pump and the throttle body and the clamp (B) securing the air thermostat housings; then position the upper coolant filter housing to the inlet housing boot;...

  • Page 35: Top-Side Components

    13. Remove the muffler; then remove the exhaust pipe.  NOTE: The front engine mounting bracket should slide free of the engine mounts first; then the rear 14. Set the parking brake; then from the underside of the engine mounting bracket and two rear engine mounts vehicle, remove the cap screws securing the drive- will lift free of the frame.
  • Page 36 CC001D CD211A 3. Loosen the cap screw on the end of the tensioner;  NOTE: Keep the mounting hardware with the covers then remove the two cap screws securing the ten- for assembly purposes or thread them back into the sioner adjuster assembly and remove the assembly.
  • Page 37 CC013D CC017D 6. While holding the chain, slide the sprocket and cam- shaft out of the cylinder head.  NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase. CC018D 9. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins;...
  • Page 38 CC022D CC025D 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.

  • Page 39: Servicing Top-Side Components

    2. Place the valve cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish.
  • Page 40 CC136D ATV-1004  NOTE: The valve seals must be replaced. 2. Acceptable width ranges must be within specifica- tions. 3. Remove the valve springs; then invert the cylinder Measuring Valve Face Radial head and remove the valves. Runout Measuring Valve Stem Runout 1.
  • Page 41 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends the components be taken to a qualified machine shop for servicing. ATV-1011A CAUTION 4. Place a spring retainer over the valve springs; then...
  • Page 42 PISTON ASSEMBLY  NOTE: Whenever a piston or pin is out of tolerance, it must be replaced. Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove. 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove.
  • Page 43 CC127D ATV-1024B 2. Measure the corresponding piston diameter at a point CAUTION 15 mm above the piston skirt at a right angle to the Incorrect installation of the piston rings will result in piston-pin bore. Subtract this measurement from the engine damage.
  • Page 44 Measuring Cylinder Head Inspecting Cam Chain Guide Distortion 1. Inspect cam chain guide for cuts, tears, breaks, or chips. 1. Remove any carbon buildup in the combustion chamber. 2. If the chain guide is damaged, it must be replaced. 2. Lay a straightedge across the cylinder head; then Honing Cylinder using a feeler gauge, check the distortion factor between the head and the straightedge.
  • Page 45 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. CC005D 2.

  • Page 46: Installing Top-Side Components

    1. Install the piston on the connecting rod making sure the circlip on each side is fully seated in the piston.  NOTE: The piston should be installed so the arrow points toward the exhaust. CC287D  NOTE: If the journals are worn, replace the cam- shaft;...
  • Page 47 4. Loosely install the two nuts which secure the cylin- der to the crankcase.  NOTE: The two cylinder-to-crankcase nuts will be tightened in step 10. CC020D CC023D 5. Install the coolant hose onto the crankcase union and tighten the clamp. C.
  • Page 48 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 cam- shaft/sprocket assembly onto the cylinder ensuring the following. CD461 13. 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.
  • Page 49 CD464 CC012D 18. Rotate the crankshaft until the second cap screw 21. Install the cylinder head plug in the cylinder head securing the sprocket to the camshaft can be with the open end facing downward and toward the installed; then install the cap screw (threads coated inside.
  • Page 50 CD469 CC005D 24. Using a flat-blade screwdriver, rotate the adjuster 26. Apply a thin coat of Three Bond Sealant to the mat- screw inside the tensioner counterclockwise until all ing surfaces of the cylinder head and valve cover. tension is released; then install the cap screw into the end of the chain tensioner.

  • Page 51: Right-Side Components

    CC001D PR465 32. If removed, install the spark plug. Tighten securely. 3. Using a cold chisel, scribe a mark showing the rela- tive position of the shift arm to the shift arm shaft to aid in installing; then remove the shift arm. Right-Side Components ...
  • Page 52 CD939A CD214 6. Remove the two cap screws securing the water pump to the engine; then remove the water pump.  NOTE: The water pump is not a serviceable compo- nent. If the pump is defective or if the mechanical seal is leaking (coolant dripping from the discharge hole), the water pump must be replaced (see Section 7.

  • Page 53: Servicing Right-Side Components

    12. 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. PR434A Servicing Right-Side Components CD944 13. Remove the snap ring securing the water pump driven gear;...
  • Page 54 FI572 FI578 REPLACING STARTER GEAR REPLACING STARTER CLUTCH BEARING ASSEMBLY 1. Support the starter clutch gear in a press making sure 1. Remove the cap screws securing the one-way to support the hub around the entire circumference; clutch assembly to the flywheel; then remove from then using a suitable bearing driver, press the bearing the flywheel.

  • Page 55: Installing Right-Side Components

    2. Inspect the bearings in the magneto housing for dis- 1. Install the water pump driven gear alignment pin and coloration, roughness when rotated, and secure fit in the driven gear (with the beveled side of the gear fac- bearing bores. ing outward as noted in removing);...
  • Page 56 CD946A PR447A 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 105 ft-lb. CD944  NOTE: The sharp side of the snap ring should be facing outward.
  • Page 57 8. Lubricate the magneto cover gasket with fresh engine oil; then place it into position on the two alignment pins. Make sure the outer shift shaft washer is in place. CD934 6. Install the shift cam stopper, spring, and two wash- ers;...

  • Page 58: Left-Side Components

    Removing Left-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover 1. Remove the cap screws securing the V-belt cover noting the location of the different-lengthed cap screws for installing purposes; then using a rubber mallet, gently tap on the cover tabs to loosen the GZ254 13.
  • Page 59 PR388 CD974A 4. Remove the fixed drive face and V-belt.  NOTE: For steps 7-13, refer to illustration PR398B. 5. Using an impact driver, remove the cap screws  NOTE: To aid in installing, it is recommended the securing the air intake plate; then remove the plate assemblies are kept together and IN ORDER.
  • Page 60 CC596 FI279A 11. Remove the cap screw securing the oil pump drive  NOTE: Account for and inspect the clutch housing gear (B). Account for a cap screw, washer, pin, and seal. spacer. CF088A CC606 9. Remove the two Allen-head screws securing the gear position switch;...

  • Page 61: Servicing Left-Side Components

    12. Using an impact driver, remove the Allen-head screws securing the final drive carrier bearing hous- ing (E); then remove the housing and account for two alignment pins. CD988 Servicing Left-Side Components CD999 13. Remove the snap ring securing the oil pump driven gear (A);...

