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General Information/Foreword
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for 2016 Arctic Cat Prowler XT ROV (Recreational Off-Highway Vehicle) 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. This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The procedures found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special tools to be completed. The technician should use sound judgement when determining which procedures can be completed based on their skill level and access to appropriate special tools. NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is necessary.
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 Parts Manual for the correct part number, quantity, and description. 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 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.
Product Service and Warranty Department Arctic Cat Inc.
General Specifications
NOTE: Specifications subject to change without notice.
Dry Weight (approx)
ROPS Tested Curb Weight Length (overall) Height (overall) Width (overall) Tire Size (700)
Tire Size (1000)
Tire Inflation Pressure
CHASSIS
567 kg (1251 lb) - 700 596 kg (1315 lb) - 1000 645 kg (1428 lb) 301.5 cm (118.7") 201 cm (79") 156.2 cm (61.5") 26 x 9R-14 (front) 26 x 11R-14 (rear) 27 x 9R-14 (front) 27 x 11R-14 (rear) 0.84-1.41 kg/cm² (12-20 psi)
MISCELLANY
Spark Plug Type Spark Plug Gap Gas Tank Capacity Coolant Capacity
Front Differential Capacity
NGK CPR8E 0.5-0.6 mm (0.019-0.024") 31 L (8.2 U.S. gal.) 2.9 L (3.0 U.S. qt) - 700 3.3 L (3.5 U.S. qt) - 1000 275 ml (9.3 fl oz)* Rear Drive Capacity 250 ml (8.5 fl oz)* Engine Oil Capacity (700/1000) 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
Drive Belt Width 35.0 mm (1.38") - (700) 35.1 mm (1.38”) - (1000)
Clutch Roller (O.D.) Brake Fluid 30.0 mm (1.18") DOT 4
Taillight/Brakelight
12V/8W/27W Headlight 12V/60W/55W
ELECTRICAL SYSTEM
Spark Plug Cap Resistance 5000 ohms Ignition Coil Resistance (primary) 0.75 ohm ± 10% (secondary) N/A Ignition Coil Primary Voltage Battery Voltage Stator Coil (crankshaft position sensor) 104-156 ohms Resistance (AC generator) Less than 1 ohm Crankshaft Position Sensor AC Voltage 2.0 or more AC Generator Output (no load) @ 5000 60 AC volts - 700 RPM 75 AC volts - 1000 Ignition Timing @3000 RPM 16° BTDC - 700 13° BTDC - 1000
VALVES AND GUIDES
Valve Face Diameter
31.6mm - intake 27.9mm - exhaust Valve/Tappet Clearance (cold engine) 0.1016 mm - intake (max) 0.1524 mm - exhaust Valve Guide/Stem Clearance (max) 0.013mm Valve Guide Inside Diameter 5.000-5.012mm Valve Head Thickness (min) 2.3mm Valve Seat Angle 45° +15’/+30’ Valve Spring Free Length (min) 38.7mm Valve Spring Tension @ 31.5mm 16.0 kg (36 lb) * Visible at plug threads.
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min) (Ex/In) 33.60mm - 700 (Ex) 33.40 mm - 1000 (In) 33.53 mm - 1000 Camshaft Journal Oil Clearance (max) 0.04mm Camshaft Journal (right & center) 21.98-22.04 mm Holder Inside Diameter (left) 17.48-17.53 mm Camshaft Journal (right & center) 21.96-21.98 mm - 700 Outside Diameter 21.94-21.98 - 1000 (left) 17.48-17.53 mm - 700 17.44-17.48 - 1000 Camshaft Runout (max) 0.05 mm Cylinder Head/Cover Distortion (max) 0.05 mm
CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder Clearance 0.025-0.075 mm Cylinder Bore 101.992-102.008 mm - 700 91.992-92.008 mm - 1000 Piston Diameter 15mm from Skirt End 101.940-101.985 mm - 700 92.940-92.975 mm - 1000 Piston Ring Free End Gap (min) (1st/2nd)12.5 mm Bore x Stroke 102 x 85 mm - 700 92 x 71.6 mm - 1000 Cylinder Trueness (max) 0.02 mm Piston Ring End Gap - Installed 0.38 mm Piston Ring to Groove Clearance (max) 0.35 mm Piston Ring Groove Width (1st/2nd) 1.202-1.204 mm (oil) 2.01-2.03 mm - 700 2.501-2.503 mm - 1000 Piston Ring Thickness (1st/2nd) 1.970-1.990 mm - 700 1.170-1.195 mm - 1000 Piston Pin Bore (max) 23.012 mm - 700 20.012 mm - 1000 Piston Pin Outside Diameter (min) 22.99 mm - 700 19.995 mm - 1000
