Arctic Cat Prowler User manual

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2008 Arctic
Cat UTV models (see cover). The complete manual is designed to aid service personnel in service-oriented applica-
tions.
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:
• 2008 Prowler XTX Service Manual
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.
© 2007 Arctic Cat Inc. July 2007
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Back to TOC

PRowler
Prowler XT
Prowler
Prowler XT
08
08
Service Manual
MORE TO GO ON.
TM
UTV
UTV
TABLE OF CONTENTS
Foreword
Click on the red text to go.
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
Back to TOC

1-2
General Specifications*
* Specifications subject to change without notice.
** 1 inch below plug threads.
Torque Specifications
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
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.)
Tracking (front)
(rear)
128.3 cm (50.5 in.)
123.2 cm (48.5 in.)
Tire Size (front)
(rear)
26 x 9-14
26 x 11-14
Tire Inflation Pressure 0.70 kg/cm² (10 psi)
Turning Radius 3.3 m (10.8 ft)
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)
Gasoline (recommended) 87 Octane Regular
Unleaded
Engine Oil (recommended) SAE 5W-30
Differential/Rear Drive Lubricant SAE Approved
80W-90 Hypoid
Belt Width 35.0 mm (1.38 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (2)
Starting System Electric
DRIVE TRAIN COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Engine Cradle Engine 40 54
Engine Cradle Rubber Mount 25 34
Front Differential* Frame/Differential
Bracket
38 52
Rear Output Flange Rear U-Joint Flange 40 54
Input Housing Differential Housing 23 31
Diff 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
Inspection Plug Rear Drive 48 in.-lb 5
Wheel Hub 45 61
Front Shaft Flange Front U-Joint 20 27
EXHAUST COMPONENTS
Exhaust Pipe Engine 20 27
Spark Arrester Muffler 48 in.-lb 5
ELECTRICAL COMPONENTS
Coil* Frame 8 11
Ground Wire Engine 8 11
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 Frame 50 68
Tie Rod End Knuckle 30 41
Jam Nut Tie Rod End 8 11
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 Mecha-
nism
Frame 20 27
Hydraulic Caliper Knuckle 20 27
Rear Caliper Rear Drive Gear Case 20 27
Drive-line Brake Rear Drive Input
Flange
12 16
CHASSIS COMPONENTS
Shift Lever* Shift Axle Bracket 20 27
Back to TOC Back to Section TOC Next

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)
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 5 7
CANOPY ASSEMBLY
Front/Rear Canopy Tube Arm Rest/Steering Post
Support
20 27
Top Canopy Support Front/Rear Canopy
Tubes
10 14
Rear Canopy Tube Lower Canopy Support 8 11
ENGINE/TRANSMISSION
Clutch Shoe** Crankshaft 221 300
Clutch Cover/ Housing
Assembly
Crankcase 10 14
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
Cylinder Head Cover Cylinder Head 9 12
Driven Pulley Nut Driveshaft 221 300
Fixed Driven Clutch Shaft 221 300
Ground Wire Engine 8 11
Magneto 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
Rotor/Flywheel Nut Crankshaft 105 143
Cam Sprocket** Camshaft 10 14
V-Belt Cover Crankcase 8 11
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
Back to TOC Back to Section TOC Next
Back

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 4-Cycle
Engine Oil or an equivalent oil which is rated SE, SF,
or SG under API service classification. These oils
meet all of the lubrication requirements of the Arctic
Cat engine. The recommended engine oil viscosity is
SAE 5W-30. Ambient temperature should determine
the correct weight of oil. See the following viscosity
chart for details.
OILCHARTC
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/rear
drive damage.
Back to TOC Back to Section TOC Next
Back

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 Illus-
trated Parts Manual for the correct part number, quan-
tity, and description.
Preparation For Storage
Arctic Cat recommends the following procedure to
prepare the vehicle 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; then using Arctic Cat Engine Storage
Preserver, 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 hous-
ing cover.
4. Drain the carburetor float chamber.
5. Plug the exhaust hole in the exhaust system with a
clean cloth.
6. Apply light oil to the plungers of the shock absorb-
ers.
7. 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.
8. Fill the cooling system to the bottom of the stand
pipe in the radiator neck with properly mixed cool-
ant.
9. Disconnect the battery cables; then remove the
battery, clean the battery posts and cables, and
store in a clean, dry area.
10. 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.
Back to TOC Back to Section TOC Next
Back

