Arctic Cat 2009 Prowler XTZ Service Manual Download

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3-8



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.

PR641A



NOTE: The grafoil gasket may remain in the cylin-

der head.

25. Mark the components on the front driveshaft; then

remove the three cap screws securing the drive-

shaft to the front differential. Slide the spline boot

forward and remove the driveshaft from the output

yoke.

PR638A

PR639A

26. Remove four cap screws securing the rear drive-

shaft to the output flange. The rear driveshaft can

remain on the vehicle.

PR647

27. Remove the lock nuts from the engine

through-bolts; then attach a lifting chain to the

engine/transmission.

PR630

PR629

PR631

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Back to Section TOC

Next

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

www.mymowerparts.com

Summary of Contents for 2009 Prowler XTZ

Page 1: ...RNING 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 infor...

Page 2: ... Up 3 Engine Transmission 4 Fuel Lubrication Cooling 5 Electrical System 6 Drive System 7 Suspension 8 Steering Frame 9 Controls Indicators 1 2 3 4 5 6 7 8 9 Foreword Click on the blue text to go FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 3: ...ns 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 1 5 Preparation After Storage 1 6 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 4: ... SUSPENSION COMPONENTS Front Part Part Bolted To Torque ft lb N m A Arm Frame 40 54 Ball Joint Cap Screw Knuckle 35 48 Shock Absorber Upper Frame 33 45 Shock Absorber Lower Upper A Arm 33 45 Knuckle A Arm 33 45 SUSPENSION COMPONENTS Rear Sway Bar Bracket Frame 33 45 A Arm Frame 33 45 Shock Absorber Upper Frame 33 45 Shock Absorber Lower Lower A Arm 33 45 Knuckle A Arm 33 45 Cargo Box Hinge Cargo B...

Page 5: ... 8 11 Shift Cam Plate Shift Cam Shaft 8 11 Shifter Housing Crankcase 8 11 Starter Motor Crankcase 8 11 V Belt Housing Crankcase 8 11 Oil Pump Cover Crankcase 8 11 Oil Strainer Cap Crankcase 8 11 ft lb N m ft lb N m ft lb N m ft lb N m 1 1 4 26 35 4 51 69 4 76 103 4 2 2 7 27 36 7 52 70 7 77 104 7 3 4 1 28 38 1 53 72 1 78 106 1 4 5 4 29 39 4 54 73 4 79 107 4 5 6 8 30 40 8 55 74 8 80 108 8 6 8 2 31 4...

Page 6: ... minimum octane regular unleaded In many areas oxygenates either ethanol or MTBE are added to the gasoline Oxygenated gasolines containing up to 10 ethanol 5 methane or 5 MTBE are acceptable gasolines When using ethanol blended gasoline it is not neces sary to add a gasoline antifreeze since ethanol will pre vent the accumulation of moisture in the fuel system RECOMMENDED ENGINE TRANSMISSION OIL T...

Page 7: ...hole in the exhaust system with a clean cloth 5 Apply light oil to the plungers of the shock absorb ers 6 Tighten all nuts bolts cap screws and screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts cap screws and bolts are tightened to specifications 7 Fill the cooling system to the bottom of the stand pipe in the radiato...

Page 8: ... level pads etc all controls headlights taillight brakelight and headlight aim adjust or replace as necessary 8 Tighten all nuts bolts cap screws and screws making sure all calibrated nuts cap screws and bolts are tightened to specifications 9 Check tire pressure Inflate to recommended pres sure as necessary 10 Make sure the steering moves freely and does not bind 11 Check the spark plugs Clean or...

Page 9: ...mpression 2 5 Spark Plugs 2 6 Muffler Spark Arrester 2 6 Engine Transmission Oil Filter 2 7 Front Differential Rear Drive Lubricant 2 8 Driveshaft Coupling 2 8 Nuts Bolts Cap Screws 2 8 Headlight Taillight Brakelight 2 9 Shift Lever 2 10 Hydraulic Brake System 2 10 Parking Brake 2 12 Burnishing Brake Pads 2 14 Checking Replacing V Belt 2 14 Troubleshooting Brake System 2 16 Back to TOC FOR ARCTIC ...

Page 10: ...ark Arrester C R Gas Vent Hoses I I R 2 Yrs Throttle Cable Ends Accelerator Pedal Pivot I I C L A R Engine Transmission Oil Level I A Engine Transmission Oil Filter R R R R R Oil Strainer I I C Differential Gear Case Lubricant I I R 4 Yrs Tires Air Pressure I I R Steering Components I I I R V Belt I l R Suspension Ball joint boots drive axle boots front and rear tie rods dif ferential and rear dri...

Page 11: ...s securing the air cleaner housing cover and remove the cover 3 Remove the air filter frame A then remove the foam filter element B PR576A 4 Fill a wash pan larger than the filter with a non flammable cleaning solvent then dip the filter in the solvent and wash it NOTE Foam Filter Cleaner and Foam Filter Oil are available from Arctic Cat 5 Dry the filter 6 Put the filter in a plastic bag then pour...

Page 12: ...Using a feeler gauge check each valve tappet clearance If clearance is not within specifications loosen the jam nut and rotate the tappet adjuster screw until the clearance is within specifications Tighten each jam nut securely after completing the adjustment CC007DC 4 Rotate the engine 270 to the TDC position of the rear cylinder then repeat step 3 The stamped R must be visible GZ059 5 Install th...

Page 13: ...ockwise until proper valve tappet clearance is attained NOTE Refer to the appropriate specifications in Feeler Gauge Procedure sub section for the proper valve tappet clearance NOTE Rotating the valve adjuster dial counter clockwise will open the valve tappet clearance by 0 05 mm 0 002 in per mark 7 While holding the adjuster dial at the proper clear ance setting tighten the jam nut securely with ...

Page 14: ...he plug is cor rect A white or dark insulator indicates that the engine may need to be serviced To maintain a hot strong spark keep the plug free of carbon ATV 0051 Adjust the gap to 0 7 0 8 mm 0 028 0 032 in ATV0052C When installing the spark plugs be sure to tighten it securely A new spark plug should be tightened 1 2 turn once the washer contacts the cylinder head A used spark plug should be ti...

Page 15: ...e drain plug and tighten to 16 ft lb Pour the specified amount of the recommended oil in the filler hole Install the oil level stick filler plug 7 Start the engine while the vehicle is outside on level ground and allow it to idle for a few min utes 8 Turn the engine off and wait approximately one minute 9 Unscrew the oil level stick and wipe it with a clean cloth 10 Install the oil level stick and...

Page 16: ...until lubricant is visible at the level plug threads 6 Install the fill and level plugs Tighten to 16 ft lb NOTE If the lubricant is contaminated with water inspect the drain plug fill and level plugs and or bladder Driveshaft Coupling The following drive system components should be inspected periodically to ensure proper operation A Spline lateral movement slop B Coupling cracked damaged or worn ...

Page 17: ...ace 4 Install the taillight brakelight assembly on the can opy support CHECKING ADJUSTING HEADLIGHT AIM The headlights can be adjusted vertically The geomet ric center of the HIGH beam light zone is to be used for vertical aiming 1 Position the vehicle on a level floor so the head lights are approximately 6 1 m 20 ft from an aiming surface wall or similar aiming surface NOTE There should be an ave...

