Arctic Cat 2009 Prowler XT Service Manual
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Arctic Cat 2009 Prowler XT Service Manual

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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2009 Arctic
Cat UTV (Utility Terrain Vehicle) models (see cover). The complete manual is designed to aid service personnel in ser-
vice-oriented applications.
Arctic Cat offers an additional publication (when it becomes available) to aid in servicing the other UTV model. To ser-
vice the model not included in this manual, please refer to the following publication:
•
2009 UTV Service Manual - Prowler XTZ
This manual is divided into sections. Each section covers a specific vehicle 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 this 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 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 severe personal injury or even death. The symbol
! CAUTION identifies unsafe practices which may result in vehicle-related damage. Follow the directive because
it deals with the possibility of damaging part or parts of the vehicle. The symbol
information worthy of particular attention. The symbol
specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic
Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2008 Arctic Cat Inc.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
AT THIS POINT directs the technician to certain and
Back to TOC
NOTE: identifies supplementary
September 2008

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Glenn Winsor
February 20, 2025

lookingforamanualonhowtorebuildaprowler2009suv700

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Mr. Anderson
February 20, 2025

You can find the service manual for the 2009 Arctic Cat Prowler XT in the 2009 Prowler XT Arctic Cat Manual. This manual contains service, maintenance, and troubleshooting information. It includes instructions for disassembly, inspection, and reassembly of various components. If your model is not covered in this manual, you may need the 2009 UTV Service Manual - Prowler XTZ for additional details.

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Summary of Contents for Arctic Cat 2009 Prowler XT

  • Page 1 Cat UTV (Utility Terrain Vehicle) models (see cover). The complete manual is designed to aid service personnel in ser- vice-oriented applications. Arctic Cat offers an additional publication (when it becomes available) to aid in servicing the other UTV model. To ser- vice the model not included in this manual, please refer to the following publication: •...
  • Page 2 TABLE OF CONTENTS Click on the blue text to go. Foreword General Information/Specifications Periodic Maintenance/Tune-Up 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System Drive System Suspension 8. Steering/Frame Controls/Indicators...

  • Page 3: Table Of Contents

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

  • Page 4: General Specifications

    1.9 L (2.0 U.S. qt) - Change Brake Hose Master Cylinder Gasoline (recommended) 87 Octane Regular Unleaded Master Cylinder Frame Engine Oil (recommended) Arctic Cat ACX All Weather Syn- thetic Parking Brake Mechanism Frame Front Differential Lubricant SAE Approved 80W-90 Hypoid Hydraulic Caliper Holder Knuckle...

  • Page 5: Tightening Torque (General Bolts)

    ENGINE/TRANSMISSION Torque Conversions Torque Part Part Bolted To ft-lb N-m (ft-lb/N-m) Clutch Shoe** Crankshaft Clutch Cover/Housing Crankcase Assembly Crankcase Half (6 mm) Crankcase Half ft-lb ft-lb ft-lb ft-lb Crankcase Half (8 mm) Crankcase Half 35.4 69.4 103.4 Cylinder Head (Cap Screw) Crankcase 36.7 70.7...

  • Page 6: Break-In Procedure

    During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle. Varying the engine The recommended oil to use is Arctic Cat ACX All RPM during the break-in period allows the compo- Weather synthetic engine oil, which has been specifi- nents to “load”...

  • Page 7: Genuine Parts

    Remove the air filter hous- ing cover and air filter. Start the engine and allow it to idle. Using Arctic Cat Engine Storage Pre- server, rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds; then stop the engine.

  • Page 8: Preparation After Storage

    6. Charge the battery; then install. Connect the bat- tery cables. Preparation After Storage ! CAUTION The ignition switch must be in the OFF position prior to installing the battery or damage may occur to the Taking the vehicle out of storage and correctly prepar- ignition system.
  • Page 9 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 (Feeler Gauge Procedure) ........2-4 Valve/Tappet Clearance (Valve Adjuster Procedure) ........2-4 Testing Engine Compression........2-5 Spark Plug...............

  • Page 10: Periodic Maintenance Chart

    * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year. Next...

  • Page 11: Periodic Maintenance

    Use the following procedure to remove the filter and which show common maintenance procedures for the inspect and/or clean it. Arctic Cat UTV. CLEANING AND INSPECTING NOTE: Arctic Cat recommends the use of new FILTER gaskets, lock nuts, and seals and lubricating all internal components...

  • Page 12: Valve/Tappet Clearance (Feeler Gauge Procedure)

    8. Place the foam filter in the air filter housing; then ! CAUTION position the filter frame on top. 9. Install the air filter housing cover and secure with The feeler gauge must be positioned at the same the retaining clips; then install the center console angle as the valve and valve adjuster for an accurate and seats making sure the seats lock securely.

  • Page 13: Testing Engine Compression

    3. Place the valve adjuster onto the jam nut securing the tappet adjuster screw; then rotate the valve Testing Engine adjuster dial clockwise until the end is seated in Compression the tappet adjuster screw. 4. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut;...

  • Page 14: Spark Plug

    1. Remove the cap screws securing the spark arrester screen assembly to the muffler; then loosen and Spark Plug remove the spark arrester. Account for a gasket. A light brown insulator indicates that the plug is cor- rect. A white or dark insulator indicates that the engine may need to be serviced or the carburetor (if applica- ble) may need to be adjusted.

  • Page 15: Front Differential - Rear Drive/Differential Lubricant

    10. Install the oil level stick and thread into the engine case. NOTE: The oil level stick should be threaded into the case for checking the oil level. 11. Remove the oil level stick; the engine oil level should be above the illustrated “L” mark but not higher than the illustrated “F”...

