Arctic Cat 2007 User manual

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
!CAUTIONidentifies unsafe practices which may result in vehicle-related damage. Follow the directive because
it deals with the possibility of damaging part or parts of the vehicle. The symbol NOTE: identifies supplementary
information worthy of particular attention. The symbol AT THIS POINT directs the technician to certain and
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. September 2006
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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Prowler
Prowler
Service Manual
Service Manual
Prowler
Prowler XT
2007
TABLE OF CONTENTS
Foreword
Click on the red text to go.
Section
1. General Information
2. Periodic Maintenance/Tune-Up
3. Engine/Transmission
4. Fuel/Lubrication/Cooling
5. Electrical System
6. Drive System
7. Suspension
8. Steering/Frame
9. Controls/Indicators
10. Aids for Maintenance
11. Troubleshooting
1
2
3
4
5
6
7
8
9
10
11
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1-1
1
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........................................ 1-5
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1-2
General Specifications*
* Specifications subject to change without notice.
** 1 inch below plug threads.
CARBURETOR
Ty p e Ke i h i n C V K 3 6
Main Jet 132
Slow Jet 40
Low Speed Fuel Screw Setting
(turns)
1 1/4
Jet Needle Fixed
Needle Jet 6.0/4.0
Idle RPM 1250-1350
Starter Jet 85
Float Arm Height 17 mm (0.7 in.)
ELECTRICAL
Ignition Timing 10° BTDC @ 1500 RPM
Spark Plug Type Champion RG6YC
Spark Plug Gap 0.7-0.8 mm
(0.028-0.032 in.)
Spark Plug Cap 3750-6250 ohms
Ignition Coil (primary)
Resistance
(secondary)
Less than 1 ohm
(terminal to ground)
5200-7800 ohms
(high tension - plug cap
removed - to ground)
Ignition Coil Peak Voltage
(primary/CDI)
142.4-213.6 DC volts
(blue/white to ground)
Magneto Coil (trigger)
Resistance
(source)
(charging)
160-240 ohms
(green to blue)
Less than 1 ohm
(yellow to white)
Less than 1 ohm
(black to black)
Magneto Coil Peak (trigger)
Voltage
(source)
4.2-6.3 volts
(green to blue)
0.40-0.62 volt
(yellow to white)
Stator Coil Output (no load) 60 AC volts @ 5000 RPM
(black to black)
Magneto Output (approx) 325W @ 5000 RPM
CHASSIS
Dry Weight (approx) 526 kg (1160 lb)
Length (overall) 292 cm (115 in.)
Height (overall) 197 cm (77.5 in.)
Width (overall) 156 cm (61.3 in.)
Suspension Travel (front)
(rear)
25.4 cm (10 in.)
25.4 cm (10 in.)
Brake Type Hydraulic
Wheelbase 190 cm (75 in.)
Tracking (front)
(rear)
128.3 cm (50.5 in.)
123.2 cm (48.5 in.)
Tire Size (front)
(rear)
26 x 9-14
26 x 11-14
Tire Inflation Pressure 0.70 kg/cm² (10 psi)
Turning Radius 3.3 m (10.8 ft)
MISCELLANY
Gas Tank Capacity (rated) 31 L (8.2 U.S. gal.)
Coolant Capacity 2.9 L (3.0 U.S. qt)
Differential Capacity 275 ml (9.3 fl oz)**
Rear Drive Capacity 250 ml (8.5 fl oz)**
Engine Oil Capacity 2.5 L (2.6 U.S. qt)
Gasoline (recommended) 87 Octane Regular
Unleaded
Engine Oil (recommended) SAE 5W-30
Differential/Rear Drive
Lubricant
SAE Approved
80W-90 Hypoid
Belt Width 35.0 mm (1.38 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (2)
Starting System Electric
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1-3
1
Break-In Procedure
A new vehicle and an overhauled engine require a
“break-in” period. The first 10 hours (or 200 miles)
are most critical to the life of this vehicle. Proper
operation during this break-in period will help
assure maximum life and performance from the
vehicle.
During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the engine
RPM during the break-in period allows the compo-
nents to “load” (aiding the mating process) and then
“unload” (allowing components to cool). Although
it is essential to place some stress on the engine
components during break-in, care should be taken
not to overload the engine too often. Do not pull a
trailer or carry heavy loads during the 10-hour
break-in period.