Page 18: ...e hous ing to align the throttle cable end to the shift arm stud C PR568A PR572A 4 Install the E clip then tighten the nuts A and B securely 5 Check each gear shift position for proper gear selec tion and make sure the proper icon illuminates on the LCD then install the center console and seats Hydraulic Brake System NOTE This vehicle is equipped with four wheel disc brakes The following procedure...

Page 19: ...der screw then move to the REAR bleeder screws and follow the same pro cedure E Repeat steps B and C until the brake pedal is firm 4 Carefully check the entire hydraulic brake system that all hose connections are tight the bleed screws are tight the protective caps are installed and no leakage is present INSPECTING HOSES Carefully inspect the hydraulic brake hoses for cracks or other damage If fou...

Page 20: ...ING 1 Remove the seats and center console 2 With the parking brake lever released loosen the adjuster nut A then turn the jam nut B clock wise several turns PR682A 3 Turn the adjuster nut clockwise to remove cable slack 4 Check for proper adjustment by applying the park ing brake and attempting to move the vehicle The vehicle should not move 5 If adjustment is correct tighten the adjuster nut secu...

Page 21: ... B Account for two springs and spacers C PR678A 5 Install the new brake pads and anchor bolts with springs and spacers then secure with new lock nuts PR679 6 Install the brake caliper onto the gear case mount ing bracket then secure with two cap screws coated with blue Loctite 243 and tighten to 20 ft lb PR683A 7 Install the cap screws securing the cable support to the caliper and tighten securely...

Page 22: ...dal to decelerate to 0 5 mph 3 Repeat procedure five times until brake pads are burnished 4 Adjust the parking brake if necessary 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 2 Remove the center storage compartment then remove the floor PR611 3 Remove the gas tank hold ...

Page 23: ...ap screws into the driven pulley fixed face then turn the cap screw clockwise to spread the pulley faces Remove the V belt GZ076 GZ085 INSTALLING 1 Place the V belt into position on the driven pulley and over the front shaft GZ085 NOTE The arrows on the V belt should point in direction of engine rotation forward 2 Pinch the V belt together near its center and slide the spacer and movable drive fac...

Page 24: ... the spacer when tighten ing the nut or false torque readings could occur The assembly could loosen after starting the engine causing damage to the shaft and pulley Problem Braking poor Condition Remedy 1 Pad worn 2 Pedal free play excessive 3 Brake fluid leaking 4 Hydraulic system leaking air 5 Master cylinder brake cylinder seal worn 1 Replace pads 2 Adjust free play 3 Repair replace hydraulic s...

Page 25: ...ANSMISSION TABLE OF CONTENTS Engine Transmission 3 2 Specifications 3 2 Prowler XTZ Table of Contents 3 3 Troubleshooting 3 58 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 26: ... 35 mm Valve Guide Inside Diameter 5 000 5 012 mm Valve Stem Outside Diameter intake exhaust 4 972 4 987 mm Valve Stem Runout max 0 1 mm Valve Head Thickness min 2 3 mm Valve Stem End Length min 3 97 mm Valve Face Seat Width intake exhaust 2 25 mm 2 60 mm Valve Seat Angle intake exhaust 45 15 45 30 Valve Face Radial Runout max 0 2 mm Valve Spring Free Length min 38 7 mm Valve Spring Tension 31 5 m...

Page 27: ... 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 storage console then remove the floor and drain the oil into a suitable container PR611 3 Clamp off the lower radiator hose near the water pump then place a suitable container and funnel under the wat...

Page 28: ...side remove the fuel injector connector A mani fold absolute pressure MAP sensor B parking brake warning switch C reverse override switch connector D and idle speed control ISC valve E PR595A 9 Disconnect the front ignition coil and remove the front spark plug then route the engine harness out of the engine compartment PR596 10 From the left rear disconnect the speed sensor connector F stator coil...

Page 29: ...icle PR662A NOTE The parking brake cable does not need to be disconnected 14 Using a shop towel to absorb any spilled gasoline remove the quick disconnect fuel couplers from the fuel injectors PR663A CAUTION The gear shift position switch wires are secured to the frame with a nylon tie connector This must be removed prior to removing the engine transmission or harness damage will occur WARNING Alw...

Page 30: ...k and breather hoses PR606A 18 Remove the upper radiator hose from the thermo stat housing then move the coolant pipe to the left side of the vehicle PR607A 19 Remove the sheet metal screws securing the con stant variable transmission CVT cooling duct to the frame then loosen the hose clamps and remove the duct from the front elbow and CVT boot PR671A 20 Remove the inlet boot from the CVT housing ...

Page 31: ... muffler Account for a grafoil seal PR668 PR661B 23 Remove two cap screws securing the front exhaust pipe to the cylinder head then remove two springs securing the front and rear exhaust pipes together Remove the front exhaust pipe Account for a gra foil seal and a grafoil gasket PR643A PR661A PR625A Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 6...

Page 32: ...crews securing the drive shaft to the front differential Slide the spline boot forward and remove the driveshaft from the output yoke PR638A PR639A 26 Remove four cap screws securing the rear drive shaft to the output flange The rear driveshaft can remain on the vehicle PR647 27 Remove the lock nuts from the engine through bolts then attach a lifting chain to the engine transmission PR630 PR629 PR...

Page 33: ...rocedure Removing Top Side Components A Valve Cover Rocker Arms B Cylinder Head Camshaft 1 Remove the timing inspection plug spark plugs and magneto housing cover then install the 10 mm cap screw left hand threads in the crankshaft and rotate the desired cylinder to top dead center of the compression stroke GZ027 GZ026 NOTE Timing marks on the rotor flywheel are stamped with an F front cylinder an...

Page 34: ...ecuring the tensioner adjuster assembly and remove the assembly Account for a gasket GZ200 5 Using an awl rotate the C ring in its groove until it is out of the cylinder head then remove the C ring NOTE Care should be taken not to drop the C ring into the crankcase GZ155 6 Bend the washer tabs down and remove the two cap screws securing the sprocket to the camshaft then drop the sprocket off the c...

Page 35: ... serviced apply tension to the loose timing chain and rotate the second cylinder to top dead center of the com pression stroke then repeat steps 2 9 on the other cylinder head C Cylinders D Pistons NOTE Steps 1 10 in the preceding sub section must precede this procedure 11 Remove the cap screws securing the water hose union to the cylinder then remove the union from the cylinder Account for an O r...

Page 36: ...side circlip Remove the piston NOTE It is advisable to remove the opposite side circlip prior to using the puller NOTE Support the connecting rod with rubber bands or a piece of hose to avoid damaging the rod or install a suitable connecting rod holder GZ146A AT THIS POINT To service cylinder see Servicing Top Side Compo nents sub section CAUTION When removing the cylinder be sure to support the p...

Page 37: ...ight metallic finish Correct any high spots before assembly by continuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained CC130D Removing Valves NOTE Keep all valves and valve components as a set Note the original location of each valve set for use during installation Return each valve set to its original location during installation 1 Using a va...

Page 38: ...e face ATV 1004 2 Acceptable width range must be within specifica tions Measuring Valve Face Radial Runout 1 Mount a dial indicator on the surface plate then place the valve stem on a set of V blocks 2 Position the dial indicator contact point on the out side edge of the valve face then zero the indicator ATV1082A 3 Rotate the valve in the V blocks 4 Maximum runout must not exceed specifications M...

Page 39: ...face of the valve seals then place a lower spring seat and valve guide seal over each valve guide CC144D 2 Insert each valve into its original location 3 Install the valve springs with the painted end of the spring facing away from the cylinder head NOTE If the paint is not visible install the ends of the springs with the closest wound coils toward the head ATV 1011A 4 Place a spring retainer over...

