Arctic Cat 2011 Prowler HDX User manual

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arctic Cat
Prowler HDX. 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 serious personal injury or even death. A CAUTION identi-
fies 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 wor-
thy of particular attention. The symbol AT THIS POINT directs the technician to certain and specific proce-
dures 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.
© 2010 Arctic Cat Inc. September 2010
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Manual
Table of Contents

2011
Service
Manual
TM
SHARE OUR PASSIO
N.
T
Prowler HDX
Prowler
H
D
er H
TABLE OF CONTENTS
1. General Information/Specifications
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
1
2
3
4
5
6
7
8
9

1-1
1
SECTION 1 - GENERAL INFORMATION
TABLE OF CONTENTS
General Specifications ............................................ 1-2
Torque Specifications .............................................. 1-2
Torque Conversions (ft-lb/N-m) ............................... 1-3
Tightening Torque (General Bolts) .......................... 1-3
Break-In Procedure ................................................. 1-4
Gasoline - Oil - Lubricant ........................................ 1-4
Genuine Parts ......................................................... 1-5
Preparation For Storage.......................................... 1-5
Preparation After Storage........................................ 1-5
Manual
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1-2
General Specifications
Specifications subject to change without notice.
* Visible at plug threads.
Torque Specifications
NOTE: Torque specifications have the following tol-
erances:
* w/Blue Loctite #243 *** w/Green Loctite #270
** w/Red Loctite #271 **** w/“Patch-Lock”
CHASSIS
Dry Weight (approx) 618 kg (1363 lb)
Length (overall) 327.6 cm (129 in.)
Height (overall) 193.3 cm (76.5 in.)
Width (overall) 153 cm (60.25 in.)
Suspension Travel 25.4 cm (10 in.)
Brake Type Hydraulic
Tire Size (front)
(rear)
26 x 10R-14
26 x 12R-14
Tire Inflation Pressure 1.41 kg/cm² (20 psi)
MISCELLANY
Gas Tank Capacity 31 L (8.2 U.S. gal.)
Coolant Capacity 2.9 L (3.0 U.S. qt)
Front 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) - Overhaul
1.9 L (2.0 U.S. qt) - Change
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather Syn-
thetic
Front 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 (4)
Torque (ft-lb) Tolerance
0-15 ±20%
16-39 ±15%
40+ ±10%
EXHAUST COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Exhaust Pipe Cylinder Head 20 27
Spark Arrester Muffler 48 in.-lb 5
ELECTRICAL COMPONENTS
Coil* Frame 811
Ground Wire Engine 811
CHASSIS/ROPS ASSEMBLY
Shift Axle Support Frame 48 in.-lb 5
Front/Rear ROPS Tube Arm Rest/Steering Post
Support 20 27
Top ROPS Support Front/Rear ROPS Tubes 811
Rear ROPS Tube Lower ROPS Support 811
Shift Cable Shift Axle Arm 811
Shift Cable Mounting/
Adjuster
Shift Cable 20 27
STEERING COMPONENTS
Part Part Bolted To Torqu e
ft-lb N-m
Steering Wheel** Steering Wheel Shaft 25 34
Steering Wheel Shaft*** Intermediate Shaft (Upper) 36 49
Intermediate Shaft
(Lower)***
Steering Pinion Shaft 36 49
Rack and Pinion Assembly Frame 35 48
Tie Rod Rack 37 50
Tie Rod End** Knuckle 30 41
Jam Nut Tie Rod End 10 14
Steering Shaft Coupler EPS Input Shaft 11 15
EPS Cradle Bracket Frame 20 27
EPS Assembly Frame 35 48
EPS Assembly Rack Coupler 11 15
Intermediate Shaft Coupler Intermediate Shaft 31 42
Steering Shaft Housing
(6 mm)
Frame 811
Steering Shaft Housing
(8 mm)
Frame 20 27
SUSPENSION COMPONENTS (Front)
A-Arm Frame 33 45
Knuckle Ball Joint 35 48
