Arctic Cat 2008 Prowler Service Manual
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Arctic Cat 2008 Prowler Service Manual

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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2008 Arctic
Cat UTV models. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific vehicle component or system and, in addition to the
standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual
as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.
The service technician should become familiar with the operation and construction of each component or system by
carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient
with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.
All Arctic Cat publications and decals display the words Warning, Caution, Note, and At This Point to emphasize
important information. The symbol ! WARNING identifies personal safety-related information. Be sure to fol-
low the directive because it deals with the possibility of 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
information worthy of particular attention. The symbol
specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic
Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2008 Arctic Cat Inc.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
AT THIS POINT directs the technician to certain and
Back to TOC
NOTE: identifies supplementary
March 2008

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  • Page 1 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to fol- low the directive because it deals with the possibility of severe personal injury or even death.
  • Page 2 TABLE OF CONTENTS Click on the red text to go. Foreword MORE TO GO ON. General Information/Specifications Prowler PRowler Prowler XT Prowler XT Periodic Maintenance/Tune-Up PROWLER XTX PROWLER XTX 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System Drive System Suspension UTV UTV 8. Steering/Frame Controls/Indicators Service Manual...

  • Page 3: Table Of Contents

    SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications ..........1-2 Torque Specifications ..........1-2 Torque Conversions (ft-lb/N-m) ....... 1-3 Tightening Torque (General Bolts) ......1-3 Break-In Procedure ..........1-4 Gasoline - Oil - Lubricant ........1-4 Genuine Parts ............1-5 Preparation For Storage..........

  • Page 4: General Specifications

    2.5 L (2.6 U.S. qt) Rear Drive/Differential Gasoline (recommended) 87 Octane Regular Oil Drain Plug Engine Unleaded Wheel Engine Oil (recommended) Arctic Cat ACX All- Front Shaft Flange Front U-Joint Weather Synthetic EXHAUST COMPONENTS Front Differential Lubricant SAE Approved 80W-90 Hypoid Exhaust Pipe...

  • Page 5: Engine/Transmission

    SUSPENSION COMPONENTS (Front) Torque Conversions Torque Part Part Bolted To (ft-lb/N-m) ft-lb N-m A-Arm Frame Ball Joint Cap Screw Knuckle Shock Absorber (Upper) Frame ft-lb ft-lb ft-lb ft-lb Shock Absorber (Lower) Upper A-Arm 35.4 69.4 103.4 Knuckle A-Arm 36.7 70.7 104.7 SUSPENSION COMPONENTS (Rear) 38.1...

  • Page 6: Break-In Procedure

    During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle. Varying the engine The recommended oil to use is Arctic Cat ACX All- RPM during the break-in period allows the compo- Weather synthetic engine oil, which has been specifi- nents to “load”...

  • Page 7: Genuine Parts

    Remove the air filter hous- ing cover and air filter. Start the engine and allow it to idle. Using Arctic Cat Engine Storage Pre- server, rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds; then stop the engine.

  • Page 8: Preparation After Storage

    6. Charge the battery; then install. Connect the bat- tery cables. Preparation After Storage ! CAUTION The ignition switch must be in the OFF position prior to installing the battery or damage may occur to the Taking the vehicle out of storage and correctly prepar- ignition system.
  • Page 9 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart ........2-2 Periodic Maintenance..........2-3 Lubrication Points............ 2-3 Battery..............2-3 Fuses ..............2-4 Air Filter ..............2-5 Valve/Tappet Clearance (Feeler Gauge Procedure) ........2-6 Valve/Tappet Clearance (Valve Adjuster Procedure) ........2-6 Testing Engine Compression........

  • Page 10: Periodic Maintenance Chart

    A = Adjust I = Inspect C = Clean L = Lubricate Periodic Maintenance D = Drain R = Replace Chart T = Tighten Initial Every Month Every 3 Every 6 Service After Every Year Every Months or Months or Item Break-In or Every...

  • Page 11: Periodic Maintenance

    Arctic Cat UTV. NOTE: To access the battery box, the left-rear NOTE: Arctic Cat recommends the use of new fender splash panel must be removed. gaskets, lock nuts, and seals and lubricating all After being in service, batteries require regular clean-...

  • Page 12: Fuses

    10. Place the battery in the battery compartment; then NOTE: At this point, if the meter reads as speci- coat the battery posts and cable ends with a light fied, the battery may be returned to service (see coat of multi-purpose grease. step 10).

  • Page 13: Air Filter

    1. Inspect one-way drains beneath the main housing in the solvent and wash it. for debris and for proper sealing. NOTE: Foam Filter Cleaner and Foam Filter Oil are available from Arctic Cat. 5. Dry the filter. Next Back Back to TOC...

  • Page 14: Valve/Tappet Clearance (Feeler Gauge Procedure)

    ! CAUTION The feeler gauge must be positioned at the same angle as the valve and valve adjuster for an accurate measurement of clearance. Failure to measure the valve clearance accurately could cause valve com- ponent damage. VALVE/TAPPET CLEARANCE Intake 0.1016 mm (0.004 in.) Exhaust 0.1524 mm (0.006 in.)

  • Page 15: Testing Engine Compression

    3. Place the valve adjuster onto the jam nut securing the tappet adjuster screw; then rotate the valve Testing Engine adjuster dial clockwise until the end is seated in Compression the tappet adjuster screw. 4. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut;...

  • Page 16: Spark Plug

    1. Remove the cap screws securing the spark arrester screen assembly to the muffler; then loosen and Spark Plug remove the spark arrester. Account for a gasket. A light brown insulator indicates that the plug is cor- rect. A white or dark insulator indicates that the engine may need to be serviced or the carburetor (if applica- ble) may need to be adjusted.

  • Page 17: Engine/Transmission Oil - Filter

    To properly adjust the idle RPM, a tachometer is nec- essary. To adjust idle RPM, use the following proce- dure. NOTE: To access the idle adjustment screw, it will be necessary to remove the seats and center console. The idle adjustment screw is located on the left-side of the carburetor.

  • Page 18: Front Differential - Rear Drive/Differential Lubricant

    10. Install the oil level stick and thread into the engine 1. Place the vehicle on level ground. case. 2. Remove each fill/level plug. NOTE: The oil level stick should be threaded into 3. Drain the lubricant into a drain pan by removing in the case for checking the oil level.

