Arctic Cat 2011 Prowler HDX Service Manual
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Arctic Cat 2011 Prowler HDX Service Manual

2011 arctic cat prowler hdx
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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arctic Cat
Prowler Hdx. 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 serious personal injury or even death. A CAUTION identi-
fies 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 wor-
thy of particular attention. The symbol
dures 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.
© 2010 Arctic Cat Inc.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
AT THIS POINT directs the technician to certain and specific proce-
Manual
Table of Contents
September 2010

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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 serious personal injury or even death.

  • Page 2: Electrical System

    Click on the blue text to go. Service TABLE OF CONTENTS Manual Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the Table of Contents bookmarks on the left side of the screen, or click the blue text below. To return to this page, click the Manual Table of Contents button at the bottom of each page.

  • Page 3: Table Of Contents

    SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications ..........1-2 Torque Specifications ..........1-2 Torque Conversions (ft-lb/N-m) ....... 1-3 Tightening Torque (General Bolts) ......1-3 Break-In Procedure ..........1-4 Gasoline - Oil - Lubricant ........1-4 Genuine Parts ............1-5 Preparation For Storage..........
  • Page 4 1.9 L (2.0 U.S. qt) - Change (8 mm) Gasoline (recommended) 87 Octane Regular Unleaded SUSPENSION COMPONENTS (Front) Engine Oil (recommended) Arctic Cat ACX All Weather Syn- thetic A-Arm Frame Front Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Knuckle Ball Joint Belt Width 35.0 mm (1.38 in.)

  • Page 5: Table Of Contents

    DRIVE TRAIN COMPONENTS Torque Conversions Torque Part Part Bolted To (ft-lb/N-m) ft-lb N-m Rear Differential/Gear Case Frame Drive Coupler (Front) Front Drive Flange Front Engine Mounting Frame Bracket ft-lb ft-lb ft-lb ft-lb Rear Engine Mounting Bracket Frame 35.4 69.4 103.4 Engine Mounting Through-Bolt Frame 36.7 70.7...

  • Page 6: Break-In Procedure

    During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle. Varying the engine The recommended oil to use is Arctic Cat ACX All RPM during the break-in period allows the components Weather synthetic engine oil, which has been specifi- to “load”...
  • Page 7 Preparation After Storage When replacement of parts is necessary, use only genuine Arctic Cat parts. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illustrated Parts Manual for the correct part number, quantity, and Taking the vehicle out of storage and correctly preparing description.
  • Page 8 6. Charge the battery; then install. Connect the battery 7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, cables. and headlight aim; adjust or replace as necessary. CAUTION 8. Tighten all nuts, bolts, cap screws, and screws mak- ing sure all calibrated nuts, cap screws, and bolts are The ignition switch must be in the OFF position prior tightened to specifications.

  • Page 9: Table Of Contents

    SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart ........2-2 Periodic Maintenance..........2-3 Lubrication Points............ 2-3 Air Filter ..............2-3 Valve/Tappet Clearance........... 2-3 Testing Engine Compression........2-4 Spark Plug............... 2-5 Muffler/Spark Arrester ..........2-5 Engine/Transmission Oil - Filter....... 2-6 Front Differential - Rear Drive Lubricant....
  • Page 10 * 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 and strainer inspection interval can be increased to every 1,000 miles or every year.

  • Page 11: Periodic Maintenance

    2. Unsnap the four spring-clip fasteners and remove the cover. This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat ROV. NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all...

  • Page 12: Testing Engine Compression

    NOTE: The engine must be cold for this proce- D. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise dure. until proper valve/tappet clearance is attained. NOTE: The seat, seat back, seat base, and spark NOTE: Refer to the appropriate specifications in plug must be removed for this procedure.

  • Page 13: Muffler/Spark Arrester

    6. If compression is abnormally low, inspect the following items. A. Starter cranks engine over. B. Gauge is functioning properly. C. Throttle in the full-open position. D. Valve/tappet clearance correct. E. Valve bent or burned. F. Valve seat burned. ATV0052C G.
  • Page 14 NOTE: If the screen or gasket is damaged in any way, it must be replaced. 3. Install the spark arrester assembly and gasket and secure with the cap screws. Tighten the cap screws to 48 in.-lb. Engine/Transmission Oil - Filter OIL - FILTER HDX042A CAUTION...
  • Page 15 4. After all the lubricant has been drained, install the drain plugs and tighten to 45 in.-lb. Front Differential - Rear 5. Pour the appropriate amount of recommended lubri- Drive Lubricant cant into the fill hole. 6. Install the fill plug. To check lubricant, use the following procedure.

  • Page 16: Shift Lever

    TAILLIGHT-BRAKELIGHT To replace the taillight-brakelight bulb, use the following procedure. 1. Remove the two machine screws and remove the light assembly. 2. Rotate the bulb socket counterclockwise to remove it from the light assembly; then pull straight out on the bulb.
  • Page 17 PR567A HDX177 3. Loosen nuts (A) and (B) and adjust the cable housing 2. Loosen the lower mounting nut on the shift cable to align the shift cable end to the shift arm stud (C). several turns; then while holding the shifter firmly against the park gate, adjust the upper mounting nut against the mounting bracket.

