2012 Arctic Cat Prowler hdx UTV/ATV service & repair manual

TM SHARE OUR PASSION. T O RO RO V V Manual n Service M S S n v u c a a r M u l a a i e e M S S M n a a r v c ervice S S T T XT XT X X er X ler X Prow Prowl X P P l T e o o owle X Prowler XT X X X TX TX XT XT X X er X ler X Prow Prowl X X P P l T e o X X o owle X X X Prowler X Z TZ Z Z TZ XT X XT X X r X er X e ler X Prow w Prowl X P P l TZ Z TZ e o o owle X Prowler X TABLE OF CONTENTS 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/Controls 1 2 3 4 5 6 7 8

1-1 1 SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications ............................................ 1-2 Torque Specifications .............................................. 1-3 Torque Conversions (ft-lb/N-m) ............................... 1-4 Break-In Procedure ................................................. 1-4 Gasoline - Oil - Lubricant ........................................ 1-5 Genuine Parts ......................................................... 1-5 Preparation For Storage .......................................... 1-6 Preparation After Storage........................................ 1-6 Manual Table of Contents

1-2 General Specifications * Visible at plug threads. Specifications subject to change without notice. CHASSIS Dry Weight (approx) (XT) (XTX) (XTZ) 558 kg (1230 lb) 567 kg (1251 lb) 596 kg (1315 lb) ROPS Tested Curb Weight 645 kg (1428 lb) Length (overall) 301.5 cm (118.7 in.) Height (overall) 201 cm (79 in.) Width (overall) 156.2 cm (61.5 in.) Suspension Travel 25.4 cm (10 in.) Brake Type Hydraulic Wheelbase 190 cm (75 in.) Tire Size (XT/XTX) 26 x 9R-14 (front) 26 x 11R-14 (rear) Tire Size (XTZ) 27 x 9R-14 (front) 27 x 11R-14 (rear) Tire Inflation Pressure (XT/XTX) 0.70 kg/cm² (10 psi) Tire Inflation Pressure (XTZ) 0.84 kg/cm² (12 psi) (front) 0.84-1.41 kg/cm² (12-20 psi) (rear) 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 (XT/XTX) (XTZ) 2.9 L (3.0 U.S. qt) 3.3 L (3.5 U.S. qt) Front 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) - 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) ELECTRICAL SYSTEM - XT/XTX 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 (-)) Stator Coil Resistance (crankshaft position sensor) (AC generator) 150-250 ohms (blue to white) 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 ELECTRICAL SYSTEM - XTZ Spark Plug Cap 5000 ohms Ignition Coil (primary) Resistance (secondary) 4.8 ohms (terminal (+) to ground (-)) 12k-19k ohms (high tension - plug cap to terminal (+)) Ignition Coil Primary Voltage Battery Voltage (orange (+) to ground) Stator Coil Resistance (crankshaft position sensor) (AC generator) 150-250 ohms (blue to green) Less than 1 ohm (black to black) Crankshaft Position Sensor AC Voltage 2.0 or more (blue to green) AC Generator Output (no load) 75 AC volts @ 5000 RPM (black to black) 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) (max) (exhaust) 0.1016 mm 0.1524 mm Valve Guide/Stem Clearance (max) 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 (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 Journal Holder (right & center) Inside Diameter (left) 21.98-22.04 mm 17.48-17.53 mm Camshaft Journal Outside (right & center) Diameter (left) 21.96-21.98 mm 17.48-17.53 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 - XT/XTX Piston Skirt/Cylinder Clearance 0.06 mm Cylinder Bore (550 cc) (700 cc) 91.995-92.005 mm 101.992-102.008 mm Piston Diameter 15 mm (550 cc) from Skirt End (700 cc) 91.900-91.960 mm 101.930-101.949 mm Piston Ring Free End Gap (min) (1st/2nd) 12.5 mm Bore x Stroke (550 cc) (700 cc) 92 x 82 mm 102 x 85 mm Cylinder Trueness (max) 0.01 mm Piston Ring End Gap - Installed 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 CYLINDER, PISTON, AND RINGS - XTZ Piston Skirt/Cylinder Clearance 0.05 mm Cylinder Bore 91.992-92.008 mm Piston Diameter 15 mm from Skirt End 91.949-91.959 mm Piston Ring Free End Gap (min) (1st/2nd) 12.5 mm Bore x Stroke 92 x 71.6 mm Cylinder Trueness (max) 0.0075 mm Piston Ring End Gap - Installed 0.38 mm Piston Ring to Groove Clearance 1st (max) (2nd) 0.034 mm 0.033 mm Piston Ring Groove Width (1st/2nd) (oil) 1.202-1.204 mm 2.501-2.503 mm Piston Ring Thickness (1st/2nd) 1.170-1.195 mm Piston Pin Bore (max) 20.012 mm Piston Pin Outside Diameter (min) 19.995 mm Section Table of Contents Manual Table of Contents