  • Page 19: Steering Components

    TIRE INFLATION PRESSURE D. Shock absorber eyelets broken, bent, or cracked. Front and rear tire inflation pressure should be 0.70 E. Shock absorber eyelet bushings worn, deterio- kg-cm² (10 psi). rated, cracked, or missing. A low-pressure gauge is provided in the tool kit to F.

  • Page 20: Headlight/Taillight-Brakelight

    NOTE: There should be an average operating load on the vehicle when adjusting the headlight Headlight/Taillight- aim. Brakelight 2. Measure the distance from the floor to the mid-point of each headlight. HEADLIGHT 3. Using the measurements obtained in step 2, make horizontal marks on the aiming surface.

  • Page 21: Shift Lever

    B. 2WD/4WD selector switch — differential will engage (4WD)/disengage (2WD). C. Reverse/neutral/high/low switch — R/N/H/L will be indicated on the LCD. D. Headlight switch — high beam, low beam, and lights off can be selected. E. Brake switch — brakelight illuminates and starter can be engaged with vehicle in gear.
  • Page 22 NOTE: During the bleeding procedure, watch the reservoir very closely to make sure there is always a sufficient amount of brake fluid. When the level falls below MIN, refill the reservoir before the bleeding procedure is continued. Failure to main- tain a sufficient amount of fluid in the reservoir will result in air in the system.

  • Page 23: Parking Brake

    2. If the rear wheels are locked, it is adjusted prop- NOTE: The brake pads should be replaced as a erly. set. 3. If the rear wheels are not locked, it must be 4. To replace the brake pads, use the following proce- adjusted (set up).
  • Page 24 2. Lift the cargo box; then disconnect the lower lift support and allow the cargo box to tilt all the way back. Account for the washer. PR089A 3. Install the actuator lever in the position noted in step 1; then install the actuator nut and tighten to 35 ft-lb.

  • Page 25: Burnishing Brake Pads

    2. Slide brake caliper assembly over the brake disc and into position on the knuckle; then secure the Checking/Replacing caliper with the cap screws tightened to 20 ft-lb. V-Belt 3. Connect the parking brake cable (see Adjusting in this sub-section). 4.
  • Page 26 CD966A PR109 4. Install one of the V-belt cover cap screws into the NOTE: The arrows on the V-belt should point driven pulley fixed face; then turn the cap screw rearward. clockwise to spread the pulley faces. Remove the V-belt. 2.

  • Page 27: Troubleshooting Brake System

    Troubleshooting Brake System Problem: Braking poor Condition Remedy 1. Pad worn 1. Replace pads 2. Pedal free-play excessive 2. Adjust free-play 3. Brake fluid leaking 3. Repair - replace hydraulic system 4. Hydraulic system leaking air 4. Bleed hydraulic system 5.
  • Page 28 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 Prowler/XT/XTX (Table of Contents) ....... 3-3 Troubleshooting ............. 3-48 Back to TOC...
  • Page 29 0.35 mm (0.014 in.) removed from the frame. Deflection (wobble method) Valve Guide Inside Diameter 5.000-5.012 mm NOTE: Arctic Cat recommends the use of new (0.1969-0.1973 in.) gaskets, lock nuts, and seals and lubricating all Valve Stem Outside (intake/exhaust) 4.972-4.987 mm Diameter (0.1957-0.1963 in.)
  • Page 30 CYLINDER, PISTON, AND RINGS Removing Engine/ Piston Skirt/Cylinder Clearance 0.045 mm (0.0018 in.) Transmission Piston Diameter 15 mm (0.6 in.) 97.948-97.962 mm from Skirt End (Prowler/XT) (3.856-3.857 in.) Piston Diameter 12 mm (0.47 in.) 101.930-101.949 mm from Skirt End (XTX) (4.013-4.014 in.) Many service procedures can be performed without Piston Ring Free End Gap...
  • Page 31 PR156A PR157A 3. Remove the negative cable from the battery; then 5. From the left-side, disconnect the starter wire, remove the positive cable. alternator connector, CDI connector (Prowler/XT), gear shift position switch, and electric choke con- 4. From the left-side, remove the spark plug cap; nector;...
  • Page 32 6. Remove the E-clip from the transmission shift arm; then disconnect the shifter linkage. Account for a washer and a bushing. PR118 9. Remove four self-tapping screws securing the air filter mounting bracket to the frame; then remove the air filter and mounting bracket as an assembly. PR461B 7.
  • Page 33 PR150A PR152A 12. Remove the exhaust duct from the V-belt housing; then remove the inlet boot connecting the inlet duct to the V-belt housing. PR120A 15. Separate the drive coupler flanges; then remove the driveshafts from the splined slip-joints being careful not to damage the rubber boots.

  • Page 34: Top-Side Components

    17. Remove two flange nuts securing the engine mounting bracket to the front engine mounts. Top-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components.
  • Page 35 4. 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 down into the crankcase. CD205 CC012D 5. Bend the washer tabs down and remove the two cap screws securing the sprocket to the camshaft;...
  • Page 36 CC266D CC016D 9. Remove the cylinder head from the cylinder, NOTE: Loop the chain over the cylinder and remove the gasket, and account for two alignment secure it to keep it from falling into the crankcase. pins; then remove the cam chain guide. 8.
  • Page 37 C. Cylinder D. Piston NOTE: Steps 1-9 in the preceding sub-section must precede this procedure. 10. Loosen the clamp securing the coolant hose to the union; then detach the hose. 11. Remove the two nuts securing the cylinder to the crankcase.

