Arctic Cat Prowler XTZ 2009 Service Manual
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Arctic Cat Prowler XTZ 2009 Service Manual

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2009 Arctic
Cat Prowler XTZ. The complete manual is designed to aid service personnel in service-oriented applications.
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  NOTE: identifies supplementary
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.
© 2009 Arctic Cat Inc.
www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
AT THIS POINT directs the technician to certain and
Back to TOC
January 2009

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  • Page 1 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.
  • Page 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TABLE OF CONTENTS Click on the blue text to go. Foreword 1. General Information/Specifications 2. Periodic Maintenance/Tune-Up 3. Engine/Transmission 4. Fuel/Lubrication/Cooling 5. Electrical System 6. Drive System 7. Suspension 8. Steering/Frame 9.

  • Page 3: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 ........

  • Page 4: General Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SUSPENSION COMPONENTS (Front) General Specifications* Torque Part Part Bolted To ft-lb N-m A-Arm Frame Ball Joint Cap Screw Knuckle CHASSIS Shock Absorber (Upper) Frame Dry Weight (approx) 564 kg (1243 lb)

  • Page 5: Tightening Torque (General Bolts)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 Lower Crankcase Cover Crankcase ft-lb ft-lb ft-lb ft-lb (6 mm) 35.4 69.4 103.4...

  • Page 6: Break-In Procedure

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RECOMMENDED ENGINE/ TRANSMISSION OIL Break-In Procedure ! CAUTION Any oil used in place of the recommended oil could A new vehicle and an overhauled engine require a cause serious engine damage. Do not use oils which “break-in”...

  • Page 7: Genuine Parts

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FILLING GAS TANK Preparation For Storage ! WARNING Always fill the gas tank in a well-ventilated area. Never add fuel to the gas tank near any open flames ! CAUTION or with the engine running.

  • Page 8: Preparation After Storage

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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) ........

  • 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. www.mymowerparts.com...

  • Page 11: Periodic Maintenance

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING FILTER Periodic Maintenance ! CAUTION Failure to inspect the air filter frequently if the vehi- This section has been organized into sub-sections cle is used in dusty, wet, or muddy conditions can which show common maintenance procedures for the damage the engine.

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

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CHECKING AND CLEANING 3. Using a feeler gauge, check each valve/tappet clearance. If clearance is not within specifications, DRAINS loosen the jam nut and rotate the tappet adjuster screw until the clearance is within specifications.

  • Page 13: Valve/Tappet Clearance (Valve Adjuster Procedure)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut; Valve/Tappet Clearance then rotate the tappet adjuster screw clockwise until friction is felt.

  • Page 14: Spark Plugs

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. While holding the throttle in the full-open posi- tion, crank the engine over with the electric starter until the gauge stops climbing (five to 10 compres- sion strokes). NOTE: The compression should be within a...

  • Page 15: Engine/Transmission Oil - Filter

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Using a suitable brush, clean the carbon deposits NOTE: Clean up any excess oil after removing from the screen taking care not to damage the the filter. screen. 5. Apply oil to a new filter O-ring and check to make NOTE: If the screen or gasket is damaged in any...

  • Page 16: Front Differential - Rear Drive Lubricant

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Front Differential - Rear Drive Lubricant To check lubricant, use the following procedure. 1. Remove the level plug; the lubricant level should be visible at the plug threads. PR530B 4. After all the lubricant has been drained, install the drain plugs and tighten to 45 in.-lb.

  • Page 17: Headlight/Taillight-Brakelight

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: There should be an average operating load on the vehicle when adjusting the headlight Headlight/Taillight- aim. Brakelight 2. Measure the distance from the floor to the mid-point of each headlight.

  • Page 18: Shift Lever

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Shift Lever CHECKING SHIFT LEVER CABLE Set the parking brake and turn the ignition switch on; then with the shift lever in the neutral position, look for the (N) indication on the LCD. Shift into high range and look for the (H) indication, low range for the (L) indication, and reverse for the (R) indication.
  • Page 19 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.

  • Page 20: Parking Brake

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 21 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR681A PR678A 2. Remove the two cap screws and nuts securing the 5. Install the new brake pads and anchor bolts with cable support to the brake caliper. springs and spacers; then secure with new lock nuts.

