Arctic Cat 2007 Service Manual
  1. Manuals
  2. Brands
  3. Arctic Cat Manuals
  4. Offroad Vehicle
  5. 2007
  6. Service manual

Arctic Cat 2007 Service Manual

Prowler/xt
Hide thumbs Also See for 2007:
Table of Contents

Advertisement

Quick Links

See also: Operator's Manual
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2007 Arctic
Cat Prowler/XT. 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.
© 2006 Arctic Cat Inc.
www.mymowerparts.com
®™ 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
September 2006

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 2007 and is the answer not in the manual?

Questions and answers

Related Manuals for Arctic Cat 2007

Summary of Contents for Arctic Cat 2007

  • 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 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TABLE OF CONTENTS Foreword Click on the red text to go. Section General Information Periodic Maintenance/Tune-Up 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System Drive System Suspension 8. Steering/Frame Controls/Indicators 2007 10. Aids for Maintenance 11.

  • Page 3: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications ..........1-2 Break-In Procedure ..........1-3 Gasoline - Oil - Lubricant ........1-3 Genuine Parts ............1-4 Preparation For Storage .......... 1-4 Preparation After Storage........

  • Page 4: General Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Specifications* CHASSIS CARBURETOR Dry Weight (approx) 526 kg (1160 lb) Type Keihin CVK36 Length (overall) 292 cm (115 in.) Main Jet Height (overall) 197 cm (77.5 in.) Slow Jet Width (overall) 156 cm (61.3 in.)

  • Page 5: Break-In Procedure

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Do not be reluctant to heat up the brake pads during the burnishing procedure. Break-In Procedure After the completion of the break-in period, the engine oil and oil filter should be changed. Other...

  • Page 6: Genuine Parts

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Since gasoline expands as its temperature rises, the gas tank must be filled to its rated capacity only. Expansion room must be maintained in the tank par- ticularly if the tank is filled with cold gasoline and then moved to a warm area.

  • Page 7: Preparation After Storage

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Either drain the gas tank or add Fuel Stabilizer 3. Check all control wires and cables for signs of to the gas in the gas tank. Remove the air filter wear or fraying.
  • Page 8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart ........2-2 Lubrication Points............ 2-3 Battery..............2-3 Fuses ..............2-4 Air Cleaner/Filter ............. 2-4 Valve/Tappet Clearance (Feeler Gauge Procedure) ........2-6 Valve/Tappet Clearance (Valve Adjuster Procedure) ........

  • Page 9: Periodic Maintenance Chart

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A = Adjust I = Inspect C = Clean L = Lubricate Periodic Maintenance D = Drain R = Replace Chart T = Tighten Initial Every Month Every 3 Every 6...

  • Page 10: Lubrication Points

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! WARNING Lubrication Points Anytime service is performed on a battery, the fol- lowing must be observed: keep sparks, open flame, cigarettes, or any other flame away. Always wear It is advisable to lubricate certain components peri- safety glasses.

  • Page 11: Fuses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Trickle charge the battery at 1.5 amps for 10 hours. ! CAUTION Always replace a blown fuse with a fuse of the same ! CAUTION type and rating. Never exceed the standard charging rate.
  • Page 12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD747 CD670 4. Fill a wash pan larger than the filter with a CHECKING AND CLEANING non-flammable cleaning solvent; then dip the DRAINS filter in the solvent and wash it.

  • Page 13: Valve/Tappet Clearance (Feeler Gauge Procedure)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the spark plug; then install the timing inspection plug. Valve/Tappet Clearance 5. Place the two tappet covers with O-rings into position. Tighten the cap screws securely. (Feeler Gauge Procedure)

  • Page 14: Testing Engine Compression

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely ! WARNING with the valve adjuster handle. Always wear safety glasses when using compressed air.

  • Page 15: Muffler/Spark Arrester

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-0051 CF105A ! CAUTION Before removing the spark plug, be sure to clean the area around the spark plug. Dirt could enter engine when removing or installing the spark plug.

  • Page 16: Engine/Transmission Oil - Filter

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 17: Front Differential/Rear Drive Lubricant

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Unscrew the oil level stick and wipe it with a clean cloth. 10. Install the oil level stick until the threads touch engine case. NOTE: The oil level stick should not be threaded into the case for checking the oil level.

  • Page 18: Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A. Steering wheel secure. Rear Drive B. Steering has equal and complete full-left and full-right capability. C. Steering sector mounting bolts tight. D. Ball joints not worn, cracked, or damaged.

  • Page 19: Nuts/Bolts/Cap Screws

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 HEADLIGHT Nuts/Bolts/Cap Screws NOTE: The bulb portion of the headlight is frag- ile. HANDLE WITH CARE. When replacing the headlight bulb, do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned Tighten all nuts, bolts, and cap screws.