Shock Absorber Frame/Upper A-Arm 33 45
Knuckle A-Arm 35 48
SUSPENSION COMPONENTS (Rear)
Sway Bar Bracket Frame 33 45
A-Arm Frame 33 45
Shock Absorber (Lower) Lower A-Arm 20 27
Shock Absorber (Upper) Frame 33 45
Knuckle A-Arm 35 48
Cargo Box Hinge Cargo Box Frame 20 27
Side Panel/Spacer Cargo Box Frame 25 34
Tilt Pivot Bushing Cargo Box Frame 15 20
Latch Striker Cargo Box Liner 60 in.-lb 7
BRAKE COMPONENTS
Brake Disc** Hub 15 20
Brake Hose Caliper 20 27
Brake Hose Master Cylinder 20 27
Master Cylinder Frame 25 34
Caliper Holder**** Knuckle 20 27
Driveline Rear Drive Input Flange 20 27
Manual
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1-3
1
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #270
Torque Conversions
(ft-lb/N-m)
Tightening Torque
(General Bolts)
DRIVE TRAIN COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Rear Differential/Gear Case Frame 38 48
Drive Coupler (Front) Front Drive Flange 40 54
Front Engine Mounting
Bracket
Frame 45 61
Rear Engine Mounting Bracket Frame 45 61
Engine Mounting Through-Bolt Frame 40 54
Front Differential Frame/Differential Bracket 38 52
Rear Output Flange Rear Driven Flange 40 54
Input Shaft Assembly Gear Case Housing 23 31
Pinion Housing Differential Housing 23 31
Secondary Shaft Bearing
Housing
Crankcase 28 38
Rear Cradle Frame 25 34
Driveshaft (Front/Rear) Engine 20 27
Shift Cable Bracket Engine 811
Front Input Drive Flange Front Drive Yoke Flange 20 27
Differential Housing Cover*** Differential Housing 23 31
Drive Bevel Gear Nut*** Shaft 87 118
Lock Collar Differential Housing 125 170
Hub Nut Front/Rear Shaft/Axle
(min) 200 272
Oil Drain Plug Front Differential - Rear
Drive 45 in.-
lb
5
Oil Fill Plug Front Differential - Rear
Drive 16 22
Oil Drain Plug Engine 16 22
Wheel Hub 80 108
ENGINE/TRANSMISSION
Clutch Shoe** Crankshaft 221 300
Clutch Cover/Housing
Assembly
Crankcase 811
Crankcase Half (6 mm) Crankcase Half 10 14
Crankcase Half (8 mm) Crankcase Half 20 27
Cylinder Head (Cap Screw) Crankcase 40 54
Cylinder Head Nut (6 mm) Cylinder 811
Cylinder Head Nut (8 mm) Cylinder 18 24
Valve Cover Cylinder Head 8.5 11.5
Driven Pulley Nut Driveshaft 80 109
Movable Drive Face Nut** Driveshaft 165 224
Ground Wire Engine 811
Magneto Cover Crankcase 811
Tappet Cover Valve Cover 912
Crankshaft Spacer Crankshaft 28 38
Oil Pump Cover** Crankcase 811
Oil Pump Drive Gear** Crank Balancer Shaft 62 84
Output Shaft Flange Nut Output Shaft** 62 84
Outer Magneto Cover Magneto Cover 811
Magneto Rotor Nut** Crankshaft 105 143
Cam Sprocket** Camshaft 11 15
Speed Sensor Housing Crankcase 811
V-Belt Cover Crankcase 811
Output Yoke Nut Secondary Driven Output
Shaft 74 100
Ouput Shaft Flange Yoke/Nut Output Shaft** 59 80
Secondary Shaft Bearing
Housing
Crankcase Half 28 38
Stator Coil* Magneto Cover 8.5 11.5
Intake Boot Clamp Intake Boot 30 in.-
lb
3.4
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
11.4 26 35.4 51 69.4 76 103.4
22.7 27 36.7 52 70.7 77 104.7
34.1 28 38.1 53 72.1 78 106.1
45.4 29 39.4 54 73.4 79 107.4
56.8 30 40.8 55 74.8 80 108.8
68.2 31 42.2 56 76.2 81 110.2
79.5 32 43.5 57 77.5 82 111.5
810.9 33 44.9 58 78.9 83 112.9
912.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
Type of Bolt
Thread
Diameter A
(mm)
Tightening
Torque
(Conventional or 4 Marked Bolt) 5 12-36 in.-lb
6 36-60 in.-lb
8 7-11 ft-lb
10 16-25 ft-lb
(7 Marked Bolt) 5 24-48 in.-lb
6 6-8 ft-lb
8 13-20 ft-lb
10 29-43 ft-lb
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1-4
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 components
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 dur-
ing the 10-hour break-in period.