  • Page 18: Hydraulic Brake System

    3. Tighten the lower mounting nut to 20 ft-lb; then turn the ignition switch to the ON position and check that the park indicator light only illuminates when fully in the park position. 4. With the ignition switch still on, shift to each gear position and observe the gear position icons on the LCD gauge.
  • Page 19 CHECKING/REPLACING PADS The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear. The only maintenance that is required is replacement of the brake pads when they show excessive wear. Check the thick- ness of each of the brake pads as follows. 1.
  • Page 20 3. Remove the nut securing the movable drive face; then remove the face. Account for the flat washer and spacer. NOTE: Keep the drive face plate in contact with the drive face when removing or installing the drive face to prevent the rollers from falling out. GZ085 INSTALLING 1.
  • Page 21 NOTE: At this point, remove the cap screw from 4. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws mak- the driven pulley face. ing sure the different-lengthed cap screws are in their proper location.

  • Page 22: Troubleshooting Brake System

    Troubleshooting Brake System Problem: Braking poor Condition Remedy 1. Pad worn 1. Replace pads 2. Brake fluid leaking 2. Repair - replace hydraulic system 3. Master cylinder/brake cylinder seal worn 3. Replace seal(s) Problem: Brake pedal travel excessive Condition Remedy 1.
  • Page 23 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 Troubleshooting ............3-3 Prowler HDX (Table of Contents) ......3-6 Manual Table of Contents...

  • Page 24: Specifications

    Valve Guide Inside Diameter 5.000-5.012 mm Valve Stem Outside Diameter (intake/exhaust) 4.972-4.987 mm NOTE: Arctic Cat recommends the use of new Valve Stem Runout (max) 0.1 mm gaskets, lock nuts, and seals and lubricating all Valve Head Thickness (min) 2.3 mm...
  • Page 25 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 26 Problem: Engine noisy (Noise seems to come from crankshaft) Condition Remedy 1. Main bearing worn - burned 1. Replace bearing 2. Lower rod-end bearing worn - burned 2. Replace bearing 3. Connecting rod side clearance too large 3. Replace crankshaft assembly 4.
  • Page 27 Problem: Engine lacks power Condition Remedy 1. Valve clearance incorrect 1. Adjust clearance 2. Valve springs weak 2. Replace springs 3. Valve timing out of adjustment 3. Time camshaft 4. Piston ring(s) - cylinder worn 4. Replace - service rings - cylinder 5.
  • Page 28 3. Remove the center floorboard. Prowler HDX 4. Marking all nylon tie locations for installing pur- poses, from the right side disconnect the MAP (Table of Contents) sensor connector (A), fuel injector connector (B), ISC connector (C), and TPS connector (D). Removing Engine/Transmission......
  • Page 29 7. Remove four sheet metal screws securing the air filter mounting bracket to the frame; then loosen the air inlet boot clamp and disconnect the IAT sensor connector and remove the air filter assem- bly. HDX137A 10. Remove the E-clip from the shift arm; then remove the cap screws securing the shift cable bracket to the engine case.
  • Page 30 14. Remove the two exhaust springs at the muffler; then remove the exhaust pipe. Account for a gra- foil seal in the cylinder head and a grafoil seal at the muffler. HDX146A HDX153A 15. Remove the cap screws securing the driveshafts to the front and rear engine flanges;...
  • Page 31 Removing Top-Side Components A. Valve Cover B. Cylinder Head NOTE: Remove the spark plug and timing inspec- tion plug; then using an appropriate wrench, rotate the crankshaft to top-dead-center of the compres- sion stroke. HDX157A 1. Remove the two tappet covers. HDX156A 18.
  • Page 32 CD206 CC012D 5. Bend the washer tabs down and remove the two cap screws securing the sprocket to the camshaft; then drop the sprocket off the camshaft. CD211A 3. Loosen the cap screw on the end of the tensioner; then remove the two cap screws securing the ten- sioner adjuster assembly and remove the assembly.
  • Page 33 9. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins; then remove the cam chain guide. CC014D NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase. CC020D 8.
  • Page 34 CC023D CC026D 12. Lift the cylinder off the crankcase taking care not to AT THIS POINT  allow the piston to drop against the crankcase. Account for the gasket and two alignment pins. To service cylinder, see Servicing Top-Side Compo- nents sub-section.
  • Page 35 NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install a suit- able connecting rod holder. CAUTION Do not allow the connecting rod to go down inside the crankcase. If the rod is down inside the crank- case and the crankshaft is rotated, severe damage will result.
  • Page 36 3. Remove the valve springs; then invert the cylinder head and remove the valves. Measuring Valve Stem Runout 1. Support each valve stem end with the V Blocks; then check the valve stem runout using a dial indicator. ATV1082A 3. Rotate the valve in the V blocks. 4.
