Arctic Cat PROWLER XT 2014 Service Manual
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Arctic Cat PROWLER XT 2014 Service Manual

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2014
SERVICE MANUAL
[ROV]

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Summary of Contents for Arctic Cat PROWLER XT 2014

  • Page 1 2014 SERVICE MANUAL [ROV]...
  • Page 2 This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The procedures found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special tools to be completed.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS General Information ............2 Liquid Cooling System...........151 Radiator .................151 General Specifications ............2 Thermostat (XT/XTX) ............152 Torque Specifications ............3 Thermostat (XTZ) ............153 Torque Conversions (ft-lb/N-m) ......... 4 Fan.................153 Gasoline - Oil - Lubricant ..........4 Water Pump (XT/XTX)...........153 Genuine Parts ..............

  • Page 5: General Information

    87 Octane Regular Piston Ring End Gap - Installed 0.38 mm Unleaded Piston Ring to Groove Clearance (max) 0.35 mm Engine Oil (recommended) Arctic Cat ACX All Weather Piston Ring Groove Width (1st/2nd) 1.202-1.204 mm Synthetic (oil) 2.01-2.03 mm - XT/XTX...

  • Page 6: Torque Specifications

    CHASSIS/ROPS ASSEMBLY Torque Specifications Torque Part Part Bolted To ft-lb N-m Front Bumper Frame  NOTE: Torque specifications have the following tolerances: Front/Rear ROPS Tube* Arm Rest/Steering Sup- port Rear ROPS Tube ROPS Support Torque (ft-lb) Tolerance Top ROPS Support Front/Rear ROPS Tubes 0-15 ±20%...

  • Page 7: Torque Conversions (Ft-Lb/N-M)

    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.

  • Page 8: Genuine Parts

    Also, not recom- mended are racing, vegetable, non-detergent, and cas- tor-based oils. The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil, which has been specifi- cally formulated for use in this Arctic Cat engine.

  • Page 9: Preparation After Storage

    Start the engine and allow it to system. idle. Using Arctic Cat Engine Storage Preserver, rap- idly inject the preserver into the air filter opening for 3. Check all control wires and cables for signs of wear a period of 10 to 20 seconds;...

  • Page 10: Periodic Maintenance

    * 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 11: Lubrication Points

    2. Rotate the crankshaft to the TDC position on the compression stroke (front cylinder on the XTZ).  NOTE: Foam Filter Cleaner and Foam Filter Oil are available from Arctic Cat. 5. Dry the filter. 6. Put the filter in a plastic bag; then pour in air filter oil...

  • Page 12: Testing Engine Compression

    GZ059 GZ063  NOTE: At this point, the rocker arms and adjuster Valve Adjuster Procedure screws must not have pressure on them. A. Place the Valve Clearance Adjuster onto the jam nut securing the tappet adjuster screw; then rotate Feeler Gauge Procedure the valve adjuster dial clockwise until the end is A.

  • Page 13: Spark Plug(S)

     NOTE: The engine should be warm (operating tem- perature) and the battery fully charged for an accurate Spark Plug(s) compression test. On the XT/XTX, throttle must be in the wide-open throttle (WOT) position. In the event the engine cannot be run, cold values are included. A light brown insulator indicates that the plug is correct.

  • Page 14: Engine/Transmission Oil - Filter

    PR837 GZ415A 2. Using a suitable brush, clean the carbon deposits 3. Remove the drain plug from the bottom of the engine from the screen taking care not to damage the screen. and drain the oil into a drain pan. ...

  • Page 15: Front Differential - Rear Drive Lubricant

    GZ461A HDX255 CAUTION Rear Drive Do not over-fill the engine with oil. Always make sure that the oil level is not above the upper mark. 12. Inspect the area around the drain plug and oil filter for leaks. Front Differential - Rear Drive Lubricant To check lubricant, use the following procedure.

  • Page 16: Headlight/Taillight-Brakelight

    4. Make vertical marks which intersect the horizontal marks on the aiming surface directly in front of the Headlight/Taillight-Brake- headlights. light 5. Switch on the lights. Make sure the HIGH beam is on. DO NOT USE LOW BEAM. 6. Observe each headlight beam aim. Proper aim is HEADLIGHT when the most intense beam is centered on the verti- cal mark 5 cm (2 in.) below the horizontal mark on...

  • Page 17: Shift Lever/Shift Cable (Xtx)

    PR571 PR572A 4. Install the E-clip; then tighten the nuts (A) and (B) ADJUSTING SHIFT CABLE securely. To adjust the shift cable, use the following procedure. 5. Check each gear shift position for proper gear selec- tion and make sure the proper icon illuminates on the 1.

  • Page 18: Hydraulic Brake System

    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 19: Parking Brake (Xt/Xtz)

    4. Carefully check the entire hydraulic brake system C. Install the new brake pads. that all hose connections are tight, the bleed screws D. Secure the caliper holder to the knuckle with new are tight, the protective caps are installed, and no patch-lock cap screws.
  • Page 20 UTV355 PR682A 3. Remove the two cap screws securing the brake cali- 3. Turn the adjuster nut clockwise to remove cable slack. per to the rear drive housing and remove the caliper. 4. Check for proper adjustment by applying the parking 4.
  • Page 21  NOTE: Whenever installing new pads, the new pads must be burnished (see Burnishing Brake Pads in this section). MEASURING/REPLACING BRAKE PADS (XTZ)  NOTE: The brake pads should be replaced as a set. 1. Disconnect the parking brake cable from the actuator arm.

  • Page 22: Burnishing Brake Pads

    8. Connect the brake cable to the actuator arm with the 3. Remove the cap screws securing the V-belt cover pin and flat washer and secure with the cotter pin; noting the location of the different-lengthed cap then adjust the parking brake. screws for installing purposes;...
  • Page 23 2. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the driveshaft. Secure the drive face with a washer and nut (coated with red Loctite #271). Using Spanner Wrench, tighten the nut to 165 ft-lb. CAUTION Make sure the movable drive face plate is fully engaged onto the splines of the clutch shaft before tightening the nut or...