  • Page 22: Burnishing Brake Pads

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Verify that the brakelight illuminates when the brake pedal is depressed. Checking/Replacing V-Belt REMOVING 1. Remove the seats and center console; then remove the seat bases. PR677A 8. Connect the brake cable to the actuator arm with 2.
  • Page 23 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR168A GZ076 5. Remove the cap screws securing the CVT cover; then using a rubber mallet, gently tap on the cover tabs to loosen the cover. Remove the cover. 6. Remove the nut securing the movable drive face;...

  • Page 24: Troubleshooting Brake System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: At this point, remove the cap screw from ! CAUTION the driven pulley face. Make sure the drive belt does not prevent the mov- 3. Rotate the V-belt and driven pulley/clutch until the able face from contacting the spacer when tighten- V-belt is flush with the top of the driven pulley.
  • Page 25 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 Prowler XTZ (Table of Contents) ......3-3 Troubleshooting ............. 3-58 www.mymowerparts.com Back to TOC...

  • Page 26: Special Tools

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine/Transmission Specifications* This section has been organized into sub-sections VALVES AND GUIDES which show a progression for the complete servicing Valve Face Diameter (intake) 31.6 mm of the Arctic Cat UTV engine/transmission.
  • Page 27 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Prowler XTZ (Table of Contents) Removing Engine/Transmission......3-3 Top-Side Components..........3-9 Removing Top-Side Components ......3-9 Servicing Top-Side Components......3-13 Installing Top-Side Components ......3-20 Left-Side Components .......... 3-27 Removing Left-Side Components ......3-27 Installing Left-Side Components ......
  • Page 28 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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;...
  • Page 29 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR658A PR666A ! CAUTION 13. Remove the E-clip from the transmission shift arm; then remove the shifter cable mounting bracket The gear shift position switch wires are secured to from the crankcase and move the shift support the frame with a nylon tie connector.
  • Page 30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 15. Remove four sheet metal screws securing the air filter mounting bracket to the frame; then loosen the intake boot clamp and remove the air filter assembly. PR606A 18. Remove the upper radiator hose from the thermo- stat housing;...
  • Page 31 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR670A PR661B 21. Remove the oil cooler hoses from the fittings on 23. Remove two cap screws securing the front exhaust the oil filter base and crankcase; then plug the pipe to the cylinder head;...
  • Page 32 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: The grafoil gasket may remain in the cylin- der head. 24. Remove the cap screws securing the rear exhaust pipe to the cylinder head and remove the exhaust pipe. Account for a grafoil gasket.

  • Page 33: Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 28. Using a suitable engine hoist, remove the weight from the through-bolt; then remove the bolts. Account for a flat washer on each bolt and noting the front bolt is longer than the rear.
  • Page 34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the cap screws securing the valve cover to the head; account for the four rubber washers on the top side cap screws. Remove the valve cover. Account for and note the orientation of the cam- shaft plug.
  • Page 35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC266D GZ151 NOTE: Loop the chain over the cylinder head and secure it to keep it from falling into the crankcase. 8. Remove the five nuts securing the cylinder head to the cylinder;...
  • Page 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ140A GZ144 12. Remove the two nuts securing the cylinder to the  AT THIS POINT crankcase. 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 piston.