  • Page 37 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 surface is worn, the valve must be replaced.
  • Page 38 2. Using the sharpened ring as a tool, clean carbon from the ring-grooves. Be sure to position the ring with its tapered side up. CAUTION Improper cleaning of the ring-grooves by the use of the wrong type of ring-groove cleaner will result in severe damage to the piston.
  • Page 39 Cleaning/Inspecting Cylinder Head CAUTION The cylinder head studs must be removed for this procedure. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber being careful not to nick, scrape, or damage the com- bustion chamber or the sealing surface. 2.
  • Page 40 Honing 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 41 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 measur- ing clearance.
  • Page 42 Inspecting Camshaft Spring/Drive 1. Inspect the spring and drive pin for damage. CC032D 2. Place the two alignment pins into position. Place the cylinder gasket into position; then place a piston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase. CF061A CF060A CF083...
  • Page 43 CC023D CF057A 5. Install the coolant hose onto the crankcase union and 8. Install the four cylinder head cap screws. Tighten tighten the clamp. only until snug. C. Cylinder Head D. Valve Cover NOTE: Steps 1-5 in the preceding sub-section must precede this procedure.
  • Page 44 732-307B CF013A A. Piston still at top-dead-center. NOTE: At this point, oil the camshaft journals, cam lobes, and the three seating surfaces on the B. Camshaft lobes directed down (toward the pis- ton). cylinder. C. Camshaft alignment marks parallel to the valve 14.
  • Page 45 CD464 CC012D 18. Rotate the crankshaft until the second cap screw 21. Install the cylinder head plug in the cylinder head securing the sprocket to the camshaft can be with the open end facing downward and toward the installed; then install the cap screw (threads coated inside.
  • Page 46 CD469 CC005D 24. Using a flat-blade screwdriver, rotate the adjuster 26. Apply a thin coat of Three Bond Sealant to the mat- screw inside the tensioner counterclockwise until all ing surfaces of the cylinder head and valve cover. tension is released; then install the cap screw into the end of the chain tensioner.
  • Page 47 CC001D PR465 32. If removed, install the spark plug. Tighten securely. 3. Using a cold chisel, scribe a mark showing the rela- tive position of the shift arm to the shift arm shaft to aid in installing; then remove the shift arm. Left-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which...
  • Page 48 CD939A CD214 6. Remove the two cap screws securing the water pump to the engine; then remove the water pump.  NOTE: The water pump is not a serviceable com- ponent. If the pump is defective or if the mechani- cal seal is leaking (coolant dripping from the discharge hole), the water pump must be replaced (see Section 4).
  • Page 49 12. Remove the snap ring securing the water pump drive gear; then remove the gear noting the direction of the sides of the gear for installing purposes. Account for the drive gear alignment pin. PR434A Installing Left-Side Components CD944 13. Remove the snap ring securing the water pump driven gear;...
  • Page 50 CD949 CD139 NOTE: The sharp side of the snap ring should be facing outward. 2. Install the water pump drive gear drive pin and the drive gear (with the flat side of the gear facing out- ward as noted in removing); then secure with the snap ring.
  • Page 51 5. Install the shift cam plate onto the shift cam shaft; then coat the cap screw threads with red Loctite #271 and tighten securely. CD954A CD935A CD927A 8. Lubricate the magneto cover gasket with fresh engine oil; then place it into position on the two alignment pins.
  • Page 52 GZ232 PR465 14. Place the water pump into position and secure with 11. Tighten the cap screws (from step 9) to 8 ft-lb. two cap screws. Tighten securely. 12. Clean the countershaft and trigger splines thoroughly 15. Install the crossover tube on the water pump and cyl- and install the inner snap ring onto the shaft;...
  • Page 53 5. Using an impact driver, remove the cap screws securing the air intake plate; then remove the plate cushion. CD079 2. Remove the nut securing the movable drive face; then remove the face. Account for a flat washer and spacer. PR393 6.
  • Page 54 CF088A 9. Remove the two Allen-head screws securing the gear A. Oil Pump Driven Gear D. One-Way Clutch position switch; then remove the sensor. Account for (Green Dot MUST Show) B. Oil Pump Drive Gear two neutral contact pins and two springs. E.
  • Page 55 13. Remove the snap ring securing the oil pump driven gear (A); then remove the gear noting the direction of the sides of the gear for installing purposes. Account for a pin and a washer. CC606 CD984 CD987 CD895A 14. Remove the cap screws securing the oil pump; then remove the pump.