Page 40: ...o position the ring with its tapered side up Measuring Piston Ring End Gap Installed 1 Place each compression ring in the wear portion of the cylinder Use the piston to position each ring squarely in the cylinder 2 Using a feeler gauge measure each piston ring end gap Acceptable ring end gap must be within specifications CC280D Measuring Piston Pin Outside Diameter and Piston Pin Bore 1 Measure th...

Page 41: ...mpression ring then rotate the rings so the ring gaps are approximately 180 apart and orientated to the piston pin GZ187A CYLINDER CYLINDER HEAD ASSEMBLY NOTE If the cylinder cylinder head assembly cannot be trued they must be replaced Cleaning Inspecting Cylinder Head 1 Using a non metallic carbon removal tool remove any carbon buildup from the combustion chamber being careful not to nick scrape ...

Page 42: ... tion of high spots A high spot can be noted by a bright metallic finish Correct any high spots before assembly by continuing to move the cylin der in a figure eight motion until a uniform bright metallic finish is attained CC129D Inspecting Cam Chain Guide 1 Inspect cam chain guide for cuts tears breaks or chips 2 If the chain guide is damaged it must be replaced Inspecting Cylinder 1 Using a sli...

Page 43: ...measure each cam lobe height ATV1013A 2 The lobe heights must not exceed minimum speci fications Inspecting Camshaft Bearing Journal 1 Inspect the bearing journal for scoring seizure marks or pitting 2 If excessive scoring seizure marks or pitting is found the cylinder head assembly must be replaced Measuring Camshaft to Cylinder Head Clearance 1 Remove the adjuster screws and jam nuts CC005D 2 Pl...

Page 44: ...onents 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 NOTE The piston should be installed so the arrow points toward the exhaust of the respective cylinder GZ166 2 Place the two alignment pins into position Place the cylinder gasket into position then place a pis ton holder or suitable subst...

Page 45: ... Head D Valve Cover NOTE Steps 1 5 in the preceding sub section must precede this procedure 6 Place the chain guide into the cylinder GZ161A 7 Place a new head gasket into position on the cylin der Place the alignment pins into position then place the head assembly into position on the cylin der while guiding the cam chain through the cylin der head GZ151 CAUTION The cylinder should slide on easil...

Page 46: ...this point do not seat the sprocket onto the shaft 732 307B GZ130 NOTE At this point oil the camshaft bearings cam lobes and the three seating journals on the cylinder 13 With the cam lobes directed down toward the pis ton maneuver the camshaft sprocket assembly through the chain and towards its seating position then loop the chain over the sprocket NOTE Note the position of the alignment marks on...

Page 47: ...irst cap screw from step 16 can be tightened then tighten to 11 ft lb Bend the tab to secure the cap screw 19 Keeping tension on the rear cam chain rotate the engine forward 270 until rear piston is at TDC indicated by timing mark R GZ060 20 With the cam lobes directed down toward the pis ton maneuver the camshaft sprocket assembly through the chain and towards its seating position then loop the c...

Page 48: ... the cam lobes E Camshaft alignment pin and sprocket alignment hole smallest are aligned 22 Place tab washer onto the sprocket making sure it covers the pin in the alignment hole ATV 1027 23 Install the first cap screw threads coated with red Loctite 271 securing the sprocket and tab washer to the camshaft Tighten only until snug GZ195 24 Rotate the crankshaft until the second cap screw securing t...

Page 49: ...hain tensioner then using a flat blade screwdriver rotate the adjuster screw inside the tensioner clockwise until the screw bottoms CD501 NOTE The adjuster shaft will be drawn into the tensioner as the adjuster screw is rotated clock wise The adjuster shaft tension will be released in step 30 29 Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with th...

Page 50: ...oil then place the valve cover into posi tion GZ206 NOTE At this point the rocker arms and adjuster screws must not have pressure on them 34 Install the top side cap screws with rubber wash ers then install the remaining cap screws Tighten only until snug CC003D 35 In a crisscross pattern starting from the center and working outward tighten the cap screws on both valve covers securely 36 Adjust va...

Page 51: ...iven gear A starter countershaft bushing B and starter coun tershaft gear C then remove the starter gear shafts D noting that the longer shaft is nearest the starter GZ224A NOTE The starter is not serviceable and must be replaced as a complete assembly 3 Remove the rotor flywheel nut then install the appropriate crankshaft protector into the crank shaft PR440 4 Install Magneto Rotor Remover Set an...

Page 52: ...pump Account for an O ring GZ230A NOTE The water pump is a non serviceable com ponent and must be replaced as a complete assembly 8 Remove the cap screws securing the gear shift cover to the crankcase then remove the gear shift cover Account for a gasket and washer NOTE Inspect the inside of the left side cover for any shaft washers that may have come off with the cover Make sure they are returned...

Page 53: ...ensor trigger to the shaft and remove the trigger using a suitable two jawed puller Account for a gasket GZ243 GZ235 12 Remove the cap screws securing the oil filler cover to the crankcase then remove the cover Account for an O ring GZ250 Installing Left Side Components 1 Thoroughly clean all gasket material and sealant from mating surfaces 2 Install a new O ring on the oil filler cover and coat i...

Page 54: ...en to 8 ft lb GZ232 5 If removed install the shift cam stopper on the support then with the flat washer in place install the shift cam stopper assembly into the crankcase and tighten to 8 ft lb GZ255 GZ256 6 Install the shift cam stopper spring onto the shift cam stopper and secure with a flat washer and flange nut Tighten to 8 ft lb GZ259 7 Install the shift cam plate onto the shift cam shaft and...

Page 55: ...ghten in a crisscross pattern to 8 ft lb GZ262 10 Install the spacer washer on the crankshaft then install the starter ring gear GZ249 GZ226 11 Place the key into the keyway in the crankshaft then wipe all oil from the crankshaft surface and rotor flywheel bore and install the rotor flywheel onto the crankshaft aligning the keyway with the key Secure with the nut coated with red Loctite 271 and ti...

Page 56: ...ervice only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to be removed from the frame for this procedure Removing Right Side Components A CVT Cover B Driven Pulley C Clutch Cover D Centrifugal Clutch 1 Remove the cap screws securing the CVT cover then using a rubber mallet gently tap on the cover tabs to loosen the cover Accoun...

Page 57: ...5 Remove the fixed drive face 6 Remove the cap screws securing the V belt hous ing to the crankcase then remove the V belt hous ing Account for two alignment pins GZ246A 7 Remove the cap screws securing the clutch cover then using a rubber mallet carefully remove the cover Account for two alignment pins GZ246B Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678...

Page 58: ...nside the fixed drive spacer CF085 CC596 NOTE Account for and inspect the clutch hous ing seal 10 Remove the two cap screws securing the gear shift position switch then remove the switch Account for two contact pins and two springs CD997 11 Remove the nut left hand threads securing the clutch shoe assembly GZ248A Servicing Right Side Components NOTE Whenever a part is worn excessively cracked dama...

Page 59: ...t be replaced DRIVEN PULLEY ASSEMBLY NOTE The driven pulley is a non serviceable component If the pulley faces cam ramps or face bushing are worn or loose the pulley must be replaced as an assembly Do not disassemble the driven pulley Installing Right Side Components 1 Apply silicone to the mating surfaces then install the gear shift position switch making sure the two contact pins and the two spr...

