Arctic Cat 2013 Prowler XT User manual

®™
Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-530
Prowler XT/XTX/XTZ

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2013 Arctic
Cat ROV (Recreational Off-Highway Vehicle) models (see cover). The complete manual is designed to aid service per-
sonnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific vehicle component or system and, in addition to the
standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual
as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.
The service technician should become familiar with the operation and construction of each component or system by
carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient
with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.
All Arctic Cat publications and decals display the words Warning, Caution, Note, and At This Point to emphasize
important information. The symbol ! WARNING identifies personal safety-related information. Be sure to fol-
low the directive because it deals with the possibility of serious personal injury or even death. A CAUTION identi-
fies unsafe practices which may result in vehicle-related damage. Follow the directive because it deals with the
possibility of damaging part or parts of the vehicle. The symbol NOTE: identifies supplementary information wor-
thy of particular attention. The symbol AT THIS POINT directs the technician to certain and specific proce-
dures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic
Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2012 Arctic Cat Inc. October 2012
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

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/Controls
1
2
3
4
5
6
7
8

1-1
1
SECTION 1 - GENERAL INFORMATION
TABLE OF CONTENTS
General Specifications ............................................ 1-2
Torque Specifications .............................................. 1-3
Torque Conversions (ft-lb/N-m) ............................... 1-4
Break-In Procedure ................................................. 1-4
Gasoline - Oil - Lubricant ........................................ 1-5
Genuine Parts ......................................................... 1-5
Preparation For Storage.......................................... 1-6
Preparation After Storage........................................ 1-6