When the engine starts, allow it to warm up properly. 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 throttle is
recommended; however, brief full-throttle accelerations
and variations in driving speeds contribute to good
engine break-in.
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 (see Periodic
Maintenance Chart in Section 2).
Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum octane
regular unleaded. In many areas, oxygenates (either etha-
nol 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 necessary
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.
RECOMMENDED ENGINE/
TRANSMISSION OIL
The recommended oil to use is Arctic Cat ACX All
Weather synthetic engine oil, which has been specifi-
cally formulated for use in this Arctic Cat engine.
Although Arctic Cat ACX All Weather synthetic engine
oil is the only oil recommended for use in this engine,
use of any API certified SM 5W-50 oil is acceptable.
OILCHARTI
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.
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.
CAUTION
Any lubricant used in place of the recommended
lubricant could cause serious front differential/rear
drive damage.
Manual
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1-5
1
FILLING GAS TANK
ATV0049B
Since gasoline expands as its temperature rises, the gas
tank must be filled to its specified capacity only. Expan-
sion room must be maintained in the tank particularly 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 appropriate Illustrated
Parts Manual for the correct part number, quantity, and
description.
Preparation 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 vehi-
cle. Allow it to dry thoroughly. DO NOT get water
into any part of the engine or air intake.
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. Using Arctic Cat Engine Storage Preserver, rap-
idly inject the preserver into the air filter opening for
a period of 10 to 20 seconds; then stop the engine.
Install the air filter and housing cover.
4. Plug the exhaust hole in the exhaust system with a
clean cloth.
5. Apply light oil to the plungers of the shock absorb-
ers.
6. Tighten all nuts, bolts, cap screws, and screws. Make
sure rivets holding components together are tight.
Replace all loose rivets. Care must be taken that all
calibrated nuts, cap screws, and bolts are tightened to
specifications.
7. Fill the cooling system to the bottom of the stand
pipe in the radiator neck with properly mixed cool-
ant.
8. Disconnect the battery cables; then remove the bat-
tery, clean the battery posts and cables, and store in a
clean, dry area.
9. Store the vehicle indoors in a level position.
Preparation After
Storage
Taking the vehicle out of storage and correctly preparing
it will assure many miles and hours of trouble-free riding.
1. Clean 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.
! 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.
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.
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1-6
6. Charge the battery; then install. Connect the battery
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 mak-
ing sure all calibrated nuts, cap screws, and bolts are
tightened to specifications.
9. Check tire pressure. Inflate to recommended pres-
sure as necessary.
10. Make sure the steering moves freely and does not
bind.
11. Check the spark plug. Clean or replace as necessary.
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.
Manual
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2-1
2
SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP
TABLE OF
CONTENTS
Periodic Maintenance Chart .................................... 2-2
Periodic Maintenance.............................................. 2-3
Lubrication Points.................................................... 2-3
Air Filter................................................................... 2-3
Valve/Tappet Clearance........................................... 2-3
Testing Engine Compression................................... 2-4
Spark Plug............................................................... 2-5
Muffler/Spark Arrester ............................................. 2-5
Engine/Transmission Oil - Filter............................... 2-6
Front Differential - Rear Drive Lubricant.................. 2-7
Driveshaft/Coupling ................................................. 2-7
Nuts/Bolts/Cap Screws............................................ 2-7
Headlight/Taillight-Brakelight ................................... 2-7
Shift Lever ............................................................... 2-8
Hydraulic Brake System ........................................ 2-10
Burnishing Brake Pads .......................................... 2-11
Checking/Replacing V-Belt.................................... 2-11
Troubleshooting Brake System.............................. 2-14
Manual
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2-2
Periodic Maintenance
Chart
A = Adjust I = Inspect
C = Clean L = Lubricate
R = Replace T = Tighten
* Service/Inspect more frequently when operating in adverse conditions.
** When using an API certified SM 5W-50 oil.
*** When using Arctic Cat ACX All Weather synthetic oil, oil change and strainer inspection interval can be increased to every
1,000 miles or every year.
Item
Initial Service
After Break-In
(First Month
or 100 Miles)
Every
Day
Every Month
or
Every 100
Miles
Every 3
Months or
Every 300
Miles
Every 6
Months or
Every 500
Miles
Every Year
or Every
1500 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 Hoses I I R (2 Yrs)
Throttle Cable Ends/Accelerator Pedal
Pivot
II C-L A-R
Engine-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R*/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, differential
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)
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
Manual
Table of Contents