  • Page 38: Servicing Top-Side Components

    2. Place the valve cover on the Surface Plate covered NOTE: Support the connecting rod with rubber with #400 grit wet-or-dry sandpaper. Using light bands to avoid damaging the rod or install the pressure, move the valve cover in a figure eight Connecting Rod Holder.
  • Page 39 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal. ATV-1004 2. Acceptable width range must be within specifica- tions. CC136D Measuring Valve Face Radial NOTE: The valve seals must be replaced. Runout 3. Remove the valve springs; then invert the cylinder 1.
  • Page 40 3. If a valve guide is out of tolerance, it must be replaced. Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the com- ponents be taken to a qualified machine shop for ser- vicing. ! CAUTION ATV-1011A If valves are discolored or pitted or if the seating 4.
  • Page 41 PISTON ASSEMBLY 2. Using the sharpened ring as a tool, clean carbon from the ring-grooves. Be sure to position the ring with its tapered side up. NOTE: Whenever a piston, rings, or pin are out of tolerance, they must be replaced. ! CAUTION Cleaning/Inspecting Piston Improper cleaning of the ring-grooves by the use of...
  • Page 42 NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. 2. The ring with the orientation mark (MTOP) should be installed in the second (middle) groove and the ring with the orientation mark (M) should be installed in the first (top) groove.
  • Page 43 ! CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or dam- age to the sealing surface may result. CC128D Measuring Cylinder Head Distortion 1. Remove any carbon buildup in the combustion chamber. CC129D Inspecting Cam Chain Guide 2.
  • Page 44 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 clean cylinder after honing using soap and hot water.

  • Page 45: Installing Top-Side Components

    CC003D CF061A 5. Match the width of the plasti-gauge with the chart found on the plasti-gauge packaging to determine camshaft to cylinder head and valve cover clear- ance. CF060A 2. If damaged, the camshaft must be replaced. Installing Top-Side CC145D Components 6.
  • Page 46 ATV-1085B CC032D 2. Place the two alignment pins into position. Place NOTE: Note the direction of the exhaust side of the cylinder gasket into position; then place a pis- the piston (5) for correct ring end gap orientation. ton holder (or suitable substitute) beneath the pis- ton skirt and square the piston in respect to the B.
  • Page 47 NOTE: The two cylinder-to-crankcase nuts will be tightened in step 10. CC020D CC023D 5. Install the coolant hose onto the crankcase union and tighten the clamp. C. Cylinder Head D. Valve Cover NOTE: Steps 1-5 in the preceding sub-section must precede this procedure. 6.
  • Page 48 15. Seat the cam sprocket onto the camshaft making sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket; then place the camshaft/sprocket assembly onto the cylinder ensuring the following. 732-307B NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder.
  • Page 49 17. Install the first cap screw (threads coated with red Loctite #271) securing sprocket tab-washer to the camshaft. Tighten only until snug. CC012D 21. Install the cylinder head plug in the cylinder head with the open end facing downward and toward the inside.
  • Page 50 23. Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the two cap screws. CC005D 26. Apply a thin coat of Three Bond Sealant to the mating surfaces of the cylinder head and valve cover.

  • Page 51: Right-Side Components

    CC001D PR465 32. If removed, install the spark plug. Tighten to 12 3. Using a cold chisel, scribe a mark showing the rel- ft-lb. ative position of the shift arm to the shift arm shaft to aid in installing; then remove the shift arm. Right-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which...
  • Page 52 CD214 CD939A 6. Remove the two cap screws securing the water pump to the engine; then remove the water pump. NOTE: The water pump is not a serviceable com- ponent. If the pump is defective or if the mechani- cal seal is leaking (coolant dripping from the discharge hole), the water pump must be replaced (see Section 4).

  • Page 53: Installing Right-Side Components

    CD140 PR430A 12. Remove the snap ring securing the water pump 15. Remove the gear shift cam plate; then remove the drive gear; then remove the gear noting the direc- cam stopper and cam stopper spring. Account for tion of the sides of the gear for installing purposes. two washers.
  • Page 54 CD952A CD944 NOTE: The sharp side of the snap ring should be facing outward. NOTE: Once the 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 intermediate gear facing inward as noted in removing).
  • Page 55 6. Install the shift cam stopper, spring, and two wash- ers; then coat the threads on the mounting stud with red Loctite #271 and install the nut. Tighten securely. CD948A PR434A 7. Install the shift shaft with two washers making sure to align the timing mark on the shift shaft with the mark on the shift cam plate.

  • Page 56: Left-Side Components

    15. Install the shift arm on the shift arm shaft making sure the scribed marks (from removing) are aligned. Tighten securely. 16. Place the gasket and outer magneto cover into position on the right-side cover; then tighten four screws to 8 ft-lb. Left-Side Components NOTE: For efficiency, it is preferable to remove PR431A...
  • Page 57 CD963 PR393 6. Remove the cap screws securing the clutch cover. Note the location of the different-lengthed cap screws for installing purposes. Using a rubber mal- let, carefully remove the cover. Account for two alignment pins. CD966A 3. Remove the nut securing the fixed driven assem- bly;...
  • Page 58 CF088A A. Oil Pump Driven Gear D. One-Way Clutch 9. Remove the two Allen-head screws securing the (Green Dot MUST Show) B. Oil Pump Drive Gear gear shift position switch; then remove the sensor. E. Final Drive Carrier Bearing C. Clutch Shoe Assembly Account for two neutral contact pins and two Housing springs.

  • Page 59: Servicing Left-Side Components

    13. Remove the snap ring securing the oil pump driven gear (A); then remove the gear noting the direction of the sides of the gear for installing pur- poses. Account for a pin and a washer. CC606 CD984 CD987 CD895A 14.

  • Page 60: Installing Left-Side Components

    INSPECTING CENTRIFUGAL CLUTCH SHOE 1. Inspect the clutch shoes for uneven wear, chips, cracks, or discoloration. If any shoe is damaged, replace the complete set. 2. Inspect the clutch shoes for wear or damage. If any shoe is worn to the bottom of the groove, replace the complete set.
  • Page 61 2. Install the secondary shaft bearing housing making sure the two alignment pins are properly posi- tioned. Tighten the Allen-head screws securely. CD991 5. Grease the driven gear pin and insert it into the oil pump shaft; then install the driven gear (noting the direction of the sides of the gear from removing).
  • Page 62 PR399A PR410A 7. Lightly grease the clutch housing seal; then insert ! CAUTION the left fixed drive spacer. When installed correctly, the green dot (or the word OUTSIDE) on the one-way clutch is visible. 11. Place the clutch cover/clutch housing assembly into position on the crankcase;...

  • Page 63: Center Crankcase Components

    15. Spread the faces of the driven pulley by threading a 6 mm cap screw into the threaded boss; then turn clockwise until pulley faces are opened approxi- mately 1/2 in. 16. Place the V-belt into position on the driven pulley and over the front shaft.

