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PROWLER HDX

[ROV]

SERVICE MANUAL

2014

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Содержание 2014 Prowler HDX

Страница 1: ...PROWLER HDX ROV SERVICE MANUAL 2014...

Страница 2: ...s Warning Caution Note and At This Point to emphasize important information The symbol WARNING identifies personal safety related information Be sure to fol low the directive because it deals with the...

Страница 3: ......

Страница 4: ...ing Engine 500 40 Servicing Engine 700 79 Installing Engine Transmission 118 Fuel Lubrication Cooling 121 Electronic Fuel Injection 121 Gas Tank 122 Gas Vent Hoses 124 Oil Filter Oil Pump 124 Liquid C...

Страница 5: ...nd Gap Installed min 0 15 mm Piston Ring to Groove Clearance max 1st 2nd 0 06 mm Piston Ring Groove Width 1st 2nd oil 1 01 1 03 mm 1 21 1 23 mm 2 01 2 03 mm Piston Ring Thickness 1st 2nd 0 97 99 mm 1...

Страница 6: ...COMPONENTS Part Part Bolted To Torque ft lb N m Rear Differential Gear Case Frame 38 48 Drive Coupler Front Front Drive Flange 40 54 Front Engine Mounting Bracket Frame 45 61 Rear Engine Mounting Bra...

Страница 7: ...er 11 15 Valve Inspection Cover Cylinder Head Cover 8 11 Cam Chain Tensioner Cylinder 10 13 5 Magneto Cover Crankcase 8 11 Rear Driveline Output Drive Flange 20 27 Water Pump Cover Housing Magneto Cov...

Страница 8: ...moved to a warm area 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 5...

Страница 9: ...Store the vehicle indoors in a level position Preparation After Storage Taking the vehicle out of storage and correctly preparing it will assure many miles and hours of trouble free riding 1 Clean th...

Страница 10: ...55 Item Initial Service After Break In First Month or 100 Miles Every Day Every Month or Every 100 Miles Every 3 Months or Every 300 Miles Every 6 Months or Every 500 Miles Every Year or Every 1500 Mi...

Страница 11: ...the fol lowing procedure NOTE The engine must be cold for this procedure NOTE The seat seat back seat base and spark plug must be removed for this procedure 1 Remove the spark plug and timing inspect...

Страница 12: ...ot be run cold values are included NOTE The seat seat back and seat base must be removed for this procedure 1 Remove the high tension lead from the spark plug 2 Using compressed air blow any debris fr...

Страница 13: ...he cap screws Tighten the cap screws to 48 in lb Engine Transmission Oil Filter OIL FILTER Change the engine oil and oil filter at the scheduled inter vals The engine should always be warm when the oi...

Страница 14: ...he appropriate lubricant until it appears at the bottom of the level plug threads To change the lubricant use the following procedure 1 Place the vehicle on level ground 2 Remove each fill plug 3 Drai...

Страница 15: ...light bulb use the following procedure 1 Remove the two machine screws and remove the light assembly 2 Rotate the bulb socket counterclockwise to remove it from the light assembly then pull straight o...

Страница 16: ...PR568A 4 Install the E clip then tighten the nuts A and B to 8 ft lb 5 Check each gear shift position for proper gear selec tion and make sure the proper icon illuminates on the LCD Hydraulic Brake S...

Страница 17: ...al is firm 3 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 HOS...

Страница 18: ...rake pedal to decelerate to 0 5 mph 3 Repeat procedure 20 times until brake pads are bur nished Checking Replacing V Belt REMOVING 1 Remove the seat seat back and seat base 2 Remove the floor see Stee...

Страница 19: ...face 3 Rotate the V belt and driven pulley clutch until the V belt is flush with the top of the driven pulley 4 Place the V belt cover gasket into position then with the dowel pins in position instal...

Страница 20: ...leshoot the EPS system prior to replacing the EPS assem bly see the Electrical System section as there are several possible external causes for system fail ure 1 Support the vehicle on appropriate sta...

Страница 21: ...ible until the EPS is engaged with the coupler 3 Install the EPS assembly into the coupler turning the EPS shaft slightly to align the index spline then seat the EPS firmly onto the frame 4 Install fo...

Страница 22: ...Assembly in this section 2 Support the steering rack assembly in a suitable holding fixture or bench vise then cut the securing band and slide the boot toward the outer tie rod end 3 Using a punch or...

Страница 23: ...the steering rack assembly to the rack bracket and remove from the left side INSPECTING 1 Inspect the tie rod ends for damaged threads torn boots or excessive wear 2 Inspect the tie rods for bends or...

Страница 24: ...nspect the splines for wear 3 Check that the steering wheel is not bent INSTALLING 1 Install the steering wheel aligning the two match marks then apply a drop of red Loctite 271 to the threads of the...