CRANKSHAFT
Connecting Rod (small end inside 23.021mm - 700 diameter) (max) 20.021mm - 1000 Connecting Rod (big end side-to-side) 0.6mm - 700 0.95mm - 1000
Connecting Rod (small end deflection) (max) 0.3mm
Crankshaft (web-to-web) 71mm - 700 98mm - 1000 Crankshaft Runout (max) 0.03mm Oil Pump Gerotor Clearance (1000) 0.15 mm (max)
Torque Specifications
NOTE: Torque specifications have the following tol-
erances:
Torque (ft-lb) Tolerance
0-15 ±20% 16-39 ±15% 40+ ±10%
MISCELLANEOUS COMPONENTS Part Part Bolted To Torque ft-lb N-m
Exhaust Pipe Cylinder Head 20 27 O2 Sensor Exhaust Pipe 20 27 Spark Arrester Muffler 50 5 in.-lb Voltage Regulator Storage Box 8 11 Coolant Bottle Storage Box 48 5 in.-lb Radiator Frame 8 11 Ground Wire Engine 8 11 Coil Mount 6 1 in.-lb
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
SUSPENSION COMPONENTS (Front)
Upper A-Arm Frame 40 54 Knuckle Ball Joint 35 48 Shock Absorber Frame/Upper A-Arm 35 48 Lower A-Arm Frame 35 48
SUSPENSION COMPONENTS (Rear)
Sway Bar Bracket (1000) Frame 35 48 Sway Bar Bracket (700) Frame 35 48 A-Arm Frame 35 48 Shock Absorber (Lower) Lower A-Arm 35 48 Shock Absorber (Upper) Frame 35 48 Knuckle A-Arm 35 48
STEERING COMPONENTS
Steering Wheel* Upper Steering Shaft 25 34 Steering Wheel Shaft** Intermediate 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 8 11 EPS Assembly Frame 35 48 EPS Assembly Rack Coupler 11 15 EPS Mounting Bracket Frame 20 27 Intermediate Shaft Coupler Intermediate Shaft 31 42 Intermediate Shaft EPS Input Shaft 25 34 Steering Shaft Housing Frame 20 27 Tilt Assembly Steering Support 20 27
* w/Red Loctite #271** w/Green Loctite #609 *** w/“Patch-Lock”
CHASSIS/ROPS ASSEMBLY Part Part Bolted To Torque ft-lb N-m
Seat Base Frame 6 8 Seat Belt Loop ROPS 35 48 Seat Belt Buckle Frame 60 81 Front ROPS Tube Steering Support 35 48 Top ROPS Support Front/Rear ROPS Tubes 35 48 Rear ROPS Tube Lower ROPS Support 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
DRIVE TRAIN COMPONENTS
Drive Coupler (Front) (700) Drive Flange 20 27 Front Input Drive Flange (1000)Front U-Joint 40 54 Driveline Rear Drive Input Flange 20 27 Differential/Gear case Frame/Differential 38 52 Bracket Rear Output Flange Rear U-Joint Flange 20 27 Input Shaft Assembly Gear Case Housing 23 31 Pinion Housing Differential Housing 23 31 Thrust Button Gear Case Cover 9 12 Differential Housing Cover** Differential Housing 23 31 Drive Bevel Gear Nut** Shaft 87 118 Hub Axle (min) 200 272 Oil Drain Plug Front Differential - Rear 45 in.-lb 5 Drive Oil Fill Plug Front Differential - Rear 16 22 Drive Wheel (Aluminum w/chrome nuts)Hub 80 108 Wheel (Aluminum w/black nuts)Hub 60 81 Wheel (Steel) Hub 40 54
ENGINE/TRANSMISSION
Clutch Shoe* Crankshaft 221 300 Clutch Cover/Housing Crankcase 9.5 13 Assembly Cylinder Head Nut (6 mm) Cylinder 8.5 11.5 Cylinder Head Nut (8 mm) Cylinder 18 25 Cylinder Head (Cap Screw)* Crankcase (step 1) 20 27 (step 2) 30 41 (final) 37 50 Valve Cover Cylinder Head 8.5 11.5 Driven Clutch Nut* Driveshaft 162 220 Movable Drive Face Nut* Driveshaft 162 220 Magneto Cover Crankcase 9.5 13 Rotor/Flywheel Nut* Crankshaft 107 145 Tappet Cover Valve Cover 8.5 11.5 Crankshaft Spacer Crankshaft 28 38 Oil Pump Cover* Crankcase 8.5 11.5 Outer Magneto Cover Magneto Cover 8.5 11.5 Cam Sprocket Camshaft 10 14 Speed Sensor Housing Crankcase 8.5 11.5 Clutch Cover Crankcase 10 14 Oil Drain Plug Engine 16 27 Shift Lever Shift Axle Bracket 20 27 Intake Boot Clamp Intake Boot 30 in.-lb 3.4 Intake Manifold Engine 8 11 Oil Pump Drive Gear* Crank Balancer Shaft 63 85 Starter Motor Crankcase 10 14 Output Yoke Nut* Output Shaft 200 270 Starter One-Way Clutch* Flywheel 26 35 Cylinder Crankcase 8 11 Shift Cam Stopper* Shift Cam Shaft 8 11 Stator Coil Magneto Cover (New) 13 18 Stator Coil Magneto Cover 11 15 (Existing)
ENGINE/TRANSMISSION - 700 Part Part Bolted To Torque ft-lb N-m
