2009 Arctic Cat Prowler XT and XTX service and repair manual
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Official service manual for the 2009 Arctic Cat Prowler, Prowler XT and Prowler XTX.
This official service repair manual gives complete step by step information on repair, servicing and preventative maintenance. The official manual is highly detailed with photos and illustrations to help guide you through every repair and troubleshooting procedure. This manual contains all you need to know to keep your ATV working right and is the only service repair manual you will need. It will help you understand, care for, and lower the repair and maintenance cost for your ATV or Quad.
With the abundance of service oriented companies provided in the global economy today, added with the addition of a fast paced, throw away society, repairing an ATV yourself may seem like a waste of time and money. With that said, the cost effectiveness and pride that comes with repairing an ATV at your home can be one of the greatest feelings in the world. This can be easily done with this official repair manual at your disposal, and a minimal amount of time and space.
The first and foremost benefit of having a repair manual for your ATV at arms reach is the fact that most problems associated with a ATV are simple and easy fixes. With all products, the manual will have a section that gives you many options on symptoms of the problem, and a troubleshooting method to go along with the issues at hand. The simple repairs included in this section can not only save you a large amount of money in repair and replacement costs, but also give you the added benefit of immediate results without the time having to be spent either taking it to the repair shop, or going to your local dealer to purchase a new product.
A small sample of some of the topics covered in this manual are: carburettor kits, oil filters, pistons, gaskets, brakes, sprockets, chains, wheel bearings, tires, tyres, lamps, bulbs, guards, gearbox, throttle, handlebar, seat, rack, start, kill, switch, button, tank, fuel, gasoline, petrol, diesel, quad, polaris, Yamaha, rings, wheels, steering, wheels, electrical, suspension, exhaust, body, muffler, drivetrain, con rod, cdi, filter, spark plug, radiator, starter, stator, water pump, recoil, thermostat, intake, head, cams, clutch, cv joint, drive belt, transfer case, chain, sprocket, hub, diff, differential, pegs, cover, guards, skid plate, decals, oil tank, scoop and much more.
As with any product in your home, the average ATV may come across a point in time when a more serious repair is needed. Many people in todays society will go and trade in a perfectly good ATV and purchase an over the top model that is not really used to its fullest capacity. While the cost of ATVs has gone down over the years, the repair kits and parts for the models are a fraction of the cost, and can easily installed with the proper repair manual. This manual will provide step by step instruction on disassembly, repair methods, and illustrations related to the repair. With this knowledge at your disposal, when the next issue comes up, you will have the knowledge and experience to fix the problem with ease.
In the end, you have a simple choice to make. You can be well informed, and pro active in your life by having the skill and drive to repair the items in your home using something as simple as a few inexpensive parts, a little time, and a good repair manual, or you can go about your way spending absurd amounts of money to purchase a product that will come across the same problem at some time or another, providing you with a never ending cycle of spending your hard earned money. At some point, every ATV will have an issue, as a machines quality is measured solely by the users commitment to maintenance. A good way to keep your ATV giving you years of quality service without having years of service bills is to purchase a good repair manual, and learn to do it yourself.
Book marked chapters for easy navigation allowing you to identify exact repair service procedures in the quickest time possible.
Notes, cautions and warnings throughout each chapter pinpoint critical service information.
Numbered instructions guide you through every repair procedure in a step-by-step fashion.
Bold figured numbers help you quickly match illustrations with instructions.
Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure.
Numbered table of contents easy to use so that you can find the information you need fast.
Manual Language: English
File Format: PDF
File Delivery: PDF (Instant Download)
Pages:174
To purchase this repair manual just click on the green instant download button at the upper left hand corner of this page. After purchasing just download it to your computer to save it and print pages from it whenever you need it.
This official service repair manual gives complete step by step information on repair, servicing and preventative maintenance. The official manual is highly detailed with photos and illustrations to help guide you through every repair and troubleshooting procedure. This manual contains all you need to know to keep your ATV working right and is the only service repair manual you will need. It will help you understand, care for, and lower the repair and maintenance cost for your ATV or Quad.
With the abundance of service oriented companies provided in the global economy today, added with the addition of a fast paced, throw away society, repairing an ATV yourself may seem like a waste of time and money. With that said, the cost effectiveness and pride that comes with repairing an ATV at your home can be one of the greatest feelings in the world. This can be easily done with this official repair manual at your disposal, and a minimal amount of time and space.