  • Page 62: Installing Left-Side Components

    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. CD994 2. Install the secondary shaft bearing housing making sure the two alignment pins are properly positioned.
  • Page 63 6. Install the clutch shoe assembly and secure with the flange nut (threads coated with red Loctite #271). Tighten to 221 ft-lb. CD992 PR410A 7. Install the clutch cover alignment pins into the crank- case, apply oil to the cover gasket, and install the gasket onto the crankcase.
  • Page 64 CF086 CD970 10. Apply grease to the outer edges of the clutch hous- 13. Place the driven pulley assembly into position and ing; then from inside the clutch cover, install the secure with the nut. Using Spanner Wrench, tighten clutch housing into the cover using a rubber mallet. to 80 ft-lb.

  • Page 65: Center Crankcase Components

    Separating Crankcase Halves 1. Remove the left-side cap screws securing the crank- case halves. Note the location of the differ- ent-lengthed cap screws. 2. Remove the right-side cap screws securing the crankcase halves. Note the location of the differ- ent-lengthed cap screws. CF261 3.
  • Page 66  NOTE: To aid in installing, it is recommended 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. CC674  NOTE: Do not disassemble the countershaft assem- bly unless necessary.

  • Page 67: Servicing Center Crankcase Components

    Servicing Center Crankcase Components  NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. SECONDARY OUTPUT DRIVE GEARS Initial Set-Up CD832B 9. Remove the snap ring securing the water pump ...
  • Page 68 MT012 MT016A 6. To adjust tooth contact, use the following chart to correctly shim the driven shaft. Tooth Contact Shim Correction Contact at Top Increase Shim Thickness Contact at Root Decrease Shim Thickness 7. After correct tooth contact is established, proceed to Checking Backlash in this sub-section.
  • Page 69 2. If backlash measurement is more than specified, 2. Using a feeler gauge, measure the gap between the remove an existing shim, measure it, and install a connecting rod and crankshaft journal. thicker shim.  NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance.
  • Page 70 2. Remove the drive gear; then remove the snap ring securing the reverse driven gear dog and bushing to the countershaft. ATV-1017 2. Acceptable width range must not exceed specifica- tions. COUNTERSHAFT GZ296 GZ312 GZ281A 3. Remove the reverse driven gear dog. CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog,...
  • Page 71 Assembling 5. Remove the reverse driven washer; then remove the low driven gear locking washer. 1. From the drive gear end, install a thrust washer, bushing, and bearing; then install the low driven gear and washer. GZ320 GZ317A GZ319 GZ318 2.

  • Page 72: Assembling Crankcase Half

    3. Install the reverse driven bushing and bearing; then install the reverse driven gear. GZ313A GZ286A GZ312 6. From the opposite end of the countershaft, install the high/low driven gear dog (A), thrust washer (B), GZ287 bushing (C), bearing (D), high/low driven gear (E), 4.
  • Page 73 MT014 CD832B 2. Apply a liberal amount of engine oil to the crank-  NOTE: It will be necessary to rotate the crank bal- shaft bearing. Using a propane torch, heat the bear- ancer until the counterweight is facing away from the ing until the oil begins to smoke;...

  • Page 74: Joining Crankcase Halves

    CC674 CC668 7. Place a washer on the end of the gear shift shaft; then 10. Install the front and rear secondary driven shaft install the shaft assembly making sure the two holes assemblies into the left side of the crankcase making on the end of the shaft are positioned vertically.

  • Page 75: Installing Engine/Transmission

    Installing Tighten the four flange nuts to 45 ft-lb. Engine/Transmission  NOTE: Arctic Cat recommends new gaskets and O-rings be installed whenever servicing the vehicle. 1. Attach suitable lifting chains to the engine/transmis- sion; then using an engine hoist, lower the assembly into the engine compartment.
  • Page 76 5. 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 20 ft-lb. 6. Install the inlet boot on the V-belt housing; then install the exhaust duct connecting the outlet housing to the V-belt housing.
  • Page 77 10. Install the throttle body and tighten the intake boot 14. Fill the engine/transmission with the appropriate clamp to 30 in.-lb; then connect the gasline hose, lubricant. vacuum line, and throttle cable. 15. Remove the coolant bleed screw from the upper coolant pipe near the thermostat;...
  • Page 78 Prowler XTZ (Table of Contents) Removing Engine/ Transmission......3-51 Top-Side Components........... 3-57 Removing Top-Side Components ......3-57 Servicing Top-Side Components......3-61 Installing Top-Side Components ......3-68 Left-Side Components .......... 3-74 Removing Left-Side Components ......3-74 PR611 Servicing Left-Side Components ......3-77 3.
  • Page 79 PR590 PR594A 8. Remove the rear spark plug cap; then from the left 6. Mark all cable tie locations with an appropriate side, remove the fuel injector connector (A), mani- marker; then remove the ties. fold absolute pressure (MAP) sensor (B), parking brake warning switch (C), reverse override switch connector (D), and idle speed control (ISC) valve (E).
  • Page 80 PR658A PR666A CAUTION 13. Remove the E-clip from the transmission shift arm; then remove the shifter cable mounting bracket from The gear position switch wires are secured to the frame the crankcase and move the shift support assembly with a nylon tie connector. This must be removed prior and cable to right side of the vehicle.
  • Page 81 18. Remove the upper radiator hose from the thermostat housing; then move the coolant pipe to the left side of the vehicle. PR603A 16. Disconnect the engine/harness ground; then discon- nect the starter cable from the starter. PR607A 19. Remove the sheet metal screws securing the constant variable transmission (CVT) cooling duct to the frame;...
  • Page 82 23. Remove two cap screws securing the front exhaust pipe to the cylinder head; then remove two springs securing the front and rear exhaust pipes together. Remove the front exhaust pipe. Account for a grafoil seal and a grafoil gasket. PR617A PR643A PR616A’...
  • Page 83 PR641A PR647 27. Remove the lock nuts from the engine through-bolts;  NOTE: The grafoil gasket may remain in the cylinder then attach a lifting chain to the engine/transmission. head. 25. Mark the components on the front driveshaft; then remove the three cap screws securing the driveshaft to the front differential.

  • Page 84: Top-Side Components

    29. Lift the engine/transmission enough to clear the engine mounting tabs on the frame; then remove the assembly from the right side of the vehicle. GZ027 PR633 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.
  • Page 85 3. Remove the 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 camshaft plug. Note the location of two alignment pins. GZ200 5.
  • Page 86 CC266D GZ132B 9. Remove the cylinder head from the cylinder, remove  NOTE: Loop the chain over the cylinder head and the gasket, and account for two alignment pins; then secure it to keep it from falling into the crankcase. remove the cam chain guide.
  • Page 87 C. Cylinders D. Pistons  NOTE: Steps 1-10 in the preceding sub-section must precede this procedure. 11. Remove the cap screws securing the water hose union to the cylinder; then remove the union from the cylinder. Account for an O-ring. GZ142 GZ140A 12.