  • Page 16: Driveshaft/Coupling

    1. Place the vehicle on level ground. Nuts/Bolts/Cap Screws 2. Remove each fill/level plug. 3. Drain the lubricant into a drain pan by removing in turn the drain plug from each. Tighten all nuts, bolts, and cap screws. Make sure riv- ets holding components together are tight.

  • Page 17: Shift Lever (Prowler/Xtx)

    CHECKING/ADJUSTING HEADLIGHT AIM Shift Lever (Prowler/XTX) The headlights can be adjusted vertically. The geomet- ric center of the HIGH beam light zone is to be used for vertical aiming. CHECKING SHIFT LEVER CABLE 1. Position the vehicle on a level floor so the head- lights are approximately 6.1 m (20 ft) from an Set the parking brake and turn the ignition switch on;...

  • Page 18: Shift Lever (Xt)

    ADJUSTING SHIFT LEVER LINKAGE To adjust the shift lever linkage, use the following pro- cedure. 1. Set the parking brake; then remove the seats and center console. 2. Make sure the shift lever is in neutral; then loosen the jam nut on the linkage. 3.
  • Page 19 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.

  • Page 20: Parking Brake

    4. To replace the brake pads, use the following proce- 3. If the rear wheels are not locked, it must be dure. adjusted (set up). A. Remove the wheel. ADJUSTING B. Remove the cap screws securing the caliper To adjust (set up) the parking brake, use the following holder to the knuckle;...
  • Page 21 3. Install the actuator lever in the position noted in step 1; then install the actuator nut and tighten to 35 ft-lb. PR473A 3. Remove the two cap screws securing the brake caliper to the rear drive housing and remove the caliper.

  • Page 22: Burnishing Brake Pads

    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).
  • Page 23 NOTE: The arrows on the V-belt should point rearward. 2. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the drive- shaft. Secure the drive face with a washer and nut (coated with red Loctite #271). Tighten the nut to 165 ft-lb.

  • Page 24: Troubleshooting Brake System

    Troubleshooting Brake System 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.
  • Page 25 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 Prowler/XT/XTX (Table of Contents) ....... 3-3 Troubleshooting ............. 3-49 Back to TOC...
  • Page 26 Valve Guide Inside Diameter 5.000-5.012 mm Valve Stem Outside Diameter (intake/exhaust) 4.972-4.987 mm NOTE: Arctic Cat recommends the use of new Valve Stem Runout (max) 0.1 mm gaskets, lock nuts, and seals and lubricating all Valve Head Thickness (min) 2.3 mm...
  • Page 27 NOTE: Use a small funnel between the frame and coolant drain plug to prevent coolant from drain- Prowler/XT/XTX ing on the frame and splashing. (Table of Contents) Removing Engine/Transmission......3-3 Top-Side Components..........3-7 Removing Top-Side Components ......3-7 Servicing Top-Side Components......3-11 Installing Top-Side Components ......
  • Page 28 PR155A PR474B 6. Remove the E-clip from the transmission shift arm; then on the XT, disconnect the shifter linkage and account for a washer and a bushing. On the Prowler/XTX, disconnect the cable. PR157A 5. From the left-side, disconnect the starter wire, alternator connector, CDI connector (650 cc), gear shift position switch, and electric choke connector;...
  • Page 29 PR123A PR154A 8. Loosen the clamp (A) securing the air intake boot 11. Remove the coolant hoses from the water pump to the carburetor/throttle body and the clamp (B) and thermostat housings; then position the upper securing the air filter housing to the inlet housing coolant line to the left-side of the engine compart- boot;...
  • Page 30 PR153B PR148A 13. Remove the muffler; then remove the exhaust 16. Remove two flange nuts from the underside of the pipe. rear engine mounts. 14. Set the parking brake; then from the underside of the vehicle, mark the flanges of the drive-line cou- plers 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...

  • Page 31: Top-Side Components

    Removing Top-Side Components A. Valve Cover B. Cylinder Head NOTE: Remove the spark plug and timing inspec- tion plug; then using an appropriate wrench, rotate the crankshaft to top-dead-center of the compres- PR114 sion stroke. NOTE: The front engine mounting bracket should 1.
  • Page 32 CD206 CC012D 5. Bend the washer tabs down and remove the two cap screws securing the sprocket to the camshaft; then drop the sprocket off the camshaft. CD211A 3. Loosen the cap screw on the end of the tensioner; then remove the two cap screws securing the ten- sioner adjuster assembly and remove the assembly.
  • Page 33 9. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins; then remove the cam chain guide. CC266D NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase. CC020D 8.
  • Page 34 AT THIS POINT To service cylinder, see Servicing Top-Side Compo- nents sub-section. ! CAUTION When removing the cylinder, be sure to support the piston to prevent damage to the crankcase and pis- ton. 13. Using an awl, remove one piston-pin circlip. CC023D 12.

  • Page 35: Servicing Top-Side Components

    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. AT THIS POINT To service piston, see Servicing Top-Side Compo- nents sub-section.
  • Page 36 3. Remove the valve springs; then invert the cylinder 2. Position the dial indicator contact point on the out- head and remove the valves. side edge of the valve face; then zero the indicator. Measuring Valve Stem Runout 1. Support each valve stem end with the V Blocks; then check the valve stem runout using a dial indi- cator.
  • Page 37 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the com- ponents be taken to a qualified machine shop for ser- vicing. ! CAUTION If valves are discolored or pitted or if the seating surface is worn, the valve must be replaced.
  • Page 38 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. CC400D 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove.
  • Page 39 2. Measure the corresponding piston diameter at a point 15 mm above the piston skirt at a right angle to the piston-pin bore. Subtract this measurement from the measurement in step 1. The difference (clearance) must be within specifications. Installing Piston Rings 1.
  • Page 40 ! 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. CC128D Measuring Cylinder Head Distortion 1. Remove any carbon buildup in the combustion chamber. CC129D Inspecting Cam Chain Guide 2.
  • Page 41 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.