  • Page 20: Switches

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Measure the distance from the floor to the B. 2WD/4WD selector switch — differential mid-point of each headlight. will engage (4WD)/disengage (2WD). 3. Using the measurements obtained in step 2, C.

  • Page 21: Frame/Welds

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. With the master cylinder in a level position, check the fluid level in the reservoir. If the level in the reservoir is not above the MIN, add DOT 4 brake fluid.
  • Page 22 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR377A PR376A 3. If thickness of either brake pad is less than 1.0 NOTE: During the bleeding procedure, watch the mm (0.039 in.), the brake pads must be replaced. reservoir very closely to make sure there is always a sufficient amount of brake fluid.

  • Page 23: Parking Brake

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 E. Install the wheel. Tighten to specifications (see Section 10). 5. Burnish the brake pads (see Burnishing Brake Pads in this section). Parking Brake CHECKING PR098 Although the parking brake has been adjusted at the 2.
  • Page 24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR466A PR097A 4. Remove the anti-rattle springs; then push in on ! CAUTION the caliper holder and remove the outer brake pad. Remove the inner pad. If after adjusting the parking brake cable the parking...

  • Page 25: Burnishing Brake Pads

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Burnishing Brake Pads Checking/Replacing V-Belt Brake pads must be burnished to achieve full brak- ing effectiveness. Braking distance will be extended REMOVING until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure.
  • Page 26 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR108 PR109 4. Install one of the V-belt cover cap screws into NOTE: The arrow on the V-belt should point rear- the driven pulley fixed face; then turn the driven ward.
  • Page 27 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 Prowler/XT (Table of Contents) ....... 3-3 www.mymowerparts.com Back to TOC...
  • Page 28 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAMSHAFT AND CYLINDER HEAD Engine/Transmission Cam Lobe Height (min) (intake/exhaust) 13.97 mm (0.55 in.) Camshaft Journal Oil (max) 0.04 mm (0.0016 in.) Clearance This section has been organized into sub-sections Camshaft Journal (right &...
  • Page 29 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Use a small funnel between the frame and coolant drain plug to prevent coolant from drain- Prowler/XT ing on the frame and splashing. (Table of Contents) Removing Engine/Transmission ......3-3 Top-Side Components..........
  • Page 30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR155B PR474A 6. Remove the E-clip from the transmission shift arm; then disconnect the shifter linkage. Account for a washer and a bushing. PR157A 5. From the left-side, disconnect the starter wire,...
  • Page 31 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR127A PR154A 11. Remove the coolant hoses from the water pump and thermostat housings; then position the upper coolant line to the left-side of the engine com- partment. PR118 9. Remove four self-tapping screws securing the air filter mounting bracket to the frame;...
  • Page 32 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR153B PR148A 13. Remove the muffler; then remove the exhaust 16. Remove two flange nuts from the underside of pipe. the rear engine mounts. 14. Set the parking brake; then from the underside...

  • Page 33: Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Top-Side Components A. Valve Cover B. Cylinder Head NOTE: Remove the spark plug and timing inspection plug; then using the recoil starter, rotate the crankshaft to top-dead-center of the PR114 compression stroke.
  • Page 34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD206 CC012D 5. Bend the washer tabs down and remove the two cap screws securing the sprocket to the cam- shaft; then drop the sprocket off the camshaft. CD211A 3. Loosen the cap screw on the end of the ten- sioner;...
  • Page 35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 align- secure it to keep it from falling into the crankcase.
  • Page 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.

  • Page 37: Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the Removing Right-Side Connecting Rod Holder (p/n 0444-006). Components ! CAUTION Do not allow the connecting rod to go down inside A.
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD920A CF075A 5. Loosen the clamps securing the coolant hose to 9. Remove the nut securing the magneto rotor to the water pump; then remove the crossover tube the crankshaft; then install the magneto rotor from the cylinder head.
  • Page 39 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD136 CD952A NOTE: There is an oil passage beneath the driven gear/drive gear assembly. This passage should be plugged prior to removing the driven gear and drive gear. Failure to do so could result in the loss of an alignment pin into the crankcase.

  • Page 40: Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR434A CD079 2. Remove the nut securing the movable drive face; then remove the face. Account for a spacer. Left-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 41 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR388 CD974A 5. Remove the fixed drive face. NOTE: For steps 8-14, refer to illustration CC829B. 6. Using an impact driver, remove the cap screws securing the air intake plate; then remove the NOTE: To aid in installing, it is recommended that plate cushion.
  • Page 42 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC596 FI279A NOTE: Account for and inspect the clutch hous- NOTE: The washer is also directional. The flat ing seal. side of the washer must face toward the centrifu- gal clutch assembly when installing.
  • Page 43 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD987 CD984 CD993 CD895A 13. Using an impact driver, remove the Allen-head 15. Using an impact driver, remove the three Phil- screws securing the final drive carrier bearing lips-head screws securing the oil pump; then housing (E);...