Страница 25: ...Assembly REMOVING With the upper steering shaft removed remove the cap screw from the intermediate shaft coupler and remove the shaft from the EPS and vehicle INSPECTING NOTE The lower steering shaft...

Страница 26: ...l 2 Remove the cotter pin from the axle 3 Remove the nut securing the hub 4 Remove the brake caliper 5 Remove the hub assembly 6 Remove the cotter pin from the tie rod end and remove the tie rod end f...

Страница 27: ...with red Loctite 271 Tighten to 30 ft lb then install a new cotter pin and spread the pin NOTE During assembling new cotter pins should be installed 4 Apply a small amount of grease to the hub splines...

Страница 28: ...cable holding grommet from the actuator arm then remove two torx head screws and nuts securing the accelerator pedal assembly to the splash panel and remove the accelerator pedal PR709 HDX256 INSTALL...

Страница 29: ...ransmission HDX137B 4 Remove the center floorboard and remove all nylon ties securing the cable housing to the frame then remove the shift cable NOTE If the cable is being replaced connect the new cab...

Страница 30: ...the components PR181A 5 Remove the nuts securing the gauge assembly to the dash then unplug the multi pin connector and remove the gauge from the vehicle PR284A 6 Place the new gauge into the dash pa...

Страница 31: ...side and left side jam nuts HDX098B 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 Assembl...

Страница 32: ...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 flange nuts Finger tighten only at this ti...

Страница 33: ...then lower the rear and push past the seat locating studs 2 Secure the floor with the cap screws and self tap pings screws 3 Install the center floorboard then install the seat base seat back and sea...

Страница 34: ...ECTING MUFFLER 1 Inspect muffler externally for cracks holes and dents 2 Inspect the muffler internally by shaking the muffler back and forth and listening for rattles or loose debris inside the muffl...

Страница 35: ...position Taillight Assembly REMOVING 1 Remove the cap screws and lock nuts securing the taillight assembly to the ROPS tube 2 Disconnect the wire connector then remove the socket assembly and remove...

Страница 36: ...en 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 Tir...

Страница 37: ...first 10 hours or 200 miles are most critical to the life of this ATV Proper operation during this break in period will help assure maximum life and performance from the ATV Instruct the customer to f...

Страница 38: ...lace fuel injector 5 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance excessive 2 Valve spring s weak broken 3 Rocker arm rocker arm shaft worn 4 Camsha...

Страница 39: ...y Condition Remedy 1 Engine oil overfilled contaminated 2 Piston rings cylinder worn 3 Valve guides worn 4 Cylinder wall scored scuffed 5 Valve stems worn 6 Stem seals defective 1 Drain excess oil cha...

Страница 40: ...gasline hose connector with a shop cloth then remove the gasline hose connector from the fuel rail HDX138A 6 Loosen the clamp securing the air filter intake tube to the air filter then remove the moun...

Страница 41: ...t to the engine case Remove the cap screw from the shift arm and disconnect the gear position switch connector Slide the gear position switch off the engine HDX254 HDX251 NOTE On the 500 shifting the...

Страница 42: ...ings at the muffler then remove the exhaust pipe Account for a grafoil seal in the cylinder head and a grafoil seal at the muffler HDX153A 16 Remove the cap screws securing the driveshafts to the fron...

Страница 43: ...e only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to removed fr...

Страница 44: ...ve the cap screw from the tension adjuster then using a flat blade screwdriver relax the cam chain tension by rotating the adjuster screw clock wise until it locks FI607A FI608 4 Bend the washer tabs...

Страница 45: ...nd secure it to keep it from falling into the crankcase FI620 FI617A 7 Remove the cam chain tensioner pivot bolt and remove the chain tensioner then remove the two nuts securing the cylinder head to t...

Страница 46: ...alignment pins FI624A 13 Using an awl remove one piston pin circlip Take care not to drop it into the crankcase FI625 14 Using Piston Pin Puller remove the piston pin Account for the opposite side cir...

Страница 47: ...igure eight motion until a uniform bright metallic finish is attained CC130D Removing Valves NOTE Index all valves springs and cotters to their original position when removing When installing all valv...

Страница 48: ...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...

Страница 49: ...e valve springs and install the valve keepers CC132D PISTON ASSEMBLY NOTE Whenever a piston rings or pin are out of tolerance they must be replaced Cleaning Inspecting Piston 1 Using a non metallic ca...

Страница 50: ...be replaced see Center Crankcase Components in this section 3 Insert an inside dial indicator into the piston pin bore Take two measurements to ensure accuracy The diameter must not exceed specificati...