  • Page 24: Steering/Frame/Controls

    Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Steering wheel secure. B. Steering has equal and complete full-left and full-right capability. C. Steering sector mounting bolts tight. PR333A D. Ball joints not worn, cracked, or damaged. ...
  • Page 25 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. 1. Inspect the tie rod ends for damaged threads, torn boots, or excessive wear. 2.

  • Page 26: 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 27 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 28 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 29: 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 30: 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 31: 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 32: 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 33: 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 34 9. Remove the snap ring securing the bearing in the knuckle; then press the bearing out of the knuckle. PR202 PR289 CLEANING AND INSPECTING 1. Clean all knuckle components. 2. Inspect the bearing for pits, scoring, rusting, or pre- mature wear. 3.

  • Page 35: Checking/Adjusting Front Wheel Alignment

    CD009 PR377B 6. Using Hub Retaining Wrench, secure the hub assem- 9. Install the wheel; then tighten in a crisscross pattern bly with the nut. Tighten to 200 ft-lb. in 20 ft-lb increments to 80 ft-lb (aluminum wheels) or 45 ft-lb (steel wheels). 10.

  • Page 36: Front Bumper Assembly

    PR084A PR327A CLEANING AND INSPECTING 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; then secure with the four cap screws and nuts making sure the flat washers and lock washers are properly posi- tioned.

  • Page 37: Fenders

    Fenders REMOVING Remove three torx-head screws securing each fender to the frame. Account for a stiffener bracket on the front fenders. PR332A 3. Finish removing the cap screws and flange nuts (from step 2); then remove the hood assembly. CLEANING AND INSPECTING 1.

  • Page 38: Belly Panel

    Accelerator Pedal REMOVING Dislodge the throttle cable holding grommet from the actuator arm; then remove two torx-head screws and nuts securing the accelerator pedal assembly to the splash panel and remove the accelerator pedal. PR164 4. From the opposite side of the vehicle repeat step 3; then lift the rear of the floor up and lift the floor out of the vehicle.

  • Page 39: Shift Lever (Xtx)

    LCD Gauge/Indicator Lights REPLACING 1. Remove the six screws securing the dash panel to the frame; then remove the parking brake handle and jam nut. 2. Slide the dash panel to the rear sufficiently to access the components. PR340 INSTALLING 1.

  • Page 40: Exhaust System

    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. PR131 2. Slide the muffler assembly clear of the holder pins. INSPECTING MUFFLER 1.

  • Page 41: Taillight Assembly

    INSTALLING Taillight Assembly 1. Connect the three-prong connector to the bulb socket; then place the taillight assembly into position on the rear ROPS tube. 2. Install the two torx-head screws and tighten securely. REMOVING 1. Remove two torx-head screws securing the taillight assembly to the rear ROPS tube;...
  • Page 42 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 43: Engine/Transmission

    Secondary Drive Gear Holder 0444-253 the frame. Spanner Wrench 0544-005  NOTE: Arctic Cat recommends the use of new gas- Surface Plate 0644-016 kets, lock nuts, and seals and lubricating all internal V Blocks 0644-535 components when servicing the engine/transmis- ...

  • Page 44: Troubleshooting

    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 45 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 46: Prowler Xt/Xtx (Table Of Contents)

    Prowler XT/XTX (Table of Contents) Removing Engine/ Transmission........43 Top-Side Components ............ 46 Removing Top-Side Components ........46 Servicing Top-Side Components........50 Installing Top-Side Components ........57 Right-Side Components..........61 Removing Right-Side Components......... 62 PR122A Servicing Right-Side Components ........64 Installing Right-Side Components........
  • Page 47 6. On the XT, remove the E-clip from the transmission shift arm; then disconnect the cable. PR157A 5. From the left-side, disconnect the starter wire, alter- nator connector, and gear position switch connector PR567A (XT); then remove the cap screw securing the main 7.
  • Page 48 PR598A PR154A 9. Loosen the clamp (A) securing the air intake boot to 12. 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 49: Top-Side Components

    14. Disconnect the O2 sensor; then remove the O2 sensor. PR114  NOTE: The front engine mounting bracket should slide PR859A free of the engine mounts first; then the rear engine 15. Remove the muffler; then remove the exhaust pipe. mounting bracket and two rear engine mounts will lift free of the frame.
  • Page 50 1. Remove the two tappet covers. CD211A 5. Loosen the cap screw on the end of the tensioner; CC001D then remove the two cap screws securing the ten-  NOTE: Keep the mounting hardware with the covers sioner adjuster assembly and remove the assembly. for assembly purposes or thread them back into the Account for a gasket.
  • Page 51 CC013D CC017D 8. 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 11. Remove the four cylinder head bolts. ...
  • Page 52 AT THIS POINT  To service valves and cylinder head, see Servicing Top-Side Components sub-section. AT THIS POINT  To inspect cam chain guide, see Servicing Top-Side Components sub-section. CC025D CC022D C. Cylinder D. Piston  NOTE: Steps 1-12 in the preceding sub-section must precede this procedure.

  • Page 53: 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 54 2. Acceptable width ranges must not exceed specifica- tions. Measuring Valve Face Radial Runout 1. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks. 2. Position the dial indicator contact point on the out- side edge of the valve face;...
  • Page 55 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- nents be taken to a qualified machine shop for servicing. CAUTION If valves are discolored or pitted or if the seating sur- ATV-1011A 4.
  • Page 56 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 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove.
  • Page 57 Installing Piston Rings CYLINDER/CYLINDER HEAD ASSEMBLY 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the  NOTE: If the cylinder/cylinder head cannot be trued, expander making sure the expander ends do not they must be replaced as an assembly.
  • Page 58 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 59 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 60: Installing Top-Side Components

    Inspecting Camshaft Spring/Drive 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 1. Inspect the spring and drive pin for damage. and square the piston in respect to the crankcase. CF061A CF083 3.
  • Page 61 5. Install the coolant hose onto the crankcase union and tighten the clamp. C. Cylinder Head D. Valve Cover  NOTE: Steps 1-5 in the preceding sub-section must precede this procedure. 6. Place the chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss.
  • Page 62 14. With the alignment pin installed in the camshaft, loosely B. Camshaft lobes directed down (toward the pis- place the cam sprocket (with the recessed side facing the ton). cam shaft lobes) onto the camshaft. At this point, do not C.
  • Page 63 CD465 CD468 20. Rotate the crankshaft until the first cap screw (from 23. Remove the cap screw from the end of the chain ten- step 18) can be accessed; then tighten to 10 ft-lb. sioner; then using a flat-blade screwdriver, rotate the Bend the tab to secure the cap screw.

