Arctic Cat Prowler XTZ 2009 User manual

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2009 Arctic
Cat Prowler XTZ. 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.
© 2009 Arctic Cat Inc. January 2009
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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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
Foreword
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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........................................ 1-6
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1-2
General Specifications*
* Specifications subject to change without notice.
** Visible at plug threads.
Torque Specifications
* w/Blue Loctite #243 *** w/Green Loctite #609
** w/Red Loctite #271 **** w/Green Loctite #270
CHASSIS
Dry Weight (approx) 564 kg (1243 lb)
Length (overall) 301 cm (118.5 in.)
Height (overall) 190.5 cm (75 in.)
Width (overall) 152.4 cm (60.0 in.)
Suspension Travel (front)
(rear)
25.4 cm (10 in.)
25.4 cm (10 in.)
Brake Type Four-Wheel Hydraulic Disc w/Driv-
eline Parking Brake
Wheelbase 190 cm (75 in.)
Tire Size (front)
(rear)
26 x 9-14
26 x 11-14
Tire Inflation Pressure 0.70 kg/cm² (10 psi)
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 2.8 L (3.0 U.S. qt) - Overhaul
2.4 L (2.5 U.S. qt) - Change
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather Syn-
thetic
Front Differential Lubricant SAE Approved 80W-90 Hypoid
Rear Drive Lubricant Arctic Cat 80W-90 Hypoid Friction
Modified
Belt Width 35.0 mm (1.38 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (2)
Starting System Electric
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
STEERING COMPONENTS
Steering Wheel Shaft** Steering Wheel 25 34
Steering Wheel Shaft**** Intermediate Shaft (Upper) 36 49
Intermediate Shaft (Lower)**** Steering Pinion Shaft 36 49
Rack and Pinion Assembly Frame 50 68
Tie Rod** Rack 59 80
Tie Rod End** Knuckle 30 41
Jam Nut Tie Rod End 811
SUSPENSION COMPONENTS (Front)
Part Part Bolted To Torque
ft-lb N-m
A-Arm Frame 40 54
Ball Joint Cap Screw Knuckle 35 48
Shock Absorber (Upper) Frame 33 45
Shock Absorber (Lower) Upper A-Arm 33 45
Knuckle A-Arm 33 45
SUSPENSION COMPONENTS (Rear)
Sway Bar Bracket Frame 33 45
A-Arm Frame 33 45
Shock Absorber (Upper) Frame 33 45
Shock Absorber (Lower) Lower A-Arm 33 45
Knuckle A-Arm 33 45
Cargo Box Hinge Cargo Box Frame 20 27
Cargo Box Cargo Box Frame 20 27
Latch Pivot Bushing Cargo Box Frame 15 20
Latch Striker Cargo Box Liner 57
BRAKE COMPONENTS
Brake Disc** Hub 15 20
Brake Hose Caliper 20 27
Brake Hose Master Cylinder 20 27
Master Cylinder Frame 25 34
Parking Brake Mechanism Frame 20 27
Hydraulic Caliper Holder Knuckle 20 27
Driveline Rear Drive Input Flange 20 27
Parking Brake Actuator Lever Caliper 35 48
Parking Brake Caliper
Assembly*
Mounting Bracket 20 27
CHASSIS/CANOPY ASSEMBLY
Shift Lever* Shift Axle 20 27
Front/Rear Canopy Tube Arm Rest/Steering Post
Support 20 27
Top Canopy Support Front/Rear Canopy Tubes 811
Rear Canopy Tube Lower Canopy Support 811
DRIVE TRAIN COMPONENTS
Rear Drive Frame 38 48
Drive Coupler Drive Flange 40 54
Engine Frame 40 54
Front Differential Frame/Differential Bracket 38 52
Rear Output Flange Rear U-Joint Flange 40 54
Pinion Housing Differential Housing 23 31
Differential Housing Cover*** Differential Housing 23 31
Drive Bevel Gear Nut*** Shaft 80 108
Lock Collar Differential Housing 120 163
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 45 61
Front Input Drive Flange Front Drive Yoke Flange 20 27
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1-3
1
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
Torque Conversions
(ft-lb/N-m)
Tightening Torque
(General Bolts)
ENGINE/TRANSMISSION
Part Part Bolted To Torque
ft-lb N-m
Clutch Shoe** Crankshaft 221 300
Clutch Cover/Housing
Assembly
Crankcase 811
Lower Crankcase Cover
(6 mm)
Crankcase 811
Lower Crankcase Cover
(8 mm)
Crankcase 20 27
Crankcase Half Crankcase Half 811
Cylinder Head (Cap Screw) Crankcase 38 52
Cylinder Head Nut (6 mm) Cylinder 811
Cylinder Head Nut (8 mm) Cylinder 18 24
Cylinder Head 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 Drive Gear** Crank Balancer Shaft 62 84
Output Shaft Flange Yoke/Nut Output Shaft** 59 80
Outer Magneto Cover Magneto Cover 811
Magneto Rotor Nut** Crankshaft 105 143
Cam Sprocket** Camshaft 11 15
CVT Cover Crankcase 811
Secondary Drive Gear Nut** Secondary Drive Output
Shaft 74 100
Oil Filter Cover Crankcase 811
Speed Sensor Housing Crankcase 811
Shift Cam Stopper Crankcase 811
Shift Cam Stopper Spring Shift Cam Stopper 811
Shift Cam Plate Shift Cam Shaft 811
Shifter Housing Crankcase 811
Starter Motor Crankcase 811
V-Belt Housing Crankcase 811
Oil Pump Cover Crankcase 811
Oil Strainer Cap Crankcase 811
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 opera-
tion during this break-in period will help assure maxi-
mum 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 compo-
