2012 Arctic Cat 700i HDX Prowler Factory Service & Work Shop Manual

FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2012 Arctic Cat Prowler HDX. 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 serious personal injury or even death. A 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 wor- thy 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. © 2011 Arctic Cat Inc. December 2011 ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

TM SHARE OUR PASSION. 2012 2012 Service Manual Service Manual ROV ROV Service Manual Service Manual Prowler HDX Prowler HDX Prowler HDX 1 Table of Contents General Information ........................................................ 2 General Specifications......................................................... 2 Torque Specifications .......................................................... 3 Torque Conversions (ft-lb/N-m)............................................ 4 Break-In Procedure ............................................................. 4 Gasoline - Oil - Lubricant ..................................................... 4 Genuine Parts...................................................................... 5 Preparation For Storage ...................................................... 5 Preparation After Storage .................................................... 5 Periodic Maintenance...................................................... 7 Periodic Maintenance Chart ................................................ 7 Lubrication Points ................................................................ 8 Air Filter ............................................................................... 8 Valve/Tappet Clearance ....................................................... 8 Testing Engine Compression ............................................... 9 Spark Plug ........................................................................... 9 Muffler/Spark Arrester ....................................................... 10 Engine/Transmission Oil - Filter ......................................... 10 Front Differential - Rear Drive Lubricant ............................ 11 Driveshaft/Coupling ........................................................... 12 Nuts/Bolts/Cap Screws ...................................................... 12 Headlight/Taillight-Brakelight ............................................. 12 Shift Lever.......................................................................... 13 Hydraulic Brake System .................................................... 14 Burnishing Brake Pads ...................................................... 16 Checking/Replacing V-Belt ................................................ 16 Troubleshooting Brake System .......................................... 17 Engine/Transmission .................................................... 18 Troubleshooting ................................................................. 19 Removing Engine/Transmission ........................................ 21 Top-Side Components ....................................................... 23 Removing Top-Side Components ...................................... 24 Servicing Top-Side Components ....................................... 27 Installing Top-Side Components ........................................ 34 Left-Side Components ....................................................... 39 Removing Left-Side Components...................................... 39 Servicing Left-Side Components ....................................... 42 Installing Left-Side Components........................................ 43 Right-Side Components .................................................... 46 Removing Right-Side Components ................................... 47 Servicing Right-Side Components ................................... 50 Installing Right-Side Components ..................................... 50 Center Crankcase Components ........................................ 53 Separating Crankcase Halves ........................................... 54 Disassembling Crankcase Half .......................................... 54 Servicing Center Crankcase Components ........................ 56 Assembling Crankcase Half............................................... 61 Joining Crankcase Halves ................................................. 63 Installing Engine/Transmission .......................................... 63 Fuel/Lubrication/Cooling .............................................. 67 Electronic Fuel Injection .................................................... 67 Gas Tank ........................................................................... 68 Gas/Vent Hoses................................................................. 70 Oil Filter/Oil Pump ............................................................. 70 Liquid Cooling System....................................................... 71 Radiator ............................................................................. 71 Thermostat ........................................................................ 73 Fan..................................................................................... 73 Water Pump ....................................................................... 73 Electric Fuel Pump/Fuel Level Sensor............................... 74 Troubleshooting ................................................................. 76 Electrical System........................................................... 77 Battery ............................................................................... 77 RPM Limiter ....................................................................... 78 Testing Electrical Components .......................................... 78 Switches ............................................................................ 78 Electrical Connections....................................................... 78 Accessory Receptacle/Connector ..................................... 78 Brakelight Switch............................................................... 78 Engine Coolant Temperature (ECT) Sensor ..................... 79 Fan Motor .......................................................................... 79 Power Distribution Module (PDM) ..................................... 80 Ignition Coil ....................................................................... 80 EFI Sensors/Components ................................................. 81 Speed Sensor ................................................................... 81 Electronic Power Steering (EPS) ...................................... 82 Ignition Switch ................................................................... 83 Headlight Switch ............................................................... 83 Drive Select Switch ........................................................... 84 Reverse Override Switch................................................... 84 Front Drive Actuator .......................................................... 84 Stator Coil/Crankshaft Position (CKP) Sensor .................. 85 Starter Motor ..................................................................... 86 Starter Relay ..................................................................... 86 Electronic Control Unit (ECU) ........................................... 87 Regulator/Rectifier ............................................................ 87 Headlights ......................................................................... 87 Taillight-Brakelight ............................................................. 88 Ignition Timing ................................................................... 88 ECU Error Codes .............................................................. 88 Tilt Sensor ......................................................................... 89 Throttle Position Sensor (TPS).......................................... 90 Troubleshooting ................................................................. 92 Drive System ..................................................................94 Front Drive Actuator .......................................................... 94 Front Differential ................................................................ 95 Drive Axles ...................................................................... 107 Rear Gear Case .............................................................. 112 Hub.................................................................................. 114 Hydraulic Brake Caliper................................................... 116 Universal Joints ............................................................... 119 Troubleshooting ............................................................... 121 Suspension...................................................................122 Front Shock Absorbers.................................................... 122 Rear Shock Absorbers .................................................... 122 Front A-Arms ................................................................... 128 Rear A-Arms ................................................................... 130 Wheels and Tires ............................................................ 132 Troubleshooting ............................................................... 133 Steering/Frame/Controls .............................................134 Electronic Power Steering (EPS) .................................... 134 Steering Assembly .......................................................... 137 Steering Wheel................................................................ 138 Upper Steering Shaft....................................................... 138 Intermediate Steering Shaft Assembly ............................ 139 Steering Knuckles ........................................................... 140 Accelerator Pedal ............................................................ 142 Shift Lever ....................................................................... 142 Shift Cable....................................................................... 143 LCD Gauge/Indicator Lights ............................................ 144 Checking/Adjusting Front Wheel Alignment .................... 145 Front Bumper Assembly .................................................. 145 Hood................................................................................ 146 Fenders ........................................................................... 146 Floor ................................................................................ 147 Dashboard....................................................................... 147 Belly Panel ...................................................................... 148 Exhaust System .............................................................. 148 Cargo Box ....................................................................... 148 Taillight Assembly ............................................................ 149 Seat ................................................................................. 149 Troubleshooting ............................................................... 150