When the engine starts, allow it to warm up prop-
erly. Idle the engine several minutes until the engine
has reached normal operating temperature. Do not
idle the engine for excessively long periods of time.
During the break-in period, a maximum of 1/2 throt-
tle is recommended; however, brief full-throttle
accelerations and variations in driving speeds con-
tribute to good engine break-in.
During the break-in period (or whenever the brake
pads are replaced), the hydraulic brake pads must be
burnished. Slow disc-speed hydraulic brakes must
be properly burnished in order to achieve maximum
stopping power.
NOTE: Do not be reluctant to heat up the brake
pads during the burnishing procedure.
After the completion of the break-in period, the
engine oil and oil filter should be changed. Other
maintenance after break-in should include checking
of all prescribed adjustments and tightening of all
fasteners.
Gasoline - Oil -
Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum
octane regular unleaded. In many areas, oxygenates
(either ethanol or MTBE) are added to the gasoline.
Oxygenated gasolines containing up to 10% ethanol,
5% methane, or 5% MTBE are acceptable gasolines.
When using ethanol blended gasoline, it is not nec-
essary to add a gasoline antifreeze since ethanol will
prevent the accumulation of moisture in the fuel sys-
tem.
RECOMMENDED ENGINE/
TRANSMISSION OIL
The recommended oil to use is Arctic Cat 4-Cycle
Engine Oil or an equivalent oil which is rated SE,
SF, or SG under API service classification. These
oils meet all of the lubrication requirements of the
Arctic Cat engine. The recommended engine oil vis-
cosity is SAE 5W-30. Ambient temperature should
determine the correct weight of oil. See the follow-
ing viscosity chart for details.
! CAUTION
BRAKE PADS MUST BE BURNISHED TO ACHIEVE
FULL BRAKING EFFECTIVENESS. Braking distance
will be extended until brake pads are properly bur-
nished.
TO PROPERLY BURNISH THE BRAKES, USE FOL-
LOWING PROCEDURE:
• Choose an area sufficiently large to safely accel-
erate vehicle to 30 mph and to brake to a stop.
• Accelerate to 30 mph; then apply the brake to
decelerate to 0-5 mph.
• Repeat procedure five times until brakes are bur-
nished.
• This procedure burnishes the brake pads, stabi-
lizes the pad material, and extends the life of the
brake pads.
! WARNING
Do not attempt sudden stops or put the vehicle into
a situation where a sudden stop will be required
until the brake pads are properly burnished.
! CAUTION
Do not use white gas. Only Arctic Cat approved gas-
oline additives should be used.
! CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These
oils can adversely affect clutch operation. Also, not
recommended are racing, vegetable, non-detergent,
and castor-based oils.
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1-4
OILCHARTC
RECOMMENDED FRONT
DIFFERENTIAL/REAR DRIVE
LUBRICANT
The recommended lubricant is Arctic Cat Gear Lube
or an equivalent gear lube which is SAE approved
80W-90 hypoid. This lubricant meets all of the
lubrication requirements of the Arctic Cat vehicle
front differential and rear drive.
FILLING GAS TANK
ATV0049B
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.
Tighten the gas tank cap securely after filling the
tank.
Genuine Parts
When replacement of parts is necessary, use only
genuine Arctic Cat parts. They are precision-made
to ensure high quality and correct fit. Refer to the
Illustrated Parts Manual for the correct part number,
quantity, and description.
Preparation
For Storage
Arctic Cat recommends the following procedure to
prepare the vehicle for storage.
1. Clean the seat cushion (cover and base) with a
damp cloth and allow it to dry.
2. Clean the vehicle thoroughly by washing dirt,
oil, grass, and other foreign matter from the
entire vehicle. Allow it to dry thoroughly. DO
NOT get water into any part of the engine or air
intake.
! CAUTION
Any lubricant used in place of the recommended
lubricant could cause serious front differential/rear
drive damage.
! WARNING
Always fill the gas tank in a well-ventilated area.
Never add fuel to the gas tank near any open flames
or with the engine running. DO NOT SMOKE while
filling the gas tank.
! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the
engine to cool before filling the gas tank.