  • Page 64: Right-Side Components

     NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. 29. Install the four top side cap screws with rubber wash- ers; then install the remaining cap screws. Tighten only until snug. CD470 CC003D 30.

  • Page 65: Removing Right-Side Components

     NOTE: The engine/transmission does not have to be removed from the frame for this procedure. Removing Right-Side Components A. Outer Magneto Cover B. Water Pump C. Cover D. Rotor/Flywheel GZ254 5. Loosen the clamps securing the coolant hose to the 1.
  • Page 66 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. CD939A CD944 13. Remove the snap ring securing the water pump driven gear;...

  • Page 67: Servicing Right-Side Components

    PR434A FI572 REPLACING STARTER CLUTCH ASSEMBLY Servicing Right-Side Components 1. Remove the cap screws securing the starter clutch assembly to the flywheel; then remove from the fly- wheel. INSPECTING STARTER CLUTCH/GEAR 1. Place the starter clutch gear onto the rotor/flywheel and attempt to rotate the starter clutch gear clock- wise.

  • Page 68: Installing Right-Side Components

    2. Inspect the bearings in the magneto housing for dis- coloration, roughness when rotated, and secure fit in bearing bores. REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR 1. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft position sen- sor, and one cap screw from the harness hold-down.
  • Page 69 1. Install the water pump driven gear alignment pin and the driven gear (with the beveled side of the gear fac- ing outward as noted in removing); then secure with the snap ring. CD946A CD950A CD944  NOTE: The sharp side of the snap ring should be facing outward.
  • Page 70 PR447A CD934 4. In order on the crankshaft, install a washer, ring gear, 6. Install the shift cam stopper, spring, and two washers key, and the magneto rotor. Secure with the nut. (thick washer closest to the nut); then coat the threads on Tighten to 107 ft-lb.

  • Page 71: Left-Side Components

    CD927A GZ254 8. Lubricate the magneto cover gasket with fresh 13. Using a new gasket, install the speed sensor housing engine oil; then place it into position on the two onto the crankcase and secure with two cap screws. alignment pins. Make sure the outer shift shaft Tighten to 8 ft-lb.

  • Page 72: Removing Left-Side Components

    4. Remove the bolt (550) or nut (700) securing the fixed driven assembly; then remove the assembly. Removing Left-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover D. Oil Pump 1. Remove the cap screws securing the V-belt cover noting the location of the different-lengthed cap screws for installing purposes;...
  • Page 73 CC596 CD974A  NOTE: Account for and inspect the clutch housing seal.  NOTE: For steps 7-13, refer to illustration CC829B.  NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. CF088A 9.

  • Page 74: Servicing Left-Side Components

    11. Remove the cap screw securing the oil pump drive gear 13. Remove the snap ring securing the oil pump driven (B). Account for a cap screw, washer, pin, and spacer. gear (A); then remove the gear noting the direction of the sides of the gear for installing purposes.

  • Page 75: Installing Left-Side Components

    2. Inspect the clutch shoes for wear or damage. If any shoe is worn to the bottom of the groove, replace the clutch Installing Left-Side assembly. Components 1. On the XT, install the gear position switch ensuring the two pins and springs are properly positioned. Tighten the cap screws securely.
  • Page 76 CD988 CD985A 4. Install the oil pump drive gear spacer onto the crank bal- ancer shaft. Grease the pin and insert it into the shaft; then install the drive gear making sure the raised side of the gear is facing toward the inside. Secure the gear with the cap screw (threads coated with red Loctite #271) and the washer.
  • Page 77 PR399A H1-023 12. Place the driven pulley assembly into position and CAUTION secure with the bolt (550) or nut (700). Tighten to 80 When installed correctly, the green alignment dot (or the ft-lb (550) or 162 ft-lb (700). word OUTSIDE) on the one-way clutch is visible. 9.

  • Page 78: Center Crankcase Components

    FI428A CF270A  NOTE: At this point, the cap screw can be removed from between the driven pulley faces. 18. With the vehicle in neutral, rotate the V-belt and clutches counterclockwise until the V-belt is flush with the top of the driven pulley.

  • Page 79: Separating Crankcase Halves

    1. Remove the secondary driven shaft assembly (A) noting the location of the bearing locating pins. Separating Crankcase Account for the bearing C-ring. Halves 1. Remove the left-side cap screws securing the crank- case halves. Note the location of the differ- ent-lengthed cap screws.
  • Page 80 CD832B CC674 9. Remove the snap ring securing the water pump driven  NOTE: Do not disassemble the countershaft assem- gear shaft. bly unless necessary. If necessary, see Servicing 10. Using a hydraulic press, remove the crankshaft assem- Center Crankcase Components sub-section. bly.

  • Page 81: Servicing Center Crankcase Components

    Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS Initial Set-Up  NOTE: If the secondary output driven shaft is replaced or disassembled, the initial set-up must be performed to MT012 establish correct gear tooth contact. If only the second- ary output drive shaft or secondary output driven gear is replaced, proceed to Correcting Backlash in this sub-section.
  • Page 82 CRANKSHAFT ASSEMBLY 6. To adjust tooth contact, use the following chart to correctly shim the driven shaft.  NOTE: The crankshaft and connecting rod is a non-serviceable assembly. If any component is out of Tooth Contact Shim Correction specification, the assembly must be replaced. Contact at Top Increase Shim Thickness Contact at Root...
  • Page 83 2. Mount a dial indicator and base on the surface plate. CAUTION Position the indicator contact at point 1 of the crankshaft. 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.
  • Page 84 GZ313A GZ318A 4. Remove the snap ring securing the reverse driven 6. Remove the low driven gear. Account for a bearing, gear and washer; then remove the washer and gear. bushing, and thrust washer. GZ314 GZ316 5. Remove the reverse driven washer; then remove the low driven gear locking washer.
  • Page 85 2. Install the low driven gear locking washer; then install the inner reverse driven gear washer. GZ288A GZ319B GZ314 5. Install the reverse driven gear dog onto the counter- shaft and secure with a snap ring. GZ320B 3. Install the reverse driven bushing and bearing; then install the reverse driven gear.

