Arctic Cat PROWLER HDX 2015 User manual

SERVICE MANUAL
SERVICE MANUAL
SERVICE MANUAL
www.arcticcat.com
PROWLER HDX

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2015 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.
This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The procedures
found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special
tools to be completed. The technician should use sound judgement when determining which procedures can be com-
pleted based on their skill level and access to appropriate special tools.
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.
© 2014 Arctic Cat Inc. October 2014
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

1
Table of Contents
General Information ........................................................ 2
General Specifications.........................................................2
Torque Specifications ..........................................................3
Torque Conversions (ft-lb/N-m)............................................5
Gasoline - Oil - Lubricant.....................................................5
Genuine Parts......................................................................6
Preparation For Storage ......................................................6
Preparation After Storage....................................................6
Periodic Maintenance...................................................... 7
Periodic Maintenance Chart ................................................7
Lubrication Points ................................................................8
Air Inlet Pre-Filter.................................................................8
Air Filter ...............................................................................8
Valve/Tappet Clearance.......................................................9
Testing Engine Compression...............................................9
Spark Plug .........................................................................10
Muffler/Spark Arrester .......................................................10
Engine/Transmission Oil - Filter.........................................11
Front Differential - Rear Drive Lubricant ............................12
Driveshaft/Coupling ...........................................................12
Nuts/Bolts/Cap Screws......................................................12
Headlight/Taillight-Brakelight .............................................13
Shift Lever..........................................................................13
Hydraulic Brake System ....................................................14
Burnishing Brake Pads ......................................................16
Checking/Replacing V-Belt ................................................16
Steering/Frame/Controls............................................... 18
Electronic Power Steering (EPS).......................................18
Tie Rods ............................................................................20
Steering Assembly.............................................................21
Steering Wheel ..................................................................22
Upper Steering Shaft .........................................................22
Intermediate Steering Shaft Assembly ..............................23
Steering Knuckles..............................................................24
Accelerator Pedal ..............................................................26
Shift Lever..........................................................................26
Shift Cable .........................................................................27
LCD Gauge/Indicator Lights ..............................................28
Checking/Adjusting Front Wheel Alignment.......................29
Front Bumper Assembly ....................................................30
Hood ..................................................................................30
Fenders..............................................................................31
Floor ..................................................................................31
Dashboard .........................................................................32
Belly Panel.........................................................................32
Exhaust System.................................................................32
Cargo Box..........................................................................33
Taillight Assembly ..............................................................33
Seat ...................................................................................33
Troubleshooting .................................................................34
Engine/Transmission .................................................... 35
Troubleshooting .................................................................36
Removing Engine/Transmission ........................................38
Servicing Engine (500) ......................................................41
Servicing Engine (700) ......................................................79
Installing Engine/Transmission ........................................116
Fuel/Lubrication/Cooling ............................................ 120
Throttle Body ...................................................................120
Gas Tank .........................................................................121
Gas/Vent Hoses .............................................................. 123
Oil Filter/Oil Pump ...........................................................123
Liquid Cooling System ....................................................124
Radiator........................................................................... 124
Thermostat ...................................................................... 125
Fan ..................................................................................126
Water Pump ....................................................................126
Troubleshooting ............................................................... 127
Electrical System ........................................................ 128
Battery.............................................................................128
Switches..........................................................................129
Accessory Receptacle/Connector ................................... 129
Brakelight Switch.............................................................129
Engine Coolant Temperature (ECT) Sensor.................... 130
Fan Motor ........................................................................130
Power Distribution Module (PDM) ...................................131
Ignition Coil .....................................................................131
EFI Sensors/Components ............................................... 132
Speed Sensor .................................................................133
RPM Limiter ....................................................................134
Electronic Power Steering (EPS).....................................134
Ignition Switch ................................................................. 136
Headlight Switch .............................................................136
Drive Select Switch .........................................................136
Reverse Override Switch................................................. 137
Front Drive Actuator ........................................................ 137
Stator Coil .......................................................................138
Starter Motor ...................................................................138
Starter Relay ...................................................................139
Electronic Control Module (ECM).................................... 139
Fuel Pump/Fuel Level Sensor .........................................140
Regulator/Rectifier ..........................................................141
Headlights .......................................................................141
Taillight-Brakelight ...........................................................142
Ignition Timing .................................................................142
Tilt Sensor ....................................................................... 142
Throttle Position Sensor (TPS)........................................ 143
EFI Diagnostic System....................................................144
Troubleshooting ............................................................... 149
Drive System ............................................................... 150
Front Drive Actuator ........................................................ 150
Front Differential ..............................................................151
Drive Axles ...................................................................... 162
Rear Gear Case ..............................................................165
Hub.................................................................................. 168
Hydraulic Brake Caliper................................................... 169
Universal Joints ...............................................................173
Troubleshooting Drive System......................................... 175
Troubleshooting Brake System........................................ 175
Suspension.................................................................. 176
Front Shock Absorbers.................................................... 176
Rear Shock Absorbers ....................................................176
Front A-Arms ................................................................... 182
Rear A-Arms ................................................................... 184
Wheels and Tires ............................................................ 186
Troubleshooting ............................................................... 187