  • Page 64: Disassembling Crankcase Half

    2. Remove the reverse idler gear assembly (F). Account for all washers, shaft, bushing, and the gear. CC665 Disassembling CC668 Crankcase Half 3. Remove the shift shaft (H); then remove the two forks taking note of the direction of the tabs on the forks for assembling purposes.

  • Page 65: Servicing Center Crankcase Components

    6. Using a rubber mallet, tap on the crankcase to 11. Remove the cap screws securing the oil strainer remove the driveshaft (E). cap; then remove the cap. 12. Remove the two cap screws securing the oil strainer; then remove the strainer. CC675 7.
  • Page 66 SECONDARY GEARS 3. Apply a thin, even coat of a machinist-layout dye to several teeth of the gear. NOTE: When checking and correcting secondary 4. Install the secondary driven output shaft assembly. gear backlash and tooth contact, the universal joint must be secured to the front shaft or false 5.
  • Page 67 Measuring Connecting Rod If tooth contact pattern is comparable to an incorrect pattern, correct tooth contact according to the follow- (Big End Side-to-Side) ing chart. 1. Push the lower end of the connecting rod to one side of the crankshaft journal. Tooth Contact Shim Correction Contacts at Top...
  • Page 68 Disassembling NOTE: Proceed to check runout on the other end of the crankshaft by positioning the indicator con- From the right side: tact at point 2 and following steps 3-4. 1. Remove the right drive gear washer (17); then Measuring Crankshaft remove drive gear #2 (2).

  • Page 69: Assembling Crankcase Half

    Assembling Crankcase Half 1. Install the output shaft assembly into the crankcase making sure the two gears, shim, washer, and nut are properly sequenced. CC688 CC686 NOTE: The beveled side of the secondary drive gear must face upward. CC689 2. Apply red Loctite #271 to the threads of the output NOTE: If heating the bearing is not possible, the shaft;...
  • Page 70 CD826A CC669 6. Install the driveshaft. 10. Install the reverse idler gear assembly noting the positioning of the two washers, gear, bushing, and shaft. CC675 7. Place a washer on each end of the countershaft assembly; then install the assembly. CC668 11.

  • Page 71: Joining Crankcase Halves

    Installing Engine/Transmission NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the vehicle. 1. Attach suitable lifting chains to the engine/trans- mission; then using an engine hoist, lower the assembly into the engine compartment.
  • Page 72 2. Align the rear engine mount studs with the holes in the frame and slowly lower into place. The front engine mounting bracket will then slip over the engine mount studs. PR148 PR146 3. Install the flange nuts on the rear engine mount studs;...
  • Page 73 PR153B PR128A 10. From the left-side, connect the speed sensor con- nector (XT/XTX), fuel level sensor connector (XT/XTX), and temperature sensor lead; then install the spark plug cap. PR144B 8. Connect the lower coolant hose to the water pump housing; then connect the upper coolant hose to the thermostat housing.
  • Page 74 12. Place the air filter assembly into position and secure with the self-tapping screws; then connect the intake boot to the carburetor/throttle body and the inlet housing boot to the air filter housing. Tighten the clamps securely. PR474B 11. Install the carburetor/throttle body and tighten the intake boot clamp securely;...
  • Page 75 Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn - seated poorly 2. Repair - replace guides 3. Valves mistimed 3.
  • Page 76 Problem: Engine noisy (Noise seems to come from timing chain) Condition Remedy 1. Chain stretched 1. Replace chain 2. Sprockets worn 2. Replace sprockets 3. Tension adjuster malfunctioning 3. Repair - replace adjuster Problem: Engine noisy (Noise seems to come from crankshaft) Condition Remedy 1.
  • Page 77 Problem: Engine runs poorly at high speed Condition Remedy 1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease speed 2. Valve springs weak 2. Replace springs 3. Valve timing out of adjustment 3. Adjust timing 4.

  • Page 78: Fuel/Lubrication/Cooling

    SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Fuel/Lubrication/Cooling ......... 4-2 Carburetor Specifications (Prowler/XT)....4-2 Carburetor Schematic (Prowler/XT) ......4-2 Carburetor (Prowler/XT) .......... 4-2 Electronic Fuel Injection (XTX)........ 4-6 Engine RPM (Idle) (Prowler/XT)......4-8 Gas Tank ..............4-8 Gas/Vent Hoses ............ 4-11 Oil Filter/Oil Pump ..........

  • Page 79: Carburetor Specifications (Prowler/Xt)

    Fuel/Lubrication/ Carburetor Schematic Cooling (Prowler/XT) NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing engine/transmission. NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions.
  • Page 80 PR160A CH015D 3. Loosen the clamp securing the intake boot to the 2. Remove the vacuum piston assembly from the car- carburetor; then separate the carburetor from the buretor body. Account for a spring, spring seat, boot. and the jet needle. 4.
  • Page 81 CC749 CC761A 7. Secure the needle jet holder with a wrench; then remove the main jet. 8. Remove the needle jet holder; then remove the needle jet, slow jet, and the starter jet. 9. Remove the pilot screw. Account for a spring, a washer, and an O-ring.
  • Page 82 4. Dry all components with compressed air only making sure all holes, orifices, and channels are unobstructed. 5. Inspect the carburetor body for cracks, nicks, stripped threads, and any other imperfections in the casting. 6. Inspect the vacuum piston/diaphragm for cracks, imperfections in the casting, or cracks and tears in the rubber.

  • Page 83: Electronic Fuel Injection (Xtx)

    CC749 CH015D 7. Place the U-ring into the pump housing. Position INSTALLING the spring and diaphragm assembly (lip toward the carburetor) onto the carburetor; then secure the assembly with the pump housing and three screws. 1. Place the carburetor into position on the engine; Tighten securely.
  • Page 84 TROUBLESHOOTING 1. Verify that the electric fuel pump is operating by listening for a “whirring” sound for approximately three seconds after the ignition switch is turned to the ON position. If no sound can be heard, see Electric Fuel Pump/Fuel Level Sensor (XTX) in this section.