  • Page 88: Servicing Top-Side Components

    CAUTION Do not remove an excessive amount of the sealing sur- face or damage to the camshaft will result. Always check camshaft clearance when resurfacing the valve cover. GZ146A CAUTION Do not allow the connecting rod to go down inside the crankcase.
  • Page 89 CC136D ATV-1004 2. Acceptable width range must be within specifica-  NOTE: The valve seals must be replaced. tions. 3. Remove the valve springs; then invert the cylinder Measuring Valve Face Radial head and remove the valves. Runout Measuring Valve Stem Runout 1.
  • Page 90 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends the components be taken to a qualified machine shop for servicing. ATV-1011A CAUTION 4. Place a spring retainer over the valve springs; then...
  • Page 91 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 speci- fications, the piston pin must be replaced. CC400D Cleaning/Inspecting Piston 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45°...
  • Page 92 Installing Piston Rings 1. Install the expander spring making sure the ends are aligned on the wire; then install the oil ring with the ring gap 90° from the spring gap and the marking “E TOP” directed toward the top of the piston. GZ187A CAUTION Incorrect installation of the piston rings will result in...
  • Page 93 Inspecting Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first measurements for a total of six measurements.
  • Page 94 2. Place a strip of plasti-gauge in each of the camshaft 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 measuring clearance.

  • Page 95: Installing Top-Side Components

    CF061A GZ159 3. Lubricate the inside wall of the cylinder; then using a ring compressor, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase.
  • Page 96 8. Apply a light coat of grease to the cylinder head cap screw threads and washers; then install the cap screws. Tighten only until snug. GZ160A 5. Install the coolant hose onto the crankcase union and tighten the clamp. C. Cylinder Head GZ132B 9.
  • Page 97 A. Piston still at top-dead-center. B. Camshaft lobes directed down (toward the pis- ton). C. Camshaft alignment marks parallel to the valve cover mating surface. D. Recessed side of the sprocket directed toward the cam lobes. E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned.
  • Page 98 17. Keeping tension on the opposite cam chain, 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 11 ft-lb. Bend the tab to secure the cap screw.
  • Page 99 22. Place tab-washer onto the sprocket making sure it covers the pin in the alignment hole. CD465 25. Rotate the crankshaft until the first cap screw (from step 23) can be addressed; then tighten to 11 ft-lb. ATV-1027 Bend the tab to secure the cap screw. CAUTION Care must be taken that the tab-washer is installed cor- rectly to cover the alignment hole on the sprocket.
  • Page 100 GZ162A GZ201 28. Remove the cap screw from the end of the chain ten- sioner; then using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner clockwise until the screw bottoms. CD471 31. Loosen the four adjuster screw jam nuts; then loosen the four adjuster screws on the rocker arms in the valve cover.

  • Page 101: Left-Side Components

    33. Lubricate the camshaft journals and lobes with engine oil; then place the valve cover into position. 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.
  • Page 102 GZ224A GZ217 5. With the flywheel key removed, remove the starter  NOTE: The starter is not serviceable and must be ring-gear and spacer washer. replaced as a complete assembly. 3. Remove the rotor/flywheel nut; then install the appropriate crankshaft protector into the crankshaft. GZ226 PR440 4.
  • Page 103 7. Remove the two cap screws securing the water pump to the crankcase; then remove the water pump. Account for an O-ring. GZ236A 10. Remove the cap screw securing the shift cam plate to the shift cam shaft and remove the shift cam plate; then remove the shift shaft.

  • Page 104: Servicing Left-Side Components

    GZ235 FI569 12. Remove the cap screws securing the oil filter cover 3. Inspect the one-way bearing for chipped surfaces, to the crankcase; then remove the cover. Account for missing rollers, or discoloration. If any of the above an O-ring. conditions exist, replace the starter clutch assembly.
  • Page 105 FI576A FI580 INSPECTING STATOR COIL/ MAGNETO COVER ASSEMBLY 1. Inspect the stator coil for burned or discolored wir- ing, broken or missing hold-down clips, or loose cap screws. 2. Inspect the bearings in the magneto housing for dis- coloration, roughness when rotated, and secure fit in bearing bores.

  • Page 106: Installing Left-Side Components

    FI595A GZ254 4. Using a new gasket, install the speed sensor housing onto the crankcase and secure with two cap screws. Installing Left-Side Tighten to 8 ft-lb. Components 1. Thoroughly clean all gasket material and sealant from mating surfaces. 2. Install a new O-ring on the oil filter cover and coat it with clean engine oil;...
  • Page 107 GZ256 GZ258 6. Install the shift cam stopper spring onto the shift cam stopper and secure with a flat washer and flange nut. Tighten to 8 ft-lb. GZ261 9. Apply grease to the lips of the shift shaft seal in the shifter housing;...

  • Page 108: Right-Side Components

    GZ226 GZ251 11. Place the key into the keyway in the crankshaft; then 14. Using Seal Protector Tool, install the outer magneto wipe all oil from the crankshaft surface and rotor/fly- cover using a new gasket and secure with the cap wheel bore and install the rotor/flywheel onto the screws.

  • Page 109: Removing Right-Side Components

    Removing Right-Side Components A. CVT Cover B. Driven Pulley C. Clutch Cover D. Centrifugal Clutch 1. Remove the cap screws securing the CVT cover; then using a rubber mallet, gently tap on the cover tabs to loosen the cover. Account for a gasket and PR388 two alignment pins.

  • Page 110: Servicing Right-Side Components

    GZ247A CC596  NOTE: To aid in installing, it is recommended the  NOTE: Account for and inspect the clutch housing assemblies are kept together and IN ORDER. seal. 8. Remove the one-way clutch from the centrifugal 10. Remove the two cap screws securing the gear posi- clutch.
  • Page 111 INSPECTING CENTRIFUGAL CLUTCH SHOE Inspect the clutch shoes for wear or damage. If any shoe is worn to the bottom of the groove, replace the clutch assembly. GZ442 2. Remove the snap ring securing the bearing in the water pump drive cover; then remove the bearing using an appropriate blind bearing remover.

  • Page 112: Installing Right-Side Components

    GZ240 GZ441 2. Install the clutch shoe assembly and secure with the 2. Install the gear onto the driveshaft noting correct ori- flange nut (threads coated with red Loctite #271). entation (from step 1 of disassembling). Tighten to 221 ft-lb. GZ442 3.
  • Page 113 GZ247 GZ244A 9. Place the driven pulley assembly into position and CAUTION secure with the nut (coated with red Loctite #271). When installed correctly, the green alignment dot (or the Tighten to 80 ft-lb. word OUTSIDE) on the one-way clutch is visible. 7.