! WARNING
Do not over-fill the gas tank.
! CAUTION
Prior to storing the vehicle, it must be properly ser-
viced to prevent rusting and component deteriora-
tion.
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1-5
1
3. Either drain the gas tank or add Fuel Stabilizer
to the gas in the gas tank. Remove the air filter
housing cover and air filter. Start the engine and
allow it to idle; then using Arctic Cat Engine
Storage Preserver, rapidly inject the preserver
into the air filter opening for a period of 10 to 20
seconds; then stop the engine. Install the air fil-
ter and housing cover.
4. Drain the carburetor float chamber.
5. Plug the exhaust hole in the exhaust system with
a clean cloth.
6. Apply light oil to the plungers of the shock
absorbers.
7. Tighten all nuts, bolts, cap screws, and screws.
Make sure rivets holding components together
are tight. Replace all loose rivets. Care must be
taken that all calibrated nuts, cap screws, and
bolts are tightened to specifications (see Section
10).
8. Fill the cooling system to the bottom of the
stand pipe in the radiator neck with properly
mixed coolant.
9. Disconnect the battery cables; then remove the
battery, clean the battery posts and cables, and
store in a clean, dry area.
10. Store the vehicle indoors in a level position.
Preparation After
Storage
Taking the vehicle out of storage and correctly pre-
paring it will assure many miles and hours of trou-
ble-free riding. Arctic Cat recommends the
following procedure to prepare the vehicle.
1. Clean the vehicle thoroughly.
2. Clean the engine. Remove the cloth from the
exhaust system.
3. Check all control wires and cables for signs of
wear or fraying. Replace if necessary.
4. Change the engine/transmission oil and filter.
5. Check the coolant level and add properly mixed
coolant as necessary.
6. Charge the battery; then install. Connect the bat-
tery cables.
7. Check the entire brake systems (fluid level,
pads, etc.), all controls, headlights, taillight,
brakelight, and headlight aim; adjust or replace
as necessary.
8. Tighten all nuts, bolts, cap screws, and screws
making sure all calibrated nuts, cap screws, and
bolts are tightened to specifications (see Section
10).
9. Check tire pressure. Inflate to recommended
pressure as necessary.
10. Make sure the steering moves freely and does
not bind.
11. Check the spark plug. Clean or replace as neces-
sary.
! CAUTION
If the interior of the air filter housing is dirty, clean
the area before starting the engine.
! CAUTION
Avoid storing outside in direct sunlight and avoid
using a plastic cover as moisture will collect on the
vehicle causing rusting.
! CAUTION
The ignition switch must be in the OFF position prior
to installing the battery or damage may occur to the
ignition system.
! CAUTION
Connect the positive battery cable first; then the
negative.
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2-1
2
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) .................................. 2-6
Testing Engine Compression................................... 2-7
Spark Plug............................................................... 2-7
Muffler/Spark Arrester ............................................. 2-8
Gas/Vent Hoses ...................................................... 2-8
Adjusting Engine RPM (Idle) ................................... 2-8
Engine/Transmission Oil - Filter............................... 2-9
Front Differential/Rear Drive Lubricant .................. 2-10
Tires ...................................................................... 2-11
Steering Components ........................................... 2-11
Driveshaft/Coupling ............................................... 2-11
Suspension/Shock Absorbers/Bushings ............... 2-11
Nuts/Bolts/Cap Screws.......................................... 2-12
Ignition Timing ....................................................... 2-12
Headlight/Taillight-Brakelight ................................. 2-12
Switches ................................................................ 2-13
Low Range/High Range/Neutral/Reverse Lever.... 2-13
Frame/Welds ......................................................... 2-14
Electrical Connections........................................... 2-14
Hydraulic Brake System ........................................ 2-14
Parking Brake........................................................ 2-16
Burnishing Brake Pads .......................................... 2-18
Coolant .................................................................. 2-18
Checking/Replacing V-Belt.................................... 2-18
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2-2
Periodic Maintenance
Chart
A = Adjust I = Inspect
C = Clean L = Lubricate
D = Drain R = Replace
T = Tighten
* Service/Inspect more frequently when operating in adverse conditions.