nents 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 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 accelera-
tions 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 pre-
scribed 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 neces-
sary to add a gasoline antifreeze since ethanol will pre-
vent 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 lubrica-
tion requirements of the Arctic Cat vehicle front differ-
ential 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 dam-
age.
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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 rated 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 gen-
uine Arctic Cat parts. They are precision-made to
ensure high quality and correct fit. Refer to the appro-
priate 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
vehicle. 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 hous-
ing cover and air filter. Start the engine and allow
it to idle. Using Arctic Cat Engine Storage Pre-
server, rapidly inject the preserver into the air filter
opening for a period of 10 to 20 seconds; then stop
the engine. 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
battery, clean the battery posts and cables, and
store in a clean, dry area.
9. Store the vehicle indoors in a level position.
! 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
Preparation After
Storage
Taking the vehicle out of storage and correctly prepar-
ing 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 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.
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 plugs. Clean or replace as neces-
sary.
! 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
Periodic Maintenance.............................................. 2-3
Lubrication Points.................................................... 2-3
Air Filter................................................................... 2-3
Valve/Tappet Clearance
(Feeler Gauge Procedure) ................................... 2-4
Valve/Tappet Clearance
(Valve Adjuster Procedure) .................................. 2-5
Testing Engine Compression................................... 2-5
Spark Plugs............................................................. 2-6
Muffler/Spark Arrester ............................................. 2-6
Engine/Transmission Oil - Filter............................... 2-7
Front Differential - Rear Drive Lubricant.................. 2-8
Driveshaft/Coupling ................................................. 2-8
Nuts/Bolts/Cap Screws............................................ 2-8
Headlight/Taillight-Brakelight ................................... 2-9
Shift Lever ............................................................. 2-10
Hydraulic Brake System ........................................ 2-10
Parking Brake........................................................ 2-12
Burnishing Brake Pads .......................................... 2-14
Checking/Replacing V-Belt.................................... 2-14
Troubleshooting Brake System.............................. 2-16
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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.
** When using an API certified SM 5W-50 oil.
*** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year.
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 Plugs 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
Engine-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R*/R**/R*** R
Oil Strainer I I C
Differential/Gear Case 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
Periodic Maintenance
This section has been organized into sub-sections
which show common maintenance procedures for the
Arctic Cat UTV.
NOTE: Arctic Cat recommends the use of new
gaskets, lock nuts, and seals and lubricating all
internal components when servicing the
engine/transmission.
NOTE: Some photographs and illustrations used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.
NOTE: Critical torque specifications are located
in Section 1.
SPECIAL TOOLS
A number of special tools must be available to the
technician when performing service procedures in this
section. Refer to the current Special Tools Catalog for
the appropriate tool description.
NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
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. Parking Brake Cable Ends
D. Shift Cable Yokes
Air Filter
Use the following procedure to remove the filter and
inspect and/or clean it.
CLEANING AND INSPECTING
FILTER
1. Remove the seats; then remove the center console.
2. Unsnap the four fasteners securing the air cleaner
housing cover and remove the cover.
3. Remove the air filter frame (A); then remove the
foam filter element (B).
PR576A
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 filter
oil and work the filter. Reattach the filter to the fil-
ter screen.
7. Clean any dirt or debris from inside the air cleaner.
Be sure no dirt enters the throttle body.