2
General Information
NOTE: Some photographs and illustrations used in
this manual are used for clarity purposes only and
are not designed to depict actual conditions.
General Specifications
Specifications subject to change without notice.
MISCELLANY
Tire Size (front)
(rear)
26 x 10R-14
26 x 12R-14
Tire Inflation Pressure 1.12 kg/cm² (16 psi) - 500
1.41 kg/cm² (20 psi) - 700
Spark Plug Type NGK CR7E - 500
NGK CPR8E - 700
Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.)
-500
0.5-0.6 mm (0.019-0.024 in.)
- 700
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 (approx) (500)
(700)
3.3 L (3.5 U.S. qt) - Overhaul
2.8L(3.0U.S.qt)-Change
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
Synthetic
Front Differential/Rear Drive Lubricant
(One inch below plug threads)
SAE Approved 80W-90 Hyp-
oid
Belt Width (minimum) 28.5 mm (1.12 in.) - 500
35.0 mm (1.38 in.) - 700
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (4)
ELECTRICAL SYSTEM
Ignition Timing 10° BTDC @ 1500 RPM
Spark Plug Cap 5000 ohms
Ignition Coil Resistance (primary)
(secondary)
Less than 5.0 ohms - 500
Less than 1 ohm - 700
12k-19k ohms - 500
1.8M ohms - 700
Ignition Coil Primary Voltage Battery Voltage
Stator Coil Resistance (CKP Sensor)
(AC generator)
104-156 ohms
Less than 1 ohm
AC Generator Output (no load) 60 AC volts @ 5000 RPM
Crankshaft Position Sensor AC Voltage 2.5 volts or more - 500
2.0 volts or more - 700
CYLINDER, PISTON, AND RINGS (500)
Piston Skirt/Cylinder Clearance 0.025-0.055 mm
Piston Diameter 8 mm from Skirt End 88.96-88.98 mm
Piston Ring Free End Gap (max) (1st)
(2nd)
11.6 mm
10.1 mm
Bore x Stroke 89.0 x 71.2 mm
Cylinder Trueness (max) 0.01 mm
Piston Ring End Gap - Installed (min) 0.15 mm
Piston Ring to Groove Clearance (max) (1st/
2nd)
0.06 mm
Piston Ring Groove Width (1st)
(2nd)
(oil)
1.01-1.03 mm
1.21-1.23 mm
2.01-2.03 mm
Piston Ring Thickness (1st)
(2nd)
0.97-.99 mm
1.17-1.19 mm
Piston Pin Bore (max) 20.008 mm
Piston Pin (min) 19.994 mm
CYLINDER, PISTON, AND RINGS (700)
Piston Skirt/Cylinder Clearance (min) 0.06 mm
Cylinder Bore 101.992-102.008 mm
Piston Diameter 15 mm from Skirt End 101.930-101.949 mm
Piston Ring Free End Gap (1st/2nd) 12.5 mm
BorexStroke 102x85mm
Cylinder Trueness (max) 0.01 mm
Piston Ring End Gap - Installed (min) 0.38 mm
Piston Ring to Groove Clearance (max)
(1st/2nd)
0.03 mm
Piston Ring Groove Width (1st/2nd)
(oil)
1.202-1.204 mm
2.01-2.03 mm
Piston Ring Thickness (1st/2nd) 1.970-1.990 mm
Piston Pin Bore (max) 23.0 mm
Piston Pin Outside Diameter (min) 22.99 mm
VALVES AND GUIDES (500)
Valve Face Diameter (intake)
(exhaust)
35.0 mm
30.5 mm
Valve/Tappet Clearance (intake)
(cold engine) (exhaust)
0.10 mm
0.17 mm
Valve Guide/Stem (intake)
Clearance (max) (exhaust)
0.10 mm
0.30 mm
Valve Guide Inside Diameter 5.000-5.012 mm
Valve Seat Angle (intake/exhaust) 45°
Valve Spring Free Length (min) 44.73 mm
Valve Spring Tension @ 35.2 mm 17.23 kg (37.98 lb)
VALVES AND GUIDES (700)
Valve Face Diameter (intake)
(exhaust)
31.6 mm
27.9 mm
Valve/Tappet Clearance (intake)
(cold engine) (exhaust)
0.1016 mm
0.1524 mm
Valve Guide/Stem Clearance 0.013 mm
Valve Guide Inside Diameter 5.000-5.012 mm
Valve Head Thickness (min) 2.3 mm
Valve Seat Angle 45° +15’/+30’
Valve Spring Free Length (min) 38.7 mm
Valve Spring Tension @ 31.5 mm 19.0 kg (42 lb)