1-2
General Specifications
* Visible at plug threads.
Specifications subject to change without notice.
CHASSIS
Dry Weight (approx) (XT)
(XTX)
(XTZ)
558 kg (1230 lb)
567 kg (1251 lb)
596 kg (1315 lb)
ROPS Tested Curb Weight 645 kg (1428 lb)
Length (overall) 301.5 cm (118.7 in.)
Height (overall) 201 cm (79 in.)
Width (overall) 156.2 cm (61.5 in.)
Suspension Travel 25.4 cm (10 in.)
Brake Type Hydraulic
Wheelbase 190 cm (75 in.)
Tire Size (XT/XTX) 26 x 9R-14 (front)
26 x 11R-14 (rear)
Tire Size (XTZ) 27 x 9R-14 (front)
27 x 11R-14 (rear)
Tire Inflation Pressure 0.84-1.41 kg/cm² (12-20 psi)
MISCELLANY
Spark Plug Type NGK CPR8E
Spark Plug Gap 0.5-0.6 mm (0.019-0.024 in.)
Gas Tank Capacity 31 L (8.2 U.S. gal.)
Coolant Capacity (XT/XTX)
(XTZ)
2.9 L (3.0 U.S. qt)
3.3 L (3.5 U.S. qt)
Front Differential Capacity 275 ml (9.3 fl oz)*
Rear Drive Capacity 250 ml (8.5 fl oz)*
Engine Oil Capacity 2.5 L (2.6 U.S. qt) - Overhaul
1.9 L (2.0 U.S. qt) - Change
Gasoline (recommended) 87 Octane Regular
Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather
Synthetic
Front Differential/Rear Drive Lubricant SAE Approved 80W-90 Hyp-
oid
Belt Width 35.0 mm (1.38 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (4)
ELECTRICAL SYSTEM - XT/XTX
Spark Plug Cap 5000 ohms
Ignition Coil (primary)
Resistance
(secondary)
Less than 1 ohm
(terminal (+) to ground (-))
12k-19k ohms (high tension
- plug cap to terminal (+))
Ignition Coil Primary Voltage Battery Voltage
(orange (+) to blue/white (-))
Stator Coil Resistance
(crankshaft position sensor)
(AC generator)
150-250 ohms (blue to
white)
Less than 1 ohm (yellow to
yellow)
Crankshaft Position Sensor AC Voltage 2.0 or more (blue to green)
AC Generator Output (no load) 60 AC volts @ 5000 RPM
(yellow to yellow)
Ignition Timing 10° BTDC @ 1500 RPM
ELECTRICAL SYSTEM - XTZ
Spark Plug Cap 5000 ohms
Ignition Coil (primary)
Resistance
(secondary)
4.8 ohms
(terminal (+) to ground (-))
12k-19k ohms (high tension
- plug cap to terminal (+))
Ignition Coil Primary Voltage Battery Voltage
(orange (+) to ground)
Stator Coil Resistance
(crankshaft position sensor)
(AC generator)
150-250 ohms (blue to
green)
Less than 1 ohm (black to
black)
Crankshaft Position Sensor AC Voltage 2.0 or more (blue to green)
AC Generator Output (no load) 75 AC volts @ 5000 RPM
(black to black)
Ignition Timing 10° BTDC @ 1500 RPM
VALVES AND GUIDES
Valve Face Diameter (intake)
(exhaust)
31.6 mm
27.9 mm
Valve/Tappet Clearance (intake)
(cold engine) (max) (exhaust)
0.1016 mm
0.1524 mm
Valve Guide/Stem Clearance (max) 0.013 mm
Valve Guide/Valve Stem Deflection (max)
(wobble method)
0.35 mm
Valve Guide Inside Diameter 5.000-5.012 mm
Valve Stem Outside Diameter 4.972-4.987 mm
Valve Stem Runout (max) 0.1 mm
Valve Head Thickness (min) 2.3 mm
Valve Face/Seat Width (intake)
(exhaust)
2.25 mm
2.60 mm
Valve Seat Angle 45° +15’/+30’
Valve Face Radial Runout (max) 0.2 mm
Valve Spring Free Length (min) 38.7 mm
Valve Spring Tension @ 31.5 mm 19.0 kg (42 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min) 33.53 mm
Camshaft Journal Oil Clearance (max) 0.04 mm
Camshaft Journal Holder (right & center)
Inside Diameter (left)
21.98-22.04 mm
17.48-17.53 mm
Camshaft Journal Outside (right & center)
Diameter (left)
21.96-21.98 mm
17.48-17.53 mm
Camshaft Runout (max) 0.05 mm
Rocker Arm Inside Diameter (max) 12.018 mm
Rocker Arm Shaft Outside Diameter (min) 11.97 mm
Cylinder Head/Cover Distortion (max) 0.05 mm
CYLINDER, PISTON, AND RINGS - XT/XTX
Piston Skirt/Cylinder Clearance 0.06 mm
Cylinder Bore (550 cc)
(700 cc)
91.995-92.005 mm
101.992-102.008 mm
Piston Diameter 15 mm (550 cc)
from Skirt End (700 cc)
91.900-91.960 mm
101.930-101.949 mm
Piston Ring Free End Gap (min) (1st/2nd) 12.5 mm
Bore x Stroke (550 cc)
(700 cc)
92 x 82 mm
102 x 85 mm
Cylinder Trueness (max) 0.01 mm
Piston Ring End Gap - Installed 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
CYLINDER, PISTON, AND RINGS - XTZ
Piston Skirt/Cylinder Clearance 0.05 mm
Cylinder Bore 91.992-92.008 mm
Piston Diameter 15 mm from Skirt End 91.949-91.959 mm
Piston Ring Free End Gap (min) (1st/2nd) 12.5 mm
Bore x Stroke 92 x 71.6 mm
Cylinder Trueness (max) 0.075 mm
Piston Ring End Gap - Installed 0.38 mm
Piston Ring to Groove Clearance 1st
(max) (2nd)
0.034 mm
0.033 mm
Piston Ring Groove Width (1st/2nd)
(oil)
1.202-1.204 mm
2.501-2.503 mm
Piston Ring Thickness (1st/2nd) 1.170-1.195 mm
Piston Pin Bore (max) 20.012 mm
Piston Pin Outside Diameter (min) 19.995 mm

