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Arctic Cat Prowler Manuals
Manuals and User Guides for Arctic Cat Prowler. We have
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Arctic Cat Prowler manuals available for free PDF download: Service Manual, Operator's Manual
Arctic Cat Prowler Service Manual (501 pages)
1990-1998
Brand:
Arctic Cat
| Category:
Snowmobiles
| Size: 30.05 MB
Table of Contents
Table of Contents
2
Quick Reference Data
5
General Information
11
Chapter One
11
Manual Organization
12
Safety Information
12
Notes, Cautions and Warnings
12
Safety First
12
Service Hints
13
Gasket Remover
14
Expendable Supplies
14
Engine and Chassis Serial Numbers
15
Engine Operation
16
Fasteners
17
Torque Specifications
17
Index
17
Screw Threads
18
Precision Measuring Tools
19
Self-Locking Fasteners
20
Washers
21
Cotter Pins
21
Snap Rings (Circlips)
21
Lubricants
22
Engine Oil
22
Threadlock
23
Grease
23
Applying RTV Sealant
23
RTV Gasket Sealant
23
Gasket Removal
24
Expendable Supplies
24
Basic Hand Tools
24
Applying Threadlocks
24
Precision Measuring Tools
29
Special Tools
33
Mechanic's Tips
35
Removing Frozen Nuts and Screws
35
Removing Broken Screws or Bolts
35
Remedying Stripped Threads
36
Removing Broken or Damaged Studs
37
Ball Bearing Replacement
38
Bearing Removal
38
Bearing Installation
39
Shrink Fit
40
Seals
41
Snowmobile Operation
42
Prestart Inspection
42
Tools and Spare Parts
43
Emergency Starting
43
Snowmobile Safety
44
Proper Clothing
44
Snowmobile Code of Ethics
44
Emergency Survival Techniques
44
Model Listing
45
General Dimensions
46
Vehicle Weight
50
Decimal and Metric Equivalents
52
General Torque Specifications
53
Technical Abbreviations
53
Metrica Tap Drill Sizes
54
Windchill Factors
54
Troubleshooting
55
Chapter Two
55
Operating Requirements
56
Troubleshooting Instruments
56
Testing Electrical Components
56
Engine Electrical System Troubleshooting
57
Ignition Troubleshooting
58
Switch Tests
60
Ignition Testing
61
Ignition Component Resistance Test
61
Ignition High-Tension Coil
61
Ignition Charge Coil
62
Ignition Trigger Coil (Coil under Flywheel)
63
Ignition Trigger Coil (Coil Outside Flywheel)
63
Lighting Coil
63
Voltage Regulator
64
Fuel System
64
Identifying Fuel System Problems
64
Engine Problems
65
Preignition
65
Detonation
65
Electronic Fuel Injection
65
Fuel System Troubleshooting
66
Poor Idling
68
Misfiring
68
Flat Spots
68
Power Loss
68
Two-Stroke Pressure Testing
69
Excessive Vibrations
69
Low Engine Power
70
Power Train Troubles
71
Abnormal Engine Noise
72
Glazed Drive Belt
72
Uneven Drive Belt Wear
72
Engine Idle Speed too High
72
Brake Not Holding Properly
73
Excessive Chaincase Noise
73
Leaking Chaincase
73
Erratic Shifting
73
Skis and Steering Troubles
74
Track Assembly Troubles
74
Electro Specialties Model 1L Settings
75
Arctco Ignition Analyzer Peak Voltages
75
Ignition High Tension Coil
78
Ignition Trigger Coil (Sensor)
80
Lubrication, Maintenance and Tune-Up
82
Break-In Procedure
82
Chapter Three
82
Pre-Ride Checks
82
Fluid Checks
82
Maintenance Schedules
83
Correct Fuel Mixing
83
Lubrication
84
Proper Fuel Selection
84
Engine Oil Tank
84
Chaincase Oil
85
Steering Spindle Lubrication
86
Slide Suspension Lubrication
86
Air Cooling System
87
Speedometer Drive Adaptor
87
Checking/ Adjusting Fan Belt Tension
87
Fan Belt Removal/Installation
88
Liquid Cooling System
89
Check/Fill Coolant
90
Coolant Change
91
Daily Maintenance
92
Drive Belt Check