Item
Initial
Service After
Break-In
(First Mo or
100 Mi)
Every
Day
Every Month
or
Every 100
Miles
Every 3
Months or
Every 300
Miles
Every 6
Months or
Every 500
Miles
Every Year
or Every
1500 Miles
As
Needed
Battery I I C
Fuses IR
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Engine Compression I
Spark Plug I I I R (4000 Mi
or 18 Mo)
Muffler/Spark Arrester CR
Gas/Vent Hoses I I R (2 Yrs)
Throttle Cable Ends/Accelerator Pedal
Pivot
II C-L A-R
Carb Float Chamber D*
Engine RPM (Idle) I I A
Engine-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R* R
Oil Strainer I I C
Front Differential/Rear Drive Lubricant I I R (4 Yrs)
Tires/Air Pressure I I R
Steering Components I I I R
V-Belt I l R
Suspension (Ball joint boots, drive
axle boots front and rear, tie rods, dif-
ferential and rear drive bellows)
II R
Nuts/Bolts/Cap Screws T T A
Ignition Timing I
Headlight/Taillight-Brakelight I I R
Switches I I R
Shift Lever IA-L
Gauges/Indicators I I R
Frame/Welds I I l
Electrical Connections lC
Complete Brake System
(Hydraulic & Parking)
II
Brake Pads I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Coolant/Cooling System I I R (2 Yrs)
Wheel Lug Nuts T T
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2-3
2
Lubrication Points
It is advisable to lubricate certain components peri-
odically to ensure free movement. Apply light oil to
the components using the following list as reference.
A. Accelerator Pedal Pivot/Cable Ends
B. Brake Pedal Pivot
C. Parking Brake Cable Ends
D. Shift Linkage
E. Differential Lock Cable End (XT)
F. Idle RPM Screw (Carburetor)
Battery
AF879D
The level of the battery fluid must be kept between
the upper and lower level lines at all times. If the
level drops below the lower level line, add only dis-
tilled water until it reaches upper level line.
If the battery is discharged, remove the battery from
the vehicle and charge the battery at the standard
charging rate of 1.5 amps for 10 hours.
To remove and charge the battery, use the following
procedure.
1. Remove the fasteners holding the left-rear
splash panel in place; then remove the battery
access panel.
PR054A
2. Remove the negative battery cable; then remove
the positive cable and the battery vent tube.
Remove the battery from the vehicle. Care
should be taken not to damage the vent tube.
3. Remove the vent plugs; then (if necessary) fill
the battery with distilled water to the UPPER
level indicated on the battery.
NOTE: Electrolyte should be at room tempera-
ture before filling. Do not use water or any other
liquid to activate a battery.
4. Allow the battery to stand for 15-30 minutes
after filling. Electrolyte level may fall during
this time. Refill with electrolyte to UPPER level
line.
! WARNING
Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a
battery.
! WARNING
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
safety glasses. Protect skin and clothing when han-
dling a battery. When servicing battery in enclosed
space, keep the area well-ventilated. Make sure bat-
tery venting is not obstructed.
! WARNING
Avoid spillage and contact with skin, eyes, and
clothing.
! CAUTION
Do not charge the battery while it is in the vehicle
with the battery terminals connected.
! WARNING
Electrolyte is a sulfuric acid solution. Avoid spillage
and contact with skin, eyes, and clothing.
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2-4
5. Trickle charge the battery at 1.5 amps for 10
hours.
6. After charging, check fluid level and fill with
distilled water as necessary; then install vent
plugs.
7. Attach the vent tube and check the vent tube to
make sure it is not crimped or obstructed in any
way and that it is properly routed through and
secured to the frame.
8. Connect cables to the proper terminals: positive
cable to the positive terminal (+) and negative
cable to the negative terminal (-). Connect the
negative cable last.
9. Place the battery into position in the vehicle and
secure with the battery access panel.
Fuses
The main fuses are located in a power distribution
module under the operator’s seat.
If there is any type of electrical system failure,
always check the fuses first.
NOTE: To remove the fuse, compress the locking
tabs on either side of the fuse case and lift out.
1411-576
Air Cleaner/Filter
The air filter inside the air filter housing must be
kept clean to provide good engine power and gas
mileage. If the vehicle is used under normal condi-
tions, service the filter at the intervals specified. If
operated in dusty, wet, or muddy conditions, inspect
and service the filter more frequently. Use the fol-
lowing procedure to remove the filter and inspect
and/or clean it.