3
Torque Specifications
NOTE: Torque specifications have the following tol-
erances:
* w/Blue Loctite #243 ** w/Red Loctite #271
*** w/Green Loctite #270 **** w/“Patch-Lock”
CRANKSHAFT (500)
Connecting Rod (small end) (max) 20.021 mm
Connecting Rod (big end side-to-side)
(max) 0.7 mm
Connecting Rod (big end width) 21.95-22.00 mm
Connecting Rod (small end deflection)
(max) 3.0 mm
Crankshaft (web-to-web) 60.9 mm
Crankshaft Runout (max) 0.03 mm
CRANKSHAFT 700)
Connecting Rod (small end inside (max)
(diameter)
23.021 mm
Connecting Rod (big end side-to-side)(min) 0.6 mm
Connecting Rod @ 150 mm (max)
(small end deflection)
0.3 mm
Crankshaft (web-to-web) (min) 71 mm
Crankshaft Runout (max) 0.03 mm
CAMSHAFT AND CYLINDER HEAD (500)
Cam Lobe Height (min) (intake)
(exhaust)
34.71 mm
34.48 mm
Camshaft Journal Holder(right & center)
Inside Diameter (left)
22.01-22.04 mm
17.51-17.54 mm
Camshaft Journal Outside(right & center)
Diameter (left)
17.466-17.480 mm
21.966- 21.980 mm
Camshaft Runout (max) 0.03 mm
Cylinder Head/Cover Distortion (max) 0.05 mm
CAMSHAFT AND CYLINDER HEAD (700)
Cam Lobe Height (min) 33.53 mm
Camshaft Journal Oil Clearance (max) 0.04 mm
Camshaft Runout (max) 0.05 mm
Cylinder Head/Cover Distortion (max) 0.05 mm
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 50
in.-lb
5
O2 Sensor Exhaust Pipe 19 26
BRAKE COMPONENTS
Brake Disc**** Hub 15 20
Brake Hose Caliper 20 27
Brake Hose Master Cylinder 20 27
Master Cylinder Frame 25 34
Caliper**** Knuckle 20 27
Rear Driveline **** Rear Differential 12 16
ELECTRICAL COMPONENTS
Coil* Frame 811
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
Thrust Button** Gear Case Cover 811
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 (Aluminum) Hub 80 108
Wheel (Steel) Hub 40 54
STEERING COMPONENTS
Steering Wheel** Steering Wheel Shaft 25 34
Steering Wheel Shaft*** Intermediate Shaft (Upper) 31 42
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
CHASSIS/ROPS ASSEMBLY
Shift Axle Support Frame 48
in.-lb
5
Front/Rear ROPS Tube Arm Rest/Steering Support 35 48
Top ROPS Support Front/Rear ROPS Tubes 35 48
Rear ROPS Tube Lower ROPS Support 35 48
Shift Cable Shift Arm Stud 834
Shift Cable Mounting/Adjuster Shift Cable 20 27
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