Страница 51: ...ed Measuring Cylinder Head Distortion 1 Remove any carbon buildup in the combustion chamber 2 Lay a straightedge across the cylinder head then using a feeler gauge check the distortion factor between...

Страница 52: ...NOTE To produce the proper 60 cross hatch pattern use a low RPM drill 600 RPM at the rate of 30 strokes per minute If honing oil is not avail able use a lightweight petroleum based oil Thor oughly cl...

Страница 53: ...ng clearance 4 Remove the cap screws securing the valve cover to the cylinder then remove the valve cover and cam shaft MD1261 5 Match the width of the plasti gauge with the chart found on the plasti...

Страница 54: ...stitute beneath the piston skirt and square the piston in respect to the crankcase MD1344 3 Lubricate the inside wall of the cylinder then using a ring compressor or the fingers compress the rings and...

Страница 55: ...om step 4 to 8 ft lb 10 With the timing inspection plug removed and the cam chain held tight rotate the crankshaft until the piston is at top dead center 11 While holding the cam chain to the front in...

Страница 56: ...the sprocket directed toward the cam lobes E Camshaft alignment pin and sprocket alignment hole smallest are aligned 16 Place the tab washer onto the sprocket making sure it covers the pin in the alig...

Страница 57: ...p side cap screws with rubber washers then install the remaining cap screws Tighten only until snug MD1261 26 In a crisscross pattern starting from the center and working outward tighten the cap screw...

Страница 58: ...sor housing assembly Account for two alignment pins a gasket and two seal washers FI543 5 Remove the cap screws securing the magneto cover to the crankcase Note the location of the two inter nal cap s...

Страница 59: ...ter motor Account for an O ring on the starter drive housing FI555 G Shift Shaft H Drive Gear NOTE Steps 1 10 in the preceding sub sections must precede this procedure 11 Remove the shift shaft noting...

Страница 60: ...chipped surfaces missing rollers or discoloration If any of the above conditions exist replace the starter clutch assembly FI572 REPLACING STARTER CLUTCH ASSEMBLY 1 Remove the cap screws securing the...

Страница 61: ...ree cap screws securing the stator coil two cap screws securing the crankshaft position sen sor and one cap screw from the harness hold down 2 Lift the rubber grommet out of the housing then remove th...

Страница 62: ...Side Components A Starter Clutch Gear B Rotor Flywheel 1 If removed place the crankshaft bearing retainer into position Apply red Loctite 271 to the three cap screws Install and tighten the three cap...

Страница 63: ...sket into position Install the magneto cover Noting the different lengthed 6 mm cap screws and the location of the two internal cap screws tighten the cap screws in a crisscross pattern to 8 ft lb FI5...

Страница 64: ...the pedal axle Account for a flat washer KC149A 2 Remove the cap screws securing the V belt cover to the clutch cover then slide the brake pedal outward and remove the V belt cover Account for two ali...

Страница 65: ...the air intake plate MD1092 9 Remove the cap screws holding the clutch cover onto the right side crankcase half Note the positions of the different lengthed cap screws for installing pur poses 10 Usi...

Страница 66: ...D1014 MD1016 13 Remove the cam chain FI630 14 Remove the oil pump drive gear cap screw MD1018 15 Remove oil pump drive gear Account for the pin MD1017 16 Remove the snap ring holding the oil pump driv...

Страница 67: ...t pins MD1060 19 Remove the four cap screws securing the oil strainer cap then remove the Phillips head screws securing the oil strainer Account for the O ring MD1337 MD1208 Servicing Right Side Compo...

Страница 68: ...cks up or turns in both directions the one way clutch must be replaced KC332A INSPECTING OIL PUMP 1 Inspect the pump for damage 2 It is inadvisable to remove the screw securing the pump halves If the...

Страница 69: ...ring when install ing the oil pump driven gear MD1020 MD1019 5 Install the cam chain NOTE Keep tension on the cam chain to avoid damaging the crankcase boss 6 Place the pin into position install the o...

Страница 70: ...crews to 8 ft lb MD1117 11 Install the air intake plate Apply red Loctite 271 to the threads of the three Phillips head cap screws then install and tighten securely MD1342 12 Place the driven pulley a...

Страница 71: ...e the V belt and drive driven assemblies until the V belt is flush with the top of the driven pulley 18 Install two alignment pins and place a new V belt cover gasket into position on the clutch cover...

Страница 72: ...ccount for two alignment pins CC869 NOTE To keep the shaft gear assemblies intact for identification tap the shafts toward the left side crankcase half when separating the halves MD1313 Disassembling...

Страница 73: ...fork locat ing shaft D out of the crankcase locating boss and allow the shift forks to disengage from the gear shift shaft F FI646 FI653A 4 Remove the gear shift shaft F noting the inner and outer wa...