CLEANING AND INSPECTING
FILTER
1. Remove the seats; then remove the center con-
sole.
2. Unsnap the four fasteners securing the air
cleaner housing cover and remove the cover.
3. Remove the air filter/filter screen assembly and
separate the foam filter from the screen.
PR101
! CAUTION
Never exceed the standard charging rate.
! CAUTION
Before installing the battery, make sure the ignition
switch is in the OFF position.
! CAUTION
Connecting cables in reverse (positive to negative
and negative to positive) can cause serious damage
to the electrical system.
Prowler/XT
! CAUTION
Always replace a blown fuse with a fuse of the same
type and rating.
! CAUTION
Failure to inspect the air filter frequently if the vehi-
cle is used in dusty, wet, or muddy conditions can
damage the engine.
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2-5
2
CD747
4. Fill a wash pan larger than the filter with a
non-flammable cleaning solvent; then dip the
filter in the solvent and wash it.
NOTE: Foam Filter Cleaner and Foam Filter Oil
are available from Arctic Cat.
5. Dry the filter.
6. Put the filter in a plastic bag; then pour in air fil-
ter oil and work the filter. Reattach the filter to
the filter screen.
7. Clean any dirt or debris from inside the air
cleaner. Be sure no dirt enters the carburetor.
8. Place the filter assembly in the air filter housing
making sure it is properly positioned and prop-
erly seated with the filter screen down.
PR090
9. Install the air filter housing cover and secure
with the retaining clips; then install the center
console and seats making sure the seats lock
securely.
CD670
CHECKING AND CLEANING
DRAINS
1. Inspect one-way drains beneath the main hous-
ing for debris and for proper sealing.
PR141A
2. Replace any one-way drain that is cracked or
shows any signs of hardening or deterioration.
3. Wipe any accumulation of oil or gas from the
filter housing and one-way drains.
! CAUTION
A torn air filter can cause damage to the vehicle
engine. Dirt and dust may get inside the engine if the
element is torn. Carefully examine the element for
tears before and after cleaning it. Replace the ele-
ment with a new one if it is torn.
! CAUTION
The one-way drain to the left is the clean air section
of the filter housing. Any leak of this one-way drain
will allow dirt into the engine intake causing severe
engine damage.
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2-6
Valve/Tappet
Clearance
(Feeler Gauge Procedure)
To check and adjust valve/tappet clearance, use the
following procedure.
NOTE: The engine must be cold for this proce-
dure.
NOTE: The seats, center console, spark plug,
and air filter housing must be removed for this pro-
cedure.
1. Remove the timing inspection plug; then remove
the tappet covers (for more detailed information,
see Section 3 - Servicing Top-Side Components).
2. Rotate the crankshaft to the TDC position on the
compression stroke.
NOTE: At this point, the rocker arms and
adjuster screws must not have pressure on them.
3. Using a feeler gauge, check each valve/tappet
clearance. If clearance is not within specifica-
tions, loosen the jam nut and rotate the tappet
adjuster screw until the clearance is within spec-
ifications. Tighten each jam nut securely after
completing the adjustment.
CC007D
4. Install the spark plug; then install the timing
inspection plug.
5. Place the two tappet covers with O-rings into
position. Tighten the cap screws securely.
Valve/Tappet Clearance
(Valve Adjuster Procedure)
To check and adjust valve/tappet clearance, use the
following procedure.
NOTE: The engine must be cold for this proce-
dure.
NOTE: The seats, center console, spark plug,
and air filter housing must be removed for this pro-
cedure.
1. Remove the timing inspection plug; then
remove the tappet covers (for more detailed
information, see Section 3 - Servicing Top-Side
Components).
2. Rotate the crankshaft to the TDC position on the
compression stroke.
NOTE: At this point, the rocker arms and
adjuster screws must not have pressure on them.
NOTE: Use Valve Clearance Adjuster (p/n
0444-078) for this procedure.
3. Place the valve adjuster onto the jam nut secur-
ing the tappet adjuster screw; then rotate the
valve adjuster dial clockwise until the end is
seated in the tappet adjuster screw.