1-3
1
Specifications subject to change without notice.
Torque Specifications
 NOTE: Torque specifications have the following tolerances:
* w/Blue Loctite #243 *** w/Green Loctite #270
** w/Red Loctite #271 **** w/“Patch-Lock”
CRANKSHAFT - XTZ
Connecting Rod (max)
(small end inside diameter)
20.021 mm
Connecting Rod (big end side-to-side) 0.95 mm
Connecting Rod (max)
(small end deflection)
0.3 mm
Crankshaft (web-to-web) 98 mm
Crankshaft Runout (max) 0.03 mm
Oil Pump Gerotor Clearance (max) 0.15 mm
CRANKSHAFT - XT/XTX
Connecting Rod (small end inside (max)
diameter)
23.021 mm
Connecting Rod (big end side-to-side) 0.6 mm
Connecting Rod (max)
(small end deflection)
0.3 mm
Crankshaft (web-to-web) 71 mm
Crankshaft Runout (max) 0.03 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 48
in.-lb
5
BRAKE COMPONENTS
Brake Disc** Hub 15 20
Brake Hose Caliper 20 27
Brake Hose Master Cylinder 20 27
Master Cylinder Frame 25 34
Caliper Holder**** Knuckle 20 27
Brake Caliper**** Gear Case Housing 20 27
Brake Caliper Rear Drive Housing 20 27
Driveline Rear Drive Input Flange 20 27
Parking Brake Actuator Lever Caliper 20 27
Parking Brake Caliper Assembly Rear Drive Housing 20 27
SUSPENSION COMPONENTS (Front)
A-Arm Frame 35 48
Knuckle Ball Joint 35 48
Shock Absorber Frame/Upper A-Arm 35 48
Knuckle A-Arm 35 48
SUSPENSION COMPONENTS (Rear)
Sway Bar Bracket Frame 33 45
A-Arm Frame 35 48
Shock Absorber (Lower) (XT/XTX) Lower A-Arm 20 27
Shock Absorber (Lower) (XTZ) Lower A-Arm 35 48
Shock Absorber (Upper) Frame 35 48
Knuckle A-Arm 35 48
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 60
in.-lb
7
ELECTRICAL COMPONENTS
Coil* Frame 8 11
Ground Wire Engine 8 11
STEERING COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Steering Wheel** Steering Wheel Shaft 25 34
Steering Wheel Shaft*** Intermediate Shaft (Upper) 36 49
Intermediate Shaft (Lower)*** -
XT
Steering Pinion Shaft 36 49
Rack and Pinion Assembly - XT Frame 50 68
Rack and Pinion Assembly -
XTX/XTZ
Frame 35 48
Tie Rod** - XT Rack 52 70
Tie Rod** - XTX/XTZ Rack 37 50
Tie Rod End** Knuckle 30 41
Jam Nut Tie Rod End 10 14
EPS Assembly - XTX/XTZ Frame 35 48
EPS Assembly - XTX/XTZ Rack Coupler 11 15
EPS Cradle Bracket Knuckle 20 27
Intermediate Shaft Coupler Intermediate Shaft 31 42
Intermediate Shaft (lower) -
XTX/XTZ
EPS Input Shaft 11 15
Steering Shaft Housing (6 mm)
(XTX/XTZ)
Frame 8 11
Steering Shaft Housing (8 mm)
(XTX/XTZ)
Frame 20 27
CHASSIS/ROPS ASSEMBLY
Shift Lever* Shift Axle Bracket 20 27
Front/Rear ROPS Tube Arm Rest/Steering Post
Support
20 27
Top ROPS Support Front/Rear ROPS Tubes 8 11
Rear ROPS Tube Lower ROPS Support 8 11
ENGINE/TRANSMISSION - H1
Clutch Shoe** Crankshaft 221 300
Clutch Cover/Housing
Assembly
Crankcase 8 11
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 8 11
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 8 11
Magneto Cover Crankcase 8 11
Tappet Cover Valve Cover 9 12
Crankshaft Spacer Crankshaft 28 38
Oil Pump Cover** Crankcase 8 11
Oil Pump Drive Gear** Crank Balancer Shaft 62 84
Output Shaft Flange Nut** Output Shaft 62 84
Outer Magneto Cover Magneto Cover 8 11
Magneto Rotor Nut** Crankshaft 105 143
Cam Sprocket** Camshaft 11 15
Speed Sensor Housing Crankcase 8 11
V-Belt Cover Crankcase 8 11
Output Yoke Nut** Secondary Driven Output
Shaft
74 100
Output Shaft Nut** Output Shaft 59 80
Secondary Shaft Bearing Hous-
ing
Crankcase Half 28 38
Stator Coil** Magneto Cover 8.5 11.5
Intake Boot Clamp Intake Boot 30
in.-lb
3.4
Starter One-Way Clutch** Flywheel 26 35