  • Page 44: Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Center Crankcase Disassembling Components Crankcase Half NOTE: This procedure cannot be done with the NOTE: For steps 1-7, refer to illustration CC821B. engine/transmission frame. Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure.
  • Page 45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC668 CC675 3. Remove the shift shaft (H); then remove the two 7. Note the timing marks on the crank balancer forks taking note of the direction of the tabs on gear (B) and crankshaft gear (C) for assembling the forks for assembling purposes.

  • Page 46: Servicing Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Remove the cap screws securing the oil strainer cap; then remove the cap. Account for the cap O-ring. CC686 Table of Contents PR407 (Servicing Components) 12. Remove the two cap screws securing the oil strainer;...
  • Page 47 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Cleaning/Inspecting Valve Cover NOTE: If the valve cover cannot be trued, the cyl- inder head assembly must be replaced. 1. Wash the valve cover in parts-cleaning solvent. 2. Place the valve cover on the Surface Plate (p/n 0644-016) covered with #400 grit wet-or-dry sandpaper.
  • Page 48 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Valve Stem Measuring Valve Guide/Valve Stem Outside Diameter Deflection (Wobble Method) 1. Using a micrometer, measure the valve stem 1. Mount a dial indicator and base on the surface outside diameter.

  • Page 49: Piston Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Rocker Arm 4. Place a spring retainer over the valve springs; then using the valve spring compressor, com- (Inside Diameter) press the valve springs and install the valve cot- ters.
  • Page 50 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC400D CC280D 2. Remove each ring by working it toward the Measuring Piston Pin (Outside dome of the piston while rotating it out of the Diameter) and Piston-Pin Bore groove.

  • Page 51: Cylinder/Cylinder Head Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Piston Skirt/ Cylinder Clearance 1. Measure the cylinder front to back in six places. ATV-1024A ! CAUTION Incorrect installation of the piston rings will result in engine damage. CC127D 2.
  • Page 52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! 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.
  • Page 53 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 54: Servicing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 clearance. CF060A 2. If damaged, the camshaft must be replaced.

  • Page 55: Inspecting Clutch Housing

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DRIVEN PULLEY ASSEMBLY Disassembling ! WARNING This procedure involves relaxing a compressed spring assembly. DO NOT attempt disassembling without the proper tools. 1. Secure Driven Pulley Compressor (p/n 0444-121) in a suitable holding fixture such as a bench vise;...
  • Page 56 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Using a spanner and suitable breaker bar, loosen the notched-ring nut; then spin the nut free of the hub. CD067 4. Using a suitable marking pen, make alignment marks on the fixed face spring holder and both pulley faces.
  • Page 57 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Using a thin pry-bar or screwdriver, work the movable face sleeve upward and free of the O-rings; then remove the sleeve. CF092A 3. Inspect two grease seals in the movable face for nicks, cuts, or damage.
  • Page 58 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Apply multi-purpose grease to the O-rings and grease seals on the movable face; then install on the fixed face making sure the alignment marks are properly aligned. CF089A 6. Place the spring holder on the spring engaging the spring end with the appropriate anchor hole.

  • Page 59: Servicing Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Checking Backlash NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft. 1. Place the left-side crankcase cover onto the left-side crankcase half to prevent runout of the secondary transmission output shaft.

  • Page 60: Crankshaft Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the secondary driven output shaft assem- Correcting Tooth Contact bly. NOTE: If tooth contact pattern is comparable to 5. Rotate the secondary driven bevel gear several the correct pattern illustration, no correction is revolutions in both directions.
  • Page 61 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. Position the indicator contact point against the center of the connecting rod small end jour- nal.

  • Page 62: Assembling Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 COUNTERSHAFT Assembling From the left side: ! CAUTION 1. Install the sliding dog (14), driven gear washer When disassembling the countershaft, care must be (13), and bushing (9). taken to note the direction each major component (dog, gear) faces.
  • Page 63 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC687 CD832B 3. Apply a liberal amount of engine oil to the NOTE: It will be necessary to rotate the crank crankshaft bearing. Using a propane torch, heat balancer until the counterweight is facing away the bearing until the oil begins to smoke;...

  • Page 64: Joining Crankcase Halves

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Install the front and rear secondary driven shaft assemblies into the left side of the crankcase making sure the bearing locating pins are facing upward and the bearing C-ring is fully seated in the crankcase.

  • Page 65: Installing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 6. From the right side, install the remaining 8 mm cap screws (two inside the case); then tighten only until snug.
  • Page 66 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the oil pump drive gear spacer onto the crank balancer shaft. Grease the pin and insert it into the shaft; then install the drive gear making sure the raised side of the gear is facing toward the inside.
  • Page 67 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Place the clutch cover/clutch housing assembly into position on the crankcase; then secure with the cap screws making sure the differ- ent-lengthed cap screws are in their proper loca- tion.