1-3 1 Specifications subject to change without notice. Torque Specifications NOTE: Torque specifications have the following tolerances: * w/Blue Loctite #243 *** w/Green Loctite #270 ** w/Red Loctite #271 **** w/“Patch-Lock” CRANKSHAFT - XTZ Connecting Rod (max) (small end inside diameter) 20.021 mm Connecting Rod (big end side-to-side) 0.95 mm Connecting Rod (max) (small end deflection) 0.3 mm Crankshaft (web-to-web) 98 mm Crankshaft Runout (max) 0.03 mm Oil Pump Gerotor Clearance (max) 0.15 mm CRANKSHAFT - XT/XTX Connecting Rod (small end inside (max) diameter) 23.021 mm Connecting Rod (big end side-to-side) 0.6 mm Connecting Rod (max) (small end deflection) 0.3 mm Crankshaft (web-to-web) 71 mm Crankshaft Runout (max) 0.03 mm 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 BRAKE COMPONENTS Brake Disc** Hub 15 20 Brake Hose Caliper 20 27 Brake Hose Master Cylinder 20 27 Master Cylinder Frame 25 34 Caliper Holder**** Knuckle 20 27 Brake Caliper**** Gear Case Housing 20 27 Brake Caliper Rear Drive Housing 20 27 Driveline Rear Drive Input Flange 20 27 Parking Brake Actuator Lever Caliper 20 27 Parking Brake Caliper Assembly Rear Drive Housing 20 27 SUSPENSION COMPONENTS (Front) A-Arm Frame 33 45 Knuckle Ball Joint 35 48 Shock Absorber Frame/Upper A-Arm 33 45 Knuckle A-Arm 35 48 SUSPENSION COMPONENTS (Rear) Sway Bar Bracket Frame 33 45 A-Arm Frame 33 45 Shock Absorber (Lower) (XT/XTX) Lower A-Arm 20 27 Shock Absorber (Lower) (XTZ) Lower A-Arm 33 45 Shock Absorber (Upper) Frame 33 45 Knuckle A-Arm 35 48 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 60 in.-lb 7 ELECTRICAL COMPONENTS Coil* Frame 8 11 Ground Wire Engine 8 11 STEERING COMPONENTS Part Part Bolted To Torque ft-lb N-m Steering Wheel** Steering Wheel Shaft 25 34 Steering Wheel Shaft*** Intermediate Shaft (Upper) 36 49 Intermediate Shaft (Lower)*** - XT Steering Pinion Shaft 36 49 Rack and Pinion Assembly - XT Frame 50 68 Rack and Pinion Assembly - XTX/XTZ Frame 35 48 Tie Rod** - XT Rack 52 70 Tie Rod** - XTX/XTZ Rack 37 50 Tie Rod End** Knuckle 30 41 Jam Nut Tie Rod End 10 14 EPS Assembly - XTX/XTZ Frame 35 48 EPS Assembly - XTX/XTZ Rack Coupler 11 15 EPS Cradle Bracket Knuckle 20 27 Intermediate Shaft Coupler Intermediate Shaft 31 42 Intermediate Shaft (lower) - XTX/XTZ EPS Input Shaft 11 15 Steering Shaft Housing (6 mm) (XTX/XTZ) Frame 8 11 Steering Shaft Housing (8 mm) (XTX/XTZ) Frame 20 27 CHASSIS/ROPS ASSEMBLY Shift Lever* Shift Axle Bracket 20 27 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 ENGINE/TRANSMISSION - H1 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 Outer Magneto Cover Magneto 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 Nut Output Shaft** 59 80 Secondary Shaft Bearing Hous- ing Crankcase Half 28 38 Stator Coil** Magneto Cover 8.5 11.5 Intake Boot Clamp Intake Boot 30 in.-lb 3.4 Starter One-Way Clutch** Flywheel 26 35 Section Table of Contents Manual Table of Contents

