Arctic Cat 2011 Prowler Xt Xtx Xtz Service Manual-21031A320044.pdf -Bookmark created by https://wimanual.com Foreword TABLE OF CONTENTS Section 1 General Specifications Torque Specifications Torque Conversions (ft-lb Tightening Torque (General Bolts) Break-In Procedure Gasoline - Oil - Lubricant RECOMMENDED GASOLINE RECOMMENDED ENGINE RECOMMENDED FRONT DIFFERENTIAL FILLING GAS TANK Genuine Parts Preparation For Storage Preparation After Storage Section 2 Periodic Maintenance Chart Periodic Maintenance SPECIAL TOOLS Lubrication Points Air Filter CLEANING AND INSPECTING FILTER CHECKING AND CLEANING DRAINS Valve Feeler Gauge Procedure Valve Adjuster Procedure Valve Feeler Gauge Procedure Valve Adjuster Procedure Testing Engine Compression Spark Plug(s) Muffler Engine OIL - FILTER Front Differential - Rear Drive Lubricant Driveshaft Nuts Headlight HEADLIGHT TAILLIGHT-BRAKELIGHT CHECKING Shift Lever CHECKING SHIFT CABLE ADJUSTING SHIFT CABLE Hydraulic Brake System CHECKING INSPECTING HOSES CHECKING BRAKE DISC Parking Brake CHECKING ADJUSTING MEASURING Removing Inspecting and Measuring Installing MEASURING Burnishing Brake Pads Checking REMOVING INSTALLING Troubleshooting Brake System Section 3 Engine SPECIAL TOOLS Specifications Troubleshooting Prowler XT Removing Engine Top-Side Components Removing Top-Side Components A. Valve Cover B. Cylinder Head C. Cylinder D. Piston Servicing Top-Side Components VALVE ASSEMBLY Cleaning Removing Valves Measuring Valve Stem Runout Measuring Valve Stem Outside Diameter Measuring Valve Face Measuring Valve Face Radial Runout Measuring Valve Guide Measuring Valve Guide (Inside Diameter) Servicing Valves Measuring Rocker Arm (Inside Diameter) Measuring Rocker Arm Shaft (Outside Diameter) Installing Valves PISTON ASSEMBLY Removing Piston Rings Cleaning Measuring Piston-Ring End Gap (Installed) Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore Measuring Piston Skirt Installing Piston Rings CYLINDER Cleaning Measuring Cylinder Head Distortion Cleaning Inspecting Cam Chain Guide Honing Cylinder Measuring Camshaft Runout Measuring Camshaft Lobe Height Inspecting Camshaft Bearing Journal Measuring Camshaft to Cylinder Head Clearance Inspecting Camshaft Spring Installing Top-Side Components A. Piston B. Cylinder C. Cylinder Head D. Valve Cover Right-Side Components Removing Right-Side Components A. Water Pump B. Right-Side Cover C. Rotor Installing Right-Side Components Left-Side Components Removing Left-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover Servicing Left-Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE INSPECTING CLUTCH HOUSING INSPECTING PRIMARY ONE-WAY DRIVE INSPECTING OIL PUMP DRIVEN PULLEY Installing Left-Side Components Center Crankcase Components Separating Crankcase Halves Disassembling Crankcase Half Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS Initial Set-Up Checking Backlash Correcting Backlash CRANKSHAFT ASSEMBLY Measuring Connecting Rod (Small End Inside Diameter) Measuring Connecting Rod (Small End Deflection) Measuring Connecting Rod (Big End Side-to-Side) Measuring Crankshaft (Runout) Measuring Crankshaft (Web-to-Web) COUNTERSHAFT Disassembling Assembling Assembling Crankcase Half Joining Crankcase Halves Installing Engine Prowler XTZ (Table of Contents) Removing Engine