  • Page 68: Installing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 15. Spread the faces of the driven pulley by pushing 19. Place the V-belt cover gasket into position; then the inner face toward the engine while turning it install the cover and secure with the cap screws counterclockwise;...
  • Page 69 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD944 CD952A 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...
  • Page 70 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Install the shift cam stopper, spring, and two washers; then coat the threads on the mounting stud with red Loctite #271 and install the nut. Tighten securely. CD948A PR434A 7.

  • Page 71: Installing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 14. Install the crossover tube on the water pump and cylinder head making sure the O-ring is properly positioned. 15. Install the shift arm on the shift arm shaft mak- ing sure the scribed marks (from removing) are aligned.
  • Page 72 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. Install the compression rings (1 and 2) so the letter on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring end gaps are on directly opposite sides of the piston (see illustration).
  • Page 73 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Install the coolant hose onto the crankcase union and tighten the clamp. C. Cylinder Head D. Valve Cover CC020D 1. Cylinder Head 23. Intake Pipe 12. Cap Screw Assy Assy 13.
  • Page 74 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 12. With the alignment pin installed in the camshaft, loosely place the cam sprocket (with the recessed side facing the cam shaft lobes) onto the camshaft. At this point, do not “seat” the sprocket onto the shaft.
  • Page 75 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 19. Rotate the crankshaft until the first cap screw (from step 17) can be addressed; then tighten to specifications. Bend the tab to secure the cap screw. ATV1027 ! CAUTION...
  • Page 76 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 22. Remove the cap screw from the end of the chain tensioner; then using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner clockwise until the screw bottoms. CD471 25.

  • Page 77: Installing Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC003D CC001D 29. In a crisscross pattern starting from the center 32. If removed, install the spark plug. Tighten to and working outward, tighten the cap screws specifications. securely. 30. Adjust valve/tappet clearance using the follow- Installing ing procedure.
  • Page 78 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: The rear engine mounting bracket and rear engine mounts should be attached to the engine. The front engine mounting bracket should be attached to the engine, and the front engine mounts should be in the frame.
  • Page 79 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR153B PR128A 10. From the left-side, connect the speed sensor connector (XT), fuel level sensor connector (XT), and temperature sensor lead; then install the spark plug cap. PR144B 8. Connect the lower coolant hose to the water pump housing;...
  • Page 80 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 12. Place the air filter assembly into position and secure with the self-tapping screws; then con- nect the intake boot to the carburetor and the inlet housing boot to the air filter housing.
  • Page 81 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Carburetor Specifications ........4-2 Carburetor Schematic ..........4-2 Carburetor ............... 4-2 Engine RPM (Idle) ........... 4-6 Gas Tank ..............4-6 Gas/Vent Hoses ............. 4-9 Vacuum Pulse Fuel Pump ........

  • Page 82: Carburetor Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Carburetor Carburetor Specifications ! WARNING PROWLER/XT Whenever any maintenance or inspection is per- formed on the fuel system during which there may Type Keihin CVK36 be fuel leakage, there should be no welding, smok- Main Jet ing, open flames, etc., in the area.
  • Page 83 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR162A CC748 6. Disconnect the electric choke connector; then 4. Remove the Phillips-head screws securing the remove the carburetor from the engine. float chamber; then remove the chamber. Account for the O-ring.
  • Page 84 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Lift the float assembly from the carburetor. CLEANING AND INSPECTING Account for the float valve. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
  • Page 85 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ASSEMBLING 1. Thread the idle adjust screw assembly into the carburetor making sure the washer and spring are properly positioned. 2. Install the pilot screw with the spring, the washer, and the O-ring in this order.

  • Page 86: Engine Rpm (Idle)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Place the carburetor into position on the engine; then connect the electric choke connector to the main harness. 2. Connect the throttle cable to the carburetor. Tighten the jam nut securely.
  • Page 87 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR163 PR166D 6. Remove the outer cap screw securing the front tank hold-down; then swing the hold-down to the left. PR164 4. From the opposite side of the vehicle, repeat step 3;...
  • Page 88 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.

  • Page 89: Gas/Vent Hoses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR166A PR167A 4. Place the gas cap filler panel into position; then 6. Connect the gasline hose and gas tank vent hose if necessary, position the gas tank so the filler to the proper fittings;...

  • Page 90: Oil Flow Chart

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TESTING OIL PUMP PRESSURE Oil Flow Chart NOTE: The engine must be warmed up to the specified temperature for this test. 1. Remove the seats and center console; then remove the left-side seat-base.

  • Page 91: Oil Cooler

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Install the left-side seat-base; then install the center console and seats making sure the seats Oil Cooler lock securely. NOTE: If the oil pressure is lower than specified, check for an oil leak, damaged oil seal, defective...
  • Page 92 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR271A PR273A 2. Remove four machine screws (two on each side) INSTALLING OIL COOLER securing the fan shroud to the radiator noting orientation of the fan and oil cooler for assem- 1.