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. Arctic Cat recommends the following proce-
dure to prepare the vehicle.
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 plug. 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.
Back to TOC Back to Section TOC
Back

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
Battery..................................................................... 2-3
Fuses ...................................................................... 2-4
Air Filter................................................................... 2-4
Valve/Tappet Clearance
(Feeler Gauge Procedure) ................................... 2-6
Valve/Tappet Clearance
(Valve Adjuster Procedure) .................................. 2-6
Testing Engine Compression................................... 2-7
Spark Plug............................................................... 2-8
Muffler/Spark Arrester ............................................. 2-8
Gas/Vent Hoses ...................................................... 2-8
Adjusting Engine RPM (Idle) ................................... 2-8
Engine/Transmission Oil - Filter............................... 2-9
Front Differential/Rear Drive Lubricant .................. 2-10
Tires ...................................................................... 2-11
Steering Components ........................................... 2-11
Driveshaft/Coupling ............................................... 2-11
Suspension/Shock Absorbers/Bushings ............... 2-11
Nuts/Bolts/Cap Screws.......................................... 2-11
Ignition Timing ....................................................... 2-11
Headlight/Taillight-Brakelight ................................. 2-12
Switches ................................................................ 2-12
Shift Lever ............................................................. 2-13
Frame/Welds ......................................................... 2-13
Electrical Connections........................................... 2-13
Hydraulic Brake System ........................................ 2-13
Parking Brake........................................................ 2-15
Burnishing Brake Pads.......................................... 2-17
Coolant .................................................................. 2-17
Checking/Replacing V-Belt .................................... 2-17
Troubleshooting Brake System.............................. 2-19
Back to TOC

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.
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 Plug 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
Carb Float Chamber D*
Engine RPM (Idle) I I A
Engine-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R* R
Oil Strainer I I C
Front Differential/Rear Drive Lubricant I I R (4 Yrs)
Tires/Air Pressure I I R
Steering Components I I I R
V-Belt I l R
Suspension (Ball joint boots, drive
axle boots front and rear, tie rods, 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
Back to TOC Back to Section TOC Next

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.
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 Linkage
E. Differential Lock Cable End
F. Idle RPM Screw
Battery
The battery is located in a compartment in front of the
left-rear wheel under the driver seat.
NOTE: To access the battery box, the left-rear
fender splash panel must be removed.
After being in service, batteries require regular clean-
ing and recharging in order to deliver peak perfor-
mance and maximum service life. The following
procedures are recommended for cleaning and main-
taining lead-acid batteries. Always read and follow
instructions provided with battery chargers and battery
products.
1. Remove the battery hold-down; then disconnect
the battery cables (negative cable first).
2. Disconnect the vent hose.
3. Remove the battery from the vehicle; then thor-
oughly wash the battery and battery compartment
with soap and water.
NOTE: If battery posts, cable ends, or the battery
case has a build-up of white/green powder residue,
apply water and baking soda to neutralize acid;
then flush off with warm soapy water.
4. Using a wire brush, clean the battery posts and
cable ends removing all corrosive buildup.
Replace damaged cables or cable ends.
5. Add clean distilled water to bring fluid level to the
UPPER level line.
6. Using a multimeter, test the battery voltage. The
meter must read at least 12.5 DC Volts for a fully
charged battery.
Description p/n
Compression Tester Kit 0444-213
Oil Filter Wrench 0644-389
Timing Light 0644-296
Valve Clearance Adjuster 0444-078
! WARNING
Anytime service is performed on a battery, the fol-
lowing must be observed: keep sparks, open flame,
cigarettes, or any other flame away. Always wear
safety glasses. Protect skin and clothing when
handing a battery. When servicing battery in
enclosed space, keep the area well-ventilated. Make
sure battery venting is not obstructed.
! WARNING
Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a
battery.
! CAUTION
Never use electrolyte (sulfuric acid) to “top off” the
battery. Use only distilled water or severe battery
damage may occur.
Back to TOC Back to Section TOC Next
Back