  • Page 42: Installing Top-Side Components

    CC003D CF061A 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 clear- ance. CF060A 2. If damaged, the camshaft must be replaced. Installing Top-Side CC145D Components 6.
  • Page 43 NOTE: The two cylinder-to-crankcase nuts will be tightened in step 10. 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 CC023D and square the piston in respect to the crankcase. 5.
  • Page 44 CC020D 732-307B NOTE: At this point, oil the camshaft journals, cam lobes, and the three seating surfaces 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.
  • Page 45 15. Seat the cam sprocket onto the camshaft making 17. Install the first cap screw (threads coated with red sure the alignment pin in the camshaft aligns with Loctite #271) securing sprocket the smallest hole in the sprocket; then place the tab-washer to the camshaft.
  • Page 46 23. Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the two cap screws. CC012D 21. Install the cylinder head plug in the cylinder head with the open end facing downward and toward the inside.

  • Page 47: Right-Side Components

    CC005D CC001D 26. Apply a thin coat of Three Bond Sealant to the 32. If removed, install the spark plug. Tighten mating surfaces of the cylinder head and valve securely. cover. 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.
  • Page 48 PR465 CD214 3. Using a cold chisel, scribe a mark showing the rel- 6. Remove the two cap screws securing the water ative position of the shift arm to the shift arm shaft pump to the engine; then remove the water pump. to aid in installing;...
  • Page 49 CD939A CD140 12. Remove the snap ring securing the water pump drive gear; then remove the gear noting the direc- tion of the sides of the gear for installing purposes. Account for the drive gear alignment pin. CD940A AT THIS POINT To service the magneto assembly, see Section 5.

  • Page 50: Installing Right-Side Components

    PR430A CD952A 15. Remove the gear shift cam plate; then remove the shift cam stopper and cam stopper spring. Account for two washers. CD949 NOTE: The sharp side of the snap ring should be facing outward. PR434A 2. Install the water pump drive gear drive pin and the drive gear (with the flat side of the gear facing out- ward as noted in removing);...
  • Page 51 CD944 CD948A 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).
  • Page 52 6. Install the shift cam stopper, spring, and two wash- ers; then coat the threads on the mounting stud with red Loctite #271 and install the nut. Tighten securely. PR431A 9. Install the magneto cover and secure with the cap screws.

  • Page 53: Left-Side Components

    15. Install the shift arm on the shift arm shaft making sure the scribed marks (from removing) are aligned. Tighten securely. 16. Place the gasket and outer magneto cover into position on the right-side cover; then tighten four screws to 8 ft-lb. Left-Side Components NOTE: For efficiency, it is preferable to remove CD963...
  • Page 54 PR393 6. Remove the cap screws securing the clutch cover. A. Oil Pump Driven Gear D. One-Way Clutch (Green Dot MUST Show) Note the location of the different-lengthed cap B. Oil Pump Drive Gear E. Final Drive Carrier Bearing C. Clutch Shoe Assembly screws for installing purposes.
  • Page 55 CF088A CC606 9. Remove the two Allen-head screws securing the gear shift position switch; then remove the sensor. Account for two neutral contact pins and two springs. CD987 CD997 10. Remove the nut (left-hand threads) securing the clutch shoe assembly (C). CD993 12.

  • Page 56: Servicing Left-Side Components

    INSPECTING CENTRIFUGAL 13. Remove the snap ring securing the oil pump driven gear (A); then remove the gear noting the CLUTCH SHOE direction of the sides of the gear for installing pur- poses. Account for a pin and a washer. 1.

  • Page 57: Installing Left-Side Components

    2. Install the secondary shaft bearing housing making sure the two alignment pins are properly posi- tioned. Tighten the Allen-head screws securely. CD988A DRIVEN PULLEY CD999 NOTE: The driven pulley is a non-serviceable 3. Install the oil pump onto the engine; then tighten component.
  • Page 58 CD991 PR410A 5. Grease the driven gear pin and insert it into the oil 7. Lightly grease the clutch housing seal; then insert pump shaft; then install the driven gear (noting the the left fixed drive spacer. direction of the sides of the gear from removing). Secure with a snap ring.
  • Page 59 15. Spread the faces of the driven pulley by threading a 6 mm cap screw into the threaded boss; then turn clockwise until pulley faces are opened approxi- mately 1/2 in. 16. Place the V-belt into position on the driven pulley and over the front shaft.

  • Page 60: Center Crankcase Components

    CD083 CC665 Center Crankcase Disassembling Components Crankcase Half NOTE: This procedure cannot be done with the NOTE: For steps 1-7, refer to illustration CC821B. engine/transmission 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.
  • Page 61 2. Remove the reverse idler gear assembly (F). 6. Using a rubber mallet, tap on the crankcase to Account for all washers, shaft, bushing, and the remove the driveshaft (E). gear. CC675 7. Note the timing marks on the crank balancer gear CC668 3.