  • Page 37: Servicing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION ! CAUTION Do not allow the connecting rod to go down inside the Do not remove an excessive amount of the sealing crankcase. If the rod is down inside the crankcase and surface or damage to the camshaft will result.
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC136D ATV-1004 2. Acceptable width range must be within specifica- NOTE: The valve seals must be replaced. tions. 3. Remove the valve springs; then invert the cylinder Measuring Valve Face Radial head and remove the valves.
  • Page 39 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Valves 1. Apply grease to the inside surface of the valve seals; then place a lower spring seat and valve guide seal over each valve guide. CC131D 3. Push the valve from side to side; then from top to bottom.
  • Page 40 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If scuffing or seizure marks are too deep to correct with the sandpaper, replace the piston. 4. Inspect the perimeter of each piston for signs of excessive “blowby.” Excessive “blowby” indicates worn piston rings or an out-of-round cylinder.
  • Page 41 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC127D GZ167 2. Measure the corresponding piston diameter at a 3. Install the first (unmarked) compression ring; then point 15 mm (0.6 in.) above the piston skirt at a rotate the rings so the ring gaps are approximately right angle to the piston-pin bore.
  • Page 42 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Place the cylinder head on the surface plate cov- ! CAUTION ered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure Water or parts-cleaning solvent must be used in con- eight motion.
  • Page 43 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 44: Installing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC145D CF060A 6. If clearance is excessive, measure the journals of 2. If damaged, the camshaft must be replaced. the camshaft. Installing Top-Side Components A. Pistons B. Cylinders 1. Install the piston on the connecting rod making sure there is a circlip on each side and the open end of the circlip faces upwards.
  • Page 45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ159 GZ160A 3. Lubricate the inside wall of the cylinder; then 5. Install the coolant hose onto the crankcase union using a ring compressor, compress the rings and and tighten the clamp.
  • Page 46 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Install the four cylinder head cap screws with washers. Tighten only until snug. GZ130 NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder.
  • Page 47 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A. Piston still at top-dead-center. 17. Keeping tension on the opposite cam chain, rotate the crankshaft until the second cap screw securing B. Camshaft lobes directed down (toward the pis- the sprocket to the camshaft can be installed;...
  • Page 48 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Note the position of the alignment marks D. Recessed side of the sprocket directed toward the cam lobes. on the end of the camshaft. They must NOT be par- allel with the valve cover but offset slightly to the E.
  • Page 49 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 27. Install the cylinder head plugs in the cylinder heads with the open end facing downward and toward the inside. ! CAUTION The open end of the plug must be positioned downward.
  • Page 50 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 30. Using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner counterclockwise until all tension is released; then install the cap screw into the end of the chain tensioner.

  • Page 51: Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ208 GZ212A 38. If removed, install the spark plugs. Tighten  AT THIS POINT securely. To replace stator coils/crankshaft position sensor, see Section 5. Left-Side Components 2. Remove the starter motor, starter driven gear (A), starter countershaft bushing (B), and starter coun- tershaft gear (C);...
  • Page 52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Remove the hose clamps from the water pump; then remove the coolant hoses from the water pump outlets and coolant pipes. GZ216 NOTE: The puller has left-hand threads. GZ218 7.

  • Page 53: Installing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ233A GZ243 9. Remove the nut (A) from the shift cam stopper bolt (B); then remove the cam stopper spring (C). Account for a flat washer (D). GZ235 12. Remove the cap screws securing the oil filler cover to the crankcase;...
  • Page 54 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ250 GZ232 3. Clean the countershaft and trigger splines thor- 5. If removed, install the shift cam stopper on the oughly and install the inner snap ring onto the support; then with the flat washer in place, install shat;...
  • Page 55 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ260 GZ262 8. Install the shift shaft into the crankcase making 10. Install the spacer washer on the crankshaft; then sure the washers are properly located; then align install the starter ring gear.

  • Page 56: Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ225 GZ212B ! CAUTION Make sure the one-way starter clutch is properly Right-Side Components engaged with the starter ring gear before installing and tightening the rotor/flywheel nut or damage to the clutch assembly could occur.
  • Page 57 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ244B PR388 2. Remove the nut securing the movable drive face; 5. Remove the fixed drive face. then remove the face. Account for a spacer and a 6. Remove the cap screws securing the V-belt hous- flat washer.

  • Page 58: Servicing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ247A CC596 NOTE: To aid in installing, it is recommended that NOTE: Account for and inspect the clutch hous- the assemblies are kept together and IN ORDER. ing seal. 8. Remove the one-way clutch from the centrifugal 10.

  • Page 59: Installing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSPECTING CENTRIFUGAL CLUTCH SHOE Installing Right-Side Components 1. Inspect the clutch shoes for uneven wear, chips, cracks, or discoloration. If any shoe is damaged, replace the complete set. 1. Apply silicone to the mating surfaces; then install 2.
  • Page 60 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Making sure the alignment pins are correctly installed, place a bead of silicone sealant on the mating surfaces and install the V-belt housing. Secure with the cap screws tightened to 8 ft-lb.