8. Place the foam filter in the air filter housing; then
position the filter frame on top.
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.
Description p/n
Compression Tester Kit 0444-213
Oil Filter Wrench 0644-389
Timing Light 0644-296
Valve Clearance Adjuster 0444-078
! CAUTION
Failure to inspect the air filter frequently if the vehi-
cle 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 ele-
ment with a new one if it is torn.
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2-4
CHECKING AND CLEANING
DRAINS
1. Inspect one-way drains beneath the main housing
for debris and for proper sealing.
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.
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 plugs,
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).
NOTE: Remove the crankshaft end cap and
install the special cap screw (left-hand threads) to
rotate the engine.
2. Rotate the crankshaft to the TDC position on the com-
pression stroke of the front cylinder. The stamped “F”
must be visible.
GZ063
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 specifications,
loosen the jam nut and rotate the tappet adjuster
screw until the clearance is within specifications.
Tighten each jam nut securely after completing the
adjustment.
CC007DC
4. Rotate the engine 270° to the TDC position of the
rear cylinder; then repeat step 3. The stamped “R”
must be visible.
GZ059
5. Install the timing inspection plug; then remove the
cap screw and install the crankcase end cap.
6. Place the two tappet covers into position making
sure the proper cap screws are with the proper
cover. Tighten the cap screws securely.
! CAUTION
The one-way drain to the left is the clean air section
of the filter housing. Any leak of this drain will allow
dirt into the engine intake causing severe engine
damage.
! CAUTION
The feeler gauge must be positioned at the same angle
as the valve and valve adjuster for an accurate mea-
surement of clearance. Failure to measure the valve
clearance accurately could cause valve component
damage.
VALVE/TAPPET CLEARANCE
Intake 0.1016 mm (0.004 in.)
Exhaust 0.1524 mm (0.006 in.)
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2-5
2
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 plugs,
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).
CF005
2. Rotate the crankshaft to the TDC position on the
compression stroke of the front cylinder. The
stamped “F” must be visible.
GZ063
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
NOTE: Use Valve Clearance Adjuster for this pro-
cedure.
3. Place the valve 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.
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 clockwise
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 counterclockwise
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.
7. While holding the adjuster dial at the proper clear-
ance setting, tighten the jam nut securely with the
valve adjuster handle.
8. Rotate the engine 270° to the TDC position of the
rear cylinder; then repeat steps 4-7 for the rear
cylinder.
9. Place the tappet covers with O-rings into position;
then tighten the covers securely.
10. Install the timing inspection plug and crankshaft
end cap.
Testing Engine
Compression
To test engine compression, use the following proce-
dure.
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 leads from the spark
plugs.
2. Using compressed air, blow any debris from
around the spark plugs.
3. Remove the spark plugs; then attach the high ten-
sion leads to the plugs and ground the plugs on the
cylinder heads well away from the spark plug holes.
4. Attach the Compression Tester Kit.
! WARNING
Always wear safety glasses when using compressed
air.
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2-6
5. While holding the throttle in the full-open posi-
tion, crank the engine over with the electric starter
until the gauge stops climbing (five to 10 compres-
sion strokes).
NOTE: The compression should be within a
range of 75-85 psi for the front cylinder and
120-130 psi for the rear cylinder 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 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 Section 3).
Spark Plugs
A light brown insulator indicates that the plug is cor-
rect. A white or dark insulator indicates that the engine
may need to be serviced. To maintain a hot, strong
spark, keep the plug free of carbon.
ATV-0051
Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.).
ATV0052C
When installing the spark plugs, 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.
PR498
PR499
! CAUTION
Before removing the spark plugs, be sure to clean
the area around the spark plugs. Dirt could enter
engine when removing or installing the spark plugs.
! WARNING
Wait until the muffler cools to avoid burns.
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2-7
2
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
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 com-
pletely.
NOTE: To change oil and filter, the seats and cen-
ter 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 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 16 ft-lb.
Pour the specified amount of the recommended 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.
9. Unscrew the oil level stick and wipe it with a clean
cloth.
10. Install the oil level stick and thread into the engine
case.
NOTE: The oil level stick should 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-0100AA
12. Inspect the area around the drain plug and oil filter
for leaks.
! 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
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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2-8
Front Differential - Rear
Drive Lubricant
To check lubricant, use the following procedure.
1. Remove the level plug; the lubricant level should
be visible at the plug threads.
CF240A
2. If low, add SAE approved 80W-90 hypoid gear
lube as necessary.
To change the lubricant, use the following procedure.