1-4 ** w/Red Loctite #271 *** w/Green Loctite #270 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. ENGINE/TRANSMISSION - H2 Part Part Bolted To Torque ft-lb N-m Clutch Shoe** Crankshaft 221 300 Clutch Cover/Housing Assembly Crankcase 8 11 Lower Crankcase Cover (6 mm) Crankcase 8 11 Lower Crankcase Cover (8 mm) Crankcase 20 27 Crankcase Half Crankcase Half 8 11 Cylinder Head (Cap Screw) Crankcase 38 52 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 Drive Gear** Crank Balancer Shaft 62 84 Output Yoke Nut Output Shaft** 74 100 Outer Magneto Cover Magneto Cover 8 11 Rotor/Flywheel Nut** Crankshaft 105 143 Cam Sprocket** Camshaft 11 15 CVT Cover Crankcase 8 11 Secondary Drive Gear Nut** Secondary Drive Output Shaft 74 100 Oil Filter Cover Crankcase 8 11 Speed Sensor Housing Crankcase 8 11 Shift Cam Stopper Crankcase 8 11 Shift Cam Stopper Spring Shift Cam Stopper 8 11 Shift Cam Plate Shift Cam Shaft 8 11 Shifter Housing Crankcase 8 11 Starter Motor Crankcase 8 11 V-Belt Cover Crankcase 8 11 Oil Pump Cover** Crankcase 8 11 Oil Strainer Cap Crankcase 8 11 Stator Coil* Magneto Cover 8.5 11.5 Intake Boot Clamp Intake Boot 30 in.-lb 3.4 Starter One-Way Clutch** Flywheel 26 35 DRIVE TRAIN COMPONENTS Rear Differential/Gear Case Frame 38 48 Drive Coupler (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 U-Joint Flange 40 54 Input Shaft Assembly Gear Case Housing 23 31 Pinion Housing Differential Housing 23 31 Thrust Button Gear Case Cover 8 11 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 45 in.-lb 5 Oil Fill Plug Front Differential - Rear Drive 16 22 Oil Drain Plug Engine 16 22 Wheel (Aluminum) Hub 80 108 Wheel (Steel) Hub 45 61 Front Input Drive Flange Front U-Joint 20 27 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 Section Table of Contents Manual Table of Contents

1-5 1 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 Section 2). 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 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. 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. 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. Section Table of Contents Manual Table of Contents

1-6 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 absorb- ers. 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. 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(s). Clean or replace as necessary. 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. 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. Section Table of Contents Manual Table of Contents

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 Air Filter ................................................................... 2-3 Valve/Tappet Clearance (H1)................................... 2-4 Valve/Tappet Clearance (H2)................................... 2-4 Testing Engine Compression................................... 2-5 Spark Plug(s) .......................................................... 2-6 Muffler/Spark Arrester ............................................. 2-6 Engine/Transmission Oil - Filter............................... 2-7 Front Differential - Rear Drive Lubricant .................. 2-8 Driveshaft/Coupling ................................................. 2-8 Nuts/Bolts/Cap Screws............................................ 2-9 Headlight/Taillight-Brakelight ................................... 2-9 Shift Lever ............................................................... 2-9 Hydraulic Brake System ........................................ 2-10 Parking Brake ........................................................ 2-12 Burnishing Brake Pads .......................................... 2-14 Checking/Replacing V-Belt .................................... 2-14 Troubleshooting Brake System.............................. 2-16 Manual Table of Contents

2-2 Periodic Maintenance Chart A = Adjust I = Inspect C = Clean L = Lubricate R = Replace T = Tighten * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 0W-40 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. 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(s) 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 & 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 Section Table of Contents Manual Table of Contents

2-3 2 Periodic Maintenance This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat ROV. NOTE: Arctic Cat recommends the use of new gas- kets, 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 techni- cian 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. 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 Cable Air Filter Use the following procedure to remove the filter and inspect and/or clean it. 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 frame (A); then remove the foam filter element (B). PR576A 4. Fill a wash pan larger than the filter with a non-flam- mable 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 filter screen. NOTE: Carefully squeeze excessive oil from the filter element. Do not twist foam to remove oil. 7. Clean any dirt or debris from inside the air cleaner. Be sure no dirt enters the throttle body. 8. Place the foam filter in the air filter housing; then position the filter frame on top. 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. CHECKING AND CLEANING DRAINS 1. Inspect one-way drains beneath the main housing for debris and for proper sealing. Description p/n Compression Tester Kit 0444-213 Oil Filter Wrench 0644-389 Timing Light 0644-296 Valve Clearance Adjuster 0444-255 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. Section Table of Contents Manual Table of Contents

2012 Arctic Cat Prowler hdx UTV/ATV service & repair manual

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