  • Page 61: Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ065A PR386 12. Place the V-belt into position on the driven pulley NOTE: At this point, the cap screw can be and over the front shaft. removed from between the driven pulley faces.
  • Page 62 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ264 GZ322B GZ268 GZ269A 2. Remove the cap screws securing the lower crank- NOTE: Do not disassemble these assemblies case to the upper crankcase halves; then using a unless service is required. If disassembled, sec-...

  • Page 63: Disassembling Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ272B GZ299A 3. Remove the water pump driven shaft (C). Account for the driven gear and drive pin. Disassembling Crankcase Half NOTE: For steps 1-8, refer to photograph GZ298A. GZ304A 4.

  • Page 64: Servicing Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ276 GZ279 6. Remove two cap screws securing the oil pump in NOTE: Do not disassemble the countershaft the crankcase and remove the oil pump. assembly unless necessary. If necessary, see Ser- vicing Center Crankcase Components sub-sec- tion.
  • Page 65 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MT011B MT008B 3. If installing the existing shaft, start with the shims NOTE: Do not use a new lock nut at this time as removed during disassembly or if installing a new this procedure may have to be repeated.
  • Page 66 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. Backlash Measurement Shim Correction Under 0.127 mm (0.005 in.) Decrease Shim Thickness At 0.127-0.381 mm (0.005-0.015 in.) No Correction Required Over 0.381 mm (0.015 in.)
  • Page 67 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ357 GZ354A 3. Inspect the gerotor set for scoring, discoloration, 6. Remove the oil seal from the oil pump cover. or cracks; then using a feeler gauge, check the inner to outer rotor clearance. If measurements exceed specifications, the gerotor set must be replaced.
  • Page 68 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CRANKSHAFT ASSEMBLY Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and mea- sure it with micrometer.
  • Page 69 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 COUNTERSHAFT 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crankshaft. GZ281A ATV-1074 ! CAUTION 3. Zero the indicator and rotate the crankshaft slowly.
  • Page 70 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ296 GZ320 GZ312 GZ319 3. Remove the reverse driven gear dog. GZ318A 6. Remove the low driven gear. Account for a bear- GZ313A ing, bushing, and thrust washer. 4. Remove the snap ring securing the reverse driven gear and washer;...
  • Page 71 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling 1. From the drive gear end, install a thrust washer, bushing, and bearing; then install the low driven gear and washer. GZ320B 3. Install the reverse driven bushing and bearing;...

  • Page 72: Assembling Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Install the two drive gear washers and the shift forks. The countershaft is now ready for installa- tion. Assembling Crankcase Half 1. Install the oil pump gerotor assembly and oil pump cover in the crankcase and secure with two cap screws.
  • Page 73 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ304A GZ332 GZ328A GZ333 4. Install the countershaft gear onto the countershaft 7. Install the gear shift shaft into the crankcase mak- and secure with a snap ring (flat-side away from ing sure the flat washer is in place on the gear shift the gear).

  • Page 74: Joining Crankcase Halves

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Place two flat washers on the drive gear end of the countershaft and one flat washer on the high Joining Crankcase driven gear end; then with shift forks and shift fork...
  • Page 75 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ322B GZ342 7. Install two locating pins into the upper crankcase 5. Tighten the cap screws to 8 ft-lb using the pattern assembly; then apply a thin bead of silicone seal- shown and turning the shafts frequently to ensure ant to the lower crankcase cover.

  • Page 76: Installing Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Install the oil screen; then apply a thin bead of sili- cone sealant to the oil strainer cap and secure with the cap screws. Tighten to 8 ft-lb.  AT THIS POINT...
  • Page 77 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Lubricate the splines on the front driveshaft with multi-purpose grease; then align the match marks and install the driveshaft into the front output joint. PR641A 8. With a new grafoil gasket in the front cylinder...
  • Page 78 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. With a new grafoil seal in place, install the muffler 12. Install the inlet boot on the CVT housing; then and secure with two springs; then tighten the cap install the CVT cooling duct and secure with the screws from steps 7 and 8 to 20 ft-lb.
  • Page 79 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR605A PR663 17. Install the shift support assembly and secure with four cap screws; then secure the upper coolant pipe support clamp to the shift support. Tighten the cap screws securely.
  • Page 80 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR666 PR591A 20. Install the shift cable support bracket and secure 23. Connect the front spark plug cap and front ignition with two cap screws; then tighten to 8 ft-lb and coil;...
  • Page 81 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR592A PR672A 26. Connect the negative battery cable and install the 29. Start the engine and check for oil or coolant leaks; battery hold-down. then check all fluid levels and correct as necessary.
  • Page 82 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 83 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 84 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.