4
SUSPENSION COMPONENTS (Front)
Part Part Bolted To Torque
ft-lb N-m
A-Arm Frame 35 48
Knuckle Ball Joint 35 48
Shock Absorber Frame/Upper A-Arm 35 48
Shock Absorber Lower A-Arm 20 27
Knuckle A-Arm 35 48
SUSPENSION COMPONENTS (Rear)
Sway Bar Bracket Frame 35 48
A-Arm Frame 35 48
Shock Absorber Lower A-Arm 35 48
Shock Absorber Frame 35 48
Knuckle A-Arm 35 48
ENGINE/TRANSMISSION (500)
Clutch Shoe** Crankshaft 147 199
Clutch Cover/Housing Assembly Crankcase 811
Left-Side Cover Crankcase 811
Crankcase Half (6 mm) Crankcase Half 10 13.5
Crankcase Half (8 mm) Crankcase Half 21 28
Cylinder Nut Crankcase Half 811
Cylinder Head (Cap Screw) Crankcase 28 38
Cylinder Head Nut Cylinder 20 27
Cylinder Head Cover Cylinder Head 811
Oil Pump Drive Gear** Crankshaft 63 86
Driven Pulley Nut** Driveshaft 147 199
Ground Cable Engine 811
Magneto Rotor Nut Crankshaft 107 146
Cam Sprocket** Camshaft 11 15
Valve Adjuster Jam Nut Valve Adjuster 7 9.5
Starter Motor Crankcase 811
Oil Fitting Engine 811
Starter One-Way Clutch Flywheel 26 35
Oil Pump* Crankcase 811
Movable Drive Face Nut** Clutch Shaft 147 199
Output Shaft Flange Nut Output Shaft 59 80
Cam Chain Tensioner Guide Cylinder 11 15
Valve Inspection Cover Cylinder Head Cover 811
Cam Chain Tensioner Cylinder 10 13.5
Magneto Cover Crankcase 811
Rear Driveline Output Drive Flange 20 27
Water Pump Cover/Housing Magneto Cover 811
Water Pump Drive Gear Crankshaft 28 38
ENGINE/TRANSMISSION (700)
Clutch Shoe** Crankshaft 221 300
Clutch Cover/Housing Assem-
bly
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
One-Way Clutch** Rotor/Flywheel 26 35
Outer Magneto Cover Side 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
Output Shaft Flange Yoke/
Nut**
Output Shaft 59 80
Secondary Shaft Bearing
Housing
Crankcase Half 28 38
Stator Coil* Magneto Cover 13 18
Intake Manifold Boot Clamp Intake Boot 30 in.-
lb
3.4
Ground Wire Engine 811

5
Torque Conversions
(ft-lb/N-m)
Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum octane
regular unleaded. In many areas, oxygenates are added to
the gasoline. Oxygenated gasolines containing up to 10%
ethanol or 5% methane 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 0W-40 oil is acceptable.
OILCHARTJ
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
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
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
CAUTION
Do not use white gas. Only Arctic Cat approved gaso-
line 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 recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.
CAUTION
Any lubricant used in place of the recommended lubri-
cant 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.

6
.
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.
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.
! 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 serviced
to prevent rusting and component deterioration.
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 igni-
tion system.
CAUTION
Connect the positive battery cable first; then the nega-
tive.