  • Page 62: Servicing Center Crankcase Components

    Checking Backlash 11. Remove the cap screws securing the oil strainer cap; then remove the cap. NOTE: The rear shaft and bevel gear must be 12. Remove the two cap screws securing the oil removed for this procedure. Also, always start with strainer;...
  • Page 63 6. Examine the tooth contact pattern in the dye and NOTE: To correct tooth contact, steps 1 and 2 compare the pattern to the illustrations. (with NOTE) of “Correcting Backlash” must be fol- lowed and the above “Tooth Contact/Shim Correc- tion”...
  • Page 64 3. If installing the existing shaft, start with the shims removed during disassembly or if installing a new shaft, start with approximately 1.0 mm shims at point (D); then install the output drive shaft bear- ing (E) making sure the locating pin is directed toward the center of the shaft.
  • Page 65 Measuring Connecting Rod 1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a (Big End Side-to-Side) new thinner shim. 1. Push the lower end of the connecting rod to one 2. If backlash measurement is more than specified, side of the crankshaft journal.
  • Page 66 Disassembling NOTE: Proceed to check runout on the other end of the crankshaft by positioning the indicator con- From the right side: tact at point 2 and following steps 3-4. 1. Remove the right drive gear washer (17); then Measuring Crankshaft remove drive gear #2 (2).

  • Page 67: Assembling Crankcase Half

    Assembling Crankcase Half 1. Install the secondary driven output shaft assembly. CD832B NOTE: It will be necessary to rotate the crank bal- ancer until the counterweight is facing away from the crankshaft; then rotate the crankshaft clock- wise into the journal area to allow the crank bal- ancer to be fully seated.

  • Page 68: Joining Crankcase Halves

    CC674 CD268A 7. Place a washer on each end of the gear shift shaft; 11. Place the oil strainer into position; then secure then install the shaft assembly making sure the two with the two screws. holes on the end of the shaft are positioned verti- 12.

  • Page 69: Installing Engine/Transmission

    Engine/Transmission PR146 3. Install the flange nuts on the rear engine mount NOTE: Arctic Cat recommends that new gaskets studs; then secure the front engine mounting and O-rings be installed whenever servicing the bracket to the front engine mount studs with two vehicle.
  • Page 70 PR148 PR153B PR151A PR144B 8. Connect the lower coolant hose to the water pump ! CAUTION housing; then connect the upper coolant hose to the thermostat housing. Tighten the hose clamps The drive-line yokes must be aligned (timed) or dam- securely.
  • Page 71 PR128A PR474B 10. From the left-side, connect the speed sensor con- 11. Install the carburetor/throttle body and tighten the nector, fuel level sensor connector, and tempera- intake boot clamp securely; then connect the ture sensor lead; then install the spark plug cap. gasline hose, vacuum line, and throttle cable.
  • Page 72 12. Place the air filter assembly into position and 15. Fill the engine/transmission with the appropriate secure with the self-tapping screws; then connect lubricant. the intake boot to the carburetor/throttle body and 16. Fill the cooling system with the appropriate coolant. the inlet housing boot to the air filter housing.
  • Page 73 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 - seated poorly 2. Repair - replace guides 3. Valves mistimed 3.
  • Page 74 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.
  • Page 75 Problem: Exhaust smoke dirty or heavy Condition Remedy 1. Oil (in the engine) overfilled - contaminated 1. Drain excess oil - change oil 2. Piston rings - cylinder worn 2. Replace - service rings - cylinder 3. Valve guides worn 3.

  • Page 76: Fuel/Lubrication/Cooling

    SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Fuel/Lubrication/Cooling ......... 4-2 Carburetor Specifications (650 cc) ......4-2 Electric Choke (650 cc) ........... 4-2 Carburetor (650 cc) ..........4-3 Electronic Fuel Injection (550/700 cc) ..... 4-7 Engine RPM (Idle) (650 cc) ........4-8 Gas Tank ..............

  • Page 77: Carburetor Specifications (650 Cc)

    1. Inspect the plunger (A) for scoring or scratches, the needle (B) for damage to the tip, the spring (C) NOTE: Arctic Cat recommends the use of new for breakage, and the O-ring (D) for breaks. gaskets, lock nuts, and seals and lubricating all...

  • Page 78: Carburetor (650 Cc)

    INSTALLING 1. Lightly lubricate the O-ring on the choke body; then carefully insert the choke assembly into the carburetor being careful not to damage the plunger. 2. Secure the choke with the screw and tighten securely; then connect the choke connector to the wiring harness.
  • Page 79 CH015D CC749 2. Remove the vacuum piston assembly from the car- buretor body. Account for a spring, spring seat, and the jet needle. CC750 5. Remove the float pin. CC746 3. Remove the three screws securing the pump hous- ing. Account for the diaphragm assembly, spring, and U-ring (in the housing).
  • Page 80 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. 6. Inspect the vacuum piston/diaphragm for cracks, imperfections in the casting, or cracks and tears in the rubber.
  • Page 81 CC761A CC749 3. Install the slow jet. Tighten securely. 7. Place the U-ring into the pump housing. Position the spring and diaphragm assembly (lip toward the 4. Install the main jet into the needle jet holder and carburetor) onto the carburetor; then secure the tighten securely;...

  • Page 82: Electronic Fuel Injection (550/700 Cc)

    TROUBLESHOOTING 1. Verify that the electric fuel pump is operating by listening for a “whirring” sound for approximately three seconds after the ignition switch is turned to the ON position. If no sound can be heard, see Electric Fuel Pump/Fuel Level Sensor (550/700 cc) in this section.

  • Page 83: Engine Rpm (Idle) (650 Cc)

    PR487A FI104A 5. Slowly disconnect the gasline hose connector from 11. Use tape to cover and seal the intake opening. the fuel rail. ! CAUTION ! WARNING Any objects or liquid entering the intake opening will Gasoline may be under pressure. Place an absor- fall into the engine causing severe damage if the engine is turned over or started.

  • Page 84: Gas Tank

    2. Turn the idle adjustment screw clockwise one turn past the recommended RPM setting; then turn it counterclockwise to 1250-1350 RPM. 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.
  • Page 85 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.