  • Page 85: Fuel/Lubrication/Cooling

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Fuel/Lubrication/Cooling ......... 4-2 Electronic Fuel Injection .......... 4-2 Gas Tank ..............4-3 Gas/Vent Hoses ............4-6 Oil Filter/Oil Pump ........... 4-6 Oil Cooler ..............4-6 Liquid Cooling System..........

  • Page 86: Electronic Fuel Injection

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Verify that the battery is sufficiently charged to crank the engine over at normal speed. Fuel/Lubrication/ 5. Check the air filter housing and air filter for con- Cooling tamination. Clean or replace as necessary (see Sec- tion 2).

  • Page 87: Gas Tank

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Loosen the outer jam nut securing the throttle cable to the throttle body. The throttle body can Gas Tank now be removed from the vehicle. 8. Use tape to cover and seal the intake opening.
  • Page 88 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Remove four press-nuts securing the gas cap inset; then remove the gas cap and inset. Install the gas cap. PR165 5. Disconnect the vent hose (A), gasline hose (B), and fuel pump/fuel level sensor connector (C);...
  • Page 89 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area.

  • Page 90: Gas/Vent Hoses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Position the floorboard into the vehicle and secure 6. Install the center console and seats making sure with the appropriate hardware; then install the cen- the seats lock securely.

  • Page 91: Liquid Cooling System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Prior to washing, inspect the oil cooler for signs of leaks such as oily dirt build-up.
  • Page 92 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Inspect all hoses for cracks and deterioration. 4. Inspect all fasteners and grommets for damage or wear. INSTALLING 1. Place the radiator into position making sure the grommets are correctly installed; then secure to the mounts with the two shoulder bolts and nuts.

  • Page 93: Thermostat

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 94: Electric Fuel Pump/Fuel Level Sensor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ093A GZ252D ! CAUTION NOTE: Always use a large container and have sufficient floor drying material available when Do not force the water pump housing into the crank- draining the coolant in case of coolant spillage.
  • Page 95 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Disconnect the electrical plug from the main har- 1. Turn the ignition switch ON and listen for a ness; then disconnect the gasline hose from the momentary “whirring” sound of the pump build- fuel pump.

  • Page 96: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Place the fuel pump assembly into the gas tank with a new gasket aligning the match marks; then secure with the four screws. Tighten securely. NOTE: It is important to install the fuel pump with the correct orientation to ensure adequate float lever clearance.

  • Page 97: Electrical System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 ..............5-3 Electrical Connections..........5-4 Accessory Receptacle/Connector ......

  • Page 98: Electrical System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 After being in service, batteries require regular clean- ing and recharging in order to deliver peak perfor- Electrical System mance and maximum service life. The following procedures are recommended for cleaning and main- taining lead-acid batteries.

  • Page 99: Rpm Limiter

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. When using a constant-current battery charger, 11. Connect the battery cables (positive cable first); then install the battery hold-down. use the following Battery Charging Chart. ! CAUTION ! CAUTION Connecting cables in reverse (positive to negative Never exceed the standard charging rate.

  • Page 100: Electrical Connections

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Electrical Connections The electrical connections should be checked periodi- cally for proper function. In case of an electrical fail- ure, check fuses, connections (for tightness, corrosion, damage), and/or bulbs. Accessory...

  • Page 101: Engine Coolant Temperature (Ect) Sensor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the meter shows no battery voltage, troubleshoot the battery, fuse, motor, or the main Engine Coolant wiring harness. Temperature (ECT) NOTE: If the meter shows battery voltage, the Sensor main wiring harness is good.