  • Page 56: Driven Pulley

    INSPECTING CENTRIFUGAL CLUTCH SHOE 1. Inspect the clutch shoes for uneven wear, chips, cracks, or discoloration. If any shoe is damaged, replace the complete set. 2. Inspect the clutch shoes for wear or damage. If any shoe is worn to the bottom of the groove, replace the complete set.
  • Page 57 CD999 CD991 3. Install the oil pump onto the engine; then tighten the 5. Grease the driven gear pin and insert it into the oil cap screws securely. pump shaft; then install the driven gear (noting the direction of the sides of the gear from removing). Secure with a snap ring.
  • Page 58 CF086 PR410A 10. Apply grease to the outer edges of the clutch hous- 7. Install the clutch cover alignment pins into the crank- ing; then from inside the clutch cover, install the case, apply oil to the cover gasket, and install the clutch housing into the cover using a rubber mallet.

  • Page 59: Engine/Transmission

    CD970 CF261 13. Place the driven pulley assembly into position and CAUTION secure with the nut. Using Spanner Wrench, tighten to 80 ft-lb. Make sure the splines extend beyond the drive face or a false torque reading and spline damage may 14.
  • Page 60 Separating Crankcase Halves 1. Remove the left-side cap screws securing the crank- case halves. Note the location of the differ- ent-lengthed cap screws. 2. Remove the right-side cap screws securing the crankcase halves. Note the location of the differ- ent-lengthed cap screws. 3.
  • Page 61 PR380A CD826 5. Remove the countershaft assembly (D). Account for 8. Remove the crank balancer. a washer on each end of the countershaft. NOTE: There is a flat spot on the crank balancer bearing flange to allow clearance past the crank- shaft.
  • Page 62 CAUTION Unless the secondary drive gear, bevel gear, or bear- ings require service, do not remove the secondary drive assembly from the case. If removed, bevel gear backlash will have to be adjusted requiring re-shimming of the drive bevel gear shaft. 13.
  • Page 63 MT008B MT005A 5. Acceptable backlash range is 0.115-0.390 mm NOTE: Do not use a new lock nut at this time as (0.005-0.015 in.). this procedure may have to be repeated. Correcting Backlash 5. Place the assembled shaft into the left crankshaft NOTE: If backlash measurement is within the case;...
  • Page 64 CC290D ATV-1074 2. Maximum diameter must not exceed specifications. 3. Zero the indicator and rotate the crankshaft slowly. Measuring Connecting Rod (Small CAUTION End Deflection) Care should be taken to support the connecting rod 1. Place the crankshaft on a set of V-blocks and mount a when rotating the crankshaft.
  • Page 65 COUNTERSHAFT GZ296 GZ281A 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 66 Assembling 1. From the drive gear end, install a thrust washer, bushing, and bearing; then install the low driven gear and washer. GZ320 GZ317A GZ319 GZ318 2. Install the low driven gear locking washer; then install the inner reverse driven gear washer. GZ318A 6.
  • Page 67 GZ320B GZ314 3. Install the reverse driven bushing and bearing; then 5. Install the reverse driven gear dog onto the counter- install the reverse driven gear. shaft and secure with a snap ring. GZ286A GZ313A GZ287 GZ312 4. Install the outer reverse driven washer; then secure 6.
  • Page 68 7. Install the drive gear washer and the shift forks. The NOTE: If heating the bearing is not possible, the countershaft is now ready for installation. crankshaft can be installed using a crankshaft installing tool. NOTE: When installing the countershaft assem- bly, account for the washer on each end of the 3.
  • Page 69 CC674 CD268A 7. Place a washer on each end of the gear shift shaft; 11. Place the oil strainer into position; then secure with then install the shaft assembly making sure the two the two screws. holes on the end of the shaft are positioned vertically. 12.
  • Page 70 Installing Engine/Transmission NOTE: Arctic Cat recommends new gaskets and O-rings be installed whenever servicing the vehi- cle. 1. Using a suitable lifting sling and engine hoist, lower the engine into the vehicle engaging the slotted rear engine mount brackets with the engine HDX153A mounts;...

  • Page 71: Air Filter

    8. Install the starter cable to the starter motor, secure with the nut and tighten securely; then secure the engine/harness ground wires to the engine with a cap screw and tighten to 8 ft-lb. HDX137A 11. Install the throttle body into the intake manifold boot and secure with the clamp.
  • Page 72 16. Pour the recommended amount of oil and coolant into the engine and radiator; then loosen the cool- ant bleed screw to allow trapped air to escape. When clear coolant flows, tighten the bleed screw. HDX138B 15. Connect the MAP sensor connector (A), fuel injec- tor connector (B), ISC connector (C), and TPS connector (D);...

  • Page 73: Fuel/Lubrication/Cooling

    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 ............4-5 Oil Filter/Oil Pump ........... 4-5 Oil Cooler ..............4-6 Liquid Cooling System..........4-6 Radiator..............4-7 Thermostat .............. 4-8 Fan ................

  • Page 74: Torque Specifications

    REMOVING THROTTLE BODY Fuel/Lubrication/Cooling 1. Turn the ignition switch to the OFF position; then remove the ignition switch key. ! WARNING NOTE: Some photographs and illustrations used Do not turn the ignition switch to the ON position in this section are used for clarity purposes only and are not designed to depict actual conditions.
  • Page 75 5. Slowly disconnect the gasline hose connector from 2. Disconnect the vent hose (A), gasline hose (B), and fuel pump/fuel level sensor connector (C); then cap the fuel rail. the vent fitting and gas hose fitting. ! WARNING Gasoline may be under pressure. Place an absor- bant towel under the connector to absorb any gaso- line spray when disconnecting.
  • Page 76 5. Remove the joining cap screw and nut from the rear gas tank hold-down strap; then remove the inside hold-down strap. PR699A 2. Swing the front hold-down to the right into position and install the cap screw and nut. Do not tighten at this time.
  • Page 77 7. Position the floorboard into the vehicle and secure with the appropriate hardware; then install the seat base, seat back, and seat. Gas/Vent Hoses Replace the gas hose every two years. Damage from aging may not always be visible. Do not bend or obstruct the routing of the vent hoses.