  • Page 86: Assembling Crankcase Half

    CC689 GZ283B  NOTE: If heating the bearing is not possible, the crank- 7. Install the two drive gear washers and the shift forks. The countershaft is now ready for installation. shaft can be installed using a crankshaft installing tool. ...

  • Page 87: Joining Crankcase Halves

    CC675 CC669 6. Place a washer on each end of the countershaft 9. Install the reverse idler gear assembly noting the assembly; then install the assembly. positioning of the two washers, gear, bushing, and shaft. CC674 7. Place a washer on the end of the gear shift shaft; then CC668 install the shaft assembly making sure the two holes on 10.

  • Page 88: Installing Engine/Transmission

    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/transmission;...
  • Page 89 PR144B PR147 7. Connect the lower coolant hose to the water pump 4. Install the cap screws securing the drive couplers to the housing; then connect the upper coolant hose to the drive flanges and tighten to 40 ft-lb. thermostat housing. Tighten the hose clamps securely.
  • Page 90 11. Place the air filter assembly into position and secure with the self-tapping screws; then connect the intake boot to the throttle body and the inlet housing boot to the air fil- ter housing. Tighten the clamps securely. 12. Place the shifter assembly into position and secure with the four machine screws.

  • Page 91: Prowler Xtz (Table Of Contents)

    Prowler XTZ (Table of Contents) Removing Engine/Transmission........88 Top-Side Components ............ 94 Removing Top-Side Components ........94 Servicing Top-Side Components........98 Installing Top-Side Components ........104 Left-Side Components ..........111 Removing Left-Side Components ......... 111 PR611 Servicing Left-Side Components ........113 3.
  • Page 92 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 93 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 94 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 95 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 96 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 97: 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. GZ026  NOTE: Timing marks on the rotor/flywheel are stamped with an “F” (front cylinder) and “R” (rear cyl- PR633 inder) adjacent to the mark.
  • Page 98 GZ126A GZ405 4. Remove all cap screws except the two top-side cap 7. Using an awl, rotate the C-ring in its groove until it is screws next to the spark plug. These will keep the out of the cylinder head; then remove the C-ring. alignment pins in place.
  • Page 99 CC266D GZ151  NOTE: Loop the chain over the cylinder head and secure it to keep it from falling into the crankcase. GZ161 12. If the remaining cylinder head is to be serviced, apply tension to the loose timing chain and rotate the second cylinder to top-dead-center of the compression stroke;...
  • Page 100 14. Remove the two nuts securing the cylinder to the crankcase. AT THIS POINT  To service cylinder, see Servicing Top-Side Compo- nents sub-section. CAUTION When removing the cylinder, be sure to support the pis- ton to prevent damage to the crankcase and piston. 16.

  • Page 101: Servicing Top-Side Components

    Servicing Top-Side Components VALVE ASSEMBLY When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear.  NOTE: Whenever a valve is out of tolerance, it must be replaced.
  • Page 102 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. CAUTION If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced.
  • Page 103 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° angle and to a sharp edge. 2. Using the sharpened ring as a tool, clean carbon from the ring-grooves.
  • Page 104 ATV-1070 GZ168 2. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy. GZ169A 2. Install the second compression ring with the marking “E TOP” directed toward the top of the piston. ATV-1069 Measuring Piston Skirt/Cylinder Clearance...
  • Page 105 Cleaning/Inspecting Cylinder CAUTION 1. Wash the cylinder in parts-cleaning solvent. Incorrect installation of the piston rings will result in 2. Inspect the cylinder for pitting, scoring, scuffing, engine damage. warpage, and corrosion. If marks are found, repair the surface using a cylinder hone (see Inspecting CYLINDER/CYLINDER HEAD Cylinder in this sub-section).
  • Page 106  NOTE: To produce the proper 60° cross-hatch pat- tern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute. If honing oil is not available, use a lightweight petroleum-based oil. Thoroughly clean cylinder after honing using soap and hot water. Dry with compressed air;...

  • Page 107: Installing Top-Side Components

    CC145D CF060A 6. If clearance is excessive, measure the journals of the 2. If damaged, the camshaft must be replaced. camshaft. Installing Top-Side Components A. Pistons B. Cylinders 1. Install the piston on the connecting rod making sure the circlip on each side is fully seated in the piston. ...
  • Page 108 GZ159 GZ160A 3. Lubricate the inside wall of the cylinder; then using a 5. Install the coolant hose onto the crankcase union and ring compressor, compress the rings and slide the tighten the clamp. cylinder over the piston. Route the cam chain up C.
  • Page 109 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. 732-307B GZ132B 9. Loosely install the five cylinder head nuts. 10. In a crisscross pattern, tighten the four cylinder head cap screws (from step 8) initially to 20 ft-lb;...
  • Page 110 GZ190B GZ195 A. Piston still at top-dead-center. 17. Keeping tension on the opposite cam chain, rotate the crankshaft until the second cap screw securing the B. Camshaft lobes directed down (toward the piston). sprocket to the camshaft can be installed; then install the cap screw (threads coated with red Loctite #271) and C.
  • Page 111 CORRECT GZ059 GZ519 20. With the alignment pin installed in the rear camshaft, INCORRECT loosely place the cam sprocket (with the recessed side facing the cam shaft lobes) onto the camshaft. At this point, do not “seat” the sprocket onto the shaft.
  • Page 112 23. Place tab-washer onto the sprocket making sure it covers the pin in the alignment hole. CD465 26. 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 113 GZ162A GZ201 29. 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 32. Loosen the four adjuster screw jam nuts; then loosen the four adjuster screws on the rocker arms in the valve cover.

  • Page 114: Left-Side Components

    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. AT THIS POINT  To service any one specific component, only limited dis- GZ206 assembly of components may be necessary.
  • Page 115 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 H2-018 4.

