2013 Arctic Cat Prowler 700 XTX Service & Repair Manual

Arctic Cat Prowler Service Manual 2013 This manual is comprised of the 2013 Prowler XT/XTX/XTZ manual and the 2013 Prowler HDX manual. Use the links below or the bookmarks to the left to get to the manual that covers your model. 2013 Arctic Cat Prowler XT/XTX/XTZ service manual 2013 Arctic Cat Prowler HDX service manual

Prowler XT/XTX/XTZ

FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2013 Arctic Cat ROV (Recreational Off-Highway Vehicle) models (see cover). The complete manual is designed to aid service per- sonnel 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.

TABLE OF CONTENTS 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

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 0.84-1.41 kg/cm² (12-20 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 (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 Hyp- oid 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) 0.075 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

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 35 48 Knuckle Ball Joint 35 48 Shock Absorber Frame/Upper A-Arm 35 48 Knuckle A-Arm 35 48 SUSPENSION COMPONENTS (Rear) Sway Bar Bracket Frame 33 45 A-Arm Frame 35 48 Shock Absorber (Lower) (XT/XTX) Lower A-Arm 20 27 Shock Absorber (Lower) (XTZ) Lower A-Arm 35 48 Shock Absorber (Upper) Frame 35 48 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 Output 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

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

2013 Arctic Cat Prowler 700 XTX Service & Repair Manual

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