Страница 74: ...able range no correction is necessary 1 If backlash measurement is less than specified remove an existing shim measure it and install a new thinner shim 2 If backlash measurement is more than specifie...

Страница 75: ...D 2 Maximum diameter must not exceed specifications Measuring Connecting Rod Small End Deflection 1 Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate P...

Страница 76: ...rom the out side edge of one web to the outside edge of the other web H1 006 2 Acceptable width range must be within specifica tions COUNTERSHAFT Disassembling 1 Remove the reverse driven gear dog the...

Страница 77: ...Remove the slid ing dog FI668 FI669 5 Remove the circlip securing the high driven gear then remove a washer the high driven gear along with the bearing and bushing and remove the high driven washer FI...

Страница 78: ...w driven bushing 10 bearing 9 and gear 11 on the countershaft then install splined washer 12 FI667A FI666 4 Place the reverse driven bushing 13 onto the shaft then install the bearing 14 gear 15 and s...

Страница 79: ...n the output shaft flange nut to 59 ft lb Using a punch peen the nut MD1333 3 Apply a liberal amount of oil to the crankshaft bear ing Using a propane torch heat the bearing until the oil begins to sm...

Страница 80: ...tion on the assembled countershaft and install into the crankshaft as an assembly FI662 FI653 8 Align the shift forks to allow engagement with the shift cam then engage the shift forks and slide the s...

Страница 81: ...suitable substitute sealant to the mating surfaces Place the right side half onto the left side half FI639B NOTE Be sure to apply silicone to the inside radius of all cap screw locations and the enti...

Страница 82: ...t Side Components 105 Center Crankcase Components 108 Separating Crankcase Halves 108 Disassembling Crankcase Half 108 Servicing Center Crankcase Components 110 Assembling Crankcase Half 115 Joining C...

Страница 83: ...Account for and note the orientation of the cylinder head plug Note the loca tion of the two alignment pins CD206 CD211A 5 Loosen the cap screw on the end of the tensioner then remove the two cap scre...

Страница 84: ...move the cap screw securing the chain tensioner account for a washer then remove the tensioner FI617 10 Remove the five nuts securing the cylinder head to the cylinder CC017D CC018D 11 Remove the four...

Страница 85: ...D 16 Using an awl remove one piston pin circlip CC032D 17 Using the Piston Pin Puller remove the piston pin Account for the opposite side circlip Remove the piston NOTE It is advisable to remove the o...

Страница 86: ...the sealing surface for any indication of high spots A high spot can be noted by a bright metallic finish Correct any high spots before assem bly by continuing to move the valve cover in a figure eig...

Страница 87: ...te 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...

Страница 88: ...install the ends of the springs with the closest wound coils toward the head ATV 1011A 4 Place a spring retainer over the valve springs then using the valve spring compressor compress the valve spring...

Страница 89: ...e measure each piston ring end gap Acceptable ring end gap must not exceed speci fications CC280D Measuring Piston Pin Outside Diameter and Piston Pin Bore 1 Measure the piston pin outside diameter at...

Страница 90: ...g surface 2 Inspect the spark plug hole for any damaged threads Repair damaged threads using a heli coil insert 3 Place the cylinder head on the Surface Plate covered with 400 grit wet or dry sandpape...

Страница 91: ...he first measurements for a total of six measurements The trueness out of round ness is the difference between the highest and low est reading Maximum trueness out of roundness must not exceed specifi...

Страница 92: ...005D 2 Place a strip of plasti gauge in each of the camshaft lands in the cylinder head 3 Place the valve cover on the cylinder head and secure with the valve cover cap screws Tighten securely NOTE Do...

Страница 93: ...der or suitable substitute beneath the piston skirt and square the piston in respect to the crankcase CF083 3 Lubricate the inside wall of the cylinder then using a ring compressor or the fingers comp...

Страница 94: ...s 10 Using a crisscross pattern tighten the four cap screws from step 8 initially to 20 ft lb then in 10 ft lb incre ments tighten to a final torque of 40 ft lb 11 Tighten the 8 mm nuts from step 9 to...

Страница 95: ...ylinder ensuring the following CF013A A Piston still at top dead center B Camshaft lobes directed down toward the pis ton C Camshaft alignment marks parallel to the valve cover mating surface D Recess...

Страница 96: ...screwdriver rotate the adjuster screw inside the tensioner clockwise until the screw bottoms CD501 NOTE The adjuster shaft will be drawn into the ten sioner as the adjuster screw is rotated clockwise...

Страница 97: ...n starting from the center and working outward tighten the cap screws from step 29 to 8 5 ft lb 31 Adjust valve tappet clearance see Periodic Mainte nance 32 Place the two tappet covers into position...

