3-3
3
* Specifications subject to change without notice.
Prowler/XT/XTX
(Table of Contents)
Removing Engine/Transmission.............................. 3-3
Top-Side Components............................................. 3-7
Removing Top-Side Components ........................... 3-7
Servicing Top-Side Components........................... 3-11
Installing Top-Side Components ........................... 3-18
Right-Side Components ........................................ 3-24
Removing Right-Side Components....................... 3-24
Installing Right-Side Components......................... 3-26
Left-Side Components .......................................... 3-29
Removing Left-Side Components ......................... 3-29
Servicing Left-Side Components ......................... 3-32
Installing Left-Side Components ........................... 3-33
Center Crankcase Components............................ 3-36
Separating Crankcase Halves............................... 3-36
Disassembling Crankcase Half ............................. 3-37
Servicing Center Crankcase Components ........... 3-38
Assembling Crankcase Half .................................. 3-42
Joining Crankcase Halves..................................... 3-44
Installing Engine/Transmission.............................. 3-44
Removing Engine/
Transmission
Many service procedures can be performed without
removing the engine/transmission from the frame.
Closely observe the note introducing each sub-section
for this important information.
Support the vehicle on a suitable lift or jack stands
allowing room to perform work from the underside.
NOTE: Locate the jack stands to allow removing
of the center belly panel.
1. Remove the seats and center console; then remove
the left-side and right-side seat-bases.
2. Remove the center belly panel; then drain the oil
and coolant.
NOTE: Use a small funnel between the frame and
coolant drain plug to prevent coolant from drain-
ing on the frame and splashing.
PR122A
CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder Clearance
0.045 mm
(0.0018 in.)
Piston Diameter 15 mm (0.6 in.)
from Skirt End (Prowler/XT)
97.948-97.962 mm
(3.856-3.857 in.)
Piston Diameter 12 mm (0.47 in.)
from Skirt End (XTX)
101.930-101.949 mm
(4.013-4.014 in.)
Piston Ring Free End Gap
(1st/2nd) 12.5 mm (0.492 in.)
Bore x Stroke (Prowler/XT)
97.9 x 85 mm
(3.86 x 3.35 in.)
Bore x Stroke (XTX)
102 x 82 mm
(4.01 x 3.22 in.)
Cylinder Trueness
(max) 0.01 mm (0.004 in.)
Piston Ring End Gap - Installed
0.36 mm (0.014 in.)
Piston Ring to Groove
(1st/2nd)
Clearance (max)
0.03 mm
(0.0012 in.)
Piston Ring Groove Width
(1st/2nd)
(oil)
1.202-1.204 mm
(0.0473-0.0474 in.)
2.01-2.03 mm
(0.0791-0.0799 in.)
Piston Ring Thickness
(1st/2nd) 1.970-1.990 mm
(0.0776-0.0783 in.)
Piston Pin Bore
(max) 23.0 mm (0.9055 in.)
Piston Pin Outside Diameter
(min) 22.99 mm
(0.9051 in.)
CRANKSHAFT
Connecting Rod
(max)
(small end inside diameter)
23.021 mm
(0.9063 in.)
Connecting Rod (big end side-to-side)
0.6 mm (0.024 in.)
Connecting Rod (big end width)
25 mm (0.9843 in.)
Connecting Rod @ 150 mm
(max)
(5.9 in.) (small end deflection)
0.3 mm (0.0118 in.)
Crankshaft (web-to-web)
71 mm (2.79 in.)
Crankshaft Runout
(max) 0.03 mm (0.0012 in.)
Oil Pressure @2500 RPM
(Cooling Fan Cycling)
1.40-2.11 kg/cm
²
(20-30 psi)
AT THIS POINT
If the technician's objective is to service/replace
left-side cover oil seals, front output joint oil seal,
rear output joint oil seal, and/or the oil strainer (from
beneath the engine/transmission), the engine/trans-
mission does not have to be removed from the
frame.
! WARNING
Make sure the vehicle is solidly supported on the
support stands to avoid injury.
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