Arctic Cat 2012 Prowler Hdx Service Manual-21031A320054.pdf -Bookmark created by https://wimanual.com Foreword Table of Contents General Information General Specifications Torque Specifications Torque Conversions (ft-lb Break-In Procedure Gasoline - Oil - Lubricant RECOMMENDED GASOLINE RECOMMENDED ENGINE RECOMMENDED FRONT DIFFERENTIAL FILLING GAS TANK Genuine Parts Preparation For Storage Preparation After Storage Periodic Maintenance Periodic Maintenance Chart SPECIAL TOOLS Lubrication Points Air Filter CHECKING AND CLEANING DRAINS Valve Feeler Gauge Procedure Valve Adjuster Procedure Testing Engine Compression Spark Plug Muffler Engine OIL - FILTER Front Differential - Rear Drive Lubricant Driveshaft Nuts Headlight HEADLIGHT TAILLIGHT-BRAKELIGHT CHECKING Shift Lever CHECKING SHIFT CABLE ADJUSTMENT ADJUSTING SHIFT CABLE ADJUSTING PARK INDICATOR LIGHT Hydraulic Brake System CHECKING INSPECTING HOSES CHECKING BRAKE DISC Burnishing Brake Pads Checking REMOVING INSTALLING Troubleshooting Brake System Engine SPECIAL TOOLS Troubleshooting 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 Left-Side Components Removing Left-Side Components A. Water Pump B. Side Cover C. Rotor Servicing Left-Side Components INSPECTING STARTER CLUTCH REPLACING STARTER CLUTCH ASSEMBLY REPLACING STARTER GEAR BEARING INSPECTING STATOR REPLACING STATOR COIL Installing Left-Side Components Right-Side Components Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover Servicing Right-Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE INSPECTING CLUTCH HOUSING INSPECTING PRIMARY ONE-WAY DRIVE INSPECTING OIL PUMP DRIVEN PULLEY 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 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 Fuel SPECIAL TOOLS Electronic Fuel Injection TROUBLESHOOTING REMOVING THROTTLE BODY INSTALLING THROTTLE BODY Gas Tank REMOVING CLEANING AND INSPECTING INSTALLING Gas Oil Filter TESTING OIL PUMP PRESSURE REMOVING CLEANING AND INSPECTING ASSEMBLING Liquid Cooling System Radiator REMOVING CLEANING AND INSPECTING INSTALLING Thermostat REMOVING INSPECTING INSTALLING Fan REMOVING INSTALLING Water Pump REMOVING INSTALLING Electric Fuel Pump TESTING REMOVING INSPECTING INSTALLING Troubleshooting Electrical System SPECIAL TOOLS Battery Maintenance Charging Charging 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) 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) 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 VOLTAGE 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 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 REMOVING INSPECTING INSTALLING Troubleshooting Suspension Front Shock Absorbers REMOVING CLEANING AND INSPECTING INSTALLING Rear Shock Absorbers REMOVING DISASSEMBLING ASSEMBLING 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 Steering Electronic Power Steering (EPS) REMOVING EPS ASSEMBLY INSTALLING EPS ASSEMBLY REMOVING TIE RODS INSTALLING TIE RODS Steering Assembly REMOVING INSPECTING INSTALLING Steering Wheel REMOVING INSPECTING INSTALLING Upper Steering Shaft REMOVING INSPECTING INSTALLING Intermediate Steering Shaft Assembly REMOVING INSPECTING INSTALLING Steering Knuckles REMOVING AND DISASSEMBLING CLEANING AND INSPECTING ASSEMBLING AND INSTALLING Accelerator Pedal REMOVING INSTALLING Shift Lever REMOVING INSTALLING Shift Cable REMOVING INSTALLING LCD Gauge REPLACING Checking Front Bumper Assembly REMOVING CLEANING AND INSPECTING INSTALLING Hood REMOVING CLEANING AND INSPECTING INSTALLING Fenders REMOVING INSTALLING Floor REMOVING CLEANING AND INSPECTING INSTALLING Dashboard REMOVING 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 Seat REMOVING Troubleshooting . 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