  • Page 116: Servicing Left-Side Components

    7. Remove the two cap screws securing the water pump to the crankcase. H2-022A 12. Remove the snap ring securing the speed sensor trig- ger to the shaft and remove the trigger using a suit- GZ230A able “two-jawed” puller. Account for a gasket. 8.
  • Page 117 2. Inspect the starter clutch gear for chipped or missing teeth or discoloration/scoring of the clutch surface. Inspect the bearing for loose, worn, or discolored rollers. If bearing is damaged, it must be replaced. FI576A FI569 3. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration.

  • Page 118: Installing Left-Side Components

    3. Install the new stator coil assembly and secure with three cap screws using a drop of red Loctite #271 on each. If installing the existing magneto cover, tighten the cap screws to 11 ft-lb. If installing a new mag- neto cover, tighten the cap screws to 13 ft-lb.
  • Page 119 H2-019 H2-023 6. Install the shift cam plate onto the shift cam shaft and secure with the cap screw. Tighten to 8 ft-lb. GZ254 4. If removed, install the shim (E) and cam stopper (F); H2-022A then with the cam stopper support (B) in place, 7.
  • Page 120 8. Apply grease to the lips of the shift shaft seal in the speed sensor housing; then using a new gasket, install the speed sensor housing and secure with the cap screws. Tighten in a crisscross pattern to 8 ft-lb. GZ226 12.

  • Page 121: Right-Side Components

    Removing Right-Side Components A. CVT Cover B. Driven Clutch 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 GZ251 tabs to loosen the cover. Account for a gasket and 15.
  • Page 122 4. Remove the nut securing the fixed driven assembly; then remove the assembly. GZ511 PR388 5. Remove the fixed drive face. 6. Remove the cap screws securing the V-belt housing to the crankcase; then remove the V-belt housing. Account for two alignment pins. CC596 ...
  • Page 123 GZ500 GZ438A 11. Using a suitable press remove the bearing from the  NOTE: Heating the nut will aid in removal. clutch cover. 15. Remove the two cap screws securing the gear posi- tion switch; then remove the switch. 16. Remove the water pump drive housings. Account for a gasket and two locator pins.

  • Page 124: Servicing Right-Side Components

    Servicing Right-Side Components INSPECTING CENTRIFUGAL CLUTCH SHOES 1. Inspect the clutch shoes for wear, chips, cracks, dam- age, or discoloration. If any shoe is damaged, replace the centrifugal clutch. INSPECTING CLUTCH HOUSING GZ441 1. Inspect the clutch housing for burns, grooving, Inspecting cracks, or uneven wear.

  • Page 125: Installing Right-Side Components

    GZ442 GZ241 3. Install the two snap rings on the driveshaft (flat side 3. Install the one-way clutch onto the clutch shoe away from the gear). assembly. Installing Right-Side Components 1. Apply silicone to the mating surfaces; then install the gear position switch making sure the contact pins and springs are properly positioned.
  • Page 126 ATV2109 GZ501 9. Place the clutch cover/clutch housing assembly into  NOTE: It is critical to verify the seal on the bearing position on the crankcase; then secure with the cap faces the clutch cover seal before pressing in the new screws.
  • Page 127 11. Place the driven clutch assembly into position and secure with the nut (coated with red Loctite #271). Tighten to 165 ft-lb. GZ075 CAUTION Make sure the splines extend beyond the drive face and GZ066 washer or a false torque reading and spline damage 12.

  • Page 128: Center Crankcase Components

    GZ446 GZ437A 2. Remove the cap screws securing the lower crankcase to the upper crankcase halves; then using a rubber hammer, free the lower crankcase and remove. Center Crankcase Account for two alignment pins. Components  NOTE: This procedure cannot be done with the engine/transmission in the frame.

  • Page 129: Disassembling Crankcase Half

     NOTE: Do not disassemble these assemblies  NOTE: To aid in installing, it is recommended the unless service is required. If disassembled, second- assemblies are kept together and IN ORDER. ary gear sets will have to be reset for backlash and 1.

  • Page 130: 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. GZ463B 5. Remove the shift fork shaft (E); then remove the gear shift shaft assembly (F). Account for a flat washer and a spacer.
  • Page 131 FW-003A MT011A 4. Install a new seal (F), output yoke (G), washer, and nut 2. Using a suitable press, install the driven gear (C) on (H) and tighten to 200 ft-lb. the shaft until the gear firmly seats on the shoulder of the shaft.
  • Page 132 Checking Backlash 2. If backlash measurement is more than specified, remove an existing shim, measure it, and install a 1. Install the drive bevel gear assembly and driven thicker shim. bevel gear/output shaft assembly into the crankcase bottom cover.  NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance.
  • Page 133 GZ357 GZ354A 3. Inspect the gerotor set for scoring, discoloration, or 6. Remove the oil seal from the oil pump cover. cracks; then using a feeler gauge, check the inner to outer rotor clearance. If measurements exceed specifications, the gerotor set must be replaced. GZ365 Assembling GZ355...
  • Page 134 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 135 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 136 GZ313A GZ318A 4. Remove the snap ring securing the reverse driven 6. Remove the low driven gear. Account for a bearing, gear and washer; then remove the washer and gear. bushing, and thrust washer. GZ314 GZ316 5. Remove the reverse driven washer; then remove the Assembling low driven gear locking washer.
  • Page 137 2. Install the low driven gear locking washer; then install the inner reverse driven gear washer. GZ288A GZ319B GZ314 5. Install the reverse driven gear dog onto the counter- shaft and secure with a snap ring. GZ320B 3. Install the reverse driven bushing and bearing; then install the reverse driven gear.

  • Page 138: Assembling Crankcase Half

    GZ283B GZ463A 7. Install the drive gear washer and the shift forks. The 4. Install the countershaft gear onto the countershaft countershaft is now ready for installation. and secure with a snap ring (flat-side away from the gear). Assembling Crankcase Half 1.
  • Page 139 8. Place the larger flat washer on the drive gear end of the countershaft and the smaller flat washer on the high driven gear end; then with shift forks and shift fork shaft, install the countershaft assembly into the crankcase. GZ332 GZ280B GZ333...