1-4
** w/Red Loctite #271
*** w/Green Loctite #270
Torque Conversions
(ft-lb/N-m)
Break-In Procedure
A new vehicle and an overhauled engine require a
“break-in” period. The first 10 hours (or 200 miles) are
most critical to the life of this vehicle. Proper operation
during this break-in period will help assure maximum life
and performance from the vehicle.
During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the engine
RPM during the break-in period allows the components
to “load” (aiding the mating process) and then “unload”
(allowing components to cool). Although it is essential to
place some stress on the engine components during
break-in, care should be taken not to overload the engine
too often. Do not pull a trailer or carry heavy loads dur-
ing the 10-hour break-in period.
When the engine starts, allow it to warm up properly. Idle
the engine several minutes until the engine has reached
normal operating temperature. Do not idle the engine for
excessively long periods of time.
ENGINE/TRANSMISSION - H2
Part Part Bolted To Torque
ft-lb N-m
Clutch Shoe** Crankshaft 221 300
Clutch Cover/Housing
Assembly
Crankcase 8 11
Lower Crankcase Cover
(6 mm)
Crankcase 8 11
Lower Crankcase Cover
(8 mm)
Crankcase 20 27
Crankcase Half Crankcase Half 8 11
Cylinder Head (Cap Screw) Crankcase 38 52
Cylinder Head Nut (6 mm) Cylinder 8 11
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 8 11
Magneto Cover Crankcase 8 11
Tappet Cover Valve Cover 9 12
Crankshaft Spacer Crankshaft 28 38
Oil Pump Drive Gear** Crank Balancer Shaft 62 84
Output Yoke Nut** Output Shaft 74 100
Outer Magneto Cover Magneto Cover 8 11
Rotor/Flywheel Nut** Crankshaft 105 143
Cam Sprocket** Camshaft 11 15
CVT Cover Crankcase 8 11
Secondary Drive Gear Nut** Secondary Drive Output
Shaft
74 100
Oil Filter Cover Crankcase 8 11
Speed Sensor Housing Crankcase 8 11
Shift Cam Stopper Crankcase 8 11
Shift Cam Stopper Spring Shift Cam Stopper 8 11
Shift Cam Plate Shift Cam Shaft 8 11
Shifter Housing Crankcase 8 11
Starter Motor Crankcase 8 11
V-Belt Cover Crankcase 8 11
Oil Pump Cover** Crankcase 8 11
Oil Strainer Cap Crankcase 8 11
Stator Coil* Magneto Cover 8.5 11.5
Intake Boot Clamp Intake Boot 30
in.-lb
3.4
Starter One-Way Clutch** Flywheel 26 35
DRIVE TRAIN COMPONENTS
Rear Differential/Gear Case Frame 38 48
Drive Coupler (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 U-Joint Flange 40 54
Input Shaft Assembly Gear Case Housing 23 31
Pinion Housing Differential Housing 23 31
Thrust Button Gear Case Cover 8 11
Differential Housing Cover*** Differential Housing 23 31
Drive Bevel Gear Nut*** Shaft 87 118
Lock Collar Differential Housing 125 170
Hub Nut Front/Rear Shaft/Axle (min) 200 272
Oil Drain Plug Front Differential - Rear
Drive
45
in.-lb
5
Oil Fill Plug Front Differential - Rear
Drive
16 22
Oil Drain Plug Engine 16 22
Wheel (Aluminum) Hub 80 108
Wheel (Steel) Hub 45 61
Front Input Drive Flange Front U-Joint 20 27
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