  • Page 85: Engine Rpm (Idle) (Prowler/Xt)

    Gas Tank ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. REMOVING FI104A 11. Use tape to cover and seal the intake opening. 1.
  • Page 86 7. Remove four press-nuts securing the gas cap inset; then remove the gas cap and inset. Install the gas cap. PR165 5. Disconnect the vent hose, gasline hose, and fuel level sensor connector (XT/XTX); then cap the vent fitting and gas hose fitting. PR168 8.
  • Page 87 INSTALLING ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. 1. Place the gas tank into position in the vehicle; then install the inside rear hold-down strap.

  • Page 88: Gas/Vent Hoses

    6. Connect the gasline hose and gas tank vent hose to the proper fittings; then connect the fuel level sen- sor connector (XT/XTX) to the main harness. CF264A NOTE: Some oil seepage may occur when install- ing the oil pressure gauge. Wipe up oil residue with a cloth.

  • Page 89: Oil Cooler (Xtx)

    This model has an oil cooler in addition to the liquid hot, soapy water and a soft brush. cooling system. An oil cooler kit may be installed on any Arctic Cat UTV. 3. Inspect all mounting brackets and the oil inlet and outlet for cracks or bends.

  • Page 90: Radiator

    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. PR186 4. Drain the coolant into a suitable container; then disconnect the cooling fan wire connector from the main harness.

  • Page 91: Thermostat

    3. Inspect all hoses 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.

  • Page 92: Fan

    REMOVING NOTE: All coolant hoses and clamps should be replaced every four years or 4000 miles. 1. Remove the radiator cap; then remove the water INSTALLING pump coolant drain plug and drain the coolant. 1. Place the thermostat with seal (Prowler/XT) and O-ring (XTX) into the thermostat housing;...

  • Page 93: Electric Fuel Pump/Fuel Level Sensor (Xtx)

    Electric Fuel Pump/Fuel Level Sensor (XTX) The electric fuel pump and fuel level sensor are not serviceable components. If either component fails, it must be replaced. TESTING CC786A 2. Connect the two coolant hoses to the water pump and secure with the clamps; then install the water ! WARNING pump coolant drain plug.
  • Page 94 5. Connect a multimeter to the power supply leads with the red tester lead to the red wire and the black tester lead to the black wire; then turn the ignition switch to the ON position. The meter should read battery voltage. If battery voltage is indicated and the fuel pump does not run, replace the pump assembly.

  • Page 95: Vacuum Pulse Fuel Pump (Prowler/Xt)

    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. Vacuum Pulse Fuel Pump (Prowler/XT) NOTE: The vacuum pulse fuel pump is a nonser- PR280A viceable assembly.
  • Page 96 INSPECTING NOTE: If readings are erratic, clean the resistor wiper and resistor with a clean cloth soaked with 1. Inspect the fuel screen and clean with low pressure alcohol and retest. If the readings shown are not compressed air. as specified, replace the fuel level sensor assem- bly.

  • Page 97: Troubleshooting (Prowler/Xt)

    Troubleshooting (Prowler/XT) Problem: Starting impaired Condition Remedy 1. Starter jet obstructed 1. Clean jet 2. Starter jet passage obstructed 2. Clean passage 3. Carburetor leaking air 3. Replace gasket Problem: Idling or low speed impaired Condition Remedy 1. Slow jet obstructed - loose 1.

  • Page 98: Electrical System

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

  • Page 99: Specifications

    Electrical System Specifications NOTE: Some photographs and illustrations used Prowler/XT in this section are used for clarity purposes only Ignition Timing 10° BTDC @ 1500 RPM and are not designed to depict actual conditions. Spark Plug Type Champion RG6YC SPECIAL TOOLS Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.)

  • Page 100: Rpm Limiter

    NOTE: The ignition switch must be in the ON position. RPM Limiter VOLTAGE (Wiring Harness Connector) NOTE: The UTV is equipped with a CDI unit/ECU 1. Set the meter selector to the DC Voltage position. that retards ignition timing when maximum RPM is approached.

  • Page 101: Coolant Temperature And Cooling Fan Switches (Prowler/Xt)

    4. On the coolant temperature switch, allow the oil to cool, and when the temperature is within a temper- ature range of 107-113° C (225-235° F), the meter should show an open circuit. 5. On the cooling fan switch when the temperature reaches 81-99°...

  • Page 102: Fan Motor

    NOTE: To determine if the fan motor is good, con- nect the red wire from the fan connector to a 12 volt Fan Motor DC power supply; then connect the black wire from the fan connector to ground. The fan should operate. ! WARNING NOTE: The ignition switch must be in the ON position.

  • Page 103: Ignition Coil

    Spark Plug Cap 3. The meter must show less than 1 ohm resistance. If the meter shows open, replace the fuse. 1. Connect the red tester lead to one end of the cap; NOTE: Make sure the fuses are returned to their then connect the black tester lead to the other end proper position according to amperage.

  • Page 104: Efi Sensors/Components (Xtx)

    NOTE: The coil is located to the right of the engine and may be 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.

  • Page 105: Ignition Switch

    NOTE: If the meter does not show battery volt- age, troubleshoot the LIGHTS fuse on the power distribution module, the ignition switch, or the main harness. 3. Connect the red meter lead to the yellow wire; then select the high beam position on the headlight switch.

  • Page 106: Reverse Override Switch

    1. Connect the red meter lead to the black/blue wire and the black meter lead to a suitable ground; then select 2WD on the 2WD/4WD selector switch. The meter must show approximately 1.5 DC volts. 2. Depress the reverse override switch. The meter showing should not change from step 1.

  • Page 107: Stator Coils (Prowler/Xt)

    3. With the engine running at a constant 5000 RPM (with the headlights on), the meter must show 14-15.5 DC volts. ! CAUTION Do not run the engine at high RPM for more than 10 seconds. NOTE: If voltage is lower than specified, test Charging Coil - No Load.

  • Page 108: Stator Coil/Crankshaft Position

    PEAK VOLTAGE NOTE: All of the peak voltage tests should be made using the Fluke Model 73 Multimeter with Peak Voltage Reading Adapter. If any other type of tester is used, readings may vary due to internal circuitry. NOTE: The battery must be at full charge for these tests.