92
Stop and Tether Switch Operation
93
Headlight and Taillight Lens
93
Headlight and Taillight Operation
93
Steering Operation
93
Steering Bolts Check
94
Carburetor and Throttle Cable Inspection
94
Battery
94
Weekly Maintenance
95
Shock Absorbers
95
Ski and Ski Runner Check
95
Ski Alignment
96
Front Suspension Check
97
Rear Suspension Rail Wear Strip Inspection
97
Track Adjustment
98
Monthly Maintenance
100
Drive Belt
100
Non-Scheduled Maintenance
101
Brake Pad Wear Check
101
Fuel Filter
101
Brake Adjustment (Mechanical Brake)
101
Motor Mount Plate Diagram
102
Motor Mount Brackets (Powder Special) Diagram
103
Motor Mount Brackets (ZRT 600) Diagram
104
Hydraulic Brake Checking
106
Drive Chain (Non-Reverse Gear)
106
Throttle Cable Routing
107
Oil Injection Pump Adjustment
107
General Inspection and Maintenance
108
Recoil Starter Check
108
Body Fasteners Check
108
Electrical Connectors Check
109
Pulse Hose
109
Engine Tune-Up
110
Cylinder and Cylinder Head Nuts
110
Cylinder Compression
110
Correct Spark Plug Heat Rang
111
Spark Plug Conditions
112
Spark Plug Removal/Cleaning
113
Gapping and Installing the Plug
113
Reading Spark Plugs
114
Ignition Timing (Liquid-Cooled Engines)
114
Static Timing Check
115
Dynamic Timing Check
116
Setting Ignition Timing
118
Ignition Timing (Air-Cooled Engines)
120
Carburetur Adjustment
123
Idle Speed
124
Idle Mixture
124
Maintenance Schedule
125
Recommended Lubricants and Fuel
125
Approximate Refill Capacity
126
Track Tension
129
Maintenance Tightening Torques
129
Spark Plugs
131
Ignition Timing
131
Ignition Timing Type
132
Carburetor Pilot Air Screw and Idle Speed
133
Adjustments for Special Use
135
Carburetor Tuning
135
Chapter Four
135
Carburetor Adjustment
136
Carburetor Circuit Guide
136
High-Altitude Clutch Tuning
143
Gearing
143
Spring Suspension Adjustment
143
Front Suspension Spring Preload
144
Rear Suspension Adjustment
145
Slide Rails Adjustment
146
Carburetor Specifications
147
Driven Pulley Torque Bracket and Spring Application
148
Cam Arm Specifications
150
Sprocket Specifications
155
Shock Absorber Spring Settings
157
Engine Number Identification
159
Chapter Five
159
Engine Lubrication
160
Engine Service Precautions
160
Servicing Engine in Frame
161
Engine Removal
161
Engine Mounts Removal/Installation
164
Engine Installation
166
Engine Mounting Brackets Diagram
166
Engine Top End
168
Cylinder Head Removal/Installation
169
Top End Diagram
170
Cylinder Head Inspection
174
Cylinder Removal
176
Cylinder Inspection
177
Cylinder Stud Replacement
178
Threaded Holes and Screws
179
Cylinder Installation
179
Piston, Piston Pin, and Piston Rings
180
Piston and Piston Ring Removal
181
Piston (Wrist) Pin and Needle Bearing Inspection
182
Connecting Rod Inspection
184
Piston and Ring Inspection
185
Piston/Cylinder Clearance
187
Cylinder Honing
188
Piston Installation
189
Reed Valve Assembly (1990-1991 el Tigre)
190
Reed Valve Assembly (437.4, 497, 594 and 599 CC Engines)
192
Crankcase and Crankshaft
194
Crankcase Disassembly
195
Crankcase and Crankshaft Cleaning
196
Crankcase Inspection
197
Crankshaft Inspection
198
Crankshaft Bearing Replacement
200
Crankshaft Installation
203
Crankcase Assembly
206
Driveshaft for Coolant Pump and Oil Injection Pump
208
Shaft Removal
208
Engine Identification Table
212
Engine Technical Data
215
Engine Tightening Torques
218
Fuel System - Carbureted Models
221
Air Silencer
221
Carburetor Operation
221
Chapter Six
221