  • Page 93: Liquid Cooling System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Liquid Cooling System The cooling system should be inspected daily for leakage and damage. Also, the coolant level should be checked periodically. When filling the cooling system, use premixed Arc- tic Cat Antifreeze.
  • Page 94 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Flush the radiator with water to remove any con- taminants.

  • Page 95: Thermostat

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Place the storage box into position and using a 2. Remove the two cap screws securing the ther- smooth, flat pry-bar, pry the center of the box mostat housing to the cylinder head. Account for past the dash mount;...

  • Page 96: Fan

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING 1. Remove the radiator (see Radiator/Oil Cooler in this section). 2. Remove the fan assembly from the radiator. INSTALLING PR132 5. Remove the two cap screws securing the water 1.

  • Page 97: Vacuum Pulse Fuel Pump

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR132 CD815 3. Fill the engine/transmission with the proper 2. Start the engine. Fuel pump pressure should amount of recommended oil. show 0.036-0.084 kg/cm (0.5-1.2 psi). REMOVING 4. Fill the cooling system with the proper amount of recommended coolant.
  • Page 98 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the gasline hose and disconnect the fuel level sensor connector; then remove four torx-head machine screws and the fuel level sen- sor mounting plate. ATV2116 NOTE: If readings are erratic, clean the resistor wiper and resistor with a clean cloth soaked with alcohol and retest.
  • Page 99 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Specifications ............5-2 Battery..............5-2 RPM Limiter............. 5-2 Testing Electrical Components ........ 5-2 Accessory Receptacle/Connector ......5-2 Brakelight Switch............. 5-2 Coolant Temperature and Cooling Fan Switches ..5-3 Fan Motor ..............

  • Page 100: Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications Testing Electrical Components Prowler/XT All of the electrical tests should be made using the IGNITION Fluke Model 73 Multimeter (p/n 0644-191) and Ignition Timing 10° BTDC @ 1500 RPM...

  • Page 101: Coolant Temperature And Cooling Fan Switches

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VOLTAGE (Wiring Harness Connector) 1. Set the meter selector to the DC Voltage posi- tion. 2. Connect the red tester lead to the orange wire; then connect the black tester lead to ground.

  • Page 102: Fan Motor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. On the coolant temperature switch, allow the 2. Connect the red tester lead to the red wire; then water to cool, and when the temperature is connect the black tester lead to the black wire.

  • Page 103: Fuses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Set the meter selector to the DC Voltage posi- RESISTANCE tion. ! CAUTION 3. Connect the black tester lead to ground. Always disconnect the battery when performing 4. Using the red tester lead, contact each end of the resistance tests to avoid damaging the multimeter.

  • Page 104: Speed Sensor (Xt)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. The meter reading must be within specification. NOTE: If the meter does not show as specified, replace the spark plug cap. PEAK VOLTAGE NOTE: All of the peak voltage tests should be...

  • Page 105: Ignition Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Headlight Switch VOLTAGE 1. Connect the red meter lead to the gray wire; then connect the black meter lead to the black wire. 2. Turn the ignition switch to the ON position. The meter must show battery voltage.

  • Page 106: Differential Lock Switch (Xt)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Differential Lock Reverse Override Switch Switch (XT) VOLTAGE VOLTAGE NOTE: To perform the following tests, the igni- 1. Select DC Voltage on the multimeter; then con- tion switch must be in the ON position and the nect the red tester lead to the switch terminal transmission shifted into reverse gear.

  • Page 107: Magneto Coils

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VOLTAGE NOTE: If the meter does not show 0 DC volts, rock the vehicle to help engage the differential 1. Locate the 4-wire connector for the front drive lock; then troubleshoot the differential lock switch selector actuator on the frame to the right of the (see Differential Lock Switch - XT in this section).

  • Page 108: Starter Motor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RESISTANCE (Charging Coil) 4. The meter reading must be within specification. Magneto Coil (Source) ! CAUTION 1. Set the meter selector to the DC Voltage posi- Always disconnect the battery when performing tion.

  • Page 109: Starter Relay

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Set the meter selector to the DC Voltage posi- NOTE: Make sure that the ignition switch is in tion. the ON position, transmission in neutral, and park- ing brake set.

  • Page 110: Regulator/Rectifier

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VOLTAGE Regulator/Rectifier NOTE: The low beams are the outside bulbs (black and white wires) and the high beams are the inside bulbs (yellow and black wires). Always con- nect the black tester lead to the black wires. The The regulator/rectifier is located under the driver’s...

  • Page 111: Ignition Timing

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Set the meter selector to the DC Voltage posi- tion. Ignition Timing 2. Connect the red tester lead to the red/blue wire; then connect the black tester lead to the black wire.
  • Page 112 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 General Information..........6-2 Front Drive Actuator ..........6-2 Front Differential ............6-4 Drive Axles ............6-16 Rear Gear Case ............ 6-21 Hub................