  • Page 86: Gas/Vent Hoses

    PR171 PR166A 3. Install the rear hold-down strap joining cap screw and nut. Do not tighten at this time. PR167A 6. Connect the gas hose and gas tank vent hose to the proper fittings; then connect the fuel level sensor connector to the main harness.

  • Page 87: Oil Filter/Oil Pump

    5. Set the speedometer/tachometer to RPM. With the cooling system. An oil cooler kit may be installed on engine running at 2500 RPM, the pressure gauge any Arctic Cat UTV. must show 0.7-0.8 kg/cm² (10-20 psi). REMOVING 6. Install the left-side seat-base; then install the cen- ter console and seats making sure the seats lock securely.

  • Page 88: Liquid Cooling System

    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, run the engine for five minutes after the initial fill, shut the engine off, and then fill the cooling system to the bot- tom of the stand pipe in the radiator neck.
  • Page 89 PR182A PR184A 3. While lifting up on the front of the storage box, 6. Lift the radiator assembly from the vehicle. pry the rear center clear of the center dash mount Account for two upper and two lower rubber and remove the storage box. mounting grommets.

  • Page 90: Thermostat

    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.

  • Page 91: Water Pump

    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 in this section). Water Pump CC786A INSTALLING NOTE: The water pump is not a serviceable com- ponent.

  • Page 92: Electric Fuel Pump/Fuel Level Sensor (550/700 Cc)

    5. Check the entire cooling system for leakage. ! 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 neces- sary. 6. Install the right-side seat-base; then install the cen- ter console and seats making sure the seats lock securely.

  • Page 93: Vacuum Pulse Fuel Pump (650 Cc)

    INSPECTING B. Engage the tabs (C) of the fuel level sensor into the mounting slot (B) and press toward the bot- tom of the fuel pump to latch in place; then con- AT THIS POINT nect the two-wire connector (A). If the pump has failed earlier test and must be INSTALLING replaced, proceed to INSTALLING.

  • Page 94: Fuel Level Sensor (650 Cc)

    2. Remove the gasline hose and disconnect the fuel level sensor connector; then remove four torx-head machine screws and the fuel level sensor mounting plate. CD815 2. Start the engine. Fuel pump pressure should show 0.036-0.084 kg/cm (0.5-1.2 psi). REMOVING PR166C 3.
  • Page 95 INSTALLING 2. Connect the fuel level sensor connector to the main harness; then install the gasline hose and secure with the clamp. 1. Using a new seal, place the fuel level sensor into position in the gas tank; then secure the fuel level 3.

  • Page 96: Troubleshooting (650 Cc)

    Troubleshooting (650 cc) Problem: Starting impaired Condition Remedy 1. Starter jet obstructed 1. Clean jet 2. Starter jet passage obstructed 2. Clean passage 3. Carburetor leaking air 3. Replace gasket Problem: Idling or low speed impaired Condition Remedy 1. Slow jet obstructed - loose 1.

  • Page 97: Electrical System

    SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical System............. 5-2 Specifications ............5-2 Battery..............5-2 RPM Limiter............. 5-3 Testing Electrical Components ........ 5-3 Switches ..............5-4 Electrical Connections..........5-4 Accessory Receptacle/Connector ......5-4 Brakelight Switch............. 5-4 Coolant Temperature and Cooling Fan Switches (650 cc) ..............

  • Page 98: Specifications

    550/700 cc Electrical System Spark Plug Type NGK CR6E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 5000 ohms Ignition Coil (primary) Less than 1 ohm NOTE: Some photographs and illustrations used Resistance (terminal (+) to terminal (-)) in this section are used for clarity purposes only (secondary) 12k-19k ohms (high tension - plug...

  • Page 99: Rpm Limiter

    5. Add clean distilled water to bring fluid level to the 8. After charging the battery for the specified time, UPPER level line. remove the battery charger and allow the battery to sit for 1-2 hours. ! WARNING 9. Connect the multimeter and test the battery volt- age.

  • Page 100: Switches

    Switches Brakelight Switch Each time the vehicle is used, switches should be The switch connector is the two-prong black connector checked for proper operation. Use the following list below the master cylinder. for reference. NOTE: The ignition switch must be in the ON A.

  • Page 101: Coolant Temperature And Cooling Fan Switches (650 Cc)

    4. On the coolant temperature switch, allow the oil to cool, and when the temperature is within a temper- ature 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°...

  • Page 102: Fan Motor

    NOTE: To determine if the fan motor is good, con- nect the red wire from the fan connector to a 12 volt Fan Motor DC power supply; then connect the black wire from the fan connector to ground. The fan should operate. ! WARNING NOTE: The ignition switch must be in the ON position.

  • Page 103: Ignition Coil

    550/650 cc Ignition Coil The ignition coil is mounted on the fuel pump mount- ing plate adjacent to the fuel pump. VOLTAGE (Primary Side) See PEAK VOLTAGE Primary Coil (650 cc) or Pri- mary Coil (550/700 cc) in this sub-section. 1411-576 RESISTANCE 700 cc...

  • Page 104: Efi Sensors/Components (550/700 Cc)

    3. Turn the ignition switch to the ON position. The meter must show battery voltage. EFI Sensors/ Components (550/700 cc) CRANKSHAFT POSITION (CKP) SENSOR AR603D To test the CKP sensor, see Stator Coil/Crankshaft 2. The meter reading must be within specification. Position (CKP) Sensor (550/700 cc) in this section.

  • Page 105: Ignition Switch

    PR279A CD071 3. Turn the ignition switch to the ON position. 4. The meter must show approximately 6 DC volts. Ignition Switch 5. Leave the black tester lead connected; then con- nect the red tester lead to the signal lead pin (S). To access the ignition switch, dash switches, front 6.