  • Page 102: Ignition Coil

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Remove all fuses from the power distribution 3. The meter must show less than 1 ohm resistance. module. If the meter shows open, replace the fuse. 2. Set the meter selector to the DC Voltage position.

  • Page 103: Efi Sensors/Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Connect the MAP to the harness; then using Maxi- Clips, connect the red tester lead to the brown/white wire and the black tester lead to the black/green wire. With the engine running at idle speed, the meter should read approximately 1.5...

  • Page 104: Ignition Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Connect the red meter lead to the yellow/green wire; then with the black lead grounded, turn the ignition switch to the START position. The starter should engage and the meter must show battery voltage.

  • Page 105: Reverse Override Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Connect the red meter lead to the black/blue wire and the black meter lead to a suitable ground; then select 2WD on the 2WD/4WD/differential lock switch. The meter must show approximately 1.5 DC volts.

  • Page 106: Stator Coil/Crankshaft Position (Ckp) Sensor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Connect the black lead to the black wire using a 3. With the engine running at a constant 5000 RPM MaxiClip; then select 2WD on the 2WD/4WD/dif- (with the headlights on), the meter must show ferential lock switch.

  • Page 107: Crankshaft Position Sensor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RESISTANCE 3. Remove the two cap screws securing the starter with ground wires to the crankcase; then remove (Crankshaft Position Sensor) the starter. Account for the wiring forms and an The CKP sensor is the black/blue two-pin one next to O-ring.

  • Page 108: Electronic Control Unit (Ecu)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Remove the seats and center console; then using the multimeter set to the DC Voltage position, Electronic Control Unit check the relay as follows. (ECU) 2. Connect the red tester lead to the positive battery terminal (A);...

  • Page 109: Taillight-Brakelight

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VOLTAGE NOTE: If the meter shows no voltage, inspect the 10 amp ignition (IGN) fuse, brakelight switch, wir- NOTE: The low beams are the outside bulbs ing harness, or connectors.

  • Page 110: Tilt Sensor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. After ten seconds, release the reverse override switch and turn the ignition switch to the OFF position; then turn the ignition switch to the ON position. The display should read AC00 (no fault detected).

  • Page 111: Throttle Position Sensor (Tps)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Tilt the sensor 60° or more to the left and right observing the meter. The meter should read 4.0-8.0 DC volts after approximately one second in the tilted position. If the meter readings are not as specified, the tilt sensor is defective.
  • Page 112 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 113 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR533A PR540A 2. Remove the screw securing the TPS to the throttle body and remove the TPS. INSTALLING/ADJUSTING 1. Place the TPS into position on the throttle body and secure with the screw. Do not tighten at this time.

  • Page 114: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. ECU defective 4.
  • Page 115 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 116 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Front Drive Actuator ..........6-2 Front Differential ............6-3 Drive Axles ............6-15 Rear Gear Case ............ 6-20 Hub................

  • Page 117: Drive System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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”...

  • Page 118: Front Differential

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 119 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Remove the lower and upper ball joint cap screws taking care not to strip the threads on the ball joint shaft; then using a rubber mallet, tap the end of the axle and free it from the knuckle assembly.
  • Page 120 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Scribe match marks on the front input drive flange and the front drive yoke flange; then remove the cap screws securing the yoke and flange. Separate the flanges but do not remove the driveshaft.
  • Page 121 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD106 AF983 3. Remove the input shaft from the pinion housing. AF984 CD107 4. Using a seal removal tool, remove the input shaft seal. Account for a spacer. KX219 Assembling Input Shaft 1.
  • Page 122 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF993 KX222 4. Install the input shaft into the pinion housing; then secure in the bearing with a circlip. AF994 2. Install the input shaft seal making sure it is flush with the edge of the housing.
  • Page 123 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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...
  • Page 124 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 125 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Shimming Procedure/ Assembling Differential Assembly 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.
  • Page 126 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 127 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Needle Bearing NOTE: Removing the needle bearing is rarely necessary. Avoid removing the needle bearing unless the bearing is clearly damaged. NOTE: This procedure can be performed on a rear gear case.
  • Page 128 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Needle Bearing 1. Apply red Loctite #271 to the outside of a new bearing; then place the new bearing into the hous- ing. CC891 5. Install the pinion housing.
  • Page 129 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 130: Drive Axles