  • Page 109: Starter Motor

    AC VOLTAGE 3. With the starter button depressed, the meter must show battery voltage and the starter motor should operate. NOTE: The battery must be at full charge for these tests. Crankshaft Position Sensor 1. Set the meter selector to the AC Voltage position. 2.

  • Page 110: Cdi Unit (Prowler/Xt)

    3. Depress the starter button while observing the multimeter. The multimeter should drop to 0 volts Electronic Control Unit and a “click” should be heard from the relay. (ECU) NOTE: If a “click” is heard and any voltage is (XTX) indicated by the multimeter, replace the starter relay.

  • Page 111: Neutral Start/Start-In-Gear/2Wd Relays

    2. Connect the black tester lead to the black wire; then connect the red tester lead to the white wire. Neutral Start/ The meter should show battery voltage. Start-in-Gear/ 3. With the ignition key in the LIGHTS position, the 2WD Relays meter must show battery voltage.

  • Page 112: Tilt Sensor (Xtx)

    NOTE: If the LCD still displays an error code, continue troubleshooting the appropriate compo- nent. 3. Disconnect the diagnostic harness; then install the black rubber cap. 4. Install the seats making sure they lock securely in place. Tilt Sensor (XTX) ATV-112 4.

  • Page 113: Throttle Position Sensor (Tps) (Xtx)

    4. Tilt the sensor 60° or more to the left and right observing the meter. The meter should read 4.0-8.0 DC volts after approximately one second in the tilted position. If the meter readings are not as specified, the tilt sensor is defective. CD706B OUTPUT VOLTAGE NOTE: Needle adapters will be required on the...
  • Page 114 NOTE: Prior to testing the TPS, inspect the three-wire plug connector on the main harness and the three-pin plug on the TPS for contamina- tion, broken pins, and/or corrosion. 2. Make sure the ignition switch is in the OFF posi- tion;...
  • Page 115 REMOVING 1. Remove the seats and center console; then discon- nect the three-wire TPS connector plug. PR540A PR533A 2. Remove the screw securing the TPS to the throttle body and remove the TPS. INSTALLING/ADJUSTING 1. Place the TPS into position on the throttle body and secure with the screw.

  • Page 116: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace magneto 4. CDI unit/ECU defective 4. Replace CDI unit/ECU 5. Pick-up coil defective 5.
  • Page 117 Problem: Magneto overcharges Condition Remedy 1. Internal battery short circuited 1. Replace battery 2. Regulator/rectifier resistor damaged - defective 2. Replace resistor 3. Regulator/rectifier poorly grounded 3. Clean - tighten ground connection Problem: Charging unstable Condition Remedy 1. Lead wire intermittently shorting 1.
  • Page 118 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Front Drive Actuator ..........6-2 Front Differential ............6-3 Drive Axles ............6-15 Rear Gear Case (Prowler/XT)/ Rear Differential (XTX)........6-20 Hub................ 6-21 Hydraulic Brake Caliper......... 6-23 Universal Joints ............. 6-24 Troubleshooting .............

  • Page 119: Drive System

    The front drive actuator is located on the right side of the front drive input housing. With the engine stopped Drive System 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.

  • Page 120: Front Differential

    AG928 AG926 NOTE: It is important to tighten this cap screw INSTALLING while the others are loose to ensure proper seating of the actuator. 1. Lubricate the O-ring on the actuator; then ensure that all mounting surfaces are clean and free of 5.
  • Page 121 9. Remove two cap screws securing the differential lock cable support; then disconnect the differential lock cable at the differential. PR022A 3. Remove the front wheels. 4. Set the parking brake; then turn the ignition switch to the ON position and select 4WD on the PR194A 2WD/4WD selector switch.
  • Page 122 15. Using a slide hammer, remove the front axles. PR222 12. Support the axle to not allow it to drop or hang. PR199 16. Remove the lower differential mounting cap ! CAUTION screw. Account for a lock nut and four washers. Note the position of the washers for assembling.
  • Page 123 4. Using a seal removal tool, remove the input shaft seal. Account for a spacer. PR261A 2. Using a rubber mallet, remove the housing. Account for a gasket. Remove the fork, collar, and spring. Note the location of all the components for AF982 5.
  • Page 124 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. KX222 4. Install the input shaft into the pinion housing; then secure in the bearing with a circlip.
  • Page 125 PR261A KX174 NOTE: If the cover is difficult to remove, pry on Disassembling Differential the cover in more than one recessed location. Assembly 4. Remove the splined coupler, shifter fork, pin, and NOTE: This procedure can be performed on a spring of the differential lock assembly and set rear gear case (Prowler/XT)/rear differential (XTX).
  • Page 126 KX178 CC876 6. Place the differential with the open side down; 8. Using the Pinion Gear/Shaft Removal Tool and a then lift the housing off the spider assembly. hammer, remove the pinion gear from the gear Account for shim(s) and mark as right-side. case housing.
  • Page 127 Shimming Procedure/ Assembling Pinion Gear Shim Selection 1. Install the bearing onto the pinion shaft. Install the pinion shaft collar. 1. Press bearings into bores by outer ring to hard con- tact with seat. 2. Install the lock collar and tighten to 125 ft-lb; then stake the lock collar edge approximately 1.5 mm (0.060 in.) into the lower oil channel.
  • Page 128 CC890 CC893 4. Place a punch on the edge of the lock collar in the 7. Place the input shaft assembly onto the gear hous- oil gallery area; then using a hammer, stake the ing; then secure with the existing cap screws. lock collar to ensure that the collar will remain Tighten to 23 ft-lb.
  • Page 129 NOTE: This procedure can be performed on a rear gear case (Prowler/XT)/rear differential (XTX). 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 needle bearing housing. CF266A CC885 2.
  • Page 130 CC888 CC891 2. Using a suitable driver, install the needle bearing 5. Install the pinion housing. into the gear case housing making sure the bearing Removing/Installing Axle Seal is seated. NOTE: Do not push the bearing too far into the NOTE: This procedure can be performed on a housing.
  • Page 131 CC901 PR205A 3. Tighten the nuts to 38 ft-lb. NOTE: Prior to installing the seal, apply grease to the seal outside diameter. 4. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid lubricant into the differential and install the fill 4.