2-4
NOTE: At this point, if the meter reads as speci-
fied, the battery may be returned to service (see
step 10).
7. If the meter reads less than specified voltage,
charge the battery using the following guidelines.
A. When using an automatic battery charger,
always follow the charger manufacturer’s
instructions.
B. When using a constant-current battery charger,
use the following Battery Charging Chart.
NOTE: If the battery voltage is 11.5 DC Volts or
less, some chargers may “cut off” and fail to
charge. If this occurs, connect a fully charged
booster battery in parallel (positive to positive and
negative to negative) for a short period of time
with the charger connected. After 10-15 minutes,
disconnect the booster battery leaving the charger
connected and the charger should continue to
charge. If the charger “cuts off,” replace the bat-
tery.
8. After charging the battery for the specified time,
remove the battery charger and allow the battery to
sit for 1-2 hours.
9. Connect the multimeter and test the battery volt-
age. The meter should read at least 12.5 DC Volts.
If the voltage is as specified, the battery is ready
for service.
NOTE: If voltage in step 9 is below specifications,
charge the battery an additional 1-5 hours; then
retest. Recheck electrolyte level and the battery is
ready for service.
10. Place the battery in the battery compartment; then
coat the battery posts and cable ends with a light
coat of multi-purpose grease.
11. Connect the battery cables (positive cable first);
then install the battery hold-down.
Fuses
The main fuses are located in a power distribution
module under the operator’s seat.
If there is any type of electrical system failure, always
check the fuses first.
NOTE: To remove the fuse, compress the locking
tabs on either side of the fuse case and lift out.
1411-576
Air Filter
Use the following procedure to remove the filter and
inspect and/or clean it.
! CAUTION
Never exceed the standard charging rate.
! WARNING
An overheated battery could explode causing severe
injury or death. Always monitor charging times and
charge rates carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool
before resuming charging.
Battery Charging Chart (Constant-Current Charger)
Battery Voltage
(DC) Charge State
Charge Time
Required
(at 1.5-2.0 Amps)
12.5 or more 100% None
12.2-12.4 75%-99% 3-6 hours
12.0-12.2 50%-74% 5-11 hours
11.0-11.9 25%-49% 13 hours (minimum)
11.5 or less 0-24% 20 hours (minimum)
! CAUTION
Before installing the battery, make sure the ignition
switch is in the OFF position.
! CAUTION
Connecting cables in reverse (positive to negative
and negative to positive) can cause serious damage
to the electrical system.
Prowler/XT
! CAUTION
Always replace a blown fuse with a fuse of the same
type and rating.
Back to TOC Back to Section TOC Next
Back

2-5
2
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/filter screen assembly and
separate the foam filter from the screen.
PR101
CD747
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 carburetor.
8. Place the filter assembly in the air filter housing
making sure it is properly positioned and properly
seated with the filter screen down.
PR090
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.
CD670
CHECKING AND CLEANING
DRAINS
1. Inspect one-way drains beneath the main housing
for debris and for proper sealing.
! 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.
Back to TOC Back to Section TOC Next
Back

2-6
PR141A
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 plug,
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).
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.
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.
CC007D
4. Install the spark plug; then install the timing
inspection plug.
5. Place the two tappet covers with O-rings into posi-
tion. Tighten the cap screws securely.
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 plug,
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).
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.
NOTE: Use Valve Clearance Adjuster for this pro-
cedure.
! CAUTION
The one-way drain to the left is the clean air section
of the filter housing. Any leak of this one-way 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
measurement of clearance. Failure to measure the
valve clearance accurately could cause valve com-
ponent damage.
VALVE/TAPPET CLEARANCE
Intake 0.1016 mm (0.004 in.)
Exhaust 0.1524 mm (0.006 in.)
Back to TOC Back to Section TOC Next
Back

2-7
2
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. Place the two tappet covers with O-rings into posi-
tion. Tighten the cap screws securely.
CF006A
CF005
9. Install the spark plug; then install the timing
inspection plug.
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 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 ten-
sion 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 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 155-170 psi in the full-open throttle posi-
tion.
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 29.5 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).
! WARNING
Always wear safety glasses when using compressed
air.
Back to TOC Back to Section TOC Next
Back

2-8
Spark Plug
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 or the carburetor may need to
be adjusted. 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.).
ATV0052B
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.
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.
Gas/Vent Hoses
Replace the gas hose every two years. Damage from
aging may not always be visible. Do not bend or
obstruct the routing of the carburetor vent hose. Make
certain that the vent hose is securely connected to the
carburetor and the opposite end is always open.
Adjusting Engine RPM
(Idle)
To properly adjust the idle RPM, a tachometer is nec-
essary. To adjust idle RPM, use the following proce-
dure.
! 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.
Back to TOC Back to Section TOC Next
Back