Float Mechanism
222
Idle, Intermediate and Main Fuel Systems
222
Starting Enrichment
223
Carburetor Removal/Installation
223
Carburetor to Engine Boots
224
Carburetor Application
224
Carburetor Disassembly
225
Carburetor Assembly
227
Carburetor Cleaning/Inspection
228
Float Heigh Check and Adjustment
229
Jet Needleffhrottle Valve Removal/Installation
229
Fuel Pump Removal/Installation
230
Altitude Compensator
230
Fuel Tank Removal/Installation
231
Throttle Cable Replacement
232
Fuel Tank Cleaning/Inspection
232
Carburetor Application Table
233
Carburetor Pilot Air Screw Adjustment
235
Fuel System - Fuel Injected Models
237
Chapter Seven
237
Fuel Injection System Components
239
Air Flow System
240
Electronic Control System
240
Fuel Flow System
240
Fuel Injection System Testing and Troubleshooting
242
(EFI Powered by Battery)
242
Testing and Troubleshooting (EFI System Magneto-Powered)
252
Fuel Tank Service
256
Component Service
256
Throttle Cable Service
257
Console Switches View
257
Fuel Rail, Pressure Regulator and Injectors Service
258
Throttle Body Assembly Service
261
Purge the Fuel System
262
Fuel Pump Service
262
Electronic Control Unit (ECU) Service
263
Changing the EPROM Chip
263
Idle Speed and Throttle Synchronization Adjustment
264
Throttle Position Sensor (TPS) Removal/Installation
264
TPS Setting Adjustment
265
Idle Speed Stop
265
Electronic Fuel Injection Error Codes
266
Engine Coolant Temperature Sensor Specifications
267
Exhaust System Removal/Installation
272
Chapter Eight
272
Exhaust System Cleaning
273
Exhaust System Repair
276
Small Dents (Exhaust System)
276
Large Dents (Exhaust System)
277
Electrical System
278
Chapter Nine
278
Ignition System Diagram
279
Flywheel Removal/Installation
280
Stator Plate Removal/Installation
290
Ignition Generating Coil Replacement
291
Lighting Coil Replacement
291
Ignition Coil Removal/Installation
292
CDI Unit Removal/Installation
293
Lighting System
294
Headlight Replacement
294
Voltage Regulator
294
Instrument Assembly
295
Headlight Adjustment
295
Taillight Bulb Replacement
295
Warning Lamps
296
High Beam Indicator Lamp
296
Switches
297
Safety Stop Switches
297
Tether Switch Removal/Installation
297
Emergency Kill (Stop) Switch
298
Headlight Dimmer Switch
298
Brake Light Switch
298
Ignition Switch
298
Fuel Level Sensor
299
Oil Level Gauge
299
Electric Starting Motor
299
Electric Starting Motor Disassembly
300
Electric Starting Motor Inspection
301
Electric Starting Motor Assembly
302
Battery State of Charge
303
Wiring Diagrams
303
Electrical System Tightening Torques
304
0Il Injection System
305
Oil Pump Service
305
Oil Pump Bleeding
305
System Components
305
Oil Tank Removal/Installation
306
Component Replacement
306
Oil Pump Removal, Inspection, Installation
307
Cooling Systems
310
Fan Belt Removal and Installation
310
Chapter Eleven
310
Fan-Cooled Models
310
Cooling Fan Assembly
311
Fan Cooling System Diagram
311
Cowling
312
Liquid-Cooled Models
313
Thermostat Removal
314
Thermostat Testing
315
Coolant Pump
316
Heat Exchangers
319
Hoses
319
Coolant Check Valve and Filter
323
Recoil Starter
324
Chapter Twelve
324
Starter Pulley Removal/Installation
325
Starter Housing Disassembly
327
Starter Housing Inspection
329
Starter Housing Assembly
330
Drive System
334
Drive Unit
334
Chapter Thirteen
334
Drive Pulley Assembly
335
Fixed and Sliding Pulley Halves
336
Drive Pulley Spring
337
Centrifugal Weight Levers
337
Driven Pulley
338