  • Page 140: Joining Crankcase Halves

    Joining Crankcase Halves 1. Using rubber bands, support the connecting rods to align with the cylinder bores. GZ342 5. Tighten the 6 mm cap screws to 10 ft-lb and the 8 mm cap screws to 21 ft-lb using the pattern shown and turning the shafts frequently to ensure there is no binding.

  • Page 141: Installing Engine/Transmission

    Components, and to Installing Top-Side Components. Installing Engine/Transmission  NOTE: Arctic Cat recommends new gaskets and O-rings be installed whenever servicing the vehicle. 1. Attach a suitable lifting chain to the engine; then using an engine hoist, lift the engine/transmission into the GZ452A vehicle from the right side.
  • Page 142 4. Secure the rear universal joint flange to the output drive flange and tighten the four cap screws to 40 ft-lb. PR633 2. Carefully lower the engine/transmission into position between the engine mounting tabs being careful to keep all cables, wires, and hoses clear; then install PR647 the longer, front through-bolt with a flat washer.
  • Page 143 9. Install the O2 sensor and tighten the sensor to 19 ft-lb. Connect the harness to the sensor. 10. Install the two springs (A) at the juncture of front and rear exhaust pipes. With a new grafoil seal (B) in place, install the muffler and secure with two springs;...
  • Page 144 14. Connect the starter cable to the starter; then connect the engine harness ground to the engine. Tighten the fasten- ers securely. PR617A 12. Install the inlet boot on the CVT cover; then install the CVT cooling duct and secure with the sheet metal screw. Tighten all fasteners and clamps securely.
  • Page 145 PR663 PR666 17. Install the shift support assembly and secure with four 20. Install the shift cable support bracket and secure with cap screws; then secure the upper coolant pipe support two cap screws; then tighten to 8 ft-lb and install the clamp to the shift support.
  • Page 146 25. Install nylon cable ties at all locations marked prior to removing engine; then check for correct routing of all wiring, hoses, and cables. PR591A 23. Connect the front spark plug cap and front ignition coil; then install the front and rear injector connec- tors (A), MAP sensor (B), parking brake warning PR592A switch (C), reverse override switch connector (D),...

  • Page 147: Fuel/Lubrication/Cooling

    Fuel/Lubrication/Cooling remove the ignition switch key. ! WARNING  NOTE: Arctic Cat recommends the use of new gas- Do not turn the ignition switch to the ON position with kets, lock nuts, and seals and lubricating all internal the hoses removed. Gasoline will be pumped by the components when servicing the engine/transmis- electric fuel pump causing a safety hazard.

  • Page 148: 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 149: 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 150 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 151 9. Lift and slide the tank forward raising the front of the 3. Install the rear hold-down strap joining cap screw tank first; then turn the tank and lift out the right and nut. Do not tighten at this time. side.

  • Page 152: Gas/Vent Hoses

    3. Remove the upper plug from the base of the oil filter; then using an appropriate adapter, connect an oil pressure gauge to the engine. PR167A 6. Connect the vent hose (A) and gasline hose (B) to the proper fittings; then connect the fuel pump/fuel level sensor connector (C) to the main harness.

  • Page 153: Oil Cooler (Xtz)

    This model has an oil cooler in addition to the liquid cooling system. An oil cooler kit may be installed on any 3. Set the parking brake and start the engine. Allow the Arctic Cat ROV. engine to warm up to operating temperature (with cooling fan cycling).

  • Page 154: 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, open the bleed screw on the upper coolant pipe or the thermostat housing to allow air to bleed from the cooling system.

  • Page 155: Thermostat (Xt/Xtx)

    INSTALLING 6. Slide the dash forward into position; then secure the dash with the appropriate hardware. 1. Place the radiator into position making sure the grommets are correctly installed; then secure to the 7. Start the engine and warm up to operating tempera- mounts with the two shoulder bolts and nuts.

  • Page 156: Thermostat (Xtz)

    D. If the thermostat does not open, it must be replaced. 3. Inspect all coolant hoses, connections, and clamps for deterioration, cracks, and wear.  NOTE: All coolant hoses and clamps should be replaced every four years or 4000 miles. INSTALLING 1.

  • Page 157: 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. Drain the oil from the engine/transmission. 3. Remove the seats and center console; then remove the right-side seat-base.

  • Page 158: Electric Fuel Pump/Fuel Level Sensor

     NOTE: Always use a large container and have suffi- 3. Secure the water pump with the two cap screws and tighten securely; then connect the coolant hoses and cient floor drying material available when draining secure with hose clamps. the coolant in case of coolant spillage.
  • Page 159 3. Turn the ignition switch to the ON position. The fuel pressure should build until the pump shuts off. Pres- sure should read 3.0 kg-cm (43 psi). 4. If the pump is not running, disconnect the fuel pump/sensor connector by reaching under the rear rack from behind.

  • Page 160: Troubleshooting

    Troubleshooting Problem: Starting impaired Condition Remedy 1. Gas contaminated 1. Drain gas tank and fill with clean gas Problem: Idling or low speed impaired Condition Remedy 1. TPS out of adjustment 1. Adjust TPS Problem: Medium or high speed impaired Condition Remedy 1.

  • Page 161: Electrical System

    A number of special tools must be available to the techni- cian when performing service procedures in this section.  NOTE: Arctic Cat recommends the use of the CTEK Refer to the current Special Tools Catalog for the appro- Multi US 800 or the CTEK Multi US 3300 for battery priate tool description.

  • Page 162: Rpm Limiter

    B. Drive select switch — differential will engage Charging (4WD)/disengage (2WD).  NOTE: Arctic Cat recommends the use of the CTEK C. Reverse/neutral/high/low switch — R/N/H/L will be indicated on the LCD. Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging.

  • Page 163: Brakelight Switch

    Brakelight Switch The switch connector is the two-prong black connector below the master cylinder.  NOTE: The ignition switch must be in the ON posi- tion. VOLTAGE (Wiring Harness Connector) AR621D 1. Set the meter selector to the DC Voltage position. 3.

  • Page 164: Power Distribution Module (Pdm)

    2. Connect the red tester lead to the red wire; then con-  NOTE: If the meter shows no battery voltage, trou- nect the black tester lead to the black wire. bleshoot the battery, switches, power distribution module, or the main wiring harness. 2411-080 PR183A 3.