  • Page 78: Oil Cooler

    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 thermostat housing to allow air to bleed from the cooling system.
  • Page 79 Radiator REMOVING 1. Remove the two sheet metal screws securing the dash assembly to the frame (center front). PR183A 5. Remove the two shoulder bolts and nuts securing the radiator to the frame; then disconnect the upper and lower coolant hoses. HDX162A 2.
  • Page 80 Thermostat REMOVING 1. Drain approximately one quart of coolant from the cooling system. 2. Remove the two cap screws securing the thermostat housing to the cylinder head. Account for a thermo- stat with seal. INSPECTING PR184A 2. Connect the upper and lower coolant hoses to the NOTE: Whenever a part is worn excessively, radiator and secure with the appropriate hose clamps;...
  • Page 81 PR281A PR122A 2. Fill the cooling system with the recommended 2. Drain the oil from the engine/transmission. amount of antifreeze. Check for leakage. 3. Remove the seats and center console; then remove the right-side seat-base. 4. Loosen the coolant hose clamps and slide the clamps away from the hose ends.
  • Page 82 5. Check the entire cooling system for leakage. CAUTION After operating the vehicle for the initial 5-10 min- utes, stop the engine, allow the engine to cool down, and check the coolant level. Add coolant as neces- sary. 6. Install the seat base, seat back, and seat. Electric Fuel Pump/Fuel Level Sensor CC786A...
  • Page 83 4. If the pump is not running, disconnect the fuel pump/sensor connector by reaching under the rear rack from behind. 5. Connect a multimeter to the power supply leads with the red tester lead to the red wire and the black tester lead to the black wire;...

  • Page 84: 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 85: Electrical System

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

  • Page 86: Specifications

    ! WARNING Electrical System Any time service is performed on a battery, the fol- lowing must be observed: keep sparks, open flame, cigarettes, or any other flame away. Always wear NOTE: Some photographs and illustrations used safety glasses. Protect skin and clothing when in this section are used for clarity purposes only handling a battery.

  • Page 87: Troubleshooting

    ! WARNING RPM Limiter An overheated battery could explode causing severe injury or death. Always monitor charging times and charge rates carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool NOTE: The ROV is equipped with an ECU that before resuming charging.

  • Page 88: Brakelight Switch

    NOTE: If the meter shows battery voltage, the main wiring harness is good; proceed to test the Accessory switch/component, the connector, and the switch Receptacle/Connector wiring harness for resistance. RESISTANCE (Switch Connector) NOTE: This test procedure is for either the recep- CAUTION tacles or the connectors.
  • Page 89 3. On the ECT sensor when the temperature reaches If there is any type of electrical system failure, always 40° C (104° F), the meter should read approximately check the fuses first. 1136 ohms. NOTE: The fuses are located in a power distribu- 4.

  • Page 90: Efi Sensors/Components

    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 resistance tests to avoid damaging the multimeter.

  • Page 91: Speed Sensor

    NOTE: If the meter does not read as specified, replace the sensor. Speed Sensor NOTE: Prior to testing the speed sensor, inspect the three-wire connector on the speed sensor for contamination, broken pins, and/or corrosion. 1. Set the meter selector to the DC Voltage position. CD070 2.
  • Page 92 The following is a list of conditions that can generate a NOTE: Prior to troubleshooting below, make sure malfunction code. All conditions with the exception of that Ignition Key Switch has not been left on with item 5 are external to the EPS assembly and therefore can the engine not started.
  • Page 93 Ignition Switch Drive Select Switch RESISTANCE To access the ignition switch, dash switches, front acces- sory connectors, and front switched accessory connector, 1. Remove the switch assembly from the dash; then dis- the dash must be unfastened and slid to the rear. connect the harness from the switch.

  • Page 94: Reverse Override Switch

    Reverse Override Switch VOLTAGE NOTE: To perform the following tests, the ignition switch must be in the ON position and the trans- mission shifted into reverse gear. 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 drive select switch.

  • Page 95: Shift Lever

    RESISTANCE (AC Generator) Stator Coil/Crankshaft CAUTION Position (CKP) Sensor Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1. Set the meter selector to OHMS position. VOLTAGE (AC Generator - Regulated Output) 2. Test between the three yellow wires for a total of three tests.

  • Page 96: Starter Relay

    3. Connect the battery. TESTING VOLTAGE Perform this test on the starter motor positive terminal. To access the terminal, slide the boot away. NOTE: The ignition switch must be in the ON posi- tion, and the shift lever in the NEUTRAL position. 1.

  • Page 97: Ignition Timing

    The ECU is rarely the cause for electrical problems; how- NOTE: If battery voltage is not shown in any test, ever, if the ECU is suspected, substitute another ECU to inspect the LIGHTS fuse on the power distribution verify the suspected one is defective. module, headlight switch, ignition switch, switch connectors, or wiring harness.

  • Page 98: Ecu Error Codes

    2. Start the engine and using the RPM function on the • 26 = Ignition Coil #2* - H2 speedometer/tachometer, run at 1500 RPM; ignition • 32 = Fuel Injector #1* timing should be 10° BTDC. • 34 = Fuel Injector #2* - H2 •...
  • Page 99 2. Install the needle adapters to the multimeter leads; then select DC Voltage on the multimeter. 3. Connect the red tester lead to the blue/brown wire (B) and the black tester lead to the black/yellow wire (A); then turn the ignition switch ON and observe the meter.