  • Page 106: 2Wd/4Wd/Differential Lock Switch (Prowler/Xtx)

    VOLTAGE NOTE: If the meter does not show battery volt- age, troubleshoot the LIGHTS fuse on the power NOTE: Voltage tests must be made with the distribution module, the ignition switch, or the switch and the actuator connected. The meter can main harness.

  • Page 107: Differential Lock Switch (Xt)

    CF094E PR573A 4. If the differential lock engages (front wheels locked) and the voltage does not drop to 0, the A to B <1 ohm A to B Open switch is faulty and must be cleaned or replaced. E to F Open E to F <1 ohm Reverse Override Differential Lock...

  • Page 108: Front Drive Actuator

    NOTE: If battery voltage is not shown, trouble- shoot the 10 amp ignition (IGN) fuse on the power Front Drive Actuator distribution module, the ignition switch, or the main wiring harness. 4. Connect the red meter lead to the white/red wire. NOTE: With the engine stopped and the ignition The meter must show battery voltage.

  • Page 109: Stator Coil/Crankshaft Position

    3. With the engine running at the specified RPM, all 3. Crank the engine over using the electric starter. wire tests must be within specification. 4. The meter reading must be within specification. ! CAUTION Signal Coil Do not run the engine at high RPM for more than 10 1.

  • Page 110: Starter Motor

    1. Set the meter selector to the AC Voltage position. Starter Motor 2. Test between the three yellow wires for a total of three tests. 3. With the engine running at a constant 5000 RPM, all wire tests must be within specification. NOTE: The starter motor is not a serviceable component.

  • Page 111: Starter Relay

    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.

  • Page 112: Regulator/Rectifier

    Error codes can be cleared by following the procedures NOTE: If battery voltage is not shown in any test, located in the ECU Error Codes (550/700 cc) sub-sec- inspect the LIGHTS fuse on the power distribution tion in this section. module, headlight switch, ignition switch, switch connectors, or wiring harness.

  • Page 113: Ecu Error Codes (550/700 Cc)

    1. Attach the Timing Light to the spark plug high ten- • 00 = No Fault Detected (active code only) sion lead; then remove the timing inspection plug • 12 = CKP (Crankshaft Position) Sensor* from the left-side crankcase cover. •...
  • Page 114 SUPPLY VOLTAGE 1. Disconnect the three-wire connector from the sen- sor; then select DC Voltage on the multimeter and connect the red tester lead to the orange wire (C) and the black tester lead to the black wire (A). CD707 2.

  • Page 115: Throttle Position Sensor (Tps) (550/700 Cc)

    CD705A PR538A 4. Remove the black tester lead from terminal A and connect it to terminal C. The meter should read 5.0 Throttle Position DC volts. Sensor (TPS) NOTE: If the meter does not read as specified, (550/700 cc) check for poor connections at the ECU or open/broken wires in the wiring harness.
  • Page 116 NOTE: If any meter reading is not as specified, replace adjust (see INSTALL- ING/ADJUSTING in this sub-section). 7. Connect the positive lead to the battery; then con- nect the negative lead. 8. Connect the main harness TPS connector to the TPS;...
  • Page 117 6. Remove the test plug; then install the center con- sole and seats making sure the seats lock securely in place. PR541A 5. Tighten the mounting screws securely; then verify the TPS icon appears in the center position. Next Back 5-21 Back to TOC Back to Section TOC...

  • Page 118: Troubleshooting

    Troubleshooting 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/ECU defective 4. Replace CDI unit/ECU 5. Pick-up coil defective 5.
  • Page 119 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. Replace starter 4. Starter relay defective 4. Replace relay 5. Emergency stop - ignition switch off 5.
  • Page 120 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 (Prowler/XT)/ Rear Differential (XTX)........6-20 Hub................ 6-21 Hydraulic Brake Caliper......... 6-23 Universal Joints ............. 6-24 Troubleshooting .............

  • Page 121: Drive System

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

  • Page 122: Front Differential

    AG928 AG926 NOTE: It is important to tighten this cap screw INSTALLING while the others are loose to ensure proper seating of the actuator. 1. Lubricate the O-rings on the actuator; then ensure that all mounting surfaces are clean and free of 5.
  • Page 123 9. Remove two cap screws securing the differential lock cable support; then disconnect the differential lock cable at the differential. PR022A 3. Remove the front wheels. 4. Set the parking brake; then turn the ignition switch to the ON position and select 4WD on the PR194A 2WD/4WD selector switch.
  • Page 124 15. Using a slide hammer, remove the front axles. PR222 12. Support the axle to not allow it to drop or hang. PR199 16. Remove the lower differential mounting cap ! CAUTION screw. Account for a lock nut and four washers. Note the position of the washers for assembling.
  • Page 125 4. Using a seal removal tool, remove the input shaft seal. Account for a spacer. PR261A 2. Using a rubber mallet, remove the housing. Account for a gasket. Remove the fork, collar, and spring. Note the location of all the components for AF982 5.
  • Page 126 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. KX222 4. Install the input shaft into the pinion housing; then secure in the bearing with a circlip.
  • Page 127 PR261A KX174 NOTE: If the cover is difficult to remove, pry on Disassembling Differential the cover in more than one recessed location. Assembly 4. Remove the splined coupler, shifter fork, pin, and NOTE: This procedure can be performed on a spring of the differential lock assembly and set rear gear case (Prowler/XT)/rear differential (XTX).
  • Page 128 KX178 CC876 6. Place the differential with the open side down; 8. Using the Pinion Gear/Shaft Removal Tool and a then lift the housing off the spider assembly. hammer, remove the pinion gear from the gear Account for shim(s) and mark as right-side. case housing.
  • Page 129 Shimming Procedure/ Assembling Pinion Gear Shim Selection 1. Install the bearing onto the pinion shaft. Install the pinion shaft collar. 1. Press bearings into bores by outer ring to hard con- tact with seat. 2. Install the lock collar and tighten to 125 ft-lb; then stake the lock collar edge approximately 1.5 mm (0.060 in.) into the lower oil channel.
  • Page 130 CC890 CC893 4. Place a punch on the edge of the lock collar in the 7. Place the input shaft assembly onto the housing; oil gallery area; then using a hammer, stake the then secure with the existing cap screws. Tighten lock collar to ensure that the collar will remain to 23 ft-lb.
  • Page 131 NOTE: This procedure can be performed on a rear gear case (Prowler/XT)/rear differential (XTX). 1. Place a 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. CF266A CC885 2.
  • Page 132 CC888 CC891 2. Using a suitable driver, install the needle bearing 5. Install the pinion housing. into the housing making sure the bearing is seated. Removing/Installing Axle Seal NOTE: Do not push the bearing too far into the housing. NOTE: This procedure can be performed on a rear gear case (Prowler/XT)/rear differential (XTX).
  • Page 133 CC901 PR205A 3. Tighten the nuts to 38 ft-lb. NOTE: Prior to installing the seal, apply grease to the seal outside diameter. 4. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid lubricant into the differential and install the fill 4.