  • Page 165: 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 2. The meter reading must be within specification. Always disconnect the battery when performing resis- tance tests to avoid damaging the multimeter.

  • Page 166: Speed Sensor

    4. Connect the MAP/IAT to the harness; then using MaxiClips, connect the red tester lead to the brown/white wire and the black tester lead to the black/pink wire. With the engine running at idle speed, the meter should read approximately 2.5 DC volts (MAP sensor signal).

  • Page 167: Electronic Power Steering (Eps) (Xtz)

    The following is a list of conditions that can generate a malfunction code. All conditions with the exception of item 5 are external to the EPS assembly and therefore can be cleared without replacement of the EPS assembly. Make sure to thoroughly troubleshoot the entire system before replacing the EPS assembly.

  • Page 168: Electronic Power Steering (Eps) (Xtx)

     NOTE: Prior to troubleshooting below, make sure 2. Check for engine speed signal by disconnecting the 8-pin connector from the EPS assembly and using a that Ignition Key Switch has not been left on with the multi-meter set to the AC voltage position, connect engine not started.
  • Page 169 Code Fault Description Fault Condition Possible Cause EPS Fault Recovery Method C1309 Temperature Above 120° EPS internal 120° C over-temp condi- Clean the EPS housing and cooling fins. EPS will auto-recover when internal tion has been detected temperature drops below 115° C C1310 Vehicle Speed High Vehicle speed signal received by the Intermittent main harness wires, defective...

  • Page 170: Ignition Switch

    3. Disconnect 2-pin connector on the EPS assembly and 3. Connect the red meter lead to the yellow wire; then connect a volt meter set to DC voltage to the harness select the high beam position on the headlight (black meter lead to BLK and red meter lead to switch.

  • Page 171: Reverse Override Switch

    WIRE COLOR DIFFERENTIAL LOCK Black to Orange 12.0 DC Volts 12.0 DC Volts 12.0 DC Volts Black to 11.5 DC Volts 0 DC Volts 0 DC Volts White/Green Black to 11.5 DC Volts 11.5 DC Volts 0 DC Volts White/Red ...

  • Page 172: Starter Motor

    RESISTANCE 2. Connect the red tester lead to the positive battery post; then connect the black tester lead to the nega- (Crankshaft Position Sensor) tive battery post. 1. Set the meter selector to the OHMS position. 3. With the engine running at a constant 5000 RPM 2.

  • Page 173: Starter Relay

     NOTE: The ignition switch must be in the ON posi-  NOTE: Make sure the ignition switch is in the ON tion, and the shift lever in the NEUTRAL position. position, transmission in neutral, and parking brake set. 1. Set the meter selector to the DC Voltage position. 3.

  • Page 174: Regulator/Rectifier

    Regulator/Rectifier Taillight-Brakelight VOLTAGE (Taillight) The regulator/rectifier is located under the operator’s seat next to the battery. Try to verify all other charging system  NOTE: Perform this test at the socket end of the tail- components before the regulator/rectifier is replaced. light-brakelight harness (pigtail).

  • Page 175: Tilt Sensor

    OUTPUT VOLTAGE If ignition timing cannot be verified, the rotor may be damaged, the key may be sheared, the trigger coil bracket  NOTE: Needle adapters will be required on the mul- may be bent or damaged, or the ECM may be faulty. timeter leads as the following tests are made with the sensor connected.

  • Page 176: Throttle Position Sensor (Tps)

     NOTE: When replacing the sensor after testing, make sure the arrow marking is directed up. FI672 3. Using a multimeter, connect the black tester lead to the white socket (VAR) on the analyzer and the red tester lead to the red socket (+5V); then select the CD705A DC Voltage position.

  • Page 177: Ecm Error Codes (Xt/Xtz)

    4. Remove the test plug. • 95 = Sensor Power • 96 = Incorrect ECM* • 97 = ECM Memory Power (constant battery power) ECM Error Codes • 98 = ECM to Gauge Comm Link - H2 • 99 = Start/Run Not Possible (active code only) (XT/XTZ) *Will initiate code 99.
  • Page 178 Coolant (COOL) Diagnostic Mode 3. Cycle the display by depressing either the Set or Mode button to step to the desired function. EFI 003 Display: Engine coolant temperature as measured by the EFI004 ECT sensor.  NOTE: The gauge can be utilized dynamically DTC: P0116, P0117, P0118, P0119 (engine running/vehicle...
  • Page 179 Tachometer (tACH) Diagnostic TPS (tPS) Diagnostic Mode Mode EFI007 Display: % of TPS (0% closed, 95-100% WOT). EFI009 Display: Engine RPM DTC: P0121, P0122, P0123 DTC: P0336, P0337, P0339 Usage: Verify TPS signal and adjust throttle cable. Usage: Verify engine speed signal from the following. MAP (bArO) Diagnostic Mode 1.
  • Page 180 Inlet Air Temperature (AIr) Display: System DC voltage. Diagnostic Mode DTC: P0562, P0563, P2531, P2532 Usage: Verify system voltage under following conditions. 1. Battery voltage with engine and accessories off (>12.2 VDC for fully charged). 2. Battery voltage with engine running (charging = 13.8 VDC or greater).
  • Page 181 Code Fault Description Possible Cause Fault Recovery P0131 O2 Sensor Low/SG or Air-Leak Sensor or interconnect harness shorted to chassis ground or an Correct condition* air-leak exists P0132 O2 Sensor High/SP Sensor or interconnect harness shorted to battery power Correct condition* P0171 O2 Feedback Below Minimum Correction Low fuel rail pressure, dirty fuel filter, or dirty injectors...

  • Page 182: 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 183 Problem: Battery discharges too rapidly Condition Remedy 1. Electrolyte contaminated 1. Replace battery 2. Specific gravity low 2. Charge battery - add distilled water 3. Charging system (charging operation) not set properly 3. Check AC generator - regulator/rectifier - circuit connections 4.

  • Page 184: Drive System

    REMOVING Drive System 1. Select LOCK on the drive select switch; then discon- nect the connector on the actuator harness. 2. Using a T-30 torx wrench, remove the mounting cap GENERAL INFORMATION screw from the driveshaft side of the actuator. All gear cases are tagged beneath a cover bolt.