1-5
1
During the break-in period, a maximum of 1/2 throttle is
recommended; however, brief full-throttle accelerations
and variations in driving speeds contribute to good
engine break-in.
After the completion of the break-in period, the engine
oil and oil filter should be changed. Other maintenance
after break-in should include checking of all prescribed
adjustments and tightening of all fasteners (see Periodic
Maintenance Chart in Section 2).
Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum octane
regular unleaded. In many areas, oxygenates (either etha-
nol or MTBE) are added to the gasoline. Oxygenated
gasolines containing up to 10% ethanol, 5% methane, or
5% MTBE are acceptable gasolines.
When using ethanol blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.
RECOMMENDED ENGINE/
TRANSMISSION OIL
The recommended oil to use is Arctic Cat ACX All
Weather synthetic engine oil, which has been specifi-
cally formulated for use in this Arctic Cat engine.
Although Arctic Cat ACX All Weather synthetic engine
oil is the only oil recommended for use in this engine,
use of any API certified SM 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
ATV0049B
Since gasoline expands as its temperature rises, the gas
tank must be filled to its specified capacity only. Expan-
sion room must be maintained in the tank particularly if
the tank is filled with cold gasoline and then moved to a
warm area.
Tighten the gas tank cap securely after filling the tank.
Genuine Parts
When replacement of parts is necessary, use only genuine
Arctic Cat parts. They are precision-made to ensure high
quality and correct fit. Refer to the appropriate Illustrated
Parts Manual for the correct part number, quantity, and
description.
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.
! 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.

1-6
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(s). Clean or replace as neces-
sary.
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.

2-1
2
SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP
TABLE OF
CONTENTS
Periodic Maintenance Chart.................................... 2-2
Periodic Maintenance.............................................. 2-3
Lubrication Points.................................................... 2-3
Air Filter................................................................... 2-3
Valve/Tappet Clearance........................................... 2-4
Testing Engine Compression................................... 2-5
Spark Plug(s) .......................................................... 2-5
Muffler/Spark Arrester ............................................. 2-6
Engine/Transmission Oil - Filter............................... 2-6
Front Differential - Rear Drive Lubricant.................. 2-7
Driveshaft/Coupling ................................................. 2-8
Nuts/Bolts/Cap Screws............................................ 2-8
Headlight/Taillight-Brakelight ................................... 2-8
Shift Lever (XT/XTZ)................................................ 2-9
Shift Lever/Shift Cable (XTX) ..................................... 9
Hydraulic Brake System ........................................ 2-10
Parking Brake (XT/XTZ) ........................................ 2-11
Burnishing Brake Pads.......................................... 2-14
Checking/Replacing V-Belt.................................... 2-14
Troubleshooting Brake System.............................. 2-16

2-2
Periodic Maintenance
Chart
A = Adjust I = Inspect
C = Clean L = Lubricate
R = Replace T = Tighten
* Service/Inspect more frequently when operating in adverse conditions.
** When using an API certified SM 0W-40 oil.
*** When using Arctic Cat ACX All Weather synthetic oil, oil change and strainer inspection interval can be increased to every
1,000 miles or every year.
Item
Initial Service
After Break-In
(First Month or
100 Miles)
Every
Day
Every Month
or
Every 100
Miles
Every 3
Months or
Every 300
Miles
Every 6
Months or
Every 500
Miles
Every Year
or Every
1500 Miles
As
Needed
Battery I I C
Fuses IR
Air Filter I I* R
Valve/Tappet Clearance I I A
Engine Compression I
Spark Plug(s) 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 I I R
Steering Components I I I R
V-Belt I l R
Suspension (Ball joint boots, drive axle
boots front and rear, tie rods, differential
and rear drive bellows)
II R
Nuts/Bolts/Cap Screws T T A
Ignition Timing I
Headlight/Taillight-Brakelight I I R
Switches I I R
Shift Lever IA-L
Gauges/Indicators I I R
Frame/Welds I I l
Electrical Connections lC
Complete Brake System
(Hydraulic & 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

2-3
2
Periodic Maintenance
This section has been organized into sub-sections which show
common maintenance procedures for the Arctic Cat ROV.
 NOTE: Arctic Cat recommends the use of new gas-
kets, 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 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.
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
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-flam-
mable cleaning solvent; then dip the filter in the sol-
vent 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 filter screen.
NOTE: Carefully squeeze excessive oil from the fil-
ter element. Do not twist foam to remove oil.
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.
CHECKING AND CLEANING
DRAINS
1. Inspect one-way drains beneath the main housing for
debris and for proper sealing.
Description p/n
Compression Tester Kit 0444-213
Oil Filter Wrench 0644-389
Timing Light 0644-296
Valve Clearance Adjuster 0444-255
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.