  • Page 100: Throttle Position Sensor

    5. Turn the ignition switch to the OFF position. Throttle Position Sensor 6. Select the OHMS position on the meter; then per- form the following resistance tests on the TPS. (TPS) Throttle Position Pins Ohms Closed A, B, or C to Ground Infinity (Open) INSPECTING A to B...
  • Page 101 CAUTION Always make sure the ignition switch is in the OFF position before disconnecting the ECU. 9. Clear all ECU error codes after servicing is complete (see ECU Error Codes in this section). REMOVING 1. Remove the seats and center console; then discon- nect the three-wire TPS connector plug.
  • Page 102 Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. CKP sensor defective 3. Replace CKP sensor 4. ECU defective 4. Replace ECU Problem: Spark plug fouled with carbon Condition Remedy 1.
  • Page 103 Problem: Starter does not engage Condition Remedy 1. Battery charge low 1. Recharge - replace battery 2. Switch contacts defective 2. Replace switch 3. Starter motor brushes not seating 3. Replace starter 4. Starter relay defective 4. Replace relay 5. Emergency stop - ignition switch off 5.
  • Page 104 NOTES Manual 5-20 Table of Contents...

  • Page 105: Drive System

    SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Front Drive Actuator ..........6-2 Front Differential ............6-3 Drive Axles ............6-15 Rear Gear Case ............ 6-20 Hub................ 6-22 Hydraulic Brake Caliper......... 6-24 Universal Joints ............. 6-28 Troubleshooting .............

  • Page 106: Suspension

    The front drive actuator is located on the right side of the front drive input housing. With the engine stopped and Drive System the ignition switch in the ON position, a momentary “whirring” sound can be heard each time the front drive selector switch is shifted.
  • Page 107 INSTALLING NOTE: It is important to tighten this cap screw while the others are loose to ensure proper seating 1. Lubricate the O-rings on the actuator; then ensure all of the actuator. mounting surfaces are clean and free of debris. 5.
  • Page 108 PR264A PR222 7. Disconnect the front drive actuator connector from 10. 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.
  • Page 109 PR205A GC015 14. Remove the upper differential mounting cap screw. Account for a lock nut and two washers. CD106 3. Remove the snap rings from the input shaft; then remove the input shaft from the pinion housing. CD016 15. Free the differential assembly from the frame mount- ings;...
  • Page 110 5. Remove the snap ring securing the input shaft bear- ing; then place the pinion housing in a press and remove the bearing. GC012 GC011 GC011 2. Install the input shaft seal making sure it is fully seated in the edge of the housing. AF984 GC014 3.
  • Page 111 GC009A GC015 5. Place the pinion housing with new gasket onto the 2. Using a T-40 torx wrench, remove the cap screws differential housing; then secure with existing cap securing the differential cover. Account for and make screws. Tighten to 23 ft-lb. note of the ID tag location for assembling purposes.
  • Page 112 KX175 KX181 5. Remove the left differential bearing flange assembly Disassembling Pinion Gear and account for a shim. Mark the shim as left-side. NOTE: Any service of the pinion gear or related bearings will require a new gear case/differential housing. The removal of the lock collar severely damages the threads in the housing.
  • Page 113 CC878 CC883 3. Secure the pinion gear in a bearing puller; then 2. Place the pinion assembly in a bearing puller; then remove the pinion bearing using a press. Account for install the bearing using a press. a collar and a bearing. CC884 3.
  • Page 114 The following procedure can be used on both front differ- ential or rear drive gear case. 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 shimming.
  • Page 115 GC032A GC040 GC033A GC039A 4. Install the existing shim or a 0.063 in. shim on the 6. Zero the dial indicator; then while holding the pinion cover side of the ring gear; then place the assembled stationary, rock the ring gear assembly forward and gear case cover onto the gear case and secure with back and record the backlash.
  • Page 116 GC035 GC036B 2. Zero the dial indicator; then push the ring gear NOTE: The spider and ring gear assembly must toward the dial indicator and release. End-play be replaced as a complete unit. should be 0.004-0.008 in. 3. Assemble the fork and sliding collar into the cover 3.
  • Page 117 8. Place the input shaft assembly onto the gear case housing; then secure with the existing cap screws. Tighten to 23 ft-lb. 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 #270).
  • Page 118 CF278 PR198A 6. Install the front axles. CAUTION 7. Install the knuckle assemblies onto the axles and ball Make sure the tool is free of nicks or sharp edges or joints; then secure with four cap screws taking care damage to the seal may occur. not to damage the threads when installing.
  • Page 119 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 support stand to avoid injury. AF897D 9. Install the brake calipers. Secure with new 2.
  • Page 120 PR220A CD019 6. While holding the drive axle stationary, pull the top 2. Inspect boots for any tears, cracks, or deterioration. of the knuckle out and down until it is free of the NOTE: If a boot is damaged in any way, it must be drive axle.
  • Page 121 7. Using a side-cutters (or suitable substitute), remove both outside boot clamps from the shaft. Note the position of the different-sized clamps for assembling purposes. CD023 4. Note the difference inside each bearing ring end for assembling purposes; then remove the bearing ring. NOTE: The recess of the bearing must face CD751 toward the housing.
  • Page 122 CD754 ATV-1048 10. Using CV Boot Clamp Tool, secure both outside 3. Apply 80 grams (2/3 of contents) of grease from the boot clamps. pack into the bearing housing. 4. Install the bearing onto the shaft making sure the CAUTION recess of the bearing is facing the housing.
  • Page 123 NOTE: Pull the bearing ring out of the housing 2. Swing the knuckle up and onto the drive axle; then place the knuckle into place in the upper A-arm. until it contacts the snap ring; then slide the ring in Secure the knuckle to the A-arm with a cap screw half way.