  • Page 113: Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Lubricant on a new pinion housing assembly could be grease. If the front of the gear Drive System case is leaking at the rear drive boot, wipe excess lubricant from the bottom of the pinion housing;...

  • Page 114: Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR189A AG925 3. Remove the mounting cap screw from above the 3. While holding the actuator firmly forward, actuator on the suspension side. tighten the front cap screw to hold the actuator in place;...

  • Page 115: Front Differential

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Secure the wiring harness to the frame with a nylon cable tie; then install the inner fender panel. Front Differential REMOVING 1. Remove the belly panel; then place the vehicle...
  • Page 116 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Remove the lower shock bolts. Account for the lock nuts; then move the shocks and upper A-arm up and secure them with a strap. PR195A 10. Remove the lower and upper ball joint cap screws taking care not to strip the threads on the ball joint shaft;...
  • Page 117 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR205A CD103 17. Remove the upper differential mounting cap screw. Account for a lock nut and two washers. CD106 3. Remove the input shaft from the pinion housing. CD016 18. Free the differential assembly from the frame mountings;...
  • Page 118 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Remove the snap ring securing the input shaft bearing; then place the pinion housing in a press and remove the bearing. AF993 AF983 AF994 2. Install the input shaft seal making sure it is flush with the edge of the housing.
  • Page 119 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX222 PR261A 4. Install the input shaft into the pinion housing; Disassembling Pinion Gear then secure in the bearing with a circlip. NOTE: This procedure can be performed on a rear gear case.
  • Page 120 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX174 KX177 NOTE: If the cover is difficult to remove, pry on the cover in more than one recessed location. 4. On the XT, remove the splined coupler, shifter fork, pin, and spring of the differential lock assembly and set aside.
  • Page 121 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC875 CC879 NOTE: If gears are being replaced, use the exist- ing shims. The numbers are scribed onto the gears: the ring gear has the number on the oppo- site side of the gears, and the pinion gear has the number on the end of the pinion gear shaft by the splines.
  • Page 122 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 738-268B CC883 A. Cover Side - add value A on the gear case 2. Place the pinion assembly in a bearing puller; housing to value B (XT) or value C (Prowler) then install the bearing using a press.
  • Page 123 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC891 CD103 5. Install the shift fork shaft w/spring into the gear housing making sure the shaft O-ring is posi- tioned to the inside. CD110 8. Install the proper shim onto the ring gear spider assembly making sure the chamfer side of the shim is facing toward the ring gear.
  • Page 124 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Needle Bearing NOTE: Removing the needle bearing is rarely necessary. Avoid removing the needle bearing unless the bearing is clearly damaged. NOTE: This procedure can be performed on a rear gear case.
  • Page 125 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Needle Bearing 1. Apply red Loctite #271 to the outside of a new bearing; then place the new bearing into the housing. CC891 5. Install the pinion housing. Removing/Installing Axle Seal NOTE: This procedure can be performed on a rear gear case.
  • Page 126 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid lubricant into the differential and install the fill/level plug. Tighten to specifications. 5. Align the scribed match marks on the front input drive flange and the front drive yoke flange;...

  • Page 127: Drive Axles

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 14. Remove the vehicle from the support stand. 15. Install the belly panel. Drive Axles REMOVING REAR DRIVE AXLE 1. Secure the vehicle on a support stand to elevate the wheels.
  • Page 128 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING FRONT DRIVE AXLE NOTE: For removing a front drive axle, see Front Differential in this section. CLEANING AND INSPECTING NOTE: Always clean and inspect the drive axle components to determine if any service or replace- ment is necessary.
  • Page 129 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Using a side-cutters (or suitable substitute), remove the small clamp from the shaft. CD021 3. Using a snap ring pliers, remove the circlip securing the bearing ring to the shaft. Note the...
  • Page 130 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ASSEMBLING AXLES NOTE: The grease pack contains 120 grams of grease. The inside joint (double-offset) requires 1. Install the inner boot with the small clamp mak- approximately 70-90 grams of grease and the out-...
  • Page 131 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION The bearing ring must go onto the shaft with the side without splines facing toward the small clamp of the inner boot or severe damage will result. 5. Secure the bearing ring with the circlip making sure the sharp side of the circlip faces away from the boot.

  • Page 132: Rear Gear Case

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING FRONT DRIVE AXLE 1. Position the drive axle in the gear case and steer- ing knuckle; then insert the ball joints into the steering knuckles. Secure with cap screws tight- ened to specifications.

  • Page 133: Hub

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING 1. Secure the vehicle on a support stand to elevate the wheel; then remove the wheel. NOTE: Removing or tightening of the hub nuts requires that the axles be locked. To lock the rear axle, set the parking brake.
  • Page 134 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Remove the four cap screws securing the brake disc (front hub only). PR252A INSTALLING PR254A 1. Secure the brake disc (if applicable) to the hub CLEANING AND INSPECTING with the four cap screws coated with red Loctite #271.