Page 60: ...re 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 GZ263 GZ244A 9 Place the driven pulley assembly into position and secure with the nut coated with red Loctite 271 Tighten to 80 ft lb GZ066 10 Slide the fixed drive face onto the clutch shaft 11 Spread the faces of the driven pulley by thread...

Page 61: ...nstall the cover and secure with the cap screws Tighten the cap screws to 8 ft lb Center Crankcase Components NOTE This procedure cannot be done with the engine transmission in the frame Complete Removing procedures for Top Side Left Side and Right Side must precede this procedure NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to...

Page 62: ... sec ondary gear sets will have to be reset for backlash and gear contact see Servicing Center Crankcase Components in this section 4 Remove one cap screw from the right side crank case and eight cap screws from the left side crank case then using a rubber mallet separate the crankcase halves leaving all components in the right side case Account for a thrust washer on the crankshaft and flat washe...

Page 63: ...uring the water pump drive idler B to the idler shaft then remove the drive idler GZ299A 3 Remove the water pump driven shaft C Account for the driven gear and drive pin GZ304A 4 Remove the snap ring securing the oil pump driven gear D to the oil pump driveshaft then remove the gear Account for a drive pin and washer GZ301A 5 Remove the shift fork shaft E then remove the gear shift shaft assembly ...

Page 64: ... tolerance replacement is necessary SECONDARY OUTPUT DRIVE GEARS Initial Set Up NOTE If the secondary output driven shaft is replaced or disassembled the initial set up must be performed to establish correct gear tooth con tact If only the secondary output driveshaft or secondary output driven gear are replaced pro ceed to Correcting Backlash in this sub section 1 Install a new bearing A onto the ...

Page 65: ...t s lay out dye Rotate the shafts through several rotations in both directions Gear contact should extend from the root to the top of the gear teeth MT016A 6 To adjust tooth contact use the following chart to correctly shim the driven shaft 7 After correct tooth contact is established proceed to Checking Backlash in this sub section Checking Backlash 1 Install the drive bevel gear assembly and dri...

Page 66: ...oated with red Loc tite 271 on the output drive shaft and tighten to 59 ft lb MT007A 4 Using an appropriate holding fixture and wrench adapter install the secondary drive gear nut threads coated with red Loctite 271 and tighten to 74 ft lb The output drive assembly is now ready for installation GZ393B OIL PUMP ASSEMBLY Disassembling and Inspecting 1 Remove the oil pump cover then remove the gero t...

Page 67: ...equired GZ354A 6 Remove the oil seal from the oil pump cover GZ365 Assembling 1 Install a new oil seal into the oil pump cover then coat the lips of the seal with grease and install the pump driveshaft from the seal side GZ359 2 Noting the reference dots on the gerotor set sepa rate the inner rotor from the outer rotor and with the reference dot directed toward the oil pump cover place the rotor o...

Page 68: ...indicator contact point against the center of the connecting rod small end journal 2 Zero the indicator and push the small end of the connecting rod away from the dial indicator 3 Maximum deflection must not exceed specifica tions Measuring Connecting Rod Big End Side to Side 1 Push the lower end of the connecting rod to one side of the crankshaft journal 2 Using a feeler gauge measure the gap bet...

Page 69: ...ng the positions for assembling then remove the high driven gear outer washer high driven gear high driven gear bearing high driven gear bushing and high driven gear inner washer GZ283A 2 Remove the drive gear then remove the snap ring securing the reverse driven gear dog and bushing to the countershaft CAUTION Care should be taken to support the connecting rod when rotating the crankshaft CAUTION...

Page 70: ...the washer and gear GZ314 5 Remove the reverse driven washer then remove the low driven gear locking washer GZ320 GZ319 GZ318A 6 Remove the low driven gear Account for a bear ing bushing and thrust washer GZ316 Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 71: ...nstall the inner reverse driven gear washer GZ319B GZ320B 3 Install the reverse driven bushing and bearing then install the reverse driven gear GZ286A GZ287 4 Install the outer reverse driven washer then secure the reverse driven gear assembly with a snap ring GZ288A Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 72: ...nstall the oil pump gerotor assembly and oil pump cover in the crankcase and secure with two cap screws Coat the threads with blue Loctite 243 and tighten securely to 8 ft lb GZ305 2 Install a flat washer drive pin and drive gear onto the oil pump shaft then secure with a snap ring flat side away from the gear GZ347 3 Install the water pump drive gear driveshaft and drive pin then install the coun...

Page 73: ...th to engage the teeth of the oil pump and countershaft gears 6 Install the driveshaft then with a flat washer on each end of the reverse idler assembly install into the crankcase GZ332 GZ333 7 Install the gear shift shaft into the crankcase mak ing sure the flat washer is in place on the gear shift position switch end and the bearing assembly on the gear shift stop end GZ334A GZ335 Back to TOC Ba...

Page 74: ...th sides with motor oil then install the spacer washer on the crankshaft with the radius directed toward the crankshaft GZ341 3 Install the two alignment pins then apply a thin bead of silicone sealant to the crankcase mating surface GZ345A 4 Carefully join the crankcase halves by placing the left side crankcase onto the assembled right side Secure with the cap screws eight left side and one right...

Page 75: ... locating ring in the crankcase assembly then install the secondary driven shaft assembly and secondary drive assembly making sure the locating ring and bearing engage correctly GZ269A GZ322B 7 Install two locating pins into the upper crankcase assembly then apply a thin bead of silicone seal ant to the lower crankcase cover GZ322A GZ265 8 Carefully place the lower crankcase cover onto the joined ...

Page 76: ...ll cables wires and hoses clear then install the longer front through bolt with a flat washer PR634A 3 Install the rear through bolts with flat washer then secure both with new lock nuts and tighten to 40 ft lb PR629 PR630 4 Secure the rear universal joint flange to the output drive flange and tighten the four cap screws to 40 ft lb PR647 AT THIS POINT After completing center crankcase components ...

Page 77: ...on PR638A PR640 7 Install a new grafoil gasket in the rear cylinder head then place the rear exhaust pipe into position and loosely secure with two cap screws PR641A 8 With a new grafoil gasket in the front cylinder head and a new grafoil seal on the exhaust pipe install the front exhaust pipe and loosely secure with two cap screws PR643A PR642 9 Install the two springs at the juncture of front an...

Page 78: ...ing then install the CVT cooling duct and secure with the sheet metal screw Tighten all fasteners and clamps securely PR615 PR671A 13 Install and secure the CVT cooling outlet boot to the CVT housing making sure to properly orient the outlet duct PR669 14 Connect the starter cable to the starter then con nect the engine harness ground to the engine Tighten the fasteners securely Back to TOC Back t...

Page 79: ...ll 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 PR596A PR598A 18 Connect the throttle cable to the throttle arm then install the cable housing into the throttle body housing and tighten the nuts securely 19 Adjust throttle cable free play see Section 2 then install the throttle cable...

Page 80: ...cable ties PR591A 23 Connect the front spark plug cap and front ignition coil then install the front and rear injector connec tors A MAP sensor B parking brake warning switch C reverse override switch connector D and ISC valve E PR595A 24 From the right side connect the ECT sensor A IAT sensor B fuel pump fuel gauge connector C rear ignition coil D and TPS connector E PR594A 25 Install nylon cable...

Page 81: ...to the radiator When coolant with no air bubbles flows from the bleed hole install the screw and tighten securely PR672A 29 Start the engine and check for oil or coolant leaks then check all fluid levels and correct as necessary 30 Wipe off any spilled coolant or lubricant then install the floor storage console seat bases center console and seats Back to TOC Back to Section TOC Next Back FOR ARCTI...