Страница 98: ...hose to the water pump then remove the crossover tube from the cylinder head Account for an O ring 5 Remove the two cap screws securing the water pump to the engine then remove the water pump 6 Remov...

Страница 99: ...pin into the crankcase 13 Remove the shift shaft noting the timing marks for assembling purposes Account for two washers PR430A 14 Remove the gear shift cam plate and account for a washer then remove...

Страница 100: ...cap screws after applying a drop of red Loctite 271 to the threads Tighten to 26 ft lb using a crisscross pattern Make sure the one way bearing is installed with the notches directed away from the ro...

Страница 101: ...for and note the position of the harness hold down under the crankshaft position sensor FI590 3 Install the new stator coil assembly and secure with three new patch lock cap screws Tighten to 15 ft lb...

Страница 102: ...e gears are secured remove the oil passage plug from the crankcase 3 Install the two starter gear shafts then install the two starter gears with the beveled side of the intermedi ate gear facing inwar...

Страница 103: ...fresh engine oil then place it into position on the two alignment pins Make sure the outer shift shaft washer is in place PR431A 9 Install the magneto cover and secure with the cap screws Tighten only...

Страница 104: ...mble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to be remo...

Страница 105: ...OTE To aid in installing it is recommended that the assemblies are kept together and IN ORDER CC829B 7 Remove the one way clutch D from the clutch housing Note the location of the green alignment dot...

Страница 106: ...g the clutch shoe assembly C PR410A 10 Remove the cap screw securing the oil pump drive gear B Account for a cap screw washer pin and spacer CC606 CD987 CD993 11 Using an impact wrench remove the cap...

Страница 107: ...cracks or discoloration If any shoe is damaged replace the complete set 2 Inspect the clutch shoes for wear or damage If any shoe is worn to the bottom of the groove replace the clutch assembly ATV10...

Страница 108: ...he new patch lock cap screws to 28 ft lb CD999 2 Install the oil pump onto the engine then tighten the screws coated with red Loctite 271 to 8 ft lb CD988 3 Install the oil pump drive gear spacer onto...

Страница 109: ...lutch onto the clutch shoe assembly PR399A 8 Lightly grease the clutch housing seal then insert the left fixed drive spacer CF088A CF085A 9 Apply grease to the outer edges of the clutch hous ing then...

Страница 110: ...ar its center and slide the spacer and movable drive face onto the driveshaft Using an appropriate spanner wrench secure the drive face with a nut and threads coated with red Loctite 271 Tighten the n...

Страница 111: ...Crankcase Separator Crankshaft Remover and tapping lightly with a rubber mallet separate the crank case halves Account for two alignment pins NOTE To keep the shaft gear assemblies intact for identif...

Страница 112: ...CC675 7 Note the timing marks on the crank balancer assem bly B gear and crankshaft C gear for assembling purposes then slide the crank balancer gear off the crank balancer Account for the key in the...

Страница 113: ...n 1 Install a new bearing A onto the secondary driven shaft B making sure the bearing locating groove is directed away from the driven gear splines MT011A 2 Using a suitable press install the driven g...

Страница 114: ...easurement is within the acceptable range no correction is necessary 1 If backlash measurement is less than specified remove an existing shim measure it and install a new thinner shim 2 If backlash me...

Страница 115: ...connecting rod and crankshaft journal CC289D 3 Acceptable gap range must not exceed specifica tions Measuring Crankshaft Runout 1 Place the crankshaft on a set of V blocks 2 Mount a dial indicator an...

Страница 116: ...t GZ296 GZ312 3 Remove the reverse driven gear dog GZ313A 4 Remove the snap ring securing the reverse driven gear and washer then remove the washer and gear GZ314 5 Remove the reverse driven washer th...

Страница 117: ...m the drive gear end install a thrust washer bushing and bearing then install the low driven gear and washer GZ317A GZ318 2 Install the low driven gear locking washer then install the inner reverse dr...

Страница 118: ...opposite end of the countershaft install the high low driven gear dog A thrust washer B bushing C bearing D high low driven gear E and spacer washer F GZ283B 7 Install the two drive gear washers and...

Страница 119: ...k balancer CD832B NOTE It will be necessary to rotate the crank bal ancer until the counterweight is facing away from the crankshaft then rotate the crankshaft clockwise into the journal area to allow...

Страница 120: ...of the crankcase and the bearing C ring is fully seated in the crankcase PR787B 11 Place the oil strainer into position then secure with the two screws 12 Place the oil strainer cap into position mak...

Страница 121: ...the slotted rear engine mount brackets with the engine mounts then install the front through bolt 2 Tighten the flange nuts on the rear cradle to 25 ft lb then tighten the nut on the front through bol...

Страница 122: ...ngine with a cap screw and tighten to 8 ft lb HDX149A 10 Properly position the gear position switch on the engine A to A and B to B then secure the shift cable bracket to the engine case and tighten t...