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Drive Axles REMOVING REAR DRIVE AXLE 1. Secure the vehicle on a support stand to elevate the wheels. ! WARNING Make sure the vehicle is solidly supported on the PR193 support stand to avoid injury.
  • Page 131 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING AXLES NOTE: Always clean and inspect the drive axle components to determine if any service or replace- ment is necessary. 1. Using a clean towel, wipe away any oil or grease from the axle components.
  • Page 132 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD021 CD752 3. Using a snap ring pliers, remove the snap ring NOTE: At this point if the outside boot is dam- securing the bearing ring to the shaft. Note the aged, continue with step 7.
  • Page 133 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: The grease pack contains 120 grams of NOTE: The boot is positioned correctly when the grease. The inside joint (double-offset) requires small end of the boot seats down into the recessed approximately 70-90 grams of grease and the out- groove.
  • Page 134 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: To assure proper seating of the axle, give it a light pull; the axle should remain “clipped” in place. 2. Swing the knuckle up and onto the drive axle; then place the knuckle into place in the upper A-arm.

  • Page 135: Rear Gear Case

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD027 PR207 7. Install the wheel and tighten to 45 ft-lb. REAR DRIVE INPUT SHAFT/ 8. Remove the vehicle from the support stand. HOUSING 9. Check the front differential lubricant level and add Removing/Disassembling lubricant as necessary.
  • Page 136 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ176A GZ184A Cleaning and Inspecting 1. Wash all parts in parts cleaning solvent and dry with compressed air. ! WARNING Always wear safety glasses when working with com- pressed air.

  • Page 137: Hub

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ184 GZ176 2. Using a suitable seal driver, install a new oil seal 5. Using a new gasket, install the assembled rear into the front of the input housing until the seal drive input shaft/housing onto the rear drive gear flush with the housing.
  • Page 138 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Removing or tightening of the hub nuts requires that the axles be locked. To lock the rear axle, set the parking brake. To lock the front axle, turn the ignition switch to ON and engage the dif- ferential lock;...

  • Page 139: Hydraulic Brake Caliper

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR252A PR258 5. For front hubs, secure the brake calipers to the INSTALLING knuckle with two cap screws tightened to 20 ft-lb. 1. Secure the brake disc (if applicable) to the hub with the four cap screws coated with red Loctite #271.
  • Page 140 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR235 PR239B 6. Plug the fluid port with a suitable plug to prevent ! CAUTION contamination during cleaning. Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the vehicle and do not reuse brake fluid.

  • Page 141: Universal Joints

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR238 PR152A 3. Remove the cap screws securing the propeller shaft flange to the yoke flange on the appropriate drive-line; then remove the propeller shaft. PR239 3. Place the brake caliper assembly into position and secure with the “patch-lock”...
  • Page 142 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Using a suitable socket and ratchet handle, rotate the jackscrew to push the bearing cup out of the yoke; then remove the tool and the bearing cup. PR367A 3. Check splines and flanges for excessive wear, thread damage, or warpage.

  • Page 143: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR374 PR355 3. Install the retainer in the bearing cup; then remove 5. Check that the universal joint can be flexed freely the yoke from the separator tool. without binding; then apply multi-purpose grease to the splines and install the propeller shaft noting NOTE: Repeat steps 2-3 for the opposite-side...
  • Page 144 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 Front A-Arms ............7-2 Rear A-Arms ............7-5 Wheels and Tires ............ 7-6 Troubleshooting ............7-7 www.mymowerparts.com...

  • Page 145: Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Using a suitable spring compression stand, com- press the shock absorber spring, remove the Suspension retainer, and remove the spring. ! WARNING NOTE: Critical torque specifications are located Shock absorber springs are under high compres- in Section 1.
  • Page 146 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Remove the lower shock absorber eyelet from the upper A-arm. PR257 3. Remove the nut securing the hub. 4. Remove the brake caliper. Account for two cap AF626D screws.
  • Page 147 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Inspect the A-arm for bends, cracks, and worn 4. Secure the lower eyelet of the shock absorber to bushings. the upper A-arm. Tighten nut to 33 ft-lb. 4. Inspect the ball joint mounting holes for cracks or ! CAUTION damage.