2-4
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
To check and adjust valve/tappet clearance, use the fol-
lowing procedure.
NOTE: The engine must be cold for this procedure.
NOTE: The seats, center console, spark plug, and
air filter housing must be removed for this procedure.
1. Remove the spark plugs and timing inspection plug;
then remove the tappet covers (see Section 3 - Servicing
Top-Side Components).
NOTE: On the XTZ, 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
compression stroke (front cylinder on the XTZ).
GZ063
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
Feeler Gauge Procedure
A. Using a feeler gauge, check each valve/tappet clear-
ance. 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
B. On the XTZ, rotate the engine 270° to the TDC posi-
tion of the rear cylinder; then repeat step A. The
stamped “R” must be visible.
GZ059
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 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.
E. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely
with the valve adjuster handle.
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 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.)

2-5
2
F. On the XTZ, rotate the engine 270° to the TDC
position of the rear cylinder; then repeat steps
A-E for the rear cylinder.
3. Install the spark plug(s) and timing inspection plug;
then on the XTZ remove the cap screw and install the
crankcase end cap.
4. Place the two tappet covers into position making sure
the proper cap screws are with the proper cover.
Tighten the cap screws securely.
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. On the XT/XTX, throttle must be in
the wide-open throttle (WOT) position. In the event the
engine cannot be run, cold values are included.
NOTE: The seats and center console must be
removed for this procedure.
1. Remove the high tension lead from the spark plug(s).
2. Using compressed air, blow any debris from around
the spark plug(s).
3. Remove the spark plug(s); then attach the high tension
lead(s) to the plug(s) and ground the plug(s) on the cyl-
inder head(s) well away from the spark plug hole(s).
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, verify 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 not restricted.
 NOTE: To service top-side components, see Section 3.
7. Pour approximately 30 ml (1 fl oz) of oil into the
spark plug hole(s), reattach the gauge, and retest
compression.
8. If compression increases to normal, service the pis-
ton rings (see Section 3).
Spark Plug(s)
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.).
! WARNING
Always wear safety glasses when using compressed air.
Model PSI Hot (WOT) PSI Cold (WOT)
550 120-140 80-120
700 125-145 100-140
950 (Front) 125-145 80-120
950 (Rear) 165-185 150-190
CAUTION
Before removing a spark plug, be sure to clean the area
around the spark plug. Dirt could enter engine when
removing or installing the spark plug.

2-6
ATV0052E
When installing a 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.
PR837
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.
NOTE: To change oil and filter, the seats and center
console must be removed.
1. Park the vehicle on level ground.
2. Remove the oil level stick/filler plug.
PR053B
GZ415A
3. Remove the drain plug from the bottom of the engine
and drain the oil into a drain pan.
PR078A
! WARNING
Wait until the muffler cools to avoid burns.

2-7
2
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 minutes.
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 oil level must be
within the operating range but not exceeding the
upper mark.
GZ461A
12. 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 fill plug; the lubricant level should be
one inch below the plug threads.
PR530A
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 plug.
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 lubri-
cant into the fill hole.
6. Install the fill plug.
NOTE: If the lubricant is contaminated with water,
inspect the drain plug, fill plug, and/or bladder.
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 not above the upper mark.
Front Differential
Rear Drive

2-8
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.
Headlight/Taillight-Brake-
light
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 can-
opy 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 sur-
face (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 verti-
cal 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.

2-9
2
Shift Lever (XT/XTZ)
CHECKING SHIFT 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) indica-
tion, and reverse for the (R) indication. Shift the trans-
mission into neutral and turn the ignition switch off.
PR571
ADJUSTING SHIFT CABLE
To adjust the shift cable, use the following procedure.
1. Set the parking brake; then remove the seats and cen-
ter 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 housing
to align the shift 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.
Shift Lever/Shift Cable
(XTX)
CHECKING
Turn the ignition switch on; then shift the transmission into
park. The letter P should illuminate on the LCD gauge and
the park icon (P) should illuminate. The vehicle should not
be able to move.
HDX203
Move the shift lever all the way to the rear. The letter L
should illuminate on the LCD gauge.