4. While holding the valve adjuster dial in place,
use the valve adjuster handle and loosen the jam
nut; then rotate the tappet adjuster screw clock-
wise until friction is felt.
5. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
6. While holding the valve adjuster handle in
place, rotate the valve adjuster dial counter-
clockwise until proper valve/tappet clearance is
attained.
NOTE: Refer to the appropriate specifications in
Feeler Gauge Procedure sub-section for the proper
valve/tappet clearance.
NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.
! 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.)
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2-7
2
7. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely
with the valve adjuster handle.
8. Place the two tappet covers with O-rings into
position. Tighten the cap screws securely.
CF006A
CF005
9. Install the spark plug; then install the timing
inspection plug.
Testing Engine
Compression
To test engine compression, use the following pro-
cedure.
NOTE: The engine must be warm and the battery
must be fully charged for this test.
NOTE: The seats and center console must be
removed for this procedure.
1. Remove the high tension lead from the spark
plug.
2. Using compressed air, blow any debris from
around the spark plug.
3. Remove the spark plug; then attach the high ten-
sion lead to the plug and ground the plug on the
cylinder head well away from the spark plug
hole.
4. Attach the Compression Tester Kit (p/n
0444-213).
5. While holding the throttle in the full-open posi-
tion, crank the engine over with the electric
starter until the gauge shows a peak reading
(five to 10 compression strokes).
NOTE: The compression should be within a
range of 63-77 psi in the full-open throttle position.
6. If compression is abnormally low, inspect the
following items.
A. Starter cranks engine over.
B. Gauge is functioning properly.
C. Throttle lever in the full-open position.
D. Valve/tappet clearance correct.
E. Valve bent or burned.
F. Valve seat burned.
NOTE: To service valves, see Section 3.
7. Pour 29.5 ml (1 fl oz) of oil into the spark plug
hole, reattach the gauge, and retest compression.
8. If compression is now evident, service the piston
rings (see Section 3).
Spark Plug
A light brown insulator indicates that the plug is
correct. A white or dark insulator indicates that the
engine may need to be serviced or the carburetor
may need to be adjusted. To maintain a hot, strong
spark, keep the plug free of carbon.
! WARNING
Always wear safety glasses when using compressed
air.
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2-8
ATV-0051
Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.).
ATV0052B
When installing the spark plug, be sure to tighten it
securely. A new spark plug should be tightened 1/2
turn once the washer contacts the cylinder head. A
used spark plug should be tightened 1/8-1/4 turn
once the washer contacts the cylinder head.
Muffler/Spark Arrester
The muffler has a spark arrester which must be peri-
odically cleaned. At the intervals shown in the Peri-
odic Maintenance Chart, clean the spark arrester
using the following procedure.
1. Remove the three cap screws securing the spark
arrester screen assembly to the muffler; then
loosen and remove the spark arrester. Account
for a gasket.
CF105A
CF104
2. Using a suitable brush, clean the carbon deposits
from the screen taking care not to damage the
screen.
NOTE: If the screen or gasket is damaged in any
way, it must be replaced.
3. Install the spark arrester assembly and gasket
and secure with the three cap screws. Tighten
the cap screws to 0.6 kg-m (4.0 ft-lb).
Gas/Vent Hoses
Replace the gas hose every two years. Damage from
aging may not always be visible. Do not bend or
obstruct the routing of the carburetor vent hose. Make
certain that the vent hose is securely connected to the
carburetor and the opposite end is always open.
Adjusting Engine RPM
(Idle)
To properly adjust the idle RPM, a tachometer is
necessary. To adjust idle RPM, use the following
procedure.
! 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.
! WARNING
Wait until the muffler cools to avoid burns.
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2-9
2
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.
1. Set the parking brake. With the transmission in
neutral, start the engine and warm it up to nor-
mal operating temperature.
2. Turn the idle adjustment screw clockwise one
turn past the recommended RPM setting; then
turn it counterclockwise to 1250-1350 RPM.
PR081A
Engine/Transmission
Oil - Filter
OIL - FILTER
Change the engine oil and oil filter at the scheduled
intervals. The engine should always be warm when
the oil is changed so the oil will drain easily and
completely.