Страница 123: ...fuel rail HDX138B 16 Connect the MAP sensor connector A fuel injector connector B ISC connector C and TPS connector D then install new nylon ties as noted during removing HDX136A 17 Pour the recommen...

Страница 124: ...n the ignition switch to the OFF position then remove the ignition switch key 2 Remove the seat seat back and seat base then dis connect the battery 3 Remove the air inlet boot between the air filter...

Страница 125: ...OVING 1 Remove the seat seat back and seat base then remove the floorboard 2 Disconnect the vent hose A gasline hose B and fuel pump fuel level sensor connector C then cap the vent fitting and gas hos...

Страница 126: ...ump Fuel Level Sensor in this sec tion INSTALLING 1 Place the gas tank into position in the vehicle then install the inside rear hold down strap PR173 PR699A 2 Swing the front hold down to the right i...

Страница 127: ...when install ing the oil pressure gauge Wipe up oil residue with a cloth 3 Block the wheels place the transmission in neutral and start the engine Allow the engine to warm up to operating temperature...

Страница 128: ...e engine for five minutes after the initial fill shut the engine off and then top off the cooling system to the bottom of the stand pipe in the radiator neck Radiator REMOVING 1 Remove the two sheet m...

Страница 129: ...p 5 On models with a storage box place the storage box into position and using a smooth flat pry bar pry the center of the box past the dash mount then secure with the appropriate fasteners PR187 6 In...

Страница 130: ...water pump is not a serviceable com ponent If the pump is defective or if the mechani cal seal is leaking coolant dripping from the discharge hole the water pump must be replaced REMOVING 1 Remove the...

Страница 131: ...ition switch OFF 2 Disconnect the gasline hose from the fuel rail then install a suitable pressure gauge FI092A 3 Turn the ignition switch to the ON position The fuel pressure should build until the p...

Страница 132: ...top of the fuel pump to release it from the mounting slot B FI460A B Engage the tabs C of the fuel level sensor into the mounting slot B and press toward the bottom of the fuel pump to latch in place...

Страница 133: ...Gas contaminated 1 Drain gas tank and fill with clean gas Problem Idling or low speed impaired Condition Remedy 1 TPS out of adjustment 1 Adjust TPS Problem Medium or high speed impaired Condition Re...

Страница 134: ...warnings and cautions provided with the battery or battery maintainer charger Loss of battery charge may be caused by ambient temper ature ignition OFF current draw corroded terminals self discharge f...

Страница 135: ...ected to the battery for a minimum 1 hour after the Maintenance Charge Indicator D illuminates If the battery becomes hot to the touch stop charging Resume after it has cooled 7 Once the battery has r...

Страница 136: ...er is depressed the meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resistance replace the switch Engine Coolant Temperature ECT Sensor NOTE Preliminary checks may be perfor...

Страница 137: ...ned to their proper position according to amperage Refer to the amperage listed under each fuse on the power distribution module 2 Set the meter selector to the DC Voltage position 3 Connect the black...

Страница 138: ...e accessed from behind the right side seat with the cargo box raised 2 Connect the red tester lead to the orange wire and the black tester lead to the blue white wire 3 Turn the ignition switch to the...

Страница 139: ...using the diagnostic mode on the LCD gauge see EFI Diagnostic System in this section NOTE Prior to testing the speed sensor inspect the three wire connector on the speed sensor for contam ination bro...

Страница 140: ...ich way to drive the steering shaft When no steering input pressure on the steering wheel is detected no torque signal is generated and no steering assist is provided by the motor The EPS system is ba...

Страница 141: ...PS will auto recover when engine RPM signal returns to normal C1315 Engine RPM Faulty Engine RPM CAN signal received by the EPS incorrect or missing Broken main harness CAN wires or defective ECM EPS...

Страница 142: ...ead to ground 3 Meter must show battery voltage NOTE If the meter shows no battery voltage troubleshoot the main 30 amp fuse the battery or the main wiring harness 4 Connect the red meter lead to the...

Страница 143: ...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...

Страница 144: ...Voltage position 2 Connect the red tester lead to the positive battery post then connect the black tester lead to the nega tive battery post 3 With the vehicle in neutral and the engine running as sh...

Страница 145: ...n the starter then install the starter into the crankcase Secure with two machine screws and wiring forms 2 Secure the positive cable to the starter with the nut 3 Connect the battery TESTING VOLTAGE...

Страница 146: ...mode on the LCD gauge see EFI Diagnostic System in this section The regulator rectifier is located under the seat next to the battery Try to verify all other charging system components before the regu...

Страница 147: ...er verifying ignition timing can aid in troubleshooting other components To verify ignition timing use the following procedure NOTE To check ignition timing the seat seat back and seat base must be re...