7
Periodic Maintenance
This section has been organized into sub-sections which show
common maintenance procedures for the Arctic Cat ROV.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appro-
priate tool description.
NOTE: Special tools are available from the Arctic
Cat Service Department.
Periodic Maintenance
Chart
A = Adjust I = Inspect C = Clean R = Replace T = Tighten L = Lubricate
* 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.
Description p/n
Compression Tester Kit 0444-213
Oil Filter Wrench 0644-389
Timing Light 0644-296
Valve Clearance Adjuster 0444-255
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 II C
Fuses IR
Air Filter II* R
Valve/Tappet Clearance IIA
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
Front Differential - Rear Drive Lubricant I I R (4 Yrs)
Tires/Air Pressure II R
Steering Components II I R
V-Belt IlR
Suspension (Ball joint boots, drive axle
boots front and rear, tie rods, differential
and rear drive bellows)
II R
Nuts/Bolts/Cap Screws TT A
Ignition Timing I
Headlight/Taillight-Brakelight II R
Switches II R
Shift Lever IA-L
Gauges/Indicators II R
Frame/Welds II l
Electrical Connections lC
Complete Brake System
(Hydraulic) II
Brake Pads II* 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 TT

8
Lubrication Points
It is advisable to lubricate certain components periodi-
cally 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. Shift Cable
Air Inlet Pre-Filter
This vehicle is equipped with a foam pre-filter to filter
dirt from the inlet air prior to reaching the main air filter.
NOTE: To access the pre-filter, remove the seat and
backrest; then remove the seat base.
1. Gently squeeze the pre-filter cover and lift it up to
expose the pre-filter.
HDX237A
2. Loosen the clamp securing the pre-filter.
HDX235
3. Remove the pre-filter assembly and wash thoroughly
in warm, soapy water; then rinse and dry.
4. Install and secure with the clamp. Tighten securely;
then with the pre-filter cover installed, install the seat
base, seat, and backrest.
Air Filter
1. Remove any dust and debris from around the filter
housing.
2. Unsnap the four spring-clip fasteners and remove the
air filter cover.
HDX050A
3. Remove the two screws securing the filter; then
remove the filter.
4. Fill a wash pan larger than the element with a non-
flammable cleaning solvent; then dip the element in
the solvent and wash it.
NOTE: Foam Filter Cleaner and Foam Filter Oil are
available from Arctic Cat.
5. Squeeze the element by pressing it between the
palms of both hands to remove excess solvent. Do no
twist or ring the element or it will tear.
6. Dry the element.
7. Put the element in a plastic bag; then pour in air filter
oil and work the element.
8. Carefully squeeze excess oil from the element.
9. Clean any dirt or debris from inside the filter housing.
10. Install the air filter, secure with the two screws tighten
to 12 ft-lb, and install the cover.
CAUTION
Failure to inspect the air filter frequently if the vehicle is
used in dusty, wet, or muddy conditions can damage
the engine.
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 element with a new one if it is torn.

9
CHECKING AND CLEANING DRAINS
HDX089A
1. Inspect the “duck-bill” drain beneath the main hous-
ing for debris and for proper sealing.
2. Remove the drain tube and clean out any water, oil,
or debris. Reinstall and secure with the clamp.
Valve/Tappet Clearance
To check and adjust valve/tappet clearance, use the fol-
lowing procedure.
NOTE: The engine must be cold for this procedure.
 NOTE: The seat, seat back, seat base, and spark
plug must be removed for this procedure.
1. Remove the spark plug and timing inspection plug; then
remove the tappet covers (for more detailed informa-
tion, see the Engine/Transmission section - 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.
Feeler Gauge Procedure
Using a feeler gauge, check each valve/tappet clearance.
If clearance is not within specifications, loosen the jam
nut and rotate the tappet adjuster screw until the clear-
ance is within specifications. Tighten each jam nut
securely after completing the adjustment.
CC007D
Valve Adjuster Procedure
A. Place the Valve Clearance Adjuster onto the jam
nut securing the tappet adjuster screw; then rotate
the valve adjuster dial clockwise until the end is
seated in the tappet adjuster screw.
B. While holding the valve adjuster dial in place, use
the valve adjuster handle and loosen the jam nut;
then rotate the tappet adjuster screw clockwise
until friction is felt.
C. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
D. While holding the valve adjuster handle in place,
rotate the valve adjuster dial counterclockwise
until proper valve/tappet clearance is attained.
NOTE: Refer to the 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.
E. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely
with the valve adjuster handle.
3. Install the spark plug; then install the timing inspec-
tion plug.
4. Place the two tappet covers with O-rings into posi-
tion. Tighten the cap screws to 9 ft-lb.
Testing Engine
Compression
To test engine compression, use the following procedure.
 NOTE: The engine should be warm (operating tem-
perature) and the battery fully charged for an accurate
compression test. The throttle must be in the wide-
open throttle (WOT) position. In the event the engine
cannot be run, cold values are included.
CAUTION
The feeler gauge must be positioned at the same angle
as the valve and valve adjuster for an accurate measure-
ment of clearance. Failure to measure the valve clear-
ance accurately could cause valve component damage.
VALVE/TAPPET CLEARANCE
Intake 0.1016 mm (0.004 in.)
Exhaust 0.1524 mm (0.006 in.)