2-9
2
NOTE: To access the idle adjustment screw, it
will be necessary to remove the seats and center
console. The idle adjustment screw is located on
the left-side of the carburetor.
1. Set the parking brake. With the transmission in
neutral, start the engine and warm it up to normal
operating temperature.
2. Turn the idle adjustment screw clockwise one turn
past the recommended RPM setting; then turn it
counterclockwise to 1250-1350 RPM.
PR081A
Engine/Transmission
Oil - Filter
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.
! WARNING
Adjust the idle to the correct RPM. Make sure the
engine is at normal operating temperature before
adjusting the idle RPM.
! 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.
Back to TOC Back to Section TOC Next
Back

2-10
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.
Front Differential/Rear
Drive Lubricant
To check lubricant, use the following procedure.
1. Remove the fill/level plug; the lubricant level
should be 1 in. below the plug threads.
PR046A
2. If low, add SAE approved 80W-90 hypoid gear
lube as necessary.
PR065A
To change the lubricant, use the following procedure.
1. Place the vehicle on level ground.
2. Remove each fill/level plug.
3. Drain the lubricant into a drain pan by removing in
turn the drain plug from each.
ATV0082A
737-651A
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/level hole.
6. Install the fill/level plugs.
NOTE: If the differential/rear drive lubricant is
contaminated with water, inspect the drain plug,
fill/level plug, and/or bladder.
! 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.
Rear Drive
Back to TOC Back to Section TOC Next
Back

2-11
2
Tires
TIRE SIZES
The UTV models are equipped with low-pressure
tubeless tires of the size and type listed in Section 1.
Do not under any circumstances substitute tires of a
different type or size.
TIRE INFLATION PRESSURE
Front and rear tire inflation pressure should be 0.70
kg-cm² (10 psi).
A low-pressure gauge is provided in the tool kit to
measure the air pressure in the tires. Check the air
pressure in all tires before each use of the vehicle.
Steering Components
The following steering components should be
inspected periodically to ensure safe and proper opera-
tion.
A. Steering wheel secure.
B. Steering has equal and complete full-left and
full-right capability.
C. Steering sector mounting bolts tight.
D. Ball joints not worn, cracked, or damaged.
E. Tie rods not bent or cracked.
F. Knuckles not worn, cracked, or damaged.
G. Cotter pins not damaged or missing.
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.
Suspension/Shock
Absorbers/Bushings
The following suspension system components should
be inspected periodically to ensure proper operation.
A. Shock absorber rods bent, pitted, or damaged.
B. Rubber damper cracked, broken, or missing.
C. Shock absorber body damaged, punctured, or
leaking.
D. Shock absorber eyelets broken, bent, or
cracked.
E. Shock absorber eyelet bushings worn, deterio-
rated, cracked, or missing.
F. Shock absorber spring broken or sagging.
G. Sway bar mountings tight and bushings secure.
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. For proper torque values, see Section 1.
Ignition Timing
The ignition timing cannot be adjusted; however, veri-
fying ignition timing can aid in troubleshooting other
components. To verify ignition timing, use the follow-
ing procedure.
NOTE: To check ignition timing, the seats and
center console must be removed.
1. Attach the Timing Light to the spark plug high ten-
sion lead; then remove the timing inspection plug
from the left-side crankcase cover.
2. Start the engine and using the RPM function on
the speedometer/tachometer (XT) or using a suit-
able tachometer (Prowler), run at 1500 RPM; igni-
tion timing should be 10° BTDC.
3. Install the timing inspection plug.
If ignition timing cannot be verified, the rotor may be
damaged, the key may be sheared, the trigger coil
bracket may be bent or damaged, or the CDI unit may
be faulty.
! WARNING
Always use the size and type of tires specified.
Always maintain proper tire inflation pressure.
Back to TOC Back to Section TOC Next
Back

2-12
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
Switches
Each time the vehicle is used, switches should be
checked for proper operation. Use the following list
for reference.
A. Ignition/start switch — engine will run; starter
will engage.
! WARNING
Do not attempt to remove the bulb when it is hot.
Severe burns may result.
Back to TOC Back to Section TOC Next
Back