  • Page 114: Center Crankcase Components

    15. Place the CVT cover gasket into position; then install the cover and secure with the cap screws. Tighten the cap screws to 8 ft-lb. Center Crankcase Components  NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Remov- procedures Top-Side, Left-Side,...

  • Page 115: Disassembling Crankcase Half

    GZ447 GZ454A 3. Remove the secondary drive assembly; then remove the secondary driven shaft assembly and set aside. Account for one locating ring. GZ272B Disassembling Crankcase GZ448A Half  NOTE: For steps 1-8, refer to illustration GZ474A. GZ269A  NOTE: Do not disassemble these assemblies unless service is required.
  • Page 116 GZ298 GZ463B 2. Remove the snap ring securing the water pump drive 5. Remove the shift fork shaft (E); then remove the gear idler (B) to the idler shaft; then remove the drive shift shaft assembly (F). Account for a flat washer idler.

  • Page 117: Servicing Center Crankcase Components

    7. Remove the driveshaft (G); then remove the counter- shaft assembly (with shift forks) (H). Account for two flat washers on the countershaft. MT011A 2. Using a suitable press, install the driven gear (C) on the shaft until the gear firmly seats on the shoulder of the shaft.
  • Page 118 Checking Backlash 1. Install the drive bevel gear assembly and driven bevel gear/output shaft assembly into the crankcase bottom cover. 2. Mount the dial indicator so the tip is contacting a tooth on the secondary drive bevel gear. MT008A 4. Install a new seal (F), output yoke (G), and nut (H) coated with red Loctite #271 and tighten to 74 ft-lb.
  • Page 119 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. Backlash Measurement Shim Correction Under 0.127 mm (0.005 in.) Decrease Shim Thickness At 0.127-0.381 mm (0.005-0.015 in.)
  • Page 120 GZ354A GZ356 6. Remove the oil seal from the oil pump cover. GZ363 3. With the outer rotor reference dot directed toward the GZ365 oil pump cover, install the rotor onto the inner rotor. Assembling 1. Install a new oil seal into the oil pump cover; then coat the lips of the seal with grease and install the pump driveshaft from the seal side.
  • Page 121 CRANKSHAFT ASSEMBLY  NOTE: The crankshaft and connecting rod is a non-serviceable assembly. If any component is out of specification, the assembly must be replaced. Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore;...
  • Page 122 CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces. If a major component is installed facing the wrong direction, transmission damage may occur and/or the transmission will malfunction. In either case, complete disassembly and assembly will be required.
  • Page 123 2. Install the low driven gear locking washer; then install the inner reverse driven gear washer. GZ318A 6. Remove the low driven gear. Account for a bearing, bushing, and thrust washer. GZ319B GZ316 GZ320B 3. Install the reverse driven bushing and bearing; then Assembling install the reverse driven gear.

  • Page 124: Assembling Crankcase Half

    GZ288A GZ283B 7. Install the drive gear washer and the shift forks. The countershaft is now ready for installation. Assembling Crankcase Half 1. Install the oil pump gerotor assembly and oil pump cover in the crankcase and secure with two cap screws.
  • Page 125 GZ463A GZ332 4. Install the countershaft gear onto the countershaft and secure with a snap ring (flat-side away from the gear). GZ333 7. Install the gear shift shaft into the crankcase making sure the flat washer is in place on the right case end and the spacer on the gear shift stop end.

  • Page 126: Joining Crankcase Halves

    8. Place the larger flat washer on the drive gear end of the countershaft and the smaller flat washer on the Joining Crankcase Halves high driven gear end; then with shift forks and shift fork shaft, install the countershaft assembly into the crankcase.
  • Page 127 GZ448A GZ342 7. Make sure the locating pins on the front and rear 5. Tighten the 6 mm cap screws to 8 ft-lb and the 8 mm bearings are correctly seated in the crankcase. cap screws to 20 ft-lb using the pattern shown and turning the shafts frequently to ensure there is no 8.

  • Page 128: Installing Engine/Transmission

    Left-Side Components, and to Installing Top-Side Com- ponents. Installing Engine/Transmission  NOTE: Arctic Cat recommends new gaskets and O-rings be installed whenever servicing the vehicle. PR634A 3. Install the rear through-bolts with flat washer; then 1. Attach a suitable lifting chain to the engine; then...
  • Page 129 PR630 PR638A 4. Secure the rear universal joint flange to the output drive flange and tighten the four cap screws to 40 ft-lb. PR640 7. Install a new grafoil gasket in the rear cylinder head; then place the rear exhaust pipe into position and loosely secure with two cap screws.
  • Page 130 10. Connect the oil cooler hoses to the engine and secure with the hose clamps. Tighten securely. PR643A PR616A PR642 9. Install the two springs (A) at the juncture of front and rear exhaust pipes. With a new grafoil seal (B) in PR617A place, install the muffler and secure with two 11.
  • Page 131 12. Install and secure the CVT cooling outlet boot to the CVT cover making sure to properly orient the outlet duct. PR603A 15. Connect the gasline hoses to the fuel rails making sure the “quick-disconnect” couplers properly lock onto the fuel injector rails. PR669 13.
  • Page 132 PR598A PR658A 17. Connect the throttle cable to the throttle arm; then 21. Route the engine harness through the shifter support install the cable housing into the throttle body hous- brackets as marked during disassembly and secure ing and tighten the nuts securely. with nylon cable ties.
  • Page 133 25. Connect the negative battery cable and install the battery hold-down. 26. Pour the recommended amount of oil into the engine/transmission. 27. Remove the coolant bleed screw from the upper coolant pipe near the thermostat; then pour the cor- rect mixture of coolant into the radiator. When cool- ant with no air bubbles flows from the bleed hole, install the screw and tighten securely.

  • Page 134: Fuel/Lubrication/Cooling

    SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Fuel/Lubrication/Cooling ......... 4-2 Electronic Fuel Injection (XT/XTX) ......4-2 Electronic Fuel Injection (XTZ) ........ 4-3 Gas Tank ..............4-4 Gas/Vent Hoses ............4-7 Oil Filter/Oil Pump ........... 4-7 Oil Cooler (XTZ) ............4-8 Liquid Cooling System..........

  • Page 135: Electronic Fuel Injection (Xt/Xtx)

    Fuel/Lubrication/Cooling REMOVING THROTTLE BODY 1. Turn the ignition switch to the OFF position; then  NOTE: Arctic Cat recommends the use of new gas- remove the ignition switch key. kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmis- ! WARNING sion.