Page 82: ...replace inlet screen valve screen 4 Replace fuel pump Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magneto defective 3 ECU defective 4 Fuel injector obstructed 5 Valve clearance out of adjustment 1 Clean replace plug 2 Replace magneto 3 Replace ECU 4 Replace fuel injector 5 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance exces...

Page 83: ... Adjust contact 4 Replace bearing 5 Replace gears 6 Replace shaft s 7 Replace thrust washer s Problem Engine idles poorly Condition Remedy 1 Valve clearance out of adjustment 2 Valve seating poor 3 Valve guides defective 4 Rocker arms arm shaft worn 5 Magneto defective 6 ECU defective 7 Spark plug fouled gap too wide 8 Ignition coil defective 9 Fuel injector obstructed 1 Adjust clearance 2 Replace...

Page 84: ...Replace springs 3 Time camshaft 4 Replace service rings cylinder 5 Repair seats 6 Clean replace plug 7 Replace arms shafts 8 Adjust gap replace plug 9 Replace fuel injector 10 Clean element 11 Drain excess oil change oil 12 Tighten replace manifold 13 Replace cam chain sprockets Problem Engine overheats Condition Remedy 1 Carbon deposit piston crown excessive 2 Oil low 3 Octane low gasoline poor 4...

Page 85: ...4 2 Gas Tank 4 3 Gas Vent Hoses 4 6 Oil Filter Oil Pump 4 6 Oil Cooler 4 6 Liquid Cooling System 4 7 Radiator 4 7 Thermostat 4 9 Fan 4 9 Water Pump 4 9 Electric Fuel Pump Fuel Level Sensor 4 10 Troubleshooting 4 12 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 86: ...air filter for con tamination Clean or replace as necessary see Sec tion 2 REMOVING THROTTLE BODY 1 Turn the ignition switch to the OFF position then remove the ignition switch key 2 Remove the left and right seats then remove the center console and disconnect the battery 3 Remove the air inlet boot then disconnect the throttle position sensor TPS connector A man ifold absolute pressure MAP sensor...

Page 87: ...ts lock securely in place Gas Tank REMOVING 1 Remove the seats and center console then remove the left side and right side seat bases 2 Remove twelve cap screws and two self tapping screws securing the floorboard to the frame 3 While pulling forward on the upper portion of the floorboard lift the rear panel above the seat lock studs then insert a small wood block to hold in position PR163 PR164 4 ...

Page 88: ...nside hold down strap PR699A 9 Lift and slide the tank forward raising the front of the tank first then turn the tank and lift out the right side CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all gas tank components with parts cleaning solvent 2 Inspect all hoses for cracks or leaks 3 Inspect gas tank cap and tank fo...

Page 89: ...filler neck are not binding or rubbing PR176 5 Secure the filler panel with four press nuts then tighten the hardware securing the hold down straps from steps 2 3 securely PR699A PR167A 6 Connect the vent hose A and gasline hose B to the proper fittings then connect the fuel pump fuel level sensor connector C to the main harness PR698A WARNING Whenever any maintenance or inspection is made on the ...

Page 90: ...rature with cooling fan cycling 4 Set the speedometer tachometer to RPM With the engine running at 2500 RPM the pressure gauge must show 0 7 1 4 kg cm 10 20 psi 5 Remove the test kit from the vehicle and install the oil hose Tighten the clamps securely 6 Install the center console and seats making sure the seats lock securely NOTE If the oil pressure is lower than specified check for an oil leak d...

Page 91: ...ne for five minutes after the initial fill shut the engine off and then fill the cooling system to the bot tom of the stand pipe in the radiator neck Radiator REMOVING 1 Remove the cap screws securing the dash assem bly to the frame and one cap screw and nut from the center support Slide the dash rearward approx imately four inches PR181A PR475A 2 Remove four torx head screws A securing the under ...

Page 92: ...ses 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 Tighten securely PR184A 2 Connect the upper and lower coolant hoses to the radiator and secure with the appropriate hose clamps then connect the cooling ...

Page 93: ...stat should start to open at 73 5 76 5 C 164 170 F D If the thermostat does not open it must be replaced 3 Inspect all coolant hoses connections and clamps for deterioration cracks and wear NOTE All coolant hoses and clamps should be replaced every four years or 4000 miles INSTALLING 1 Place the thermostat and O ring into the thermo stat housing then secure the thermostat housing together with the...

Page 94: ...stall the radiator cap 5 Start the engine and check for coolant leaks then add coolant if necessary to proper level Electric Fuel Pump Fuel Level Sensor The electric fuel pump and fuel level sensor are not serviceable components If either component fails it must be replaced TESTING CAUTION Do not force the water pump housing into the crank case or sever engine damage may occur CAUTION After operat...

Page 95: ...table means cover the fuel pump opening INSPECTING 1 Inspect the fuel screen and blow clean with low pressure compressed air 2 Move the float lever and check for free movement The float assembly should return to the lower posi tion without force If not replace the fuel level sensor assembly 3 Test the fuel level sensor by connecting a multime ter A to the fuel level sensor leads B then select OHMS...

Page 96: ...ve battery cable then turn the ignition switch to the ON position and verify that no gas leaks are present the pump runs for 2 3 seconds and the gas gauge reading is normal 4 Start the engine to verify proper engine operation then shut off the engine and install the right side seat base center console and seats making sure the seats lock securely into place Troubleshooting Problem Starting impaire...

Page 97: ...sors Components 5 7 Speed Sensor 5 7 Ignition Switch 5 8 Headlight Switch 5 8 2WD 4WD Differential Lock Switch 5 8 Reverse Override Switch 5 9 Front Drive Actuator 5 9 Stator Coil Crankshaft Position CKP Sensor 5 10 Starter Motor 5 11 Starter Relay 5 11 Electronic Control Unit ECU 5 12 Regulator Rectifier 5 12 Headlights 5 12 Taillight Brakelight 5 13 Ignition Timing 5 13 ECU Error Codes 5 13 Tilt...

Page 98: ... test the battery voltage The meter must read at least 12 5 DC Volts for a fully charged battery NOTE At this point if the meter reads as speci fied the battery may be returned to service see step 10 7 If the meter reads less than specified voltage charge the battery using the following guidelines A When using an automatic battery charger always follow the charger manufacturer s instructions Descr...

Page 99: ...ings may vary due to internal circuitry When troubleshooting a specific component always verify first that the fuse s are good that the bulb s are good that the connections are clean and tight that the battery is fully charged and that all appropriate switches are activated NOTE For absolute accuracy all tests should be made at room temperature of 68 F Switches Each time the vehicle is used switch...

Page 100: ...ctor 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the orange wire then connect the black tester lead to ground PR276A 3 The meter must show battery voltage NOTE If the meter shows no battery voltage troubleshoot the battery fuse switch or the main wiring harness NOTE If the meter shows battery voltage the main wiring harness is good proceed to test the switc...

Page 101: ...ack tester lead to ground 3 The meter must show battery voltage NOTE If the meter shows no battery voltage troubleshoot the battery fuse motor or the main wiring harness NOTE If the meter shows battery voltage the main wiring harness is good The connector should be checked for resistance RESISTANCE Fan Motor Connector 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to t...