Top-Side Components Removing Top-Side Components A. Valve Cover C. Cylinders D. Pistons Servicing Top-Side Components VALVE ASSEMBLY Cleaning Removing Valves Measuring Valve Stem Runout Measuring Valve Stem Outside Diameter Measuring Valve Face Measuring Valve Face Radial Runout Measuring Valve Guide Measuring Valve Guide (Inside Diameter) Servicing Valves Measuring Rocker Arm (Inside Diameter) Measuring Rocker Arm Shaft (Outside Diameter) Installing Valves PISTON ASSEMBLY Removing Piston Rings Cleaning Measuring Piston-Ring End Gap (Installed) Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore Measuring Piston Skirt Installing Piston Rings CYLINDER Cleaning Measuring Cylinder Head Distortion Cleaning Inspecting Cam Chain Guide Inspecting Cylinder Measuring Camshaft Runout Measuring Camshaft Lobe Height Inspecting Camshaft Bearing Journal Measuring Camshaft to Cylinder Head Clearance Inspecting Camshaft Spring Installing Top-Side Components A. Pistons B. Cylinders C. Cylinder Head D. Valve Cover Left-Side Components Removing Left-Side Components A. Magneto Cover Installing Left-Side Components Right-Side Components Removing Right-Side Components A. CVT Cover B. Driven Pulley C. Clutch Cover D. Centrifugal Clutch Servicing Right-Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE INSPECTING CLUTCH HOUSING INSPECTING PRIMARY ONE-WAY DRIVE DRIVEN PULLEY ASSEMBLY WATER PUMP DRIVE ASSEMBLY Disassembling Inspecting Assembling Installing Right-Side Components Center Crankcase Components Separating Crankcase Halves Disassembling Crankcase Half Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS Initial Set-Up Checking Backlash Correcting Backlash OIL PUMP ASSEMBLY Disassembling and Inspecting Assembling CRANKSHAFT ASSEMBLY Measuring Connecting Rod (Small End Inside Diameter) Measuring Connecting Rod (Small End Deflection) Measuring Connecting Rod (Big End Side-to-Side) Measuring Crankshaft (Runout) Measuring Crankshaft (Web-to-Web) COUNTERSHAFT Disassembling Assembling Assembling Crankcase Half Joining Crankcase Halves Installing Engine Section 4 Fuel SPECIAL TOOLS Electronic Fuel Injection (H1) TROUBLESHOOTING REMOVING THROTTLE BODY INSTALLING THROTTLE BODY Electronic Fuel Injection (H2) TROUBLESHOOTING REMOVING THROTTLE BODY INSTALLING THROTTLE BODY Gas Tank REMOVING CLEANING AND INSPECTING INSTALLING Gas Oil Filter TESTING OIL PUMP PRESSURE (XT) TESTING OIL PUMP PRESSURE (XTX REMOVING CLEANING AND INSPECTING ASSEMBLING Oil Cooler (XTX REMOVING CLEANING AND INSPECTING INSTALLING Liquid Cooling System Radiator REMOVING CLEANING AND INSPECTING INSTALLING Thermostat (XT REMOVING INSPECTING INSTALLING Thermostat (XTZ) REMOVING INSPECTING INSTALLING Fan REMOVING INSTALLING Water Pump (XT REMOVING INSTALLING Water Pump (XTZ) REMOVING INSTALLING Electric Fuel Pump TESTING REMOVING INSPECTING INSTALLING Troubleshooting Section 5 Electrical System SPECIAL TOOLS Specifications Battery RPM Limiter Testing Electrical Components Switches Electrical Connections Accessory Receptacle VOLTAGE Brakelight Switch VOLTAGE (Wiring Harness Connector) RESISTANCE (Switch Connector) Engine Coolant Temperature (ECT) Sensor Fan Motor RESISTANCE (Fan Motor Connector) Power Distribution Module (PDM) FUSES RELAYS Ignition Coil VOLTAGE (Primary Side) RESISTANCE Primary Winding