Страница 148: ...degrees F 3 Thermostat opening approximately 180 degrees F indicated by a momentary drop or pause in the rising temperature reading 4 Fan ON 185 degrees F OFF 175 degrees F A fan motor B fan relay C...

Страница 149: ...Verify barometric pressure signal correct Note Local barometric pressure is given in in Hg Inches of Mercury 34 millibars are equal to 1 inch of mercury Example Gauge reading in the BARO mode 974 mill...

Страница 150: ...Sensor Circuit Range Performance Sensor producing an out of range voltage Correct condition P0117 ECT Sensor Circuit Low SG Sensor or interconnect harness shorted to chassis ground Correct condition P...

Страница 151: ...n low or the regulator rectifier output low Correct condition P0563 System Voltage High Battery cable connections are loose or the regulator rectifier output high Correct condition P0601 ECU Memory Ch...

Страница 152: ...tests are made with the sensor connected 1 Connect the three wire plug to the sensor then remove the right side mounting screw securing the sensor to the rear frame CD707 2 Install the needle adapters...

Страница 153: ...f specification the throttle body must be replaced If the vehicle is out of warranty the TPS may be adjusted 2 Connect the TPS Multi Analyzer Harness connector 8 to the TPS then connect the harness to...

Страница 154: ...place battery Problem Magneto overcharges Condition Remedy 1 Battery short circuited 2 Regulator rectifier defective 3 Regulator rectifier poorly grounded 1 Replace battery 2 Replace regulator rectifi...

Страница 155: ...ach time the drive select switch is shifted If no sound is heard see the Electrical System section If the actuator runs constantly or makes squealing or grinding sounds the actuator must be replaced R...

Страница 156: ...with a nylon cable tie Front Differential REMOVING 1 Remove the belly panel then place the vehicle on jack stands adjusted high enough to allow working from the underside of the vehicle NOTE The jack...

Страница 157: ...allow it to drop or hang 11 Remove the lower shock cap screws Account for the lock nuts then move the shocks and upper A arm up and secure them with a strap PR200 12 Push the axle shaft toward the di...

Страница 158: ...ormed on a rear gear case 1 Using a T 40 torx wrench remove the cap screws securing the pinion housing GC004A 2 Using a rubber mallet remove the housing Account for a gasket Remove the fork collar and...

Страница 159: ...input shaft seal making sure it is fully seated in the edge of the housing GC014 3 Lubricate the input shaft with High Performance 2 Molybdenum Disulphide Grease packing the boot ribs and splines the...

Страница 160: ...ing the pinion housing Account for the coupler fork and spring differential only GC015 2 Using a T 40 torx wrench remove the cap screws securing the differential cover Account for and make note of the...

Страница 161: ...er assembly Account for shim s and mark as right side KX179 KX181 Disassembling Pinion Gear 1 Remove the internal snap ring securing the pinion bearing in the housing WC430 2 Using the Pinion Gear Sha...

Страница 162: ...side directed away from the bearing WC429 Shimming Procedure Shim Selection It is very important to adjust bevel gears for the proper running tolerances Gear life and gear noise are greatly affected b...

Страница 163: ...install a thicker shim and recheck GC036A 3 Install the bearing flange onto the gear case cover making sure the alignment locating pin engages the locating hole in the cover then make sure the bear in...

Страница 164: ...ver side up then install a dial indicator contacting the ring gear axle flange GC035 2 Zero the dial indicator then push the ring gear toward the dial indicator and release End play should be 0 004 0...

Страница 165: ...d with green Loctite 270 Account for the ID tag Tighten the cap screws evenly to 23 ft lb NOTE Grease can be applied to the O ring for ease of assembling NOTE If a new housing is being installed tight...

Страница 166: ...nut Do not tighten at this time 2 Install the lower differential mounting cap screw washers and lock nut Note the correct location for the washers PR205A 3 Tighten the nuts to 38 ft lb 4 Pour 275 ml 9...

Страница 167: ...ts Tighten to 200 ft lb then install new cotter pins PR256 12 Install the wheels and tighten in 20 ft lb increments to 40 ft lb steel wheel or 80 ft lb aluminum wheel 13 Remove the vehicle from the su...

Страница 168: ...NT DRIVE AXLE NOTE For removing a front drive axel see Front Differential in this section CLEANING AND INSPECTING AXLES NOTE Always clean and inspect the drive axle com ponents to determine if any ser...

Страница 169: ...ed by a hex nut Finger tighten at this time 4 Install the brake caliper on the steering knuckle using new patch lock cap screws Tighten to 20 ft lb 5 Place the transmission in park then turn the ignit...