  • Page 134: Drive Axles

    PR193 AF894D 8. Secure the lower shock eyelets with cap screws 13. Install the wheels and tighten to 45 ft-lb. and lock nuts. Tighten to 33 ft-lb. 14. Remove the vehicle from the support stand. 15. Install the belly panel. Drive Axles REMOVING REAR DRIVE AXLE 1.
  • Page 135 PR221 AF935 5. Remove the cap screw and lock nut securing the REMOVING FRONT DRIVE AXLE knuckle to the upper A-arm. Discard the lock nut. NOTE: For removing a front drive axle, see Front Differential in this section. CLEANING AND INSPECTING AXLES NOTE: Always clean and inspect the drive axle components to determine if any service or replace-...
  • Page 136 CD020 CD022 2. Wipe away excess grease to access the retaining 5. Inspect the splines of the shaft, the bearing ring, ring. Using an awl or circlip pliers, remove the cir- and the housing for damage. clip. 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.
  • Page 137 8. Apply 40 grams (1/3 of contents) of grease from the grease pack included in Front Axle Boot Repair Kit into the knuckles and the new outside boot. CD024 ASSEMBLING AXLES 1. Install the inner boot with the small clamp making ATV-1052 sure the ends of the clamp are positioned correctly.
  • Page 138 CD022 CD024 8. Inspect the axle components for correct position- ! CAUTION ing of the four clamps. Also, inspect the boots for being correctly positioned on the shaft. The bearing ring must go onto the shaft with the side without splines facing toward the small clamp INSTALLING REAR DRIVE AXLE of the inner boot or severe damage will result.

  • Page 139: Rear Gear Case (Prowler/Xt)

    2. Secure the lower shock eyelet to the A-arm with a cap screw and a new lock nut. Tighten to 33 ft-lb. Rear Gear Case 3. Slide the hub w/brake disc into position in the (Prowler/XT)/ steering knuckle followed by a hex nut. Tighten Rear Differential (XTX) finger-tight at this time.

  • Page 140: Hub

    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. Install the rear drive axles (see Drive Axles in this section). 5. Install the driveline brake caliper and tighten the mounting cap screws to 20 ft-lb;...
  • Page 141 PR250 PR221 3. Using a socket and ratchet handle, tighten the nut 4. Secure the hub assembly with the nut. Tighten to until the stud is fully drawn into the hub. 200 ft-lb; then secure with a new cotter pin. NOTE: If the cotter pin can not be inserted due to misalignment of the hole in the axle and the slots in the nut, tighten the nut until properly aligned.

  • Page 142: Hydraulic Brake Caliper

    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. PR238 5. Remove the caliper holder from the caliper and ! WARNING account for the brake caliper O-ring.

  • Page 143: Universal Joints

    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 PR239C underside of the vehicle.
  • Page 144 PR121 PR375 4. Install U-Joint Separator Tool on the universal INSPECTING joint fixed yoke; then remove the bearing cup retainers. 1. Inspect the yoke bores for damage or signs of bearing cup looseness. If bearing cups are loose, the yoke must be replaced. PR354A 5.
  • Page 145 PR367C PR374 3. Install the retainer in the bearing cup; then remove INSTALLING the yoke from the separator tool. 1. Remove the bearing cups from the universal joint; NOTE: Repeat steps 2-3 for the opposite-side then insert the joint into the yoke and install one bearing cup.

  • Page 146: Troubleshooting

    Troubleshooting 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.
  • Page 147 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 ............ 7-7 Troubleshooting ............7-8 Back to TOC...

  • Page 148: Suspension

    ! CAUTION Suspension Additional support stands are necessary to support the rear axle when the shock absorbers are removed or damage may occur. NOTE: Critical torque specifications are located 3. Remove the two cap screws and nut securing each in Section 1. rear shock absorber to the frame and lower A-arm.

  • Page 149: Front A-Arms

    3. Inspect all springs, spring retainers, shock rods, sleeves, 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;...
  • Page 150 AF610D AF616D 11. Remove the snap ring from the ball joint; then 2. Install the A-arm assemblies into the frame remove the ball joint from the A-arm. mounts and secure with the cap screws. Only fin- ger-tighten at this time. AF616D AF610D CLEANING AND INSPECTING...