10
NOTE: The seat, seat back, and seat base must
be removed for this procedure.
1. Remove the high tension lead from the spark plug.
2. Using compressed air, blow any debris from around
the spark plug.
3. Remove the spark plug; then attach the high tension
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.
5. While holding the throttle in the full-open position,
crank the engine over with the electric starter until the
gauge stops climbing (five to 10 compression strokes).
6. If compression is abnormally low, inspect the
following items.
A. Starter cranks engine over.
B. Gauge is functioning properly.
C. Throttle in the full-open position.
D. Valve/tappet clearance correct.
E. Engine warmed up.
F. Intake obstructed.
 NOTE: To service top-side components, see the
Engine/Transmission section.
7. Pour approximately 30 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 the appropriate Engine/Transmission - Top Side
Components).
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. To maintain a hot, strong spark, keep
the plug free of carbon.
ATV-0051
Adjust the gap to 0.5-0.6 mm (0.019-0.024 in.).
ATV0052
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
Clean the spark arrester using the following procedure.
1. Remove the cap screws securing the spark arrester
screen assembly to the muffler; then loosen and
remove the spark arrester. Account for a gasket.
! WARNING
Always wear safety glasses when using compressed
air.
PSI Hot (WOT) PSI Cold (WOT)
125-145 100-140
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.

11
PR498
PR499
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 cap screws. Tighten the cap screws to 48 in.-lb.
Engine/Transmission Oil -
Filter
OIL - FILTER
Change the engine oil and oil filter at the scheduled inter-
vals. The engine should always be warm when the oil is
changed so the oil will drain easily and completely.
1. Park the vehicle on level ground.
2. Remove the drain plug from the bottom of the engine
and drain the oil into a drain pan; then remove the
center console, seat, seat back, and seat base.
PR078A
3. Using the Oil Filter Wrench 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 fil-
ter.
4. 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.
5. Install the engine drain plug and tighten to 16 ft-lb. Pour
the specified amount of the recommended oil in the filler
hole.
HDX251B
HDX042A
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 recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.
500
700

12
6. Start the engine (while the vehicle is outside on level
ground) and allow it to idle for a few minutes.
7. Turn the engine off and wait approximately one minute;
then unscrew the oil level stick and wipe it with a clean
cloth.
8. Install the oil level stick and thread into the engine case.
9. Remove the oil level stick; the oil level must be within
the operating range but not exceeding the upper mark.
GZ461A
10. Inspect the area around the drain plug and oil filter for
leaks.
Front Differential - Rear
Drive Lubricant
To check lubricant, use the following procedure.
1. Remove the level plug (B); the lubricant should be
level with the bottom threads.
HDX221A
2. If low, remove the fill plug (A) and add the appropriate
lubricant until it appears at the bottom of the level plug
threads.
To change the lubricant, use the following procedure.
1. Place the vehicle on level ground.
2. Remove each fill plug.
3. Drain the lubricant into a drain pan by removing in turn
the drain plug from each.
HDX255
HDX220A
4. After all the lubricant has been drained, install the drain
plugs and tighten to 45 in.-lb.
5. Pour the appropriate amount of recommended lubricant
into the fill hole.
6. Install the fill plug and tighten to 16 ft-lb.
NOTE: If the lubricant is contaminated with water,
inspect the drain plug, fill plug, and/or bladder.
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.
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.
CAUTION
Do not over-fill the engine with oil. Always make sure
that the oil level is not above the upper mark.