2 General Information NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. General Specifications Specifications subject to change without notice. * One in. below plug threads. CHASSIS Dry Weight (approx) 618 kg (1363 lb) ROPS Tested Curb Weight 680 kg (1500 lb) Length (overall) 327.6 cm (129 in.) Height (overall) 193.3 cm (76.5 in.) Width (overall) 153 cm (60.25 in.) Suspension Travel 25.4 cm (10 in.) Brake Type Hydraulic Tire Size (front) (rear) 26 x 10R-14 26 x 12R-14 Tire Inflation Pressure 1.41 kg/cm² (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 2.9 L (3.0 U.S. qt) Front Differential Capacity 275 ml (9.3 fl oz)* Rear Drive Capacity 250 ml (8.5 fl oz)* Engine Oil Capacity (approx) 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 Hypoid Belt Width 35.0 mm (1.38 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (4) IGNITION 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 (-)) MAGNETO Stator Coil (crankshaft position sensor) Resistance (AC generator) 150-250 ohms (blue to green) 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 VALVES AND GUIDES Valve Face Diameter (intake) (exhaust) 31.6 mm 27.9 mm Valve/Tappet Clearance (intake) (cold engine) (exhaust) 0.1016 mm 0.1524 mm Valve Guide/Stem Clearance 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 (min) (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 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 Piston Skirt/Cylinder Clearance (min) 0.06 mm Cylinder Bore 101.992-102.008 mm Piston Diameter 15 mm from Skirt End 101.930-101.949 mm Piston Ring Free End Gap (1st/2nd) 12.5 mm Bore x Stroke 102 x 85 mm Cylinder Trueness (max) 0.01 mm Piston Ring End Gap - Installed (min) 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 CRANKSHAFT Connecting Rod (small end inside (max) diameter) 23.021 mm Connecting Rod (big end side-to-side) (min) 0.6 mm Connecting Rod @ 150 mm (max) (small end deflection) 0.3 mm Crankshaft (web-to-web) (min) 71 mm Crankshaft Runout (max) 0.03 mm

3 Torque Specifications NOTE: Torque specifications have the following tol- erances: * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #270 **** w/“Patch-Lock” 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 CHASSIS/ROPS ASSEMBLY Shift Axle Support Frame 48 in.-lb 5 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 Shift Cable Shift Arm Stud 8 11 Shift Cable Mounting/Adjuster Shift Cable 20 27 Cargo Box Hinge Cargo Box Frame 20 27 Side Panel/Spacer Cargo Box Frame 25 34 Tilt Pivot Bushing Cargo Box Frame 15 20 Latch Striker Cargo Box Liner 60 in.-lb 7 STEERING COMPONENTS Steering Wheel** Steering Wheel Shaft 25 34 Steering Wheel Shaft*** Intermediate Shaft (Upper) 36 49 Intermediate Shaft (Lower)*** Steering Pinion Shaft 36 49 Rack and Pinion Assembly Frame 35 48 Tie Rod Rack 37 50 Tie Rod End** Knuckle 30 41 Jam Nut Tie Rod End 10 14 Steering Shaft Coupler EPS Input Shaft 11 15 EPS Cradle Bracket Frame 20 27 EPS Assembly Frame 35 48 EPS Assembly Rack Coupler 11 15 Intermediate Shaft Coupler Intermediate Shaft 31 42 Steering Shaft Housing (6 mm) Frame 8 11 Steering Shaft Housing (8 mm) Frame 20 27 SUSPENSION COMPONENTS (Front) A-Arm Frame 33 45 Knuckle Ball Joint 35 48 Shock Absorber Frame/Upper A-Arm 33 45 Shock Absorber Lower A-Arm 20 27 Knuckle A-Arm 35 48 SUSPENSION COMPONENTS (Rear) Sway Bar Bracket Frame 33 45 A-Arm Frame 33 45 Shock Absorber Lower A-Arm 33 45 Shock Absorber Frame 33 45 Knuckle A-Arm 35 48 BRAKE COMPONENTS Brake Disc** Hub 15 20 Brake Hose Caliper 20 27 Brake Hose Master Cylinder 20 27 Master Cylinder Frame 25 34 Caliper**** Knuckle 20 27 Driveline Rear Drive Input Flange 20 27 DRIVE TRAIN COMPONENTS Part Part Bolted To Torque ft-lb N-m Rear Differential/Gear Case Frame 38 48 Drive Coupler (Front) 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 Driven Flange 40 54 Input Shaft Assembly Gear Case Housing 23 31 Pinion Housing Differential Housing 23 31 Secondary Shaft Bearing Housing Crankcase 28 38 Rear Cradle Frame 25 34 Driveshaft (Front/Rear) Engine 20 27 Shift Cable Bracket Engine 8 11 Front Input Drive Flange Front Drive Yoke Flange 20 27 Differential Housing Cover*** Differential Housing 23 31 Thrust Button** Gear Case Cover 8 11 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 Hub 80 108 ELECTRICAL COMPONENTS Coil* Frame 8 11 Ground Wire Engine 8 11 ENGINE/TRANSMISSION 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 One-Way Clutch** Rotor/Flywheel 26 35 Outer Magneto Cover Side 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 Ouput Shaft Flange Yoke/Nut** Output Shaft 59 80 Secondary Shaft Bearing Housing Crankcase Half 28 38 Stator Coil* Magneto Cover 13 18 Intake Manifold Boot Clamp Intake Boot 30 in.-lb 3.4