  • Page 124: Rear Gear Case

    CD027 PR207 7. Install the wheel and tighten to 80 ft-lb. AT THIS POINT  8. Remove the vehicle from the support stand. For servicing the input shaft, pinion gear, needle bearing, ring gear, and axle seal, see Front Differen- 9.
  • Page 125 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. GZ180 GC058A 3. If clearance is as specified, remove the ring gear and thrust button;...
  • Page 126 Assembling/Installing INSTALLING 1. Install a new bearing into the input housing and 1. Slide the gear case into position down through the secure with the snap ring (flat side directed away upper-left side of the frame; then align the driveline from bearing).
  • Page 127 PR243A PR250 5. Remove the hub assembly. 3. Using a socket and ratchet handle, tighten the nut until the stud is fully drawn into the hub. 6. Remove the four cap screws securing the brake disc. PR252A PR254A INSTALLING CLEANING AND INSPECTING 1.

  • Page 128: Hydraulic Brake Caliper

    Hydraulic Brake Caliper ! WARNING Arctic Cat recommends only authorized Arctic Cat ROV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of control causing severe injury or death. REMOVING/DISASSEMBLING PR221 1. Secure the vehicle on a support stand to elevate the 4.
  • Page 129 4. Compress the caliper holder against the caliper (opposite the O-ring side) and remove the outer brake pad; then remove the inner brake pad. NOTE: If brake pads are to be returned to service, do not allow brake fluid to contaminate them. PR713A PR237A PR715...
  • Page 130 PR719C PR715 4. Install the caliper onto the caliper holder making sure the caliper and holder are correctly oriented. NOTE: It is very important to apply silicone grease to the O-rings and caliper bores prior to assembly. PR717A 2. Press the piston into the caliper housing using hand pressure only.

  • Page 131: Hydraulic Brake System

    2. Remove the cotter pin and pivot pin from the yoke; then remove two cap screws and flange nuts securing the master cylinder assembly to the frame. PR239 6. Place the brake caliper assembly into position and secure with new “patch-lock” cap screws. Tighten the caliper to 20 ft-lb.

  • Page 132: Universal Joints

    Universal Joints REMOVING NOTE: The universal joints can be accessed by removing the belly panel. To remove the belly panel, see Belly Panel in Section 8. 1. Support the vehicle on suitable jack stands elevated high enough to allow working from the underside of the vehicle.
  • Page 133 PR367C PR374 3. Install the retainer in the bearing cup; then remove INSTALLING the yoke from the separator tool. 1. Remove the bearing cups from the universal joint; NOTE: Repeat steps 2-3 for the opposite-side then insert the joint into the yoke and install one bearing cup.
  • Page 134 Troubleshooting Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shaft serration worn - broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel Condition Remedy 1. Secondary drive - driven gear teeth broken 1.

  • Page 135: Table Of Contents

    SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 Front A-Arms ............7-3 Rear A-Arms ............7-5 Wheels and Tires ............ 7-6 Troubleshooting ............7-8 Manual Table of Contents...

  • Page 136: Shock Absorbers

    3. Remove the two cap screws and nut securing each rear shock absorber to the frame and lower A-arm. Suspension Account for bushings and sleeves from each. NOTE: Critical torque specifications are located in Section 1. The following suspension system components should be inspected periodically to ensure proper operation.
  • Page 137 3. Tighten the front shock absorber cap screws to 33 ft-lb 7. Remove the cap screws securing the ball joints to the and the rear shock absorber cap screws to 33 ft-lb knuckle. (upper) or 20 ft-lb (lower). CAUTION 4. Remove the vehicle from the support stand. Support the knuckle when removing the cap screws or damage to the threads will occur.
  • Page 138 AF616D AF610D 3. Route the brake hose through the upper A-arm shock CLEANING AND INSPECTING absorber mount. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all A-arm components in parts-cleaning solvent. 2.
  • Page 139 AF618D PR260 8. Apply grease to the hub and drive axle splines; then 13. Install the wheel and tighten to 80 ft-lb. install the hub assembly onto the drive axle. 14. Remove the vehicle from the support stand. Rear A-Arms REMOVING 1.

  • Page 140: Wheels And Tires

    ! WARNING with cap screws and new lock nuts. Tighten to 35 ft-lb. Use only Arctic Cat approved tires when replacing 3. Tighten the hardware securing the A-arms to the tires. Failure to do so could result in unstable vehi- frame mounts (from step 1) to 33 ft-lb.
  • Page 141 REMOVING INSTALLING 1. Secure the vehicle on a support stand to elevate the 1. Install each wheel on its hub and secure with the exist- wheels. ing hardware. 2. Tighten to 80 ft-lb. ! WARNING CHECKING/INFLATING Make sure the vehicle is solidly supported on the support stand to avoid injury.
  • Page 142 Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring preload incorrect 1. Adjust preload 2. Spring(s) weak 2. Replace spring(s) 3. Shock absorber damaged 3. Replace shock absorber Problem: Suspension too stiff Condition Remedy 1. Spring preload incorrect 1. Adjust preload 2.