13
Headlight/Taillight-
Brakelight
HEADLIGHT
NOTE: The bulb portion of the headlight is fragile.
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 procedure.
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 com-
pletely clockwise in the housing.
4. Install the wiring harness connector.
TAILLIGHT-BRAKELIGHT
To replace the taillight-brakelight bulb, use the following
procedure.
1. Remove the two machine screws and remove the
light assembly.
2. Rotate the bulb socket counterclockwise to remove it
from the light assembly; then pull straight out on the bulb.
Push the new bulb straight into the socket.
3. Install the bulb and socket into the light assembly 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 geometric center
of the HIGH beam light zone is to be used for vertical aiming.
1. Position the vehicle on a level floor so the headlights 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.
2. Measure the distance from the floor to the mid-point of
each headlight.
3. Using the measurements obtained in step 2, make hori-
zontal marks on the aiming surface.
4. Make vertical marks which intersect the horizontal 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 cor-
rect aim is obtained.
CD714A
Shift Lever
CHECKING SHIFT CABLE
ADJUSTMENT
1. 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.
2. Shift the transmission into park and observe that the
(P) illuminates on the LCD gauge.
ADJUSTING SHIFT CABLE
To adjust the shift cable, use the following procedure.
1. Place the transmission in park; then tilt the cargo
box.
2. Make sure the shift lever is in park; then remove the
E-clip securing the cable end to the shift arm stud.
! WARNING
Do not attempt to remove the bulb when it is hot. Severe
burns may result.

14
HDX251
HDX254
3. Loosen nuts (A) and (B) and adjust the cable housing
to align the shift cable end to the shift arm stud.
PR568A
4. Install the E-clip; then tighten the nuts (A) and (B) to
8 ft-lb.
5. Check each gear shift position for proper gear selec-
tion and make sure the proper icon illuminates on the
LCD.
Hydraulic Brake System
NOTE: This ROV is equipped with hydraulic
brakes at all four wheels.
CHECKING/BLEEDING
The hydraulic brake system has been filled and bled at
the factory. To check and/or bleed a hydraulic brake sys-
tem, use the following procedure.
1. With the master cylinder in a level position, check
the fluid level in the reservoir. If the level in the res-
ervoir is not above the MIN, add DOT 4 brake fluid.
PR095
2. Depress the brake pedal several times to check for a firm
brake. If the brake is not firm, the system must be bled.
To bleed the brake system, use the following procedure.
A. Remove the cover and fill the reservoir with DOT
4 Brake Fluid; then install and secure the cover.
B. Slowly depress the brake pedal several times.
C. Remove the protective cap, install one end of a
clear hose onto the RIGHT REAR (700) or REAR
DRIVELINE (500) bleeder screw, and direct the
other end into a container; then while holding
slight pressure on the brake pedal, open the
bleeder screw and watch for air bubbles. Close the
bleeder screw before releasing the brake pedal.
Repeat this procedure until no air bubbles are
present. Then the rear left repeat B and C.
HDX236A
700
500
REAR 500