4 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 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 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 the Periodic Maintenance section). 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 0W-40 oil is acceptable. OILCHARTJ 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 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 cas- tor-based oils.

5 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. 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 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 absorbers. 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 coolant. 8. Disconnect the battery cables; then remove the battery, 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. CAUTION Any lubricant used in place of the recommended lubricant 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. 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.

6 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 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 nega- tive.

7 Periodic Maintenance This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat ROV. SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section. Refer to the current Special Tools Catalog for the appropriate tool description. NOTE: Special tools are available from the Arctic Cat Service Department. Periodic Maintenance Chart A = Adjust I = Inspect C = Clean R = Replace T = Tighten L = Lubricate * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 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. Description p/n Compression Tester Kit 0444-213 Oil Filter Wrench 0644-389 Timing Light 0644-296 Valve Clearance Adjuster 0444-255 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 I R Air Filter I I* 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 Hoses I I R (2 Yrs) Throttle Cable Ends/Accelerator Pedal Pivot I I 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) 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) 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

8 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. Shift Cable Air Filter 1. Raise the cargo box; then remove any dust and debris from around the filter housing. 2. Unsnap the four spring-clip fasteners and remove the cover. HDX050A 3. Fill a wash pan larger than the element with a non- flammable cleaning solvent; then dip the element in the solvent and wash it. NOTE: Foam Filter Cleaner and Foam Filter Oil are available from Arctic Cat. 4. Dry the element. 5. Put the element in a plastic bag; then pour in air filter oil and work the element. Reattach the filter to the filter screen. NOTE: Carefully squeeze excess oil from the element. 6. Clean any dirt or debris from inside the filter housing. Be sure no dirt enters the throttle body. 7. Install the air filter and cover and lower the cargo box. CHECKING AND CLEANING DRAINS 1. Inspect the “duck-bill” drain beneath the main housing for debris and for proper sealing. 2. Remove the drain tube and clean out any water, oil, or debris. Reinstall and secure with the clamp. Valve/Tappet Clearance To check and adjust valve/tappet clearance, use the following procedure. NOTE: The engine must be cold for this procedure. NOTE: The seat, seat back, seat base, and spark plug must be removed for this procedure. 1. Remove the spark plug and timing inspection plug; then remove the tappet covers (for more detailed information, see the Engine/Transmission section - 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. Feeler Gauge Procedure 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. 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. 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 clearance accurately could cause valve component damage. VALVE/TAPPET CLEARANCE Intake 0.1016 mm (0.004 in.) Exhaust 0.1524 mm (0.006 in.)

9 CC007D 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 specifications in Feeler Gauge Procedure sub-section for the proper valve/ tappet clearance. NOTE: Rotating the valve adjuster dial counterclockwise 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. 3. Install the spark plug; then install the timing inspection plug. 4. Place the two tappet covers with O-rings into position. Tighten the cap screws to 9 ft-lb. Testing Engine Compression To test engine compression, use the following procedure. NOTE: The engine should be warm (operating temperature) and the battery fully charged for an accurate compression test. The throttle must be in the wide-open throttle (WOT) position. In the event the engine cannot be run, cold values are included. NOTE: The seat, seat back, and seat base 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 tension 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 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, inspect 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 obstructed. NOTE: To service top-side components, see the Engine/Transmission section. 7. Pour approximately 30 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 the Engine/Transmission section). Spark Plug 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. ! WARNING Always wear safety glasses when using compressed air. PSI Hot (WOT) PSI Cold (WOT) 125-145 100-140

2012 Arctic Cat 700i HDX Prowler Factory Service & Work Shop Manual

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