  • Page 148: Rear A-Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Rear A-Arms REMOVING 1. Secure the vehicle on a support stand to elevate the wheels ! WARNING Make sure the vehicle is solidly supported on the PR290A support stand to avoid injury.

  • Page 149: Wheels And Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Never reuse a lock nut. Once a lock nut 9. Secure the boot guard to the lower A-arm with the two cap screws. Tighten securely. has been removed, it must be replaced with a new lock nut.

  • Page 150: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Clean the tires with soap and water. 2. Inspect the tires for damage, wear, or punctures. 3. Inspect each wheel for cracks, dents, or bends. ! WARNING 4. Inspect each tire for cuts, wear, missing lugs, and Do not operate the vehicle if tire damage exists.
  • Page 151 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 ..

  • Page 152: Steering/Frame

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 153 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 154 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.

  • Page 155: Steering Wheel

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Install the cotter pins and spread to secure. 3. Install the hairpin clip on the steering shaft. 7. Install the wheels and tighten to 45 ft-lb. Check NOTE: If the hole in the steering shaft does not the steering system for full and free travel;...
  • Page 156 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR313A PR696 4. Match mark the upper steering shaft joint and the 4. Hold rearward pressure on the steering wheel and steering wheel shaft; then remove the steering tighten the cap screw (from step 2) to 36 ft-lb.

  • Page 157: Lower Steering Shaft Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING Lower Steering Shaft 1. Place the steering shaft assembly into position Assembly through the opening in the splash panel. AT THIS POINT Before beginning this procedure, the upper steering shaft must be removed (see Upper Steering Shaft in this section).

  • Page 158: Steering Knuckles

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the upper steering shaft (see Upper Steering Shaft in this section). Steering Knuckles REMOVING AND DISASSEMBLING 1. Secure the vehicle on a support stand to elevate the wheel; then remove the wheel.
  • Page 159 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Tighten to 35 ft-lb. CD009 6. Secure the hub assembly with the nut. Tighten to 200 ft-lb.

  • Page 160: Checking/Adjusting Front Wheel Alignment

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR377B PR085A 9. Install the wheel; then using a crisscross pattern, tighten to 45 ft-lb. ! CAUTION 10. Remove the vehicle from the support stand. Always use a wrench to hold the tie rod ends when loosening or tightening the jam nuts or damage to the boots could occur.

  • Page 161: Hood

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is cracked, or damaged in any way, replacement is necessary.

  • Page 162: Floor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR311A PR164 4. From the opposite side of the vehicle repeat step 3; INSTALLING then lift the rear of the floor up and lift the floor out of the vehicle.

  • Page 163: Exhaust System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the belly panel. Cargo Box INSTALLING 1. Place the belly panel into position on the underside of the frame. REMOVING 2. Install the body screws. Tighten securely. 1. Raise the cargo box; then remove the cap screw and nut securing the lower lift support to the frame.

  • Page 164: Taillight Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Inspect the cargo box gate latches for smooth 2. Disconnect the three-prong connector from the operation. bulb socket and remove the taillight assembly. INSTALLING INSPECTING 1. With the help of an assistant or an adequate lift, set NOTE: Whenever a part is worn excessively,...

  • Page 165: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure incorrect 3. Adjust pressure 4.
  • Page 166 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Rear wheel oscillation Condition Remedy 1. Rear wheel hub bearings worn - loose 1. Replace bearings 2. Tires defective - incorrect 2. Replace tires 3. Wheel rim distorted 3. Replace rim 4.

  • Page 167: Controls/Indicators

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Master Cylinder Assembly........9-2 Accelerator Pedal ............ 9-2 Shift Lever ............... 9-3 Speedometer/Tachometer/LCD/ Indicator Lights............. 9-3 www.mymowerparts.com Back to TOC...

  • Page 168: Master Cylinder Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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...

  • Page 169: Shift Lever

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. With the shifter spring in place on the shift lever, install the shift lever onto the shift axle. 2. Install the shoulder screw and secure with the flange nut (threads coated with blue Loctite #243).

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2009 prowler xtz

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