  • Page 136: Electronic Fuel Injection (Xtz)

    5. Install the air filter assembly and secure with the existing hardware; then connect the IAT sensor and crankcase breather hose. 6. Install the center console and seats making sure the seats lock securely in place. Electronic Fuel Injection (XTZ) ! WARNING FI092A 6.

  • Page 137: Gas Tank

    GZ094E GZ386 4. Remove the cap screws securing the throttle body to 3. Connect the TPS connector (A), MAP sensor con- the manifold; then lift the throttle body off the mani- nector (B), and ISC connector (C) to the throttle fold.
  • Page 138 6. Remove the outer cap screw securing the front tank hold-down; then swing the hold-down to the left. PR163 PR167A PR164 4. From the opposite side of the vehicle, repeat step 3; then lift the rear of the floorboard up and lift the PR170 7.
  • Page 139 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 nec- essary.

  • Page 140: Gas/Vent Hoses

    Oil Filter/Oil Pump  NOTE: Whenever internal engine components wear excessively or break and whenever oil is contami- nated, the oil pump should be replaced. TESTING OIL PUMP PRESSURE (XT/XTX)  NOTE: The engine must be warmed up to operating temperature (cooling fan cycling) for this test.

  • Page 141: Oil Cooler (Xtz)

    This model has an oil cooler in addition to the liquid 4. Set the speedometer/tachometer to RPM. With the cooling system. An oil cooler kit may be installed on any engine running at 3000 RPM, the pressure gauge Arctic Cat ROV. must show 1.05-1.2 kg/cm (15-17 psi). REMOVING 5.

  • Page 142: Liquid Cooling System

    2. Connect the oil hoses and secure with the hose clamps. Tighten securely. Liquid Cooling System When filling the cooling system, use premixed Arctic Cat Antifreeze. While the cooling system is being filled, air pockets may develop; therefore, open the bleed screw on the upper coolant pipe or the thermostat housing to allow air to bleed from the cooling system.
  • Page 143 PR183A PR184A 5. Remove the two shoulder bolts and nuts securing the 2. Connect the upper and lower coolant hoses to the radiator to the frame; then disconnect the upper and radiator and secure with the appropriate hose clamps; lower coolant hoses. then connect the cooling fan wire connector to the main harness.

  • Page 144: Thermostat (Xt/Xtx)

    2. Fill the cooling system with the recommended amount of antifreeze. Check for leakage. Thermostat (XT/XTX) Thermostat (XTZ) REMOVING 1. Drain approximately one quart of coolant from the cooling system. REMOVING 2. Remove the two cap screws securing the thermostat ...

  • Page 145: Fan

    INSTALLING 4. Loosen the coolant hose clamps and slide the clamps away from the hose ends. 1. Place the thermostat and O-ring into the thermostat housing; then secure the thermostat housing together with the four machine screws. 2. Fill the cooling system with the recommended amount of antifreeze.

  • Page 146: Water Pump (Xtz)

     NOTE: Always use a large container and have suffi- cient floor drying material available when draining the coolant in case of coolant spillage. 2. Remove the coolant hoses from the water pump; then remove two cap screws securing the water pump to the crankcase.

  • Page 147: Electric Fuel Pump/Fuel Level Sensor

    3. Secure the water pump with the two cap screws and 3. Turn the ignition switch to the ON position. The fuel tighten securely; then connect the coolant hoses and pressure should build until the pump shuts off. Pres- secure with hose clamps. sure should read 3.0 kg-cm (43 psi).

  • Page 148: Troubleshooting

    B. Engage the tabs (C) of the fuel level sensor into the mounting slot (B) and press toward the bottom of the fuel pump to latch in place; then connect the two-wire connector (A). INSTALLING 1. Place the fuel pump assembly into the gas tank with a new gasket aligning the match marks;...
  • Page 149 NOTES 4-16...

  • Page 150: Electrical System

    SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical System............. 5-2 Battery..............5-2 RPM Limiter............. 5-3 Testing Electrical Components ........ 5-3 Switches ..............5-3 Electrical Connections..........5-3 Accessory Receptacle/Connector ......5-4 Brakelight Switch............. 5-4 Engine Coolant Temperature (ECT) Sensor.... 5-4 Fan Motor ..............

  • Page 151: Battery

    Maintenance Charging charger will automatically start again at the first step of the charge sequence.  NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging. Maintenance charging is required on all batteries not used for more than two weeks or as required by battery drain.

  • Page 152: Rpm Limiter

    Charging must be used. If any other type of meter is used, readings  NOTE: Arctic Cat recommends the use of the CTEK may vary due to internal circuitry. When troubleshooting Multi US 800 or the CTEK Multi US 3300 for battery...

  • Page 153: Accessory Receptacle/Connector

    RESISTANCE (Switch Connector) Accessory CAUTION Receptacle/Connector Always disconnect the battery when performing resis- tance tests to avoid damaging the multimeter.  NOTE: The brake pedal must be depressed for this  NOTE: This test procedure is for either the recepta- test.

  • Page 154: Fan Motor

    6. Install the sensor and tighten securely. 5. The meter must show battery voltage from one side of the connector terminal ends. 7. Connect the leads.  NOTE: Battery voltage will be indicated from only one side of the fuse holder connector terminal; the Fan Motor other side will show no voltage.

  • Page 155: Ignition Coil

    Ignition Coil The ignition coil is mounted on the fuel pump mounting plate adjacent to the fuel pump. VOLTAGE (Primary Side) See Primary Coil in this sub-section. RESISTANCE CAUTION AR603D Always disconnect the battery when performing resis- 2. The meter reading must be within specification. tance tests to avoid damaging the multimeter.

  • Page 156: Speed Sensor

     NOTE: If the meter does not read as specified, replace the sensor. Speed Sensor  NOTE: Prior to testing the speed sensor, inspect the three-wire connector on the speed sensor for con- tamination, broken pins, and/or corrosion. 1. Set the meter selector to the DC Voltage position. CD070 2.
  • Page 157 The following is a list of conditions that can generate a  NOTE: Prior to troubleshooting below, make sure malfunction code. All conditions with the exception of that Ignition Key Switch has not been left on with the item 5 are external to the EPS assembly and therefore can engine not started.

  • Page 158: Electronic Power Steering (Eps) (Xtx)

    Fault Code Possible Cause Recovery Method Description Electronic Power C1316 EEPROM Internal EPS condition Correct EPS condi- Error tion, then cycle key Steering (EPS) (XTX) switch On-Off-On C1317 CAN Bus Broken CAN wires in main Correct EPS condi- Error harness. EFI ECM connec- tion, then cycle key tor has been disconnected.

  • Page 159: Headlight Switch

    VOLTAGE 2. Using an ohmmeter, the following readings must be observed. 1. Set the meter selector to the DC Voltage position. 2. Connect the red meter lead to the red wire; then con- nect the black meter lead to ground. 3.