  • Page 135: Hydraulic Brake Caliper

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR258 PR235 5. For front hubs, secure the brake calipers to the ! CAUTION knuckle with two cap screws tightened to speci- fications. Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the vehicle and do not reuse brake fluid.
  • Page 136 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Compress the caliper holder toward the caliper and install the inner brake pad; then install the outer pad. PR239B 6. Plug the fluid port with a suitable plug to pre- vent contamination during cleaning.

  • Page 137: Universal Joints

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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-...
  • Page 138 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR375 PR367C INSPECTING INSTALLING 1. Inspect the yoke bores for damage or signs of 1. Remove the bearing cups from the universal bearing cup looseness. If bearing cups are loose, joint;...
  • Page 139 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Check that the universal joint can be flexed NOTE: Repeat steps 2-3 for the opposite-side freely without binding; then apply multi-pur- bearing cup. pose grease to the splines and install the propel- ler shaft noting the match marks made prior to 4.
  • Page 140 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 www.mymowerparts.com Back to TOC...

  • Page 141: Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Suspension NOTE: Critical torque specifications are located in Section 10. 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 retainer, and remove the spring.

  • Page 142: Front A-Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place bushings and sleeves (where appropriate) into shock eyelet; then install shock with two cap screws and nuts. Tighten all nuts to specifi- cations. ! CAUTION Do not tighten the nuts beyond the 4.8 kg-m (35 ft-lb) specification or the shock eyelet or mount WILL be damaged.
  • Page 143 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Remove the cap screws securing the A-arms to the frame. AF616D 2. Install the A-arm assemblies into the frame mounts and secure with the cap screws. Only finger-tighten at this time.

  • Page 144: Rear A-Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Install the knuckle assembly onto the ball joints and secure with cap screws. Tighten to specifi- cations. PR377B 11. Secure the hub nut (from step 9) to the shaft/axle. Tighten to specifications.
  • Page 145 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Remove the cap screws and lock nut securing 3. Inspect the frame mounts for signs of damage, the shock absorber to the frame and lower wear, or weldment damage.

  • Page 146: Wheels And Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Secure the boot guard to the lower A-arm with TIRE SIZE the two cap screws. Tighten securely. ! WARNING 10. Install the wheel and tighten to specifications. Use only Arctic Cat approved tires when replacing 11.
  • Page 147 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Clean the tires with soap and water. 3. Inspect each wheel for cracks, dents, or bends. 4. Inspect each tire for cuts, wear, missing lugs, and leaks. INSTALLING 1. Install each wheel on its hub.
  • Page 148 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Steering Assembly ..........8-2 Steering Wheel............8-4 Steering Wheel Shaft ..........8-4 Steering Shaft Assembly ......... 8-6 Steering Knuckles ........... 8-8 Checking/Adjusting Front Wheel Alignment ..

  • Page 149: Steering/Frame

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the cap screw securing the lower steer- ing shaft joint to the pinion shaft; then slide the Steering/Frame joint free of the pinion. NOTE: Critical torque specifications are located in Section 10.
  • Page 150 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect the tie rods for bends or deformation. 3. Inspect the rack and pinion-to-tie rod boots for tears or deterioration. PR309 3. Apply green Loctite #270 to the cap screw; then...

  • Page 151: Steering Wheel

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Install the steering wheel aligning the two match marks; then apply a drop of red Loctite #271 to Steering Wheel the threads of the nut and secure the steering wheel.
  • Page 152 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Align the match marks on the steering wheel shaft and the steering wheel and slide the steer- ing wheel onto the splines; then install the nut and finger-tighten. PR313A 4.

  • Page 153: Steering Shaft Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering Shaft Assembly REMOVING 1. Remove the steering wheel (see Steering Wheel in this section). 2. Remove the six torx-head screws securing the dash panel to the frame and one cap screw and PR313A nut from the center support.
  • Page 154 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING ! WARNING 1. Place the steering shaft assembly into position Allowing the lower steering shaft joint to extend too through the opening in the splash panel. far onto the pinion shaft could cause binding or lock-up of the steering joint resulting in loss of steering control.

  • Page 155: Steering Knuckles

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering Knuckles REMOVING AND DISASSEMBLING 1. Secure the vehicle on a support stand to elevate the wheel; then remove the wheel. ! WARNING Make sure the vehicle is solidly supported on the PR226 support stand to avoid injury.
  • Page 156 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Tighten to specifications. PR289 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively,...

  • Page 157: Checking/Adjusting Front Wheel Alignment

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD009 PR377B 6. Secure the hub assembly with the nut. Tighten to 9. Install the wheel; then using a crisscross pattern, specifications. tighten to specifications. 10. Remove the vehicle from the support stand.

  • Page 158: Front Bumper Assembly (Xt)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Front Bumper Assembly (XT) REMOVING To remove the front bumper assembly, remove four cap screws and nuts. Account for four lock washers and eight flat washers. PR084A PR327A CLEANING AND INSPECTING...