Page 102: ... Refer to the amperage listed under each fuse on the power distribution module RELAYS The relays are indentical plug in type located on the power distribution module Relay function can be checked by switching relay positions The relays are interchangeable NOTE The module and wiring harness are not a serviceable component and must be replaced as an assembly Ignition Coil The ignition coils are moun...

Page 103: ...ter lead to the black green wire With the engine running at idle speed the meter should read approximately 1 5 DC volts 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 2 With appro...

Page 104: ...engaged battery volt age will be approximately 10 5 DC volts Headlight Switch VOLTAGE 1 Connect the red meter lead to the gray wire then connect the black meter lead to the black wire 2 Turn the ignition switch to the ON position The meter must show battery voltage NOTE If the meter does not show battery volt age troubleshoot the LIGHTS fuse on the power distribution module the ignition switch or ...

Page 105: ... the red meter lead to the red yellow wire The meter must show approximately 1 5 DC volts Depress the reverse override switch The meter must show approximately 1 5 DC volts 6 Connect the red meter lead to the red green wire The meter should show 0 DC volts 7 Depress the reverse override switch The meter must show approximately 5 DC volts Front Drive Actuator NOTE With the engine stopped and the ig...

Page 106: ...attery post then connect the black tester lead to the nega tive battery post 3 With the engine running at a constant 5000 RPM with the headlights on the meter must show 14 15 5 DC volts NOTE If voltage is lower than specified test AC Generator No Load VOLTAGE AC Generator No Load The connector is the black three pin one on the left side next to the shift lever PR658B NOTE Test the connector that c...

Page 107: ... screws and wiring forms 2 Secure the positive cable to the starter with the nut 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 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to...

Page 108: ...ectrical problems however if the ECU is suspected substitute another ECU to verify the suspected one is defective This EFI system has a built in feature that will only allow an ECU of the same part number to be used in this model Do not attempt to substitute an ECU from a different model as the system will not allow it to start Error codes can be cleared by following the procedures located in the ...

Page 109: ...akelight harness pigtail The ignition switch must be in the ON position 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the red blue wire then connect the black tester lead to the black wire 3 With the brake applied the meter must show bat tery voltage NOTE If the meter shows no voltage inspect the 10 amp ignition IGN fuse brakelight switch wir ing harness or c...

Page 110: ...he ON position 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 NOTE If the LCD still displays an error code continue troubleshooting the appropriate compo nent 3 Disconnect the test plug then install the black rub ber cap 4 Install the seats makin...

Page 111: ...ly one second in the tilted position If the meter readings are not as specified the tilt sensor is defective NOTE When replacing the sensor after testing make sure the arrow marking is directed up PR703A Throttle Position Sensor TPS INSPECTING 1 Remove the seats and center console then discon nect the three wire TPS connector plug PR595B NOTE Prior to testing the TPS inspect the three wire plug co...

Page 112: ...y 0 6 DC volts with the throttle closed and approximately 5 0 DC volts with the throttle in the full open position NOTE If the meter readings are as specified check the main harness connector at the ECU main harness wiring If the meter readings are not as specified replace the TPS and adjust to specifi cations see INSTALLING ADJUSTING in this sub section 10 Clear all ECU error codes after servicin...

Page 113: ...ror Code List onto the plug 4 Turn the ignition switch to the ON position and note the position of the TPS indicator icon A B or C then adjust the TPS until the TPS icon appears in the center position B PR542A PR540A PR541A 5 Tighten the mounting screws securely then verify the TPS icon appears in the center position 6 Remove the test plug then install the center con sole and seats making sure the...

Page 114: ...Regulator rectifier shorted punctured 1 Repair replace tighten lead wires 2 Replace magneto coils 3 Replace regulator rectifier Problem Battery charges but charging rate is below the specification Condition Remedy 1 Lead wires shorted open loose at terminals 2 Stator coils magneto grounded open 3 Regulator rectifier defective 4 Electrolyte low 5 Cell plates battery defective 1 Repair tighten lead ...

Page 115: ...d 1 Replace battery 2 Keep electrolyte to prescribed level 3 Charge battery add distilled water 4 Replace battery 5 Replace battery Problem Battery discharges too rapidly Condition Remedy 1 Electrolyte contaminated 2 Specific gravity too high 3 Charging system charging operation not set prop erly 4 Cell plates overcharged damaged 5 Battery short circuited 6 Specific gravity too low 1 Replace batte...

Page 116: ...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 26 Troubleshooting 6 28 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 117: ... front drive actuator is located on the right side of the front drive input housing With the engine stopped and the ignition switch in the ON position a momen tary whirring sound can be heard each time the front drive selector switch is shifted If no sound is heard see Section 5 If the actuator runs constantly or makes squealing or grinding sounds the actuator must be replaced REMOVING 1 Select 4W...

Page 118: ...o ensure proper seating of the actuator 5 Tighten the remaining cap screws then connect the electrical plug to the main harness 6 Turn the ignition switch to the ON position and check the operation by shifting the switch several times 7 Secure the wiring harness to the frame with a nylon cable tie then install the inner fender panel Front Differential REMOVING 1 Remove the belly panel then place t...

Page 119: ...PR191 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 PR193 10 Pull the steering knuckle away from the axle PR222 11 Support the axle to not allow it to drop or hang 12 Remove the lower shock bolts Account for the lock nuts then move the shocks an...

Page 120: ...16 Remove the upper differential mounting cap screw Account for a lock nut and two washers CD016 17 Free the differential assembly from the frame mountings then lower the differential through the frame Disassembling Input Shaft 1 Using a T 40 torx wrench remove the cap screws securing the pinion housing PR261A 2 Using a rubber mallet remove the housing Account for a gasket Remove the fork collar a...

Page 121: ...ce the pinion housing in a press and remove the bearing AF983 AF984 KX219 Assembling Input Shaft 1 Place the pinion housing in a press and install the input shaft bearing Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mym...

Page 122: ...r then lubricate with rec ommended grease KX221 KX222 4 Install the input shaft into the pinion housing then secure in the bearing with a circlip KX210A 5 Place the pinion housing with new gasket onto the differential housing then secure with existing cap screws Tighten to 23 ft lb NOTE If a new differential housing is being installed tighten the cap screws to 28 ft lb KX209 Back to TOC Back to Se...

Page 123: ... Using a plastic mallet tap lightly to remove the differential cover Account for an O ring KX174 NOTE If the cover is difficult to remove pry on the cover in more than one recessed location 4 Remove the splined coupler shifter fork pin and spring of the differential lock assembly and set aside Note position of parts for assembling pur poses KX175 5 Remove the left differential bearing flange assem...

Page 124: ...inion bearing using a press Account for a collar and a bearing CC879 NOTE If gears are being replaced use the exist ing shims The numbers are scribed onto the gears the ring gear has the number on the oppo site side of the gears and the pinion gear has the number on the end of the pinion gear shaft by the splines If no number is present it should be con sidered as being in the 0 category NOTE If t...

Page 125: ...ion range reselect shim until backlash specification range can be verified 4 Prior to final assembling apply molybdenum dis ulfide grease to all oil seal lips 5 Prior to final assembling prelubricate journal on pinion assembly with SAE 80W 90 hypoid gear lubricant prior to pressing assembly into differen tial housing Assembling Differential Assembly 1 Install the bearing onto the pinion shaft Inst...

Page 126: ...sting cap screws Tighten to 23 ft lb NOTE If a new housing is being installed tighten the cap screws to 28 ft lb CD103 CD110 8 Install the proper shim onto the ring gear spider assembly making sure the chamfer side of the shim is facing toward the ring gear Install the ring gear in the housing then install the outside shim with the chamfer side of the shim toward the ring gear NOTE The spider and ...