Drive Belt Removal/Installation
340
Drive Belt Inspection
341
Drive Belt Deflection
342
Drive Belt Alignment
342
Drive Pulley Service
344
Cam Arm Removal
344
Driven Pulley Service
355
Drive Belt Specifications
365
Drive System Specifications
367
Engine Speeds
368
Drive Pulley Clutch Spring Application
370
Drive Pulley Spring Specifications
371
Driven Pulley Torque Bracket (Cam) and Spring Application
372
Drive System Tightening Torques
379
Brake, Driven Shaft, Dropcase and Driveshaft
380
Chapter Fourteen
380
Drive Chain and Sprockets (Models Without Reverse)
380
Drive/Dropcase Assembly Diagram
381
Drive Chain and Sprockets (Models with Reverse)
384
External Chain Tensioner Diagram
388
External Chain Tensioner Service
390
Driven Shaft
391
Driven Shaft Inspection
393
Brake Disc Inspection
393
Driven Shaft Installation
393
Driveshaft Service
394
Drive Sprockets and Idler Wheel Replacement
396
Mechanical Brake System Service
397
Hydraulic Brake System Service
403
Brake Pads Service
404
Caliper Assembly
405
Master Cylinder
406
Brake Specifications
410
Front Suspension and Steering
411
Chapter Fifteen
411
Skis
411
Front Suspension
416
Spindle Removal
416
Spindle Inspection
417
Spindle Installation
418
Lower Suspension Arm Removal/Installation
419
Lower Suspension Arm Inspection
420
Upper Suspension Arm Removal/Installation
420
Upper Suspension Arm Inspection
421
Sway (Stabilizer) Bar Removal/Installation
422
Sway Bar Diagram
422
Sway Bar Linkage Adjustment
423
Shock Absorber Removal/Installation
423
Spring Removal/Installation
424
Shock Inspection
425
Rebuildable Shock Absorbers Disassembly/ Assembly/Charging
425
Steering Assembly
432
Throttle Lever/Switch Assembly Diagram
432
Handlebar Removal/Installation
433
Brake Lever/Switch Assembly Diagram
433
Handlebar Grips Removal/Installation
434
Steering Post Removal/Installation
434
Steering Assembly Diagram
435
Steering Post Inspection
437
Drag Link and Tie Rods Removal/Installation
437
Tie Rod Inspection
437
Steering Adjustment
438
Handlebar Alignment
438
Shock Absorber Specifications
440
Track and Rear Suspension
442
Rear Suspension Removal
442
Chapter Sixteen
442
Rear Suspension Inspection
443
Rear Suspension Installation
443
Wear Strips Inspection/Replacement
444
End Caps
445
Front Shock Removal/Installation
445
Shock Absorbers
445
Rear Shock Absorber Removal/Installation
447
Front Arm Spring Removal/Installation
467
Rear Spring
467
Front Arm Removal/Installation
469
Rear Arm and Lower Arm Removal/Installation
470
Idler Wheels Inspection
471
Rear Axle Removal/Installation
471
Wheel Bearing Replacement
471
Track Removal/Installation
472
Track Inspection
472
Cleat Replacement
474
Chapter Seventeen Off-Season Storage
477
Index
481
Wiring Diagrams
483
Wiring Diagrams
484
Advertisement
Arctic Cat Prowler Service Manual (166 pages)
Brand:
Arctic Cat
| Category:
Utility Vehicle
| Size: 55.44 MB
Table of Contents
Section 1 - General Information
3
Table of Contents
3
General Specifications
4
Torque Specifications
4
Break-In Procedure
6
Gasoline - Oil - Lubricant
6
Genuine Parts
7
Preparation for Storage
7
Preparation after Storage
8
Section 2 - Periodic Maintenance/Tune-Up
9
Periodic Maintenance/Tune-Up
9
Periodic Maintenance Chart
10
Battery
11
Lubrication Points
11
Periodic Maintenance
11
Air Filter
12
Fuses
12
Valve/Tappet Clearance (Feeler Gauge Procedure)
14
Valve/Tappet Clearance (Valve Adjuster Procedure)
14
Testing Engine Compression
15
Adjusting Engine RPM (Idle)