Страница 170: ...gear with selected shim into the cover and measure the ring gear to thrust button clearance with a thickness gauge Clearance should be 0 002 0 004 in GC058A 3 If clearance is as specified remove the r...

Страница 171: ...w oil seal into the front of the input housing until the seal is flush with the housing GZ182A 3 Apply grease to the lips of the oil seal then install the input shaft into the input bearing and housin...

Страница 172: ...e drive select switch then place the transmission in park and turn the ignition switch to OFF 2 Remove the cotter pin from the axle NOTE During assembly new cotter pins should be installed PR257 3 Rem...

Страница 173: ...rews tightened to 20 ft lb PR377B 6 Install the wheel and tighten in 20 ft lb increments to 40 ft lb steel wheel or 80 ft lb aluminum wheel 7 Remove the vehicle from the support stand Hydraulic Brake...

Страница 174: ...e caliper opposite the O ring side and remove the outer brake pad then remove the inner brake pad NOTE If brake pads are to be returned to service do not allow brake fluid to contaminate them PR237A P...

Страница 175: ...the piston surface for scoring discoloration or evidence of binding or galling 5 Inspect the caliper holder for wear or bending ASSEMBLING INSTALLING 1 Install new seals into the brake caliper housing...

Страница 176: ...e from the support stand and ver ify brake operation MASTER CYLINDER ASSEMBLY NOTE The master cylinder is a non serviceable component it must be replaced as an assembly Removing 1 Slide a piece of fle...

Страница 177: ...sed by removing the belly panel To remove the belly panel see the Steering Frame Controls section 1 Support the vehicle on suitable jack stands elevated high enough to allow working from the underside...

Страница 178: ...aring cup then remove the yoke from the separator tool NOTE Repeat steps 2 3 for the opposite side bear ing cup 4 Remove the separator tool from the vise and install the universal joint bearing cups a...

Страница 179: ...Replace coupling 4 Replace joint 5 Replace gear s 6 Replace gears pinions 7 Replace fuse drive select switch front drive actuator Problem Braking poor Condition Remedy 1 Pad worn 2 Brake fluid leaking...

Страница 180: ...retainer and remove the spring CF341 CLEANING AND INSPECTING 1 Clean all shock absorber components in parts clean ing solvent 2 Inspect each shock rod for nicks pits rust bends and oily residue 3 Insp...

Страница 181: ...p then bleed the air from the air chamber FS141 2 While holding the end cap unscrew the air cham ber FS142 3 Drain the oil from the air chamber FS143 4 Remove the air chamber from the bottom of the sh...

Страница 182: ...emove the shock rod piston assembly from the shock body FS151 12 Drain the oil from the shock body into a suitable con tainer 13 Using an appropriate floating piston removal tool remove the floating p...

Страница 183: ...e to vent the shock body FS156 4 Using Fox Racing Shock Oil fill the shock body to the bottom of the threads then allow to sit 1 2 min utes to ensure no air is in the oil FS157 5 Lubricate the O ring...

Страница 184: ...the bleed ball and set screw into the bearing cap FS162 FS163 10 Charge the shock with nitrogen to 200 psi FS164 11 Using a 3 16 in Allen wrench tighten the nitrogen bladder FS165 12 Install the air...

Страница 185: ...hand tight FS171 NOTE Prior to installing the air chamber make sure the end cap O ring is properly positioned in the chamber 19 Invert the shock and secure by the end cap to assure the air chamber is...

Страница 186: ...the nut securing the hub 4 Remove the brake caliper Account for two cap screws CD007 5 Remove the hub assembly 6 Remove the cotter pin and slotted nut securing the tie rod end to the knuckle then rem...

Страница 187: ...1 Apply Loctite Primer T to the A arm socket then apply green Loctite 609 to the entire outside diame ter of the ball joint Install the ball joint into the A arm and secure with the snap ring AF616D...

Страница 188: ...the hub nut from step 9 to the shaft axle Tighten to 200 ft lb 12 Install a new cotter pin and spread the pin to secure the nut NOTE If the cotter pin cannot be inserted due to misalignment of the ho...

Страница 189: ...en only at this time 2 Slide the knuckle onto the drive axle and into position on the A arms then secure the knuckle to the A arms with cap screws and new lock nuts Tighten to 35 ft lb 3 Tighten the h...

Страница 190: ...heel CHECKING INFLATING 1 Using an air pressure gauge measure the air pressure in each tire Adjust the air pressure as necessary to meet the recommended inflation pressure 2 Inspect the tires for dama...

Страница 191: ...ated bushings worn 1 Adjust preload 2 Replace bushing Problem Suspension noisy Condition Remedy 1 Cap screws suspension system loose 2 A arm related bushings worn 1 Tighten cap screws 2 Replace bushin...

Страница 192: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2259 861...

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