  • Page 160: Front Drive Actuator

    2. Depress the reverse override switch. The meter showing should not change from step 1. 3. Select 4WD on the drive select switch. The meter must show approximately 5 DC volts. 4. Depress the reverse override switch. The meter must show approximately 1.5 DC volts.

  • Page 161: Starter Motor

    Crankshaft Position Sensor  NOTE: If voltage is lower than specified, test AC Generator - No Load. 1. Set the meter selector to the AC Voltage position. VOLTAGE (AC Generator - No Load) 2. Connect the red tester lead to the blue wire; then con- nect the black tester lead to the green wire.

  • Page 162: Starter Relay

    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. AR607D  NOTE: If the meter showed battery voltage but the starter motor did not operate or operated slowly, inspect battery voltage (at the battery), starter motor PR841B 5.

  • Page 163: Headlights

    3. Slowly increase RPM. The voltage should increase  NOTE: If battery voltage is not shown and the head- with the engine RPM to a maximum of 15.5 DC lights are illuminated, inspect the three-wire connec- volts. tor in the left-rear canopy tube at the juncture of the canopy tube and lower frame.

  • Page 164: Efi Diagnostic System (Xtx)

    3. Connect the Test Plug from Test Plug/Error Code  NOTE: If the LCD still displays an error code, con- List to the diagnostic plug. tinue troubleshooting the appropriate component. 3. Disconnect the test plug; then install the black rubber cap.
  • Page 165 NOTE: The gauge can be utilized dynamically Usage: Monitor coolant temperature to verify the follow- ing. (engine running/vehicle moving) or statically (engine/vehicle stopped). 1. ECT sensor signal 2. High Temperature indicator (on @ 230 degrees F.) Examples of Static checks: Battery voltage, fuel gauge/sensor, and TPS (0% @ closed throttle, 95-100% 3.
  • Page 166 MAP (bArO) Diagnostic Mode DTC: P0336, P0337, P0339 Usage: Verify engine speed signal from the following. 1. CKP (crankshaft position) sensor to ECM 2. ECM (CAN) signal to gauge (tachometer) 3. ECM (CAN) signal to EPS Speed (SPd) Diagnostic Mode EFI006 Display: MAP in millibars (1013 millibar = 29.92 in.
  • Page 167 Battery (bAtt) Diagnostic Mode 3. Battery voltage with electrical accessories operating, engine idling (13.5 VDC or greater). 4. Battery voltage starter cranking (10.5-11.5 VDC). 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.

  • Page 168: Tilt Sensor

    Input/ Gauge DTC Wrench Icon Status ECM PIN High/Low/Variable Description Output D1/E1 Crankshaft Angle Sensor Circuit/SG P0337 D1/E1 Crankshaft Angle Sensor Intermittent/Erratic P0339 P0480 Fan Relay Control Circuit P0484 Fan Relay Control Circuit High P0485 Fan Relay Control Circuit Low/SG/Open P0500 Gauge Direct Error-Code Vehicle Speed-Sensor...

  • Page 169: Throttle Position Sensor (Tps)

    CD706B CD709  NOTE: When replacing the sensor after testing, OUTPUT VOLTAGE make sure the arrow marking is directed up.  NOTE: Needle adapters will be required on the mul- timeter leads as the following tests are made with the sensor connected.
  • Page 170  NOTE: Prior to testing the TPS, inspect the  NOTE: If any meter reading is not as specified, three-wire plug connector on the main harness and replace or adjust the TPS (see INSTALLING/ADJUST- the three-pin plug on the TPS for contamination, bro- ING in this sub-section).
  • Page 171 INSTALLING/ADJUSTING (XT/XTZ) 5. Tighten the mounting screws securely; then verify the TPS icon appears in the center position. 1. Place the TPS into position on the throttle body and secure with the screw. Do not tighten at this time. 6. Cycle the accelerator pedal to approximately half throttle six times;...

  • Page 172: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug(s) defective 2. Replace plug(s) 3. CKP sensor defective 3. Replace CKP sensor 4. ECM defective 4. Replace ECM Problem: Spark plug fouled with carbon Condition Remedy 1.
  • Page 173 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 insufficient 2. Keep electrolyte to prescribed level 3. Specific gravity too low 3.
  • Page 174 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Front Drive Actuator ..........6-2 Front Differential ............6-3 Drive Axles ............6-15 Rear Gear Case ............ 6-20 Hub................ 6-23 Hydraulic Brake Caliper......... 6-25 Universal Joints (XTZ)........... 6-28 Troubleshooting .............

  • Page 175: Drive System

    The front drive actuator is located on the right side of the front drive input housing. With the engine stopped and Drive System the ignition switch in the ON position, a momentary “whirring” sound can be heard each time the front drive select switch is shifted.

  • Page 176: Front Differential

    INSTALLING  NOTE: It is important to tighten this cap screw while the others are loose to ensure proper seating of the 1. Lubricate the O-rings on the actuator; then ensure all actuator. mounting surfaces are clean and free of debris. 5.
  • Page 177 PR264A PR222 8. Disconnect the front drive actuator connector from 11. Support the axle to not allow it to drop or hang. the main harness. CAUTION The axle must be supported. If the axle is allowed to drop or hang, damage to the inner CV joint may occur. 12.
  • Page 178 PR729B GC004A 15. Remove the lower differential mounting cap screw. 2. Using a rubber mallet, remove the housing. Account Account for a lock nut and four washers. Note the for a gasket. Remove the fork, collar, and spring. position of the washers for assembling. Note the location of all the components for assem- bling purposes.
  • Page 179 Assembling Input Shaft 4. Using a seal removal tool, remove the input shaft seal. Account for a spacer. 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.
  • Page 180 4. Install the input shaft into the pinion housing; then secure in the bearing with a circlip. GC015 2. Using a T-40 torx wrench, remove the cap screws securing the differential cover. Account for and make GC009A note of the ID tag location for assembling purposes. 5.
  • Page 181 KX175 KX181 5. Remove the left differential bearing flange assembly Disassembling Pinion Gear and account for a shim. Mark the shim as left-side. 1. Remove the internal snap ring securing the pinion bearing in the housing. KX177 WC430 2. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing.
  • Page 182 CC879 CC884 4. Remove any reusable parts from the gear case hous- 3. Coat a new needle bearing and the bearing pocket of ing; then discard the housing and lock collar. a new gear case/differential housing with red Loctite #271; then using a suitable driver, install the bearing Assembling Pinion Gear lightly seated against the bearing seats.
  • Page 183  NOTE: All bearings must be installed in the gear case and the pinion properly installed before proceeding. Backlash  NOTE: Always set backlash prior to any other shim- ming. 1. Install the existing shim or a 0.051-0.055-in. shim on the gear case side of the ring gear assembly.
  • Page 184 2. Zero the dial indicator; then push the ring gear toward the dial indicator and release. End-play should be 0.004-0.008 in. 3. To increase end-play, decrease the shim thickness. To decrease end-play, increase the shim thickness.  NOTE: Once proper backlash and end play are established, the gear case can be assembled (see Assembling Differential Assembly in this sub-sec- tion).
  • Page 185 2. Place the ring gear with selected shim into the cover and measure the ring gear to thrust button clearance with a thickness gauge. Clearance should be 0.002-0.004 in. GC036B  NOTE: The spider and ring gear assembly must be replaced as a complete unit.
  • Page 186  NOTE: If a new housing is being installed, tighten the cap screws to 28 ft-lb. CF275A 5. Making sure the O-ring is properly positioned on the differential housing cover assembly, install the cover with existing cap screws (coated with green Loctite CD103 #270).
  • Page 187 CF278 PR198A 6. Install the front axles. CAUTION 7. Install the knuckle assemblies onto the axles and ball Make sure the tool is free of nicks or sharp edges or joints; then secure with four cap screws taking care damage to the seal may occur. not to damage the threads when installing.