16
Gas/Vent Hoses
16
Muffler/Spark Arrester
16
Spark Plug
16
Engine/Transmission Oil - Filter
17
Front Differential/Rear Drive Lubricant
18
Driveshaft/Coupling
19
Ignition Timing
19
Nuts/Bolts/Cap Screws
19
Steering Components
19
Suspension/Shock Absorbers/Bushings
19
Tires
19
Headlight/Taillight-Brakelight
20
Switches
20
Electrical Connections
21
Frame/Welds
21
Hydraulic Brake System
21
Shift Lever
21
Parking Brake
23
Burnishing Brake Pads
25
Checking/Replacing V-Belt
25
Coolant
25
Troubleshooting Brake System
27
Special Tools
29
Removing Engine/
30
Removing Top-Side Components
34
Top-Side Components
34
Servicing Top-Side Components
38
Installing Top-Side Components
45
Removing Right-Side Components
51
Right-Side Components
51
Installing Right-Side Components
54
Left-Side Components
57
Removing Left-Side Components
57
Servicing Left-Side Components
60
Installing Left-Side Components
61
Center Crankcase Components
64
Disassembling Crankcase Half
64
Separating Crankcase Halves
64
Servicing Center Crankcase Components
66
Assembling Crankcase Half
69
Joining Crankcase Halves
71
Installing Engine/Transmission
72
Section 4 - Fuel/Lubrication/Cooling
79
Fuel/Lubrication/Cooling
79
Carburetor
80
Carburetor Schematic
80
Carburetor Specifications
80
Engine RPM (Idle)
84
Gas Tank
84
Gas/Vent Hoses
87
Oil Flow Chart
87
Liquid Cooling System
88
Oil Filter/Oil Pump
88
Radiator
89
Thermostat
90
Fan
91
Water Pump
91
Vacuum Pulse Fuel Pump
92
Fuel Level Sensor (XT)
93
Troubleshooting
94
Section 5 - Electrical System
95
Accessory Receptacle/Connector
96
Battery
96
Electrical System
96
RPM Limiter
96
Specifications
96
Testing Electrical Components
96
Brakelight Switch
97
Coolant Temperature and Cooling Fan Switches
97
Fan Motor
98
Power Distribution Module
98
Fuses
99
Ignition Coil
99
Speed Sensor (XT)
100
2WD/4WD Selector Switch
101
Differential Lock Switch
101
Headlight Switch
101
Ignition Switch
101
Front Drive Selector Actuator
102
Reverse Override Switch
102
Stator Coils
103
Starter Motor
104
Starter Relay
104
CDI Unit
105
Neutral Start/Start-In-Gear/2Wd Relays
105
Regulator/Rectifier
105
Headlights
106
Ignition Timing
106
Taillight-Brakelight
106
Troubleshooting
107
Section 6 - Drive System
109
Drive System
110
Front Drive Actuator
110
Front Differential
111
Drive Axles
123
Rear Gear Case
128
Hub
129
Hydraulic Brake Caliper
131
Universal Joints
132
Troubleshooting
135
Section 7 - Suspension
136
Shock Absorbers
137
Suspension
137
Front A-Arms
138
Rear A-Arms
140
Wheels and Tires
142
Tire Size
142
Troubleshooting
143
Section 8 - Steering/Frame
144
Steering Assembly
145
Steering/Frame
145
Steering Wheel
147
Steering Wheel Shaft
147
Steering Shaft Assembly
149
Steering Knuckles
151
Checking/Adjusting Front Wheel Alignment
153
Front Bumper Assembly (XT)
154
Hood
154
Fenders
155
Floor
155
Belly Panel
156
Cargo Box
156
Exhaust System
156
Adjusting Headlights
157
Seats
158
Taillight Assembly
158
Troubleshooting
159
Controls/Indicators
161
Master Cylinder Assembly
162
Accelerator Pedal
162
Front Differential Lock
163
Shift Lever
163
Indicator Light (XT)
164
Indicator Lights (Prowler)
166
Arctic Cat Prowler Operator's Manual (66 pages)
Brand:
Arctic Cat
| Category:
Automobile
| Size: 3.57 MB
Table of Contents
California Proposition 65
2
Foreword
3
Parts and Accessories
3
Table of Contents
4
Division I - Safety
5
Safety Alert
6
Warning Labels
7
Warning Labels
8
Location of Parts and Controls
9
Warnings