Page 127: ...sing is being installed tighten the cap screws to 28 ft lb 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 1 Place a 1 4 in drill bit on the inside surface of the needle bearing against the bottom side then drill through the pinion shaft need...

Page 128: ...o 120 ft lb CC890 4 Place a punch on the edge of the lock collar in the oil gallery area then using a hammer stake the lock collar to ensure that the collar will remain securely tightened CC891 5 Install the pinion housing Removing Installing Axle Seal NOTE This procedure can be performed on a rear gear case 1 Remove the seal using a seal removal tool CC899 2 Using a press remove the bearing CC900...

Page 129: ...n the nuts to 38 ft lb 4 Pour 275 ml 9 3 fl oz of SAE 80W 90 hypoid lubricant into the differential and install the fill plug Tighten to 16 ft lb 5 Align the scribed match marks on the front input drive flange and the front drive yoke flange then secure with the cap screws tightened to 20 ft lb PR198A 6 Install the front axles see Drive Axles in this sec tion 7 Install the knuckle assemblies onto ...

Page 130: ...nd tighten to 45 ft lb 13 Remove the vehicle from the support stand 14 Install the belly panel Drive Axles REMOVING REAR DRIVE AXLE 1 Secure the vehicle on a support stand to elevate the wheels 2 Set the parking brake then remove the wheels 3 Remove the cotter pins securing the hex nuts then remove the hex nuts PR693 4 Slide the hub out of the knuckle and set aside PR221 5 Remove the cap screw and...

Page 131: ...CTING 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 CD019 2 Inspect boots for any tears cracks or deterioration NOTE If a boot is damaged in any way it must be replaced with a boot kit DISASSEMBLING AXLES 1 Using a side cutters or suitable substitute r...

Page 132: ... or the housing the drive axle must be replaced as an assembly 6 Using a side cutters or suitable substitute remove the small clamp from the shaft CD752 NOTE At this point if the outside boot is dam aged continue with step 7 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 CD751 8 Ap...

Page 133: ...itioned correctly when the small end of the boot seats down into the recessed groove CD754 2 Using the boot clamp tool secure the small clamp of the inner boot ATV 1048 3 Apply 80 grams 2 3 of contents of grease from the pack into the bearing housing 4 Install the bearing onto the shaft making sure the recess of the bearing is facing the housing CD022 5 Secure the bearing ring with the snap ring m...

Page 134: ... Tighten the hex nut finger tight at this time 4 Tighten the hub hex nut from step 3 to 200 ft lb then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut PR693 5 Install the wheel Tighten to 45 ft lb 6 Remove the vehicle from the support stand and release the parking brake INSTALLING FRONT DRIVE AXLE 1 Position the drive axle in the differential and steer ...

Page 135: ...his section 2 Remove the driveline brake caliper then remove the rear driveshaft 3 Remove the two cap screws and lock nuts securing the rear gear case to the frame then remove the gear case through the upper left side of the frame and lift out the top PR207 REAR DRIVE INPUT SHAFT HOUSING Removing Disassembling 1 Remove the cap screws securing the rear drive input shaft housing to the rear gear cas...

Page 136: ...sing for excessive wear cracks or discoloration 4 Inspect the clutch basket for wear in splines or cracks in the housing GZ178A 5 Inspect the clutch pack for signs of discoloration NOTE The clutch pack is not a serviceable com ponent If worn discolored or damaged in any way it must be replaced Assembling Installing 1 Install a new bearing into the input housing and secure with the snap ring flat s...

Page 137: ...to the input coupler and engage the driveshaft and gear case 2 Pack the driveline boot with the appropriate grease then secure with the boot clamps using CV Boot Clamp Tool 3 Secure the gear case to the frame with two through bolts and secure with lock nuts and flat washers Tighten to 38 ft lb 4 Install the rear drive axles see Drive Axles in this section 5 Install the driveline brake caliper and ...

Page 138: ...excessively cracked or damaged in any way replacement is necessary 1 Clean all hub components 2 Inspect all threads for stripping or damage 3 Inspect the brake disc if applicable for cracks or warping 4 Inspect the hub for pits cracks loose studs or spline wear REPLACING WHEEL STUDS 1 Secure the hub in a suitable holding fixture and remove the brake disc if applicable 2 Drive the damaged stud out ...

Page 139: ...gned PR258 5 For front hubs secure the brake calipers to the knuckle with two cap screws tightened to 20 ft lb PR377B 6 Install the wheel and tighten to 45 ft lb 7 Remove the vehicle from the support stand Hydraulic Brake Caliper NOTE The brake caliper is a non serviceable component it must be replaced as an assembly REMOVING DISASSEMBLING 1 Secure the vehicle on a support stand to elevate the whe...

Page 140: ...ING 1 Clean all caliper components except the brake pads with parts cleaning solvent 2 Inspect the brake pads for damage and excessive wear NOTE For measuring brake pads see Section 2 ASSEMBLING INSTALLING 1 Install the caliper onto the caliper holder making sure the caliper is correctly oriented on the holder PR239C 2 Compress the caliper holder toward the caliper and install the inner brake pad ...

Page 141: ... 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 ele vated high enough to allow working from the underside of the vehicle 2 To aid in installing match mark drive line compo nents prior to removing PR152A 3 Remove the cap screws securing the propeller shaft flange to the yoke flange on the appropriate drive li...

Page 142: ...ing cups are loose the yoke must be replaced PR367B 2 Check that yoke legs are parallel PR367A 3 Check splines and flanges for excessive wear thread damage or warpage PR367C INSTALLING 1 Remove the bearing cups from the universal joint then insert the joint into the yoke and install one bearing cup on the joint PR368 2 Secure U Joint Separator Tool in a vise then place the yoke joint and bearing c...

Page 143: ...52A 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 2 Propeller shaft serration worn broken 3 Coupling damaged 4 Coupling joint serration worn damaged 5 Front drive driven bevel gears...

Page 144: ... 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 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 145: ...r components in parts cleaning solvent 2 Inspect each shock rod for nicks pits rust bends and oily residue 3 Inspect all springs spring retainers shock rods sleeves bushings shock bodies and eyelets for cracks leaks and bends INSTALLING 1 Place the shock absorber spring over the shock absorber compress the spring and install the retainer 2 Place bushings and sleeves where appropriate into shock ey...

Page 146: ... 10 Remove the cap screws securing the A arms to the frame AF610D 11 Remove the snap ring from the ball joint then remove the ball joint from the A arm AF616D CLEANING AND INSPECTING 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 sol vent 2 Clean the ball joint mounting hole of all residual Loctite grea...

Page 147: ... the upper A arm Tighten nut to 33 ft lb 5 Secure the A arm assemblies to the frame mounts from step 2 Tighten the cap screws from the head end to 40 ft lb 6 Install the knuckle assembly onto the ball joints and secure with cap screws Tighten to 35 ft lb PR193 7 Install the tie rod end and secure with the nut coated with red Loctite 271 Tighten to 30 ft lb then install a new cotter pin and spread ...

Page 148: ...he wheels 2 Set the parking brake 3 Remove the wheel 4 Remove the cotter pin securing the hex nut then remove the hex nut 5 Remove the cap screws and lock nut securing the shock absorber to the frame and lower A arm then remove the shock absorber 6 Remove the cap screws securing the boot guard to the lower A arm AF934 7 Slide the axle out of the knuckle and set aside 8 Remove the cap screws and lo...