1. Place the vehicle on level ground.
2. Remove each fill and level plugs.
3. Drain the lubricant into a drain pan by removing in
turn the drain plug from each.
ATV0082A
PR530B
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 until lubricant is visible
at the level plug threads.
6. Install the fill and level plugs. Tighten to 16 ft-lb.
NOTE: If the lubricant is contaminated with water,
inspect the drain plug, fill and level plugs, 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 riv-
ets holding components together are tight. Replace all
loose rivets. Care must be taken that all calibrated
nuts, bolts, and cap screws are tightened to specifica-
tions.
Front Differential
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2-9
2
Headlight/Taillight-
Brakelight
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 proce-
dure.
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 follow-
ing 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 can-
opy support.
CHECKING/ADJUSTING
HEADLIGHT AIM
The headlights can be adjusted vertically. The geomet-
ric 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.
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 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 ver-
tical 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
! WARNING
Do not attempt to remove the bulb when it is hot.
Severe burns may result.
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2-10
Shift Lever
CHECKING SHIFT LEVER CABLE
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.
PR571
ADJUSTING SHIFT LEVER CABLE
To adjust the shift lever cable, use the following proce-
dure.
1. Set the parking brake; then remove the seats and
center console.
2. Make sure the shift lever is in neutral; then remove
the E-clip securing the cable end to the shaft arm.
PR567A
3. Loosen nuts (A) and (B) and adjust the cable hous-
ing to align the throttle cable end to the shift arm
stud (C).
PR568A
PR572A
4. Install the E-clip; then tighten the nuts (A) and (B)
securely.
5. Check each gear shift position for proper gear selec-
tion and make sure the proper icon illuminates on
the LCD; then install the center console and seats.
Hydraulic Brake System
NOTE: This vehicle is equipped with four-wheel
disc brakes. The following procedure is for both
front and rear brakes.
CHECKING/BLEEDING
The hydraulic brake system has been filled and bled at
the factory. To check and/or bleed a hydraulic brake
system, 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
reservoir is not above the MIN, add DOT 4 brake
fluid.
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2-11
2
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.
3. To bleed the brake system, use the following pro-
cedure.
A. Remove the cover and fill the reservoir with
DOT 4 Brake Fluid.
B. Install and secure the cover; then slowly
depress the brake pedal several times.
C. Remove the protective cap, install one end of a
clear hose onto one FRONT 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.
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
other FRONT bleeder screw; then move to the
REAR bleeder screws and follow the same pro-
cedure.
E. Repeat steps B and C until the brake pedal is
firm.
4. 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
thickness of each of the brake pads as follows.
1. Remove a wheel.
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 (both front wheels and/or both rear wheels).
! 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.
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2-12
4. To replace the brake pads, use the following proce-
dure.
A. Remove the wheel.
B. Remove the cap screws securing the caliper
holder to the knuckle; then remove the pads
from the caliper.
PR237
C. Install the new brake pads.
D. Secure the caliper holder to the knuckle with
the cap screws. Tighten to 20 ft-lb.
PR377B
E. Install the wheel. Tighten to 45 ft-lb.
5. Burnish the brake pads (see Burnishing Brake
Pads in this section).
Parking Brake
CHECKING
Although the parking brake has been adjusted at the fac-
tory, the brake should be checked for proper operation.
The brake must be maintained to be fully functional.
1. With the engine off, transmission in neutral, and
the parking brake set, attempt to move the vehicle.
2. If the rear wheels are locked, it is adjusted prop-
erly.
3. If the rear wheels are not locked, it must be
adjusted (set up).
ADJUSTING
1. Remove the seats and center console.
2. With the parking brake lever released, loosen the
adjuster nut (A); then turn the jam nut (B) clock-
wise several turns.
PR682A
3. Turn the adjuster nut clockwise to remove cable
slack.
4. Check for proper adjustment by applying the park-
ing brake and attempting to move the vehicle. The
vehicle should not move.
5. If adjustment is correct, tighten the adjuster nut
securely. If further adjustment is required, repeat
steps 2-4.
NOTE: If the parking brake cannot be “set-up”
sufficiently to hold the rear axle, new brake pads
must be installed (proceed to Replacing Brake
Pads in this sub-section).
REPLACING BRAKE PADS
NOTE: The brake pads should be replaced as a
set.
1. Disconnect the parking brake cable from the actu-
ator arm. Account for a flat washer.
! CAUTION
If after adjusting the parking brake cable the parking
brake will not hold the vehicle, the brake pads must
be replaced.
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