  • Page 185: Front Differential

     NOTE: Make sure to properly align the differential 7. Secure the wiring harness to the frame with a nylon cable tie; then install the inner fender panel. lock actuator lever with the hole in the differential lock plunger. Front Differential REMOVING 1.
  • Page 186 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 187 PR729C 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 188 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 189 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 190 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 191 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 192  NOTE: All bearings must be installed in the gear case and the pinion properly installed before pro- ceeding. 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 193 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 194 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 195  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 196 CF278 PR198A 6. Push the axle shaft into the CV coupler to release the CAUTION locking ring while pulling back on the CV coupler and Make sure the tool is free of nicks or sharp edges or slide the drive axle into place. damage to the seal may occur.

  • Page 197: Drive Axles

    PR193 PR256 8. Secure the lower shock eyelets with cap screws and 12. Install the wheels and tighten in a crisscross pattern lock nuts. Tighten to 20 ft-lb (XT/XTX) or 35 ft-lb in 20 ft-lb increments to 80 ft-lb (aluminum wheels) (XTZ).
  • Page 198 REMOVING FRONT DRIVE AXLE  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 com- ponents to determine if any service or replacement is necessary.
  • Page 199  NOTE: In the outboard boot, use the final 40 grams (1/3 of contents) of grease from the pack in the bear- ing housing. INSTALLING REAR DRIVE AXLE 1. Push the axle shaft into the CV coupler to release the lock ring while pulling back on the CV coupler and slide the drive axle into place in the gear case.

  • Page 200: Rear Gear Case

    2. Secure the lower shock eyelet to the A-arm with a 1. Drain the lubricant from the rear gear case; then cap screw and a new lock nut. Tighten to 35 ft-lb. remove both rear drive axles. 3. Slide the hub w/brake disc into position in the steer- 2.
  • Page 201 2. On the XTZ model, remove the clutch pack from the clutch basket; then remove the snap ring securing the clutch basket (A) to the input shaft (B) and remove the clutch basket. GC057A 2. Place the ring gear with selected shim into the cover and measure the ring gear to thrust button clearance with a thickness gauge.
  • Page 202 5. Inspect the clutch pack (XTZ) for signs of discolor- ation.  NOTE: The clutch pack is not a serviceable compo- nent. If worn, discolored, or damaged in any way, it must be replaced. Assembling/Installing 1. Install a new bearing into the input housing and secure with the snap ring (flat side directed away from bearing).

  • Page 203: Hub

    2. Remove the cotter pin from the axle.  NOTE: During assembly, new cotter pins should be installed. GZ176 5. Using a new gasket, install the assembled rear drive input shaft/housing onto the rear drive gear case and secure with the three cap screws. Tighten to 23 ft-lb. AT THIS POINT PR257 ...
  • Page 204 2. Inspect all threads for stripping or damage. 3. Inspect the brake disc (if applicable) for cracks or warping. 4. Inspect the hub for pits, cracks, loose studs, or spline wear. REPLACING WHEEL STUDS 1. Secure the hub in a suitable holding fixture and remove the brake disc (if applicable).

  • Page 205: Hydraulic Brake Caliper

    Hydraulic Brake Caliper do not allow brake fluid to contaminate them. ! 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 206 2. Inspect the brake pads for damage and excessive wear.  NOTE: For measuring brake pads, see the Periodic Maintenance section. 3. Inspect the brake caliper housings for scoring in the piston bores, chipped seal ring grooves, or signs of corrosion or discoloration.
  • Page 207 5. Making sure brake fluid does not contact the brake pads, compress the caliper holder toward the caliper and install the inner brake pad; then install the outer pad. CAUTION If brake pads become contaminated with brake fluid, they must be thoroughly cleaned with brake cleaning solvent or replaced with new pads.

  • Page 208: Universal Joints (Xtz)

    MASTER CYLINDER ASSEMBLY 3. Remove the oil bolt securing the banjo-fittings to the master cylinder; then remove the master cylinder.  NOTE: The master cylinder is a non-serviceable Discard the three crush washers. component; it must be replaced as an assembly. CAUTION Removing Brake fluid is highly corrosive.
  • Page 209 3. Remove the cap screws securing the propeller shaft flange to the yoke flange on the appropriate drive-line; then remove the propeller shaft. PR359 6. Install the separator tool on the opposite side of the yoke to push the second bearing cup from the yoke; then remove the tool and separate the universal joint.
  • Page 210 PR367A PR374 3. Check splines and flanges for excessive wear, thread 3. Install the retainer in the bearing cup; then remove damage, or warpage. the yoke from the separator tool.  NOTE: Repeat steps 2-3 for the opposite-side bear- ing cup. 4.

  • Page 211: Troubleshooting Drive System

    Troubleshooting Drive System 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 212: Suspension

    Suspension The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods bent, pitted, or damaged. B. Rubber damper cracked, broken, or missing. C. Shock absorber body damaged, punctured, or leaking. AF626D D. Shock absorber eyelets broken, bent, or cracked. 4.

  • Page 213: Front A-Arms

    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- port stand to avoid injury. PR193 2. Remove the cotter pin from the nut. Discard the cot- 8.
  • Page 214 AF616D AF610D 3. Route the brake hose through the upper A-arm shock CLEANING AND INSPECTING absorber mount. 1. Clean all A-arm components in parts-cleaning sol- vent. 2. Clean the ball joint mounting hole of all residual Loctite, grease, oil, or dirt for installing purposes. 3.

  • Page 215: 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 216: Wheels And Tires

    A-arms with cap screws and new lock nuts. Tighten ! WARNING to 35 ft-lb. Use only Arctic Cat approved tires when replacing tires. 3. Tighten the hardware securing the A-arms to the Failure to do so could result in unstable vehicle operation.

  • Page 217: 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 wheels. existing hardware. 2. Tighten in a crisscross pattern in 20 ft-lb increments ! WARNING to 80 ft-lb (aluminum wheels) or 45 ft-lb (steel Make sure the vehicle is solidly supported on the sup- wheels).
  • Page 218 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-857...

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