Page 149: ...nd new lock nut Tighten to 33 ft lb 9 Secure the boot guard to the lower A arm with the two cap screws Tighten securely 10 Install the wheel and tighten to 45 ft lb 11 Remove the vehicle from the support stand Wheels and Tires TIRE SIZE This UTV is equipped with low pressure tubeless tires of the size and type listed in Section 1 Do not under any circumstances substitute tires of a different type ...

Page 150: ...nment toe in and toe out and adjust as necessary see Section 8 4 Test drive the vehicle on a dry level surface and note any pulling to the left or right during acceler ation deceleration and braking NOTE Pulling could be caused by uneven tire pressure side to side steering alignment out of adjustment unequal loading or improper tire size Troubleshooting WARNING Do not operate the vehicle if tire d...

Page 151: ...ft Assembly 8 7 Steering Knuckles 8 8 Checking Adjusting Front Wheel Alignment 8 10 Front Bumper Assembly 8 10 Hood 8 11 Fenders 8 11 Floor 8 12 Belly Panel 8 12 Exhaust System 8 13 Cargo Box 8 13 Taillight Assembly 8 14 Seats 8 14 Troubleshooting 8 15 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 152: ... remove the front wheels 2 Remove the cotter pins and nuts securing the tie rod ends to the knuckles then remove the tie rod ends from the knuckles PR301 3 Make matching alignment marks on the pinion shaft and lower steering shaft joint PR333A NOTE Any time steering components are disas sembled all connecting components should be marked for proper alignment during assembling 4 Remove the cap screw...

Page 153: ...le and must be replaced as an assembly however the tie rods and boots are replaceable REPLACING TIE RODS BOOTS 1 Secure the rack and pinion assembly in a vise or other suitable holding fixture then remove the tie rod end jam nut and rack boot 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 PR523...

Page 154: ...ft aligning the match marks PR309 3 Apply green Loctite 270 to the cap screw then place the lower steering shaft joint to the pinion shaft with the cap screws making sure the shaft does not protrude into the joint beyond the clamp ing surface PR309A 4 Tighten the cap screw from step 3 to 36 ft lb then check that the steering wheel turns freely 5 Install the tie rod ends into the steering knuckles ...

Page 155: ... flat thrust washer and then the two wave washers onto the steering shaft 2 Install the steering wheel aligning the two match marks then apply a drop of red Loctite 271 to the threads of the nut and secure the steering wheel Tighten to 25 ft lb NOTE If a new steering wheel is being installed mark the wheel as close as possible to the old wheel mark then check for proper positioning with the front ...

Page 156: ...to the cap screw then install the cap screw in the upper steering shaft joint Install the nut and finger tighten 3 Align the match marks on the steering wheel shaft and the steering wheel and slide the steering wheel onto the splines then install the nut and fin ger tighten PR696 4 Hold rearward pressure on the steering wheel and tighten the cap screw from step 2 to 36 ft lb 5 Remove the steering ...

Page 157: ...splash panel PR314A 2 Align the match marks on the pinion shaft and the lower steering shaft joint then slide the steering shaft joint onto the pinion shaft PR333A 3 Apply green Loctite 270 to the cap screw then secure the lower steering shaft joint to the pinion shaft making sure the pinion shaft does not pro trude into the joint beyond the clamping surface Tighten to 36 ft lb PR309A AT THIS POIN...

Page 158: ...emove the snap ring securing the bearing in the knuckle then press the bearing out of the knuckle PR289 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all knuckle components 2 Inspect the bearing for pits scoring rusting or premature wear 3 Inspect the knuckle for cracks breaks or galling of the bearing surface ASSEMB...

Page 159: ...he hub splines PR290A 5 Install the hub assembly onto the splines of the shaft CD009 6 Secure the hub assembly with the nut Tighten to 200 ft lb PR256 7 Install a new cotter pin and secure by spreading as shown PR260 NOTE If the hole in the axle shaft does not align with the slots in the castle nut tighten the nut until the hole and slots align 8 Secure the brake caliper to the knuckle with the tw...

Page 160: ...87A To adjust the wheel alignment use the following pro cedure 1 Center the steering wheel then using an open end wrench to hold the tie rod ends loosen the right side and left side jam nuts PR085A 2 Turn the left side and right side tie rods in equal increments to achieve the proper toe out then tighten the jam nuts securely PR086 Front Bumper Assembly REMOVING Remove four cap screws and nuts Acc...

Page 161: ...from step 2 then remove the hood assembly CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all hood components with soap and water 2 Inspect the hood for cracks and or loose fasteners 3 Inspect for any missing decals INSTALLING 1 Place the hood into position on the vehicle then install the two outside cap screws and fla...

Page 162: ...ut of the vehicle PR165 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean the floor with soap and water 2 Inspect the floor for cracks or holes INSTALLING 1 Place the front of the floor into position in the vehicle first then lower the rear and push past the seat lock studs 2 Secure the floor with twelve cap screws and t...

Page 163: ...n 2 Secure the muffler to the exhaust pipe with the two exhaust springs Cargo Box REMOVING 1 Raise the cargo box then remove the cap screw and nut securing the lower lift support to the frame Account for the washer The cargo box will tilt fully rearward PR473A 2 Loosen but do not remove the four shoulder cap screws securing the pivot housings to the cargo box PR335 3 Lower the cargo box then remov...

Page 164: ...cess opening PR056 2 Disconnect the three prong connector from the bulb socket and remove the taillight assembly INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect wiring harness three prong connector lens base cap screws and socket for damage 2 Inspect all wires for corroding pinching and cracking 3 Inspect the bulb for wattage vol...

Page 165: ...blem Steering pulling to one side Condition Remedy 1 Tires inflated unequally 2 Front wheel alignment incorrect 3 Wheel hub bearings worn broken 4 Frame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Replace shock absorber Problem Steering impaired Condition Remedy 1 Tire pressure too high 2 Steering linkage connections worn 3 ...

Page 166: ...d incorrectly 6 Rear suspension arm related bushing worn 7 Rear shock absorber damaged 8 Rear suspension arm nut loose 1 Replace bearings 2 Replace tires 3 Replace rim 4 Tighten cap screws 5 Adjust parking brake 6 Replace bushing 7 Replace shock absorber 8 Tighten nut Back to TOC Back to Section TOC Back FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 167: ...S TABLE OF CONTENTS Master Cylinder Assembly 9 2 Accelerator Pedal 9 2 Shift Lever 9 3 Speedometer Tachometer LCD Indicator Lights 9 3 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 168: ...s or deterioration 3 Inspect the reservoir for cracks and leakage 4 Inspect the brake hose for cracks and deterioration and the condition of the banjo fittings INSTALLING 1 Place the master cylinder into position then using three new crush washers secure the two banjo fit tings to the master cylinder Tighten to 20 ft lb 2 Secure the master cylinder assembly to the frame with two cap screws and two...

Page 169: ...e Loctite 243 Tighten to 20 ft lb Speedometer Tachometer LCD Indicator Lights REPLACING 1 Remove the screws securing the dash panel to the frame 2 Slide the dash panel to the rear sufficiently to access the components PR181A 3 Remove the nuts securing the gauge assembly to the dash then unplug the multi pin connector and remove the gauge from the vehicle PR284A 4 Place the new gauge into the dash ...

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Arctic Cat 2009 Prowler XTZ, Service Manual

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