15
AF637D
PR377C
NOTE: During the bleeding procedure, watch the
reservoir very closely to make sure there is always
a sufficient amount of brake fluid. When the level
falls below MIN, refill the reservoir before the
bleeding procedure is continued. Failure to main-
tain a sufficient amount of fluid in the reservoir will
result in air in the system.
D. At this point, perform steps B and C on the REAR
LEFT bleeder screw (700 only); then move to the
FRONT RIGHT bleeder screw and follow the
same procedure. Finally complete the procedure
on the FRONT LEFT bleeder screw.
E. Repeat steps B and C until the brake pedal is firm.
3. Carefully check the entire hydraulic brake system
that all hose connections are tight, the bleed screws
are tight, the protective caps are installed, and no
leakage is present.
INSPECTING HOSES
Carefully inspect the hydraulic brake hoses for cracks or
other damage. If found, the brake hoses must be replaced.
CHECKING/REPLACING PADS
The clearance between the brake pads and brake discs is
adjusted automatically as the brake pads wear. The only
maintenance that is required is replacement of the brake
pads when they show excessive wear. Check the thick-
ness of each of the brake pads as follows.
1. Remove the wheel corresponding to the brake being
checked.
2. Measure the thickness of each brake pad.
PR376A
3. If thickness of either brake pad is less than 1.0 mm
(0.039 in.), the brake pads must be replaced.
NOTE: The brake pads should be replaced as a set.
4. To replace the brake pads, use the following procedure.
A. Remove the cap screws securing the caliper holder to
the knuckle; then remove the pads from the caliper.
PR237
B. Install the new brake pads.
C. Secure the caliper holder to the knuckle with new
“patch-lock”cap screws. Tighten to 20 ft-lb.
CAUTION
This hydraulic brake system is designed to use DOT 4
brake fluid only. If brake fluid must be added, care must be
taken as brake fluid is very corrosive to painted surfaces.
REAR 700
FRONT

16
PR377B
5. Install the wheel. Tighten in 20 ft-lb increments to 40
ft-lb (steel wheel) or 80 ft-lb (aluminum wheel).
6. Burnish the brake pads.
BRAKE DISC
Using a micrometer, measure the thickness of the brake
disc in the contact surface. If thickness is 0.125 in. or
less, the disc must be replaced. To replace the brake disc,
see Drive System – Hub.
Burnishing Brake Pads
Brake pads must be burnished to achieve full braking
effectiveness. Braking distance will be extended until
brake pads are properly burnished. To properly burnish
the brake pads, use the following procedure.
1. Choose an area large enough to safely accelerate the
vehicle to 30 mph and to brake to a stop.
2. Accelerate to 30 mph; then depress the brake pedal
to decelerate to 0-5 mph.
3. Repeat procedure 20 times until brake pads are bur-
nished.
Checking/Replacing V-
Belt
REMOVING
1. Remove the seat, seat back, and seat base; then
remove the floor and gas tank.
2. Remove the cap screws securing the CVT cover not-
ing the location of the different-lengthed cap screws
for installing purposes; then using a rubber mallet,
gently tap on the cover tabs to loosen the cover.
Remove the cover.
CF363
3. Remove the nut securing the movable drive face;
then remove the face. Account for the spacer.
NOTE: Keep the drive face plate in contact with the
drive face when removing or installing the drive face
to prevent the rollers from falling out.
CF364A
CD966A
4. Install one of the CVT cover cap screws into the
driven pulley fixed face; then turn the cap screw
clockwise to spread the pulley faces. Remove the V-
belt.
! WARNING
Failure to properly burnish the brake pads could lead to
premature brake pad wear or brake loss. Brake loss can
result in severe injury.

17
GZ076
GZ085
INSTALLING
1. Place the V-belt into position on the driven pulley
and over the front shaft.
GZ085
NOTE: The arrows on the V-belt should point in
direction of engine rotation (forward).
2. Pinch the V-belt together near its center and slide the
spacer and movable drive face onto the front shaft.
Secure the drive face with a new nut. Using an
appropriate spanner wrench, tighten the nut to 147 ft-
lb (500) or 165 ft-lb (700).
CF366
CF379
NOTE: At this point, the CVT cover cap screw can
be removed.
3. With the vehicle in neutral, rotate the V-belt and
clutches counterclockwise until the V-belt is flush
with the top of the driven pulley.
4. Place the CVT cover gasket into position; then install
the cover and secure with the cap screws making
sure the different-lengthed cap screws are in their
proper location. Tighten the cap screws to 8 ft-lb.
CF363
5. Install the gas tank and floor; then install the seat
back, seat base, and seat.
CAUTION
Make sure the movable drive face plate is fully engaged onto
the splines of the clutch shaft before tightening the nut or
false torque readings may occur. This will cause the assem-
bly to loosen damaging the shaft and clutch face plate.