Secondary Winding Spark Plug Cap VOLTAGE Primary Coil EFI Sensors CRANKSHAFT POSITION (CKP) SENSOR MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Speed Sensor Electronic Power Steering (EPS) (XT Ignition Switch VOLTAGE Headlight Switch VOLTAGE Drive Select Switch RESISTANCE VOLTAGE Reverse Override Switch VOLTAGE Front Drive Actuator VOLTAGE Stator Coil VOLTAGE (AC Generator - Regulated Output) VOLTAGE (AC Generator - No Load) RESISTANCE (AC Generator) RESISTANCE (Crankshaft Position Sensor) AC VOLTAGE Crankshaft Position Sensor Starter Motor REMOVING INSTALLING TESTING VOLTAGE Starter Relay Electronic Control Unit (ECU) Regulator TESTING Headlights VOLTAGE Taillight-Brakelight VOLTAGE (Taillight) VOLTAGE (Brakelight) Ignition Timing ECU Error Codes ECU Error Code List Tilt Sensor SUPPLY VOLTAGE OUTPUT VOLTAGE Throttle Position Sensor (TPS) INSPECTING REMOVING INSTALLING Troubleshooting Section 6 Drive System GENERAL INFORMATION SPECIAL TOOLS Front Drive Actuator REMOVING INSTALLING Front Differential REMOVING Disassembling Input Shaft Assembling Input Shaft Disassembling Differential Assembly Disassembling Pinion Gear Assembling Pinion Gear Shimming Procedure Backlash Ring Gear End-Play Assembling Differential Assembly Removing INSTALLING DIFFERENTIAL Drive Axles REMOVING REAR DRIVE AXLE REMOVING FRONT DRIVE AXLE CLEANING AND INSPECTING AXLES DISASSEMBLING AXLES ASSEMBLING AXLES INSTALLING REAR DRIVE AXLE INSTALLING FRONT DRIVE AXLE Rear Gear Case REMOVING RING GEAR Removing Inspecting Installing REAR DRIVE INPUT SHAFT Removing Cleaning and Inspecting Assembling INSTALLING Hub REMOVING CLEANING AND INSPECTING REPLACING WHEEL STUDS INSTALLING Hydraulic Brake Caliper REMOVING CLEANING AND INSPECTING ASSEMBLING MASTER CYLINDER ASSEMBLY Removing Inspecting Installing Universal Joints (XTZ) REMOVING INSPECTING INSTALLING Troubleshooting Section 7 Suspension Shock Absorbers REMOVING CLEANING AND INSPECTING INSTALLING Front A-Arms REMOVING CLEANING AND INSPECTING INSTALLING Rear A-Arms REMOVING CLEANING AND INSPECTING INSTALLING Wheels and Tires TIRE SIZE TIRE INFLATION PRESSURE REMOVING CLEANING AND INSPECTING INSTALLING CHECKING Troubleshooting Section 8 Steering Steering Assembly (XT) REMOVING INSPECTING REPLACING TIE RODS INSTALLING Electronic Power Steering (EPS) (XTX REMOVING EPS ASSEMBLY INSTALLING EPS ASSEMBLY REMOVING TIE RODS INSTALLING TIE RODS Steering Assembly (XTX REMOVING INSPECTING INSTALLING Steering Wheel REMOVING INSPECTING INSTALLING Upper Steering Shaft REMOVING INSPECTING INSTALLING Lower Steering Shaft Assembly REMOVING INSPECTING INSTALLING Steering Knuckles REMOVING AND DISASSEMBLING CLEANING AND INSPECTING ASSEMBLING AND INSTALLING Checking Front Bumper Assembly REMOVING CLEANING AND INSPECTING INSTALLING Hood REMOVING CLEANING AND INSPECTING INSTALLING Fenders REMOVING INSTALLING Floor REMOVING CLEANING AND INSPECTING INSTALLING Belly Panel REMOVING INSTALLING Exhaust System REMOVING MUFFLER INSPECTING MUFFLER INSTALLING MUFFLER Cargo Box REMOVING CLEANING AND INSPECTING INSTALLING Taillight Assembly REMOVING INSPECTING INSTALLING Seats REMOVING Troubleshooting Section 9 Accelerator Pedal REMOVING INSTALLING Shift Lever REMOVING INSTALLING Speedometer REPLACING Back Cover . 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