10
Warnings
18
Division II - Operation/ Maintenance
19
Specifications
19
Vehicle Operation
20
Vehicle Operation
21
Driving the Vehicle
22
Driving Uphill
22
Crossing Obstacles
23
Driving Downhill
23
Driving in Reverse
24
Skidding or Sliding
24
General Information
25
Control Locations and Functions
25
Headlight Switch
26
Foot Brake
26
Accelerator Pedal
26
Occupant Side Restraints
27
Power Steering
31
Speedometer/Lcd (Digital)
31
Diagnostic Trouble Codes
33
Oil Level Stick
34
Load Capacity Ratings Chart
35
Trailering and Towing
35
Transporting
36
Gasoline-Oil-Lubricant
36
Engine Break-In
38
Burnishing Brake Pads
38
General Maintenance
39
Maintenance Schedule
40
Liquid Cooling System
41
Oil Cooler (1000)
41
Shock Absorbers
41
General Lubrication
42
Hydraulic Brake
44
Gas Hoses
45
Protective Rubber Boots
45
Battery
46
Spark Plug(S)
49
Air Filter/Housing Drain
50
Draining V-Belt Cover
51
Tires
51
Wheels
51
Muffler/Spark Arrester (Prowler)
52
Light Bulb Replacement
53
Checking/Adjusting Headlight Aim
53
Fuses
54
Electrical Output Terminals
54
Storage Compartment/Tools
54
Seat Belts
55
Occupant Side Restraints
55
Rops
55
Preparation for Storage
56
Preparation after Storage
57
Maintenance Record
58
Limited Warranty
59
Warranty Procedure/Owner Responsibility
60
EPA Emission Control Statement/Warranty Coverage - ROV (U.S. Only)
61
Warranty Period
61
Change of Address, Ownership, or Warranty Transfer
63
Identification Numbers Record
65
Vehicle Identification
65
Advertisement
Arctic Cat Prowler Operator's Manual (60 pages)
Brand:
Arctic Cat
| Category:
Golf Cars
| Size: 1.17 MB
Table of Contents
Table of Contents
4
Foreword
3
Parts and Accessories
3
Table of Contents
4
Division I - Safety
5
Safety Alert
6
Warning Labels
7
Warning Labels
8
Location of Parts and Controls
9
Warnings
10
Warnings
18
Division II - Operation/ Maintenance
19
Specifications
19
Vehicle Operation
20
Starting the Vehicle
21
General Information
26
Vehicle Identification Numbers
26
Ignition Switch Key
26
Control Locations and Functions
26
Accelerator Pedal
28
Occupant Side Restraints
29
Power Steering
29
Speedometer/Lcd (Digital)
30
Diagnostic Trouble Codes
32
Electric Fuel Pump
33
Gas Hoses
33
Oil Level Stick
33
Load Capacity Ratings
33
Trailering and Towing
34
Transporting
34
Gasoline-Oil-Lubricant
35
Engine Break-In
36
Burnishing Brake Pads
36
General Maintenance
37
Maintenance Schedule
38
Liquid Cooling System
39
Oil Cooler (1000)
39
Shock Absorbers
39
(Front Differential - Rear Drive)
40
Engine/Transmission Oil and Filter
40
General Lubrication
40
Brake Fluid
41
Hydraulic Brake
41
Brake Hoses
42
Protective Rubber Boots
42
Battery
43
Air Filter/Housing Drain
46
Spark Plug(S)
46
Draining V-Belt Cover
47
Tires
47
Light Bulb Replacement
48
Muffler/Spark Arrester
48
Spark Arrester/Muffler
48
Wheels
48
Checking/Adjusting Headlight Aim
49
Fuses
49
Electrical Output Terminals
50
Occupant Side Restraints
50
Rops
50
Seat Belts
50
Storage Compartment/Tools
50
Preparation for Storage
51
Preparation after Storage
52
Maintenance Record
53
Limited Warranty
54
Warranty Procedure/Owner Responsibility
55
EPA Emission Control Statement/Warranty Coverage - ROV (U.S. Only)
56
Change of Address, Ownership, or Warranty Transfer
57
Identification Numbers Record
59
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Arctic Cat Sno Pro 120
Arctic Cat Sno Pro 120 2011
Arctic Cat PRO VANTAGE 3000
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