Arctic Cat 2009 Prowler XT User manual

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2009 Arctic
Cat UTV (Utility Terrain Vehicle) models (see cover). The complete manual is designed to aid service personnel in ser-
vice-oriented applications.
Arctic Cat offers an additional publication (when it becomes available) to aid in servicing the other UTV model. To ser-
vice the model not included in this manual, please refer to the following publication:
• 2009 UTV Service Manual - Prowler XTZ
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.
© 2008 Arctic Cat Inc. September 2008
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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TABLE OF CONTENTS
Click on the blue text to go.
Foreword
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........................................ 1-6
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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) 526 kg (1160 lb)
Length (overall) 292 cm (115 in.)
Height (overall) 197 cm (77.5 in.)
Width (overall) 156 cm (61.3 in.)
Suspension Travel (front)
(rear)
25.4 cm (10 in.)
25.4 cm (10 in.)
Brake Type Hydraulic
Wheelbase 190 cm (75 in.)
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 2.5 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 Lubricant SAE Approved 80W-90 Hypoid
Rear Drive Lubricant (Prowler/XT) SAE Approved 80W-90 Hypoid
Rear Differential Lubricant (XTX) 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 74 100
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 33 45
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 20 27
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
Rear Driveline Brake Caliper Rear Differential/Gear Case 20 27
Driveline Rear Drive Input Flange 12 16
Parking Brake Actuator Lever Caliper 35 48
Parking Brake Caliper
Assembly
Rear Drive Housing 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 Differential/Gear Case Frame 38 48
Drive Coupler Drive Flange 40 54
Front Engine Mounting
Bracket
Mounting Stud 25 34
Rear Engine Mounting
Bracket
Mounting Stud 25 34
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 87 118
Lock Collar Differential Housing 125 170
Hub Nut Front/Rear Shaft/Axle (min) 200 272
Oil Drain Plug Front Differential - Rear
Drive/Differential 45
in.-lb
5
Oil Fill Plug Front Differential - Rear
Drive/Differential 16 22
Oil Drain Plug Engine 16 22
Wheel Hub 45 61
Front Input Drive Flange Front U-Joint 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
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
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 Nut Output Shaft** 62 84
Outer Magneto Cover Magneto Cover 811
Magneto Rotor Nut** Crankshaft 105 143
Cam Sprocket** Camshaft 11 15
V-Belt Cover Crankcase 811
Output Yoke Nut Secondary Driven Output
Shaft 74 100
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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