  • Page 159: Fenders

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR328A PR332 2. Loosen but do not remove the four cap screws 3. Connect the four headlight connectors; then and flange nuts securing the hood hinge to the secure the wires with two new nylon ties.

  • Page 160: Floor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. 3. While pulling forward on the upper-rear of the...

  • Page 161: Exhaust System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Exhaust System REMOVING MUFFLER 1. Remove the two exhaust springs at the muf- fler/exhaust pipe juncture. PR102 2. Loosen but do not remove the four shoulder cap screws securing the pivot housings to the cargo box.

  • Page 162: Adjusting Headlights

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. With the help of an assistant or an adequate lift, set the cargo box into position on the frame; then position the two upper pivot housings between the cargo box and frame. Lightly grease the pivot housings.

  • Page 163: Seats

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Connect the three-prong connector to the bulb socket; then place the taillight assembly into position on the rear canopy tube. 2. Install the two torx-head screws and tighten securely.

  • Page 164: Controls/Indicators

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Master Cylinder Assembly........9-2 Accelerator Pedal ............ 9-3 2WD/4WD Selector ..........9-3 Front Differential Lock (XT) ........9-3 Low Range/High Range/Neutral/Reverse Lever..9-4 Speedometer/Tachometer/LCD/ Indicator Light (XT) ..........

  • Page 165: Master Cylinder Assembly

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

  • Page 166: Accelerator Pedal

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 To either engage or disengage the front wheels, move the switch to the 4WD position or to the 2WD Accelerator Pedal position. ! CAUTION REMOVING Do not attempt to engage or disengage the front dif- ferential while the vehicle is moving.

  • Page 167: Low Range/High Range/Neutral/Reverse Lever

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Select the 2WD position on the 2WD/4WD selector switch; then turn the ignition switch to Speedometer/ the ON position and select the LOCK position Tachometer/LCD/ on the toggle. The front drive actuator should operate engaging four-wheel drive.
  • Page 168 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: When the bottom segment flashes, approximately 3.8 L (1.0 U.S. gal.) of gasoline remains in the tank. 3. Mode Button - Shifts the digital gauge through three modes: speed/tachometer, distance, and time.

  • Page 169: Indicator Lights (Prowler)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 14. Parking Brake Indicator - A red light will illumi- nate when the parking brake is applied and the ignition switch is in the ON position. The light will go off when the parking brake is released.
  • Page 170 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Temperature Indicator - A red light will illumi- NOTE: Debris in front of the engine or packed nate if the engine overheats. The light should be between the cooling fins of the radiator or the oil off during normal operation.

  • Page 171: Aids For Maintenance

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 10 - AIDS FOR MAINTENANCE TABLE OF CONTENTS Torque Specifications ..........10-2 Torque Conversions ..........10-4 Tightening Torque (General Bolts) ......10-4 www.mymowerparts.com 10-1 Back to TOC...

  • Page 172: Torque Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Specifications BRAKE COMPONENTS DRIVE TRAIN COMPONENTS Torque Torque Part Part Bolted To Part Part Bolted To kg-m ft-lb kg-m ft-lb Brake Disc* 15.0 Engine Cradle Engine 40.0 Brake Hose Caliper 20.0...
  • Page 173 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ENGINE/TRANSMISSION Torque Part Part Bolted To kg-m ft-lb Clutch Shoe** Crankshaft 31.8 230.0 Clutch Cover/ Housing Crankcase Assembly Crankcase Half (6 mm) Crankcase Half 0.9-1.3 6.5-9.5 Crankcase Half (8 mm) Crankcase Half 20.0...

  • Page 174: Tightening Torque

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Conversions ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m 11.2 11.3 11.5 11.6 11.8 11.9 12.0 12.2 12.3 12.5 12.6 10.0 12.8 10.1 12.9 10.2 13.0 10.4 13.1...

  • Page 175: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 11 - TROUBLESHOOTING TABLE OF CONTENTS Engine ..............11-2 Drive ..............11-5 Fuel System ............11-6 Electrical..............11-7 Steering/Suspension ..........11-9 Brakes ..............11-10 www.mymowerparts.com 11-1 Back to TOC...

  • Page 176: Engine

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine 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.
  • Page 177 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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...
  • Page 178 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.

  • Page 179: Drive

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine overheats Condition Remedy 1. Carbon deposit (piston crown) excessive 1. Clean piston 2. Oil low 2. Add oil 3. Octane low - gasoline poor 3. Drain - replace gasoline 4.

  • Page 180: Fuel System

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

  • Page 181: Electrical

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Electrical 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 defective 4.
  • Page 182 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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...

  • Page 183: Steering/Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering/Suspension 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.

  • Page 184: Brakes

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 1. A-arm-related bushings worn 1.

This manual is also suitable for:

2007 prowler/xt

Table of Contents

Save PDF