2008 Arctic Cat 650 Prowler XT ATV OEM Service & Repair Manual

FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2008 Arctic Cat UTV models. The complete manual is designed to aid service personnel 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 follow the directive because it deals with the possibility of severe personal injury or even death. The symbol ! CAUTION identifies unsafe practices which may result in vehicle-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the vehicle. The symbol NOTE: identifies supplementary information worthy of particular attention. The symbol AT THIS POINT directs the technician to certain and specific procedures to promote efficiency and to improve clarity. At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred. All materials and specifications are subject to change without notice. Keep this manual accessible in the shop area for reference. Product Service and Warranty Department Arctic Cat Inc. © 2008 Arctic Cat Inc. March 2008 ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

PRowler Prowler XT PROWLER XTX Prowler Prowler XT PROWLER XTX 08 08 Service Manual MORE TO GO ON. TM UTV UTV TABLE OF CONTENTS Click on the red text to go. Foreword 1. General Information/Specifications 2. Periodic Maintenance/Tune-Up 3. Engine/Transmission 4. Fuel/Lubrication/Cooling 5. Electrical System 6. Drive System 7. Suspension 8. Steering/Frame 9. Controls/Indicators 1 2 3 4 5 6 7 8 9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

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 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

1-2 General Specifications* * Specifications subject to change without notice. ** Visible at 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.) Tire Size (front) (rear) 26 x 9-14 26 x 11-14 Tire Inflation Pressure 0.70 kg/cm² (10 psi) MISCELLANY Gas Tank Capacity (rated) 31 L (8.2 U.S. gal.) Coolant Capacity 2.9 L (3.0 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)** Engine Oil Capacity 2.5 L (2.6 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) Arctic Cat ACX All- Weather Synthetic Front Differential Lubricant SAE Approved 80W-90 Hypoid Rear Drive Lubricant (Prowler/XT) SAE Approved 80W-90 Hypoid Rear Differential Lubricant (XTX) Arctic Cat 80W-90 Hypoid Friction Modified Belt Width 35.0 mm (1.38 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Starting System Electric 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 Differential Housing Cover*** Differential Housing 23 31 Drive Bevel Gear Nut*** Shaft 87 118 Lock Collar Differential Housing 125 170 Hub Nut Front/Rear Shaft/Axle (min) 200 272 Oil Drain Plug Front Differential - Rear Drive/Differential 45 in.-lb 5 Oil Fill Plug Front Differential - Rear Drive/Differential 16 22 Oil Drain Plug Engine 16 22 Wheel Hub 45 61 Front 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 Assem- bly 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 Driveline Brake Rear Drive Input Flange 12 16 CHASSIS COMPONENTS Shift Lever* Shift Axle Bracket 20 27 Back to TOC Back to Section TOC Next FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

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 8 11 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 80 109 Drive Pulley Clutch Shaft 165 224 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 11 15 V-Belt Cover Crankcase 8 11 ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m 1 1.4 26 35.4 51 69.4 76 103.4 2 2.7 27 36.7 52 70.7 77 104.7 3 4.1 28 38.1 53 72.1 78 106.1 4 5.4 29 39.4 54 73.4 79 107.4 5 6.8 30 40.8 55 74.8 80 108.8 6 8.2 31 42.2 56 76.2 81 110.2 7 9.5 32 43.5 57 77.5 82 111.5 8 10.9 33 44.9 58 78.9 83 112.9 9 12.2 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 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

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 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 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 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 5W-50 oil is acceptable. OILCHARTI RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT (Prowler/XT) 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. RECOMMENDED DIFFERENTIAL LUBRICANT (Prowler XTX) NOTE: Arctic Cat recommends the use of genuine Arctic Cat lubricants. The recommended lubricant for the front differential is SAE approved 80W-90 hypoid. This lubricant meets all of the front diffrential lubrication requirements of this vehicle. ! CAUTION Do not use white gas. Only Arctic Cat approved gasoline 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 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

1-5 1 The recommended lubricant for the rear differential is Arctic Cat 80W-90 Hypoid Friction Modified. This lubricant meets all of the rear differential lubrication requirements of this vehicle. 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 genuine Arctic Cat parts. They are precision-made to ensure high quality and correct fit. Refer to the appro- priate Illustrated Parts Manual for the correct part number, quantity, and description. 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 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 housing cover and air filter. Start the engine and allow it to idle. Using Arctic Cat Engine Storage Pre- server, 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 housing cover. 4. On the carbureted models, 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 absorbers. 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 coolant. 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. ! CAUTION Any lubricant used in place of the recommended lubricant could cause serious differential 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. ! 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 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

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. 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 making sure all calibrated nuts, cap screws, and bolts are tightened to specifications. 9. Check tire pressure. Inflate to recommended pressure as necessary. 10. Make sure the steering moves freely and does not bind. 11. Check the spark plug. Clean or replace as necessary. ! 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 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

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 ................................................................... 2-5 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/ Differential Lubricant .......................................... 2-10 Tires ...................................................................... 2-10 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 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

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 I R 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 C R Gas/Vent Hoses I I R (2 Yrs) Throttle Cable Ends/Accelerator Pedal Pivot I I C-L A-R Float Chamber (Prowler/XT) D* Engine RPM (Idle) (Prowler/XT) 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/Differ- ential 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) I I R Nuts/Bolts/Cap Screws T T A Ignition Timing I Headlight/Taillight-Brakelight I I R Switches I I R Shift Lever I A-L Gauges/Indicators I I R Frame/Welds I I l Electrical Connections l C Complete Brake System (Hydraulic & Parking) I I 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 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

2008 Arctic Cat 650 Prowler XT ATV OEM Service & Repair Manual

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