CVT Cover Clutch Cover 44 5 in.-lb Crankcase Half (6 mm) Crankcase Half 10 14 Crankcase Half (8 mm) Crankcase Half 21 28 Output Shaft Flange Nut* Output Shaft 200 270 Secondary Shaft Bearing Housing***Crankcase Half 25 34 Engine Engine Cradle 40 54 Rubber Mount Frame 25 34 Engine Cradle Rubber Mount 25 34 Shift Cam Plate Shift Cam Shaft 8 11 Water Pump Engine 8 11 Secondary Drive Bevel Gear Nut Crankcase 59 80 Oil Strainer Cap Crankcase 10 14
ENGINE/TRANSMISSION - 1000
Lower Crankcase Cover (6 mm) Crankcase 10 14 Lower Crankcase Cover (8 mm) Crankcase 21 28 Clutch Cover Crankcase 10 14 Secondary Drive Gear Nut* Secondary Drive 200 270 Output Shaft Oil Filler Cover Crankcase 9.5 13 Shift Cable Bracket Crankcase 9.5 13 Oil Strainer Cap Screw Crankcase 50 6 in.-lb CVT Cover Clutch Cover 9.5 13 Engine Frame 33 45 Shift Cam Stopper Spring Shift Cam Stopper 8 11 Water Pump Drive Housing Cover Engine 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
* w/Red Loctite #271 ** w/Green Loctite #609
Torque Conversions (ft-lb/N-m)
FILLING GAS TANK ! 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.
Since gasoline expands as its temperature rises, the gas tank must be filled to its specified capacity only. Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area. ! 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.
Tighten the gas tank cap securely after filling the tank.
RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, oxygenates are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol or 5% methane. 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.
! WARNING
Do not over-fill the gas tank.
CAUTION
Do not use white gas. Only Arctic Cat approved gasoline additives should be used.
RECOMMENDED ENGINE/TRANSMISSION OIL 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.
The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil, which has been specifically 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.
CAUTION
Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive damage.
Preparation For Storage
Arctic Cat recommends the following procedure to prepare the vehicle for storage. An authorized Arctic Cat dealer should perform this service; however, the owner/operator may perform this service if desired.
1.Clean the seat cushions with a damp cloth and allow to dry. 2.Clean the vehicle thoroughly by washing dirt, oil, grass, and other foreign matter from the entire vehicle. Allow the vehicle to dry thoroughly. DO NOT get water into any part of the engine or air intake. 3.Either drain the gas tank or add a fuel stabilizer to the gas in the gas tank. 4.Clean the interior of the air filter housing. 5.Plug the hole in the exhaust system with a clean cloth. 6.Apply light oil to the upper steering shaft bushing and 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. CAUTION
Prior to storing this vehicle, it must be properly serviced to prevent rusting and component deterioration.
9.Disconnect the battery cables (negative cable first); then remove the battery, clean the battery posts and cables, and store in a clean, dry area. NOTE: For storage, use a battery maintainer or
make sure the battery is fully charged (see Battery section in this manual).
10.Store the vehicle indoors in a level position.
CAUTION
Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the vehicle causing rusting.
Preparation After Storage
Taking this vehicle out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. Arctic Cat recommends the following procedure. 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 making sure to connect the positive cable first.
7.Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, and headlight aim; adjust or replace if necessary. 8.Check the tire pressure. Inflate to recommended pressure as necessary. 9.Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap screws, and bolts are tightened to specifications. 10.Make sure the steering moves freely and does not bind. 11.Check the spark plug(s). Clean or replace as necessary. 12.Check the air filter and the air filter housing. Clean or replace as necessary.
CAUTION