  • Page 188: Drive Axles

    Drive Axles REMOVING REAR DRIVE AXLE 1. Secure the vehicle on a support stand to elevate the wheels. ! WARNING Make sure the vehicle is solidly supported on the sup- port stand to avoid injury. AF897D 2. Set the parking brake; then remove the wheels. 9.
  • Page 189 PR220A CD019 6. While holding the drive axle stationary, pull the top 2. Inspect boots for any tears, cracks, or deterioration. of the knuckle out and down until it is free of the  NOTE: If a boot is damaged in any way, it must be drive axle.
  • Page 190 7. Using a side-cutters (or suitable substitute), remove both outside boot clamps from the shaft. Note the position of the different-sized clamps for assembling purposes. CD023 4. Note the difference inside each bearing ring end for assembling purposes; then remove the bearing ring. ...
  • Page 191 CD754 ATV-1048 10. Using CV Boot Clamp Tool, secure both outside 3. Apply 80 grams (2/3 of contents) of grease from the boot clamps. pack into the bearing housing. 4. Install the bearing onto the shaft making sure the CAUTION recess of the bearing is facing the housing.
  • Page 192 4. Tighten the hub hex nut (from step 3) to 200 ft-lb; then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut. CD021 7. Slide the boot over the housing; then using the boot clamp pliers, secure the boot with the clamp.

  • Page 193: Rear Gear Case

    RING GEAR/THRUST BUTTON 8. Remove the vehicle from the support stand. Removing 9. Check the front differential lubricant level and add lubricant as necessary. 1. Remove the cap screws securing the gear case cover to the gear case; then remove the ring gear. 2.
  • Page 194 4. If clearance is not as specified, repeat steps 1 and 2 using thicker (clearance too great) or thinner (clear- ance too small) until correct specification is reached. REAR DRIVE INPUT SHAFT/ HOUSING Removing/Disassembling 1. Remove the cap screws securing the rear drive input shaft/housing to the rear gear case;...
  • Page 195 Cleaning and Inspecting 1. Wash all parts in parts cleaning solvent and dry with compressed air. ! WARNING Always wear safety glasses when working with com- pressed air. 2. Clean all gasket material and sealant from mating surfaces. 3. Inspect bearings, shafts, and housing for excessive wear, cracks, or discoloration.

  • Page 196: Hub

    2. Pack the driveline boot with the appropriate grease; then secure with the boot clamps using CV Boot Clamp Tool. 3. Secure the differential to the frame with two through-bolts and secure with lock nuts and flat washers. Tighten to 38 ft-lb. 4.
  • Page 197 PR250 PR221 3. Using a socket and ratchet handle, tighten the nut 4. Secure the hub assembly with the nut. Tighten to 200 until the stud is fully drawn into the hub. ft-lb; then secure with a new cotter pin. ...

  • Page 198: Hydraulic Brake Caliper

    Hydraulic Brake Caliper ! WARNING Arctic Cat recommends only authorized Arctic Cat ROV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- trol causing severe injury or death.
  • Page 199 PR713A PR715 PR715 PR717A 2. Press the piston into the caliper housing using hand ! WARNING pressure only. Completely seat the piston; then wipe Make sure to hold the towel firmly in place or the piston off any excessive brake fluid. could be ejected from the housing causing injury.
  • Page 200 PR719C PR239 4. Install the caliper onto the caliper holder making sure 6. Place the brake caliper assembly into position and the caliper and holder are correctly oriented. secure with new “patch-lock” cap screws. Tighten  NOTE: It is very important to apply silicone grease the caliper to 20 ft-lb.

  • Page 201: Universal Joints (Xtz)

    2. Remove the cotter pin and pivot pin from the yoke; then remove two cap screws and flange nuts securing Universal Joints (XTZ) the master cylinder assembly to the frame. REMOVING  NOTE: The universal joints can be accessed by removing the belly panel.
  • Page 202 4. Install U-Joint Separator Tool on the universal joint fixed yoke; then remove the bearing cup retainers. PR367B 2. Check that yoke legs are parallel. PR354A 5. Using a suitable socket and ratchet handle, rotate the jackscrew to push the bearing cup out of the yoke; then remove the tool and the bearing cup.

  • Page 203: Troubleshooting

    4. Remove the separator tool from the vise and install the universal joint, bearing cups, and movable yoke into the fixed yoke using the same procedure as steps 2-3 except the vise cannot be used. PR368 2. Secure U-Joint Separator Tool in a vise; then place the yoke, joint, and bearing cup into position and press the cup into the yoke.
  • Page 204 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 Front A-Arms ............7-3 Rear A-Arms ............7-5 Wheels and Tires ............ 7-6 Troubleshooting ............7-7...

  • Page 205: Suspension

    Suspension  NOTE: Critical torque specifications are located in Section 1. 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. AF626D C.

  • Page 206: Front A-Arms

    4. Remove the vehicle from the support stand. Front A-Arms REMOVING 1. Secure the vehicle on a support stand to elevate the front wheels; then remove the wheels. ! WARNING Make sure the vehicle is solidly supported on the sup- PR193 port stand to avoid injury.
  • Page 207 AF616D AF610D 3. Route the brake hose through the upper A-arm shock CLEANING AND INSPECTING absorber mount.  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. 1. Clean all A-arm components in parts-cleaning solvent. 2.