NOTE: To change oil and filter, the seats and
center console must be removed.
1. Park the vehicle on level ground.
2. Remove the oil level stick/filler plug.
PR053B
3. Remove the drain plug from the bottom of the
engine and drain the oil into a drain pan.
PR078A
4. Using the Oil Filter Wrench (p/n 0644-389) and
a ratchet handle (or a socket or box-end
wrench), remove the old oil filter.
NOTE: Clean up any excess oil after removing
the filter.
5. Apply oil to a new filter O-ring and check to
make sure it is positioned correctly; then install
the new oil filter. Tighten securely.
6. Install the engine drain plug and tighten to spec-
ifications. Pour the specified amount of the rec-
ommended oil in the filler hole. Install the oil
level stick/filler plug.
7. Start the engine (while the vehicle is outside on
level ground) and allow it to idle for a few min-
utes.
8. Turn the engine off and wait approximately one
minute.
! WARNING
Adjust the idle to the correct RPM. Make sure the
engine is at normal operating temperature before
adjusting the idle RPM.
! CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These
oils can adversely affect clutch operation. Also, not
recommended are racing, vegetable, non-detergent,
and castor-based oils.
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2-10
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.
11. Remove the oil level stick; the engine oil level
should be above the illustrated “L” mark but not
higher than the illustrated “F” mark.
ATV-0100
12. Inspect the area around the drain plug and oil fil-
ter for leaks.
Front Differential/Rear
Drive Lubricant
Check and change the lubricant according to the
Periodic Maintenance Chart. When changing the
lubricant, use approved SAE 80W-90 hypoid gear
lube. To check lubricant, use the following proce-
dure.
1. Remove the fill/level plug; the lubricant level
should be 1 in. below the plug threads.
PR046A
2. If low, add SAE approved 80W-90 hypoid gear
lube as necessary.
PR065A
To change the lubricant, use the following proce-
dure.
1. Place the vehicle on level ground.
2. Remove each fill/level plug.
3. Drain the lubricant into a drain pan by removing
in turn the drain plug from each.
ATV0082A
! CAUTION
Do not over-fill the engine with oil. Always make
sure that the oil level is above the “L” mark but not
higher than the “F”mark.
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2-11
2
737-651A
4. After all the lubricant has been drained, install
the drain plugs and tighten to specifications (see
Section 10).
5. Pour the appropriate amount of recommended
lubricant into the fill/level hole.
6. Install the fill/level plugs.
NOTE: If the differential/rear drive lubricant is
contaminated with water, inspect the drain plug,
fill/level plug, and/or bladder.
Tires
TIRE SIZES
The Prowler/XT models are equipped with
low-pressure tubeless tires of the size and type listed
(see Section 1). Do not under any circumstances
substitute tires of a different type or size.
TIRE INFLATION PRESSURE
Front and rear tire inflation pressure should be 0.70
kg-cm² (10 psi).
A low-pressure gauge is provided in the tool kit to
measure the air pressure in the tires. Check the air
pressure in all tires before each use of the vehicle.
Steering Components
The following steering components should be
inspected periodically to ensure safe and proper oper-
ation.
A. Steering wheel secure.
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.
E. Tie rods not bent or cracked.
F. Knuckles not worn, cracked, or damaged.
G. Cotter pins not damaged or missing.
Driveshaft/Coupling
The following drive system components should be
inspected periodically to ensure proper operation.
A. Spline lateral movement (slop).
B. Coupling cracked, damaged, or worn.
C. Universal joints worn or missing bearings.
Suspension/Shock
Absorbers/Bushings
The following suspension system components
should be inspected periodically to ensure proper
operation.
A. Shock absorber rods bent, pitted, or damaged.
B. Rubber damper cracked, broken, or missing.
C. Shock absorber body damaged, punctured, or
leaking.
D. Shock absorber eyelets broken, bent, or
cracked.
E. Shock absorber eyelet bushings worn, deteri-
orated, cracked, or missing.
F. Shock absorber spring broken or sagging.
G. Sway bar mountings tight and bushings
secure.
! WARNING
Always use the size and type of tires specified.
Always maintain proper tire inflation pressure.
Rear Drive
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2-12
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure
rivets holding components together are tight.