  • Page 132: Drive Axles

    PR193 AF894D 8. Secure the lower shock eyelets with cap screws 13. Install the wheels and tighten to 45 ft-lb. and lock nuts. Tighten to 35 ft-lb. 14. Remove the vehicle from the support stand. 15. Install the belly panel. Drive Axles REMOVING REAR DRIVE AXLE 1.
  • Page 133 PR221 AF935 5. Remove the cap screw and lock nut securing the REMOVING FRONT DRIVE AXLE knuckle to the upper A-arm. Discard the lock nut. NOTE: For removing a front drive axle, see Front Differential in this section. CLEANING AND INSPECTING AXLES NOTE: Always clean and inspect the drive axle components to determine if any service or replace-...
  • Page 134 CD020 CD022 2. Wipe away excess grease to access the retaining 5. Inspect the splines of the shaft, the bearing ring, ring. Using an awl or circlip pliers, remove the cir- and the housing for damage. clip. NOTE: If any damage is apparent to the splines, the bearing ring, and/or the housing, the drive axle must be replaced as an assembly.
  • Page 135 8. Apply 40 grams (1/3 of contents) of grease from the grease pack included in Front Axle Boot Repair Kit into the knuckles and the new outside boot. CD024 ASSEMBLING AXLES 1. Install the inner boot with the small clamp making ATV-1052 sure the ends of the clamp are positioned correctly.
  • Page 136 CD022 CD024 8. Inspect the axle components for correct position- ! CAUTION ing of the four clamps. Also, inspect the boots for being correctly positioned on the shaft. The bearing ring must go onto the shaft with the side without splines facing toward the small clamp INSTALLING REAR DRIVE AXLE of the inner boot or severe damage will result.

  • Page 137: Rear Gear Case (Prowler/Xt)

    2. Secure the lower shock eyelet to the A-arm with a cap screw and a new lock nut. Tighten to 33 ft-lb. Rear Gear Case 3. Slide the hub w/brake disc into position in the (Prowler/XT)/ steering knuckle followed by a hex nut. Tighten Rear Differential (XTX) finger-tight at this time.

  • Page 138: Hub

    3. Secure the differential to the frame with two through-bolts and secure with lock nuts and flat washers. 4. Install the rear drive axles (see Drive Axles in this section). 5. Install the driveline brake caliper and tighten the mounting cap screws to 20 ft-lb; then adjust the parking brake (see Parking Brake in Section 2).
  • Page 139 PR250 PR221 3. Using a socket and ratchet handle, tighten the nut 4. Secure the hub assembly with the nut. Tighten to until the stud is fully drawn into the hub. 200 ft-lb; then secure with a new cotter pin. NOTE: If the cotter pin can not be inserted due to misalignment of the hole in the axle and the slots in the nut, tighten the nut until properly aligned.

  • Page 140: Hydraulic Brake Caliper

    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 wheel; then remove the wheel. PR238 5. Remove the caliper holder from the caliper and ! WARNING account for the brake caliper O-ring.

  • Page 141: Universal Joints

    Universal Joints REMOVING NOTE: The four universal joints can be accessed by removing the belly panel. To remove the belly panel, see Belly Panel in Section 8. 1. Support the vehicle on suitable jack stands ele- vated high enough to allow working from the PR239C underside of the vehicle.
  • Page 142 PR121 PR375 4. Install U-Joint Separator Tool on the universal INSPECTING joint fixed yoke; then remove the bearing cup retainers. 1. Inspect the yoke bores for damage or signs of bearing cup looseness. If bearing cups are loose, the yoke must be replaced. PR354A 5.
  • Page 143 PR367C PR374 3. Install the retainer in the bearing cup; then remove INSTALLING the yoke from the separator tool. 1. Remove the bearing cups from the universal joint; NOTE: Repeat steps 2-3 for the opposite-side then insert the joint into the yoke and install one bearing cup.

  • Page 144: Troubleshooting

    Troubleshooting Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shaft serration worn - broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel Condition Remedy 1. Secondary drive - driven gear teeth broken 1.
  • Page 145 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 Front A-Arms ............7-3 Rear A-Arms ............7-5 Wheels and Tires ............ 7-7 Troubleshooting ............7-8 Back to TOC...

  • Page 146: Suspension

    Suspension NOTE: Critical torque specifications are located in Section 1. Shock Absorbers AF626D REMOVING 4. Using a suitable spring compression stand, com- press the shock absorber spring, remove the 1. Secure the vehicle on a support stand to elevate the retainer, and remove the spring.

  • Page 147: Front A-Arms

    2. Place bushings and sleeves (where appropriate) 5. Remove the hub assembly. into shock eyelet; then install shock with two cap 6. Remove the cotter pin and slotted nut securing the screws and nuts. Tighten all nuts to 33 ft-lb. tie rod end to the knuckle;...
  • Page 148 11. Remove the snap ring from the ball joint; then remove the ball joint from the A-arm. AF610D 3. Route the brake hose through the upper A-arm shock absorber mount. AF616D CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.

  • Page 149: Rear A-Arms

    NOTE: During assembly, new cotter pins should be installed. PR260 13. Install the wheel and tighten to 45 ft-lb. 14. Remove the vehicle from the support stand. AF618D 8. Apply grease to the hub and drive axle splines; then install the hub assembly onto the drive axle. Rear A-Arms REMOVING 1.
  • Page 150 PR220A PR221 5. Secure the hub assembly with the nut. Tighten to NOTE: Never reuse a lock nut. Once a lock nut 200 ft-lb. has been removed, it must be replaced with a new lock nut. 6. Install a new cotter pin and spread the pin to secure the nut.

  • Page 151: Wheels And Tires

    Adjust the air pressure as neces- sary to meet the recommended inflation pressure. ! WARNING Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable vehi- cle operation. The UTV models are equipped with low-pressure tubeless tires of the size and type listed in Section 1.

  • Page 152: Troubleshooting

    NOTE: Pulling could be caused by uneven tire pressure side-to-side, steering alignment out of adjustment, unequal loading, or improper tire size. Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring(s) weak 1. Replace spring(s) 2. Shock absorber damaged 2. Replace shock absorber Problem: Suspension too stiff Condition Remedy...
  • Page 153 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Steering Assembly ..........8-2 Steering Wheel............8-4 Steering Wheel Shaft ..........8-5 Steering Shaft Assembly ......... 8-7 Steering Knuckles ........... 8-9 Checking/Adjusting Front Wheel Alignment ..8-11 Front Bumper Assembly (XT/XTX) ......8-12 Hood..............