  • Page 151: Rear A-Arms

    AF628D PR377B 7. Install the tie rod end and secure with the nut 11. Secure the hub nut (from step 9) to the shaft/axle. (coated with red Loctite #271). Tighten to 30 ft-lb; Tighten to 200 ft-lb. then install a new cotter pin and spread the pin to 12.
  • Page 152 6. Remove the cap screws securing the boot guard to 2. Slide the knuckle onto the drive axle and into posi- the lower A-arm. tion on the A-arms; then secure the knuckle to the A-arms with cap screws and new lock nuts. Tighten to 33 ft-lb.

  • Page 153: Wheels And Tires

    ! WARNING 1. Install each wheel on its hub and secure with the existing hardware. Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable vehi- 2. Tighten to 45 ft-lb. cle operation.

  • Page 154: Troubleshooting

    Troubleshooting 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.
  • Page 155 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Steering Assembly ..........8-2 Steering Wheel............8-5 Upper Steering Shaft..........8-5 Lower Steering Shaft Assembly ......8-7 Steering Knuckles ........... 8-8 Checking/Adjusting Front Wheel Alignment ..8-10 Front Bumper Assembly (XT/XTX) ......8-11 Hood..............

  • Page 156: Steering/Frame

    3. Make matching alignment marks on the pinion shaft and lower steering shaft joint. Steering/Frame NOTE: Critical torque specifications are located in Section 1. The following steering components should be inspected periodically to ensure safe and proper opera- tion. A. Steering wheel secure. B.
  • Page 157 2. Slide the steering stopper (A) away from the inner tie rod end (B); then hold the rack (C) with a pipe wrench and remove the inner tie rod end from the rack. PR305 INSPECTING NOTE: Whenever a part is worn excessively, PR523A cracked, or damaged in any way, replacement is 3.
  • Page 158 PR519 PR305 2. With the rack and the steering wheel centered, NOTE: Always attach the crow-foot to the torque slide the lower steering shaft joint onto the pinion wrench with the open end 90° to the torque wrench shaft aligning the match marks. handle to ensure accurate torque application.

  • Page 159: Steering Wheel

    6. Install the cotter pins and spread to secure. 3. Check that the steering wheel is not bent. 7. Install the wheels and tighten to 45 ft-lb. Check INSTALLING the steering system for full and free travel; then check and adjust the front wheel alignment (see 1.
  • Page 160 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 posi- tion, align the match marks and slide the upper steering shaft joint onto the steering wheel shaft.

  • Page 161: Lower Steering Shaft Assembly

    PR475A PR314B INSPECTING NOTE: The lower steering shaft assembly is not repairable or rebuildable. If any damage or exces- sive 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 162: Steering Knuckles

    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. 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.
  • Page 163 NOTE: During assembling, new cotter pins should be installed. 4. Apply a small amount of grease to the hub splines. PR292A PR290A 5. Install the hub assembly onto the splines of the shaft. PR289 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws.

  • Page 164: Checking/Adjusting Front Wheel Alignment

    PR260 PR087A To adjust the wheel alignment, use the following pro- NOTE: If the hole in the axle shaft does not align cedure. with the slots in the castle nut, tighten the nut until the hole and slots align. 1. Center the steering wheel; then using an open-end wrench to hold the tie rod ends, loosen the 8.

  • Page 165: Front Bumper Assembly (Xt/Xtx)

    Hood REMOVING 1. Open the hood; then disconnect the four headlight connectors and remove two nylon ties. PR086 Front Bumper Assembly (XT/XTX) REMOVING Remove four cap screws and nuts. Account for four PR328A lock washers and eight flat washers. 2. Loosen but do not remove the four cap screws and flange nuts securing the hood hinge to the frame;...

  • Page 166: Fenders

    INSTALLING 2. Open the hood; then install the remaining two cap screws and flange nuts. Tighten all four securely. Place the appropriate fender into position and secure with existing hardware. 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.

  • Page 167: Belly Panel

    Exhaust System REMOVING MUFFLER 1. Remove the two exhaust springs at the muf- fler/exhaust pipe juncture. 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.

  • Page 168: Taillight Assembly

    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 20 ft-lb. 3. Raise the cargo box; then connect the lift support to the frame, install the cap screw and nut, and tighten the nut securely.

  • Page 169: Seats

    2. To install a seat, slide the rear of the seat into the seat retainers and push down firmly on the front of Seats seat. The seat should automatically lock into posi- tion. REMOVING/INSTALLING 1. To remove a seat, pull the seat lock lever up. Raise the front of the seat and slide it forward.
  • Page 170 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 Problem: Rear wheel oscillation Condition Remedy 1.

  • Page 171: Controls/Indicators

    SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Master Cylinder Assembly........9-2 Accelerator Pedal ............ 9-2 Front Differential Lock (XT) ........9-3 Shift Lever ............... 9-3 Speedometer/Tachometer/LCD/ Indicator Lights............. 9-4 Back to TOC...

  • Page 172: Master Cylinder Assembly

    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 PR336 a container.

  • Page 173: Front Differential Lock (Xt)

    PR342B CD560B 2. Select the 2WD position on the 2WD/4WD selec- tor switch; then turn the ignition switch to the ON position and select the LOCK position on the tog- gle. The front drive actuator should operate engag- ing 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...

  • Page 174: Indicator Lights

    2. Install the shoulder screw and secure with the 3. Remove the nuts securing the gauge assembly to flange nut (threads coated with blue Loctite #243). the dash; then unplug the multi-pin connector and Tighten to 20 ft-lb. remove the gauge from the vehicle. Speedometer/ Tachometer/LCD/ Indicator Lights...

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