Replace all loose rivets. Care must be taken that all
calibrated nuts, bolts, and cap screws are tightened
to specifications. For proper torque values, see Sec-
tion 10.
Ignition Timing
The ignition timing cannot be adjusted; however,
verifying ignition timing can aid in troubleshooting
other components. To verify ignition timing, use the
following procedure.
NOTE: To check ignition timing, the seats and
center console must be removed.
1. Attach the Timing Light (p/n 0644-296) to the
spark plug high tension lead; then remove the
timing inspection plug from the left-side crank-
case cover.
2. Start the engine and using the RPM function on
the speedometer/tachometer (XT) or using a
suitable tachometer (Prowler), run at 1500
RPM; ignition timing should be 10° BTDC.
3. Install the timing inspection plug.
If ignition timing cannot be verified, the rotor may
be damaged, the key may be sheared, the trigger coil
bracket may be bent or damaged, or the CDI unit
may be faulty.
Headlight/Taillight-
Brakelight
Each time the vehicle is used, lights should be
checked for proper function. With the ignition
switch in the ON position, select the high and/or low
beam on the light switch; the headlights and taillight
should illuminate. Test the brakelight by depressing
the brake pedal. The brakelight should illuminate.
HEADLIGHT
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
with a dry cloth before installing. Skin oil residue
on the bulb will shorten the life of the bulb.
To replace the headlight bulb, use the following pro-
cedure.
1. Remove the wiring harness connector from the
back of the headlight.
2. Grasp the bulb socket, turn it counterclockwise
and remove, and pull the bulb straight out of the
socket.
3. Install the new bulb into the socket and rotate it
completely clockwise in the housing.
4. Install the wiring harness connector.
TAILLIGHT-BRAKELIGHT
To replace the taillight-brakelight bulb, use the fol-
lowing procedure.
1. Remove the two machine screws and remove
the light assembly.
2. Rotate the bulb socket counterclockwise to
remove it from the light assembly; then pull
straight out on the bulb. Push the new bulb
straight into the socket.
3. Install the bulb and socket into the light assem-
bly and turn clockwise to lock in place.
4. Install the taillight-brakelight assembly on the
canopy support.
CHECKING/ADJUSTING
HEADLIGHT AIM
The headlights can be adjusted vertically. The geo-
metric center of the HIGH beam light zone is to be
used for vertical aiming.
1. Position the vehicle on a level floor so the head-
lights are approximately 6.1 m (20 ft) from an
aiming surface (wall or similar aiming surface).
NOTE: There should be an average operating
load on the vehicle when adjusting the headlight
aim.
! WARNING
Do not attempt to remove the bulb when it is hot.
Severe burns may result.
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2-13
2
2. Measure the distance from the floor to the
mid-point of each headlight.
3. Using the measurements obtained in step 2,
make horizontal marks on the aiming surface.
4. Make vertical marks which intersect the hori-
zontal marks on the aiming surface directly in
front of the headlights.
5. Switch on the lights. Make sure the HIGH beam
is on. DO NOT USE LOW BEAM.
6. Observe each headlight beam aim. Proper aim is
when the most intense beam is centered on the
vertical mark 5 cm (2 in.) below the horizontal
mark on the aiming surface.
0740-647
7. Using the adjuster knob, adjust each headlight
until correct aim is obtained.
CD714A
Switches
Each time the vehicle is used, switches should be
checked for proper operation. Use the following list
for reference.
A. Ignition/start switch — engine will run;
starter will engage.
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.
Low Range/High Range/
Neutral/Reverse Lever
CHECKING SHIFT LEVER LINKAGE
Set the parking brake and turn the ignition switch
on; then with the shift lever in the neutral position,
look for the (N) indication on the LCD. Shift into
high range and look for the (H) indication, low
range for the (L) indication, and reverse for the (R)
indication. Shift the transmission into neutral and
turn the ignition switch off.
PR094
ADJUSTING SHIFT LEVER LINKAGE
To adjust the shift lever linkage, use the following
procedure.
1. Set the parking brake; then remove the seats and
center console.
2. Make sure the shift lever is in neutral; then
loosen the jam nut on the linkage.
3. Remove the E-clip on the transmission shift
arm; then remove the linkage from the shift arm.
Account for a washer and a bushing.
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