  • Page 154: Steering/Frame

    4. Remove the cap screw securing the lower steering shaft joint to the pinion shaft; then slide the joint Steering/Frame free of the pinion. NOTE: Critical torque specifications are located in Section 1. Steering Assembly REMOVING 1. Secure the vehicle on a support stand to elevate the front wheels;...
  • Page 155 3. Inspect the rack and pinion-to-tie rod boots for tears or deterioration. PR526A 4. Coat the thread with red Loctite #271; then install the tire rod into the rack and using an appropriate PR307 crow-foot, tighten to 74 ft-lb. 4. Check boot clamps for security. 5.

  • Page 156: Steering Wheel

    PR528A PR309 5. Install the rack boot and secure with the clamps; 3. Apply green Loctite #270 to the cap screw; then then loosely install the jam nut and outer tie rod secure the lower steering shaft joint to the pinion end.

  • Page 157: Steering Wheel Shaft

    NOTE: Any time steering components are disas- sembled, all connecting components should be Steering Wheel Shaft marked for proper alignment during assembling. REMOVING 1. Remove the steering wheel (see Steering Wheel in this section). 2. Remove the six screws securing the dash panel to the frame and one cap screw and nut from the cen- ter support.
  • Page 158 4. Match mark the upper steering shaft joint and the steering wheel shaft; then remove the steering wheel shaft. Account for the lower thrust-washer. NOTE: Any time steering components are disas- sembled, all connecting components should be marked for proper alignment during assembling. INSPECTING 1.

  • Page 159: Steering Shaft Assembly

    Steering Shaft Assembly REMOVING 1. Remove the steering wheel (see Steering Wheel in this section). 2. Remove the six screws securing the dash panel to the frame and one cap screw and nut from the cen- PR313A ter support. 5. Remove the cap screw securing the lower steering shaft joint to the pinion shaft;...
  • Page 160 PR314A PR313A 2. Align the match marks on the pinion shaft and the 5. Apply green Loctite #270 to the cap screw; then lower steering shaft joint; then slide the steering install the cap screw in the upper steering shaft shaft joint onto the pinion shaft.

  • Page 161: Steering Knuckles

    7. Remove the two cap screws securing the ball NOTE: If the steering is stiff or the steering wheel joints in the knuckle. is difficult to turn, loosen and then tighten the cap screw on the upper steering shaft joint. Check the steering wheel nut for specified torque value.
  • Page 162 NOTE: During assembling, new cotter pins should be installed. 4. Apply a small amount of grease to the hub splines. PR292A PR290A 5. Install the hub assembly onto the splines of the shaft. PR289 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws.

  • Page 163: Checking/Adjusting Front Wheel Alignment

    PR260 PR087A To adjust the wheel alignment, use the following pro- NOTE: If the hole in the axle shaft does not align cedure. with the slots in the castle nut, tighten the nut until the hole and slots align. 1. Center the steering wheel; then using an open-end wrench to hold the tie rod ends, loosen the 8.

  • Page 164: Front Bumper Assembly (Xt/Xtx)

    Hood REMOVING 1. Open the hood; then disconnect the four headlight connectors and remove two nylon ties. PR086 Front Bumper Assembly (XT/XTX) REMOVING Remove four cap screws and nuts. Account for four PR328A lock washers and eight flat washers. 2. Loosen but do not remove the four cap screws and flange nuts securing the hood hinge to the frame;...

  • Page 165: Fenders

    INSTALLING 2. Open the hood; then install the remaining two cap screws and flange nuts. Tighten all four securely. Place the appropriate fender into position and secure with existing hardware. Floor REMOVING 1. Remove the seats and center console. 2. Remove twelve cap screws and two self-tapping screws securing the floor to the frame.

  • Page 166: Belly Panel

    Exhaust System REMOVING MUFFLER 1. Remove the two exhaust springs at the muf- fler/exhaust pipe juncture. 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.

  • Page 167: Taillight Assembly

    2. Align the holes in the upper pivot housings with the holes in the cargo box; then install the lower pivot housings and secure with the four shoulder cap screws. Tighten to 20 ft-lb. 3. Raise the cargo box; then connect the lift support to the frame, install the cap screw and nut, and tighten the nut securely.

  • Page 168: Seats

    2. To install a seat, slide the rear of the seat into the seat retainers and push down firmly on the front of Seats seat. The seat should automatically lock into posi- tion. REMOVING/INSTALLING 1. To remove a seat, pull the seat lock lever up. Raise the front of the seat and slide it forward.

  • Page 169: Troubleshooting

    Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.
  • Page 170 Problem: Rear wheel oscillation Condition Remedy 1. Rear wheel hub bearings worn - loose 1. Replace bearings 2. Tires defective - incorrect 2. Replace tires 3. Wheel rim distorted 3. Replace rim 4. Wheel hub cap screws loose 4. Tighten cap screws 5.

  • Page 171: Controls/Indicators

    SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Master Cylinder Assembly........9-2 Accelerator Pedal ............ 9-2 Front Differential Lock ..........9-3 Shift Lever ............... 9-3 Speedometer/Tachometer/LCD/ Indicator Lights............. 9-4 Back to TOC...

  • Page 172: Master Cylinder Assembly

    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 flexible tubing over one of the wheel bleeder valves and direct the other end into PR336 a container.

  • Page 173: Front Differential Lock

    2. Select the 2WD position on the 2WD/4WD selec- tor switch; then turn the ignition switch to the ON position and select the LOCK position on the tog- gle. The front drive actuator should operate engag- ing four-wheel drive. NOTE: It may be necessary to turn the steering wheel or to rock the vehicle forward and backward to align the differential lock splines and allow engagement.

  • Page 174: Indicator Lights

    3. Remove the nuts securing the gauge assembly to the dash; then unplug the multi-pin connector and Speedometer/ remove the gauge from the vehicle. Tachometer/LCD/ Indicator Lights REPLACING 1. Remove the six screws securing the dash panel to the frame; then remove the parking brake handle and jam nut.

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