  • Page 143: Steering/Frame

    SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Electronic Power Steering (EPS)......8-2 Steering Assembly ..........8-5 Steering Wheel............8-6 Upper Steering Shaft..........8-6 Intermediate Steering Shaft Assembly....8-7 Steering Knuckles ........... 8-8 Checking/Adjusting Front Wheel Alignment ..8-10 Front Bumper Assembly ........
  • Page 144 Steering/Frame NOTE: Critical torque specifications are located in Section 1. The following steering components should be inspected periodically to ensure safe and proper operation. A. Steering wheel secure. B. Steering has equal and complete full-left and full-right capability. PR760A 4. Remove the steering wheel; then remove the steering C.
  • Page 145 PR765A PR776A 7. Remove the steering shaft housing and shaft from the NOTE: Alignment need only be approximate as steering support and intermediate shaft; then remove final alignment is not possible until the EPS is the intermediate shaft from the EPS input shaft. engaged with the coupler.
  • Page 146 PR764B PR780 9. Install the cap screw in the intermediate shaft coupler 4. Using an appropriate crow-foot and backing wrench, and tighten to 31 ft-lb; then tighten the cap screw remove the tie rod assembly. (from step 6) to 11 ft-lb. NOTE: Tie rods come as a complete assembly.
  • Page 147 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. PR301 3. Remove the EPS cradle bracket; then remove the cap screws securing the steering rack assembly to the rack bracket and remove from the left side.

  • Page 148: Steering Wheel

    2. Install the EPS cradle bracket and secure with four NOTE: If a new steering wheel is being installed, cap screws. Do not tighten the cap screws at this mark the wheel as close as possible to the old time. wheel mark;...
  • Page 149 PR765A PR765A 3. Remove the steering shaft housing and shaft from the steering support and intermediate shaft; then remove Intermediate Steering the intermediate shaft from the EPS input shaft. Shaft Assembly NOTE: Any time steering components are disas- sembled, all connecting components should be marked for proper alignment during assembling.

  • Page 150: Steering Knuckles

    2. Install the steering shaft housing with steering shaft 2. Remove the cotter pin from the axle. connecting the steering shaft and intermediate shaft 3. Remove the nut securing the hub. first; then slide the housing into place on the steering support.
  • Page 151 NOTE: During assembling, new cotter pins should be installed. 4. Apply a small amount of grease to the hub splines. PR292A PR290A 5. Install the hub assembly onto the splines of the shaft. PR289 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws.

  • Page 152: Wheel Alignment

    PR260 PR087A To adjust the wheel alignment, use the following proce- NOTE: If the hole in the axle shaft does not align dure. with the slots in the castle nut, tighten the nut until 1. Center the steering wheel; then using an open-end the hole and slots align.
  • Page 153 PR086 PR328A 2. Loosen but do not remove the four cap screws and flange nuts securing the hood hinge to the frame; Front Bumper Assembly then lower the hood. REMOVING Remove four cap screws and nuts. Account for four lock washers and eight flat washers.
  • Page 154 Floor REMOVING 1. Remove the seat, seat back, and seat base. 2. Remove the self-tapping screws securing the side foot restraints. 3. Remove the center floorboard. PR332 3. Connect the four headlight connectors; then secure the wires with two new nylon ties. HDX132A 4.
  • Page 155 INSTALLING 5. From the opposite side of the vehicle repeat step 3; then lift the rear of the floor up and lift the floor out 1. Place the dash into position and connect the of the vehicle. park/seat belt indicator light, dash harness, and CLEANING AND INSPECTING gauge connector.

  • Page 156: Taillight Assembly

    INSPECTING MUFFLER 3. Lower the cargo box; then remove the four cap screws (from step 2). NOTE: Whenever a part is worn excessively, cracked, 4. With the help of an assistant or an adequate lift, or damaged in any way, replacement is necessary. remove the cargo box from the vehicle.
  • Page 157 INSTALLING 2. Disconnect the three-prong connector from the bulb socket and remove the taillight assembly. 1. Connect the three-prong connector to the bulb INSPECTING socket; then place the taillight assembly into position on the rear ROPS tube. NOTE: Whenever a part is worn excessively, cracked, 2.
  • Page 158 Problem: Tire wear rapid or uneven Condition Remedy 1. Wheel hub bearings worn - loose 1. Replace bearings 2. Front wheel alignment incorrect 2. Adjust alignment Problem: Steering noise Condition Remedy 1. Caps screws - nuts loose 1. Tighten cap screws - nuts 2.

  • Page 159: Controls/Indicators

    SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Accelerator Pedal ............ 9-2 Shift Lever ............... 9-2 Shift Cable............... 9-2 Speedometer/Tachometer/LCD/Indicator Lights ..9-3 Manual Table of Contents...

  • Page 160: Accelerator Pedal

    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. HDX166A PR709 HDX168A INSTALLING 1. Install the shift axle supports onto the shift lever; then secure the axle supports to the frame with four cap screws and tighten to 48 in.-lb.
  • Page 161 2. Remove the nut securing the shift cable to the shift arm; then loosen the upper adjuster nut on the shift cable and remove the shift cable from the shifter assembly. HDX132A INSTALLING 1. Route the cable into position making sure there are HDX166A no kinks or sharp bends.
  • Page 162 7. Plug the multi-pin connector into the gauge; then turn the ignition switch to the ON position and check gauge functions. 8. Slide the dash into position and secure with the six screws. 9. Install the shifter handle; then install the steering boot support.
  • Page 163 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2258-933 ®™...

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