  • Page 208: Rear A-Arms

    AF618D PR260 8. Apply grease to the hub and drive axle splines; then 13. Install the wheel and tighten in a crisscross pattern in install the hub assembly onto the drive axle. 20 ft-lb increments to 80 ft-lb (aluminum wheels) or 45 ft-lb (steel wheels).

  • Page 209: Wheels And Tires

    Tighten to 35 ft-lb. ! WARNING 3. Tighten the hardware securing the A-arms to the Use only Arctic Cat approved tires when replacing tires. frame mounts (from step 1) to 35 ft-lb. Failure to do so could result in unstable vehicle operation.

  • Page 210: Troubleshooting

    REMOVING INSTALLING 1. Secure the vehicle on a support stand to elevate the 1. Install each wheel on its hub and secure with the exist- wheels. ing hardware. ! WARNING 2. Tighten in a crisscross pattern in 20 ft-lb increments to 80 ft-lb (aluminum wheels) or 45 ft-lb (steel Make sure the vehicle is solidly supported on the sup- wheels).
  • Page 211 NOTES...

  • Page 212: Steering/Frame/Controls

    SECTION 8 - STEERING/FRAME/CONTROLS TABLE OF CONTENTS Steering/Frame/Controls ......... 8-2 Steering Assembly (XT) .......... 8-2 Electronic Power Steering (EPS) (XTX/XTZ) ..8-4 Steering Assembly (XTX/XTZ) ........ 8-7 Steering Wheel............8-8 Upper Steering Shaft..........8-9 Lower Steering Shaft Assembly ......8-10 Steering Knuckles ..........

  • Page 213: Steering Assembly (Xt)

    Steering/Frame/Controls  NOTE: Critical torque specifications are located in Section 1. 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. PR333A ...
  • Page 214 PR305 PR523A 3. Clean all Loctite from the threads in the rack and if INSPECTING the tie rod is to be reused, clean the tie rod threads also.  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary.

  • Page 215: Electronic Power Steering (Eps) (Xtx/Xtz)

     NOTE: Always attach the crow-foot to the torque wrench with the open end 90° to the torque wrench handle to ensure accurate torque application. 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.
  • Page 216 1. Support the vehicle on appropriate stands or a lift; then remove the left front wheel and left front shock absorber. 2. Remove the front storage box; then disconnect the two electrical connectors from the EPS assembly. PR764A PR759A 3. Remove the cap screw securing the intermediate shaft yoke to the EPS assembly input shaft.
  • Page 217 7. Install the steering shaft housing with steering shaft connecting the steering shaft and intermediate shaft first; then slide the housing into place on the steering support. 8. Secure the steering shaft housing to the frame with four cap screws and nuts. Tighten the 6 mm nuts to 8 ft-lb and the 8 mm nuts to 20 ft-lb.

  • Page 218: Steering Assembly (Xtx/Xtz)

     NOTE: Always attach the crow-foot to the torque wrench with the open end 90° to the torque wrench handle to ensure accurate torque application. PR780 4. Using an appropriate crow-foot and backing wrench, remove the tie rod assembly.  NOTE: Tie rods come as a complete assembly. No PR528A further disassembly is required.

  • Page 219: Steering Wheel

    PR301 PR773A 3. Remove the EPS cradle bracket; then remove the cap 3. Place the tie rod ends into the knuckles and secure screws securing the steering rack assembly to the with the castle nuts (coated with red Loctite #271). rack bracket and remove from the left side.

  • Page 220: Upper Steering Shaft

    INSPECTING 1. Inspect the steering wheel for cracks, missing pad- ding, 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.

  • Page 221: Lower Steering Shaft Assembly

    7. Move the dash panel into position and secure to the frame and with the existing hardware. PR313A 2. Apply green Loctite #270 to the cap screw; then install the cap screw in the upper steering shaft joint. PR181A Install the nut and finger-tighten. 3.

  • Page 222: Steering Knuckles

    INSPECTING  NOTE: The lower steering shaft assembly is not repairable or rebuildable. If any damage or excessive wear is detected, the assembly must be replaced. 1. Inspect the joints for excessive wear or looseness. 2. Inspect welds and slip-joints for cracks. 3.
  • Page 223 9. Remove the snap ring securing the bearing in the 2. Install the knuckle to the upper and lower ball joints knuckle; then press the bearing out of the knuckle. and secure with the two cap screws. Tighten to 35 ft-lb.

  • Page 224: Checking/Adjusting Front Wheel Alignment

    CD009 PR377B 6. Secure the hub assembly with the nut. Tighten to 200 9. Install the wheel; then tighten in a crisscross pattern ft-lb. in 20 ft-lb increments to 80 ft-lb (aluminum wheels) or 45 ft-lb (steel wheels). 10. Remove the vehicle from the support stand. Checking/Adjusting Front Wheel Alignment ...

  • Page 225: Front Bumper Assembly

    PR084A PR327A CLEANING AND INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. 1. Clean all bumper components with hot, soapy water. 2. Inspect all welds for cracking or bending. INSTALLING Place the bumper assembly into position on the frame;...

  • Page 226: Fenders

    PR332A PR332B 3. Finish removing the cap screws and flange nuts (from step 2); then remove the hood assembly. Fenders CLEANING AND INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- REMOVING essary.

  • Page 227: Belly Panel

    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 underside of the frame. PR163 2. Install the body screws. Tighten securely. Accelerator Pedal REMOVING Dislodge the throttle cable holding grommet from the...

  • Page 228: Shift Lever (Xt/Xtz)

    INSTALLING 1. Place the shift assembly into position and secure Shift Lever (XT/XTZ) with two shift axle retainer plates and four cap screws. Tighten securely. 2. Connect the shift cable to the shift arm and secure REMOVING with the flange nut. Tighten securely. 1.

  • Page 229: Exhaust System

    6. Slide the dash into position and secure with the six screws. 7. Install the parking brake handle and jam nut. Exhaust System REMOVING MUFFLER 1. Remove the two exhaust springs at the muf- fler/exhaust pipe juncture. PR473A 2. Loosen but do not remove the four shoulder cap screws securing the pivot housings to the cargo box.

  • Page 230: Taillight Assembly

    4. Lower the cargo box and lock into position. 2. Inspect all wires for corroding, pinching, and cracking. 3. Inspect the bulb for wattage, voltage, and proper operation. Taillight Assembly INSTALLING 1. Connect the three-prong connector to the bulb socket; then place the taillight assembly into position REMOVING on the rear ROPS tube.

  • Page 231: Troubleshooting

    Troubleshooting 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.
  • Page 232 NOTES 8-21...
  • Page 233 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-530 ®™...

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2013 prowler xtx2013 prowler xtz

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