The first and foremost benefit of having a repair manual for your ATV at arms reach is the fact that most problems associated with a ATV are simple and easy fixes. With all products, the manual will have a section that gives you many options on symptoms of the problem, and a troubleshooting method to go along with the issues at hand. The simple repairs included in this section can not only save you a large amount of money in repair and replacement costs, but also give you the added benefit of immediate results without the time having to be spent either taking it to the repair shop, or going to your local dealer to purchase a new product.
A small sample of some of the topics covered in this manual are: carburettor kits, oil filters, pistons, gaskets, brakes, sprockets, chains, wheel bearings, tires, tyres, lamps, bulbs, guards, gearbox, throttle, handlebar, seat, rack, start, kill, switch, button, tank, fuel, gasoline, petrol, diesel, quad, polaris, Yamaha, rings, wheels, steering, wheels, electrical, suspension, exhaust, body, muffler, drivetrain, con rod, cdi, filter, spark plug, radiator, starter, stator, water pump, recoil, thermostat, intake, head, cams, clutch, cv joint, drive belt, transfer case, chain, sprocket, hub, diff, differential, pegs, cover, guards, skid plate, decals, oil tank, scoop and much more.
As with any product in your home, the average ATV may come across a point in time when a more serious repair is needed. Many people in todays society will go and trade in a perfectly good ATV and purchase an over the top model that is not really used to its fullest capacity. While the cost of ATVs has gone down over the years, the repair kits and parts for the models are a fraction of the cost, and can easily installed with the proper repair manual. This manual will provide step by step instruction on disassembly, repair methods, and illustrations related to the repair. With this knowledge at your disposal, when the next issue comes up, you will have the knowledge and experience to fix the problem with ease.
In the end, you have a simple choice to make. You can be well informed, and pro active in your life by having the skill and drive to repair the items in your home using something as simple as a few inexpensive parts, a little time, and a good repair manual, or you can go about your way spending absurd amounts of money to purchase a product that will come across the same problem at some time or another, providing you with a never ending cycle of spending your hard earned money. At some point, every ATV will have an issue, as a machines quality is measured solely by the users commitment to maintenance. A good way to keep your ATV giving you years of quality service without having years of service bills is to purchase a good repair manual, and learn to do it yourself.
Book marked chapters for easy navigation allowing you to identify exact repair service procedures in the quickest time possible.
Notes, cautions and warnings throughout each chapter pinpoint critical service information.
Numbered instructions guide you through every repair procedure in a step-by-step fashion.
Bold figured numbers help you quickly match illustrations with instructions.
Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure.
Numbered table of contents easy to use so that you can find the information you need fast.
Manual Language: English
File Format: PDF
File Delivery: PDF (Instant Download)
Pages:174
To purchase this repair manual just click on the green instant download button at the upper left hand corner of this page. After purchasing just download it to your computer to save it and print pages from it whenever you need it.
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General Specifications* A-Arm SUSPENSION COMPONENTS (Front) Part Part Bolted To Frame Knuckle Frame Upper A-Arm A-Arm Torque ft-lb N-m CHASSIS Dry Weight (approx) Length (overall) Height (overall) Width (overall) Suspension Travel Brake Type Wheelbase Tire Size Tire Inflation Pressure Gas Tank Capacity (rated) Coolant Capacity Differential Capacity Rear Drive Capacity Engine Oil Capacity Gasoline (recommended) Engine Oil (recommended) Front Differential Lubricant Rear Drive Lubricant (Prowler/XT) Rear Differential Lubricant (XTX) Belt Width Brake Fluid Taillight/Brakelight Headlight Starting System 526 kg (1160 lb) 292 cm (115 in.) 197 cm (77.5 in.) 156 cm (61.3 in.) (front) 25.4 cm (10 in.) (rear) 25.4 cm (10 in.) Hydraulic 190 cm (75 in.) (front) 26 x 9-14 (rear) 26 x 11-14 0.70 kg/cm² (10 psi) Ball Joint Cap Screw Shock Absorber (Upper) Shock Absorber (Lower) Knuckle Sway Bar Bracket A-Arm Shock Absorber (Upper) Shock Absorber (Lower) Knuckle Cargo Box Hinge Cargo Box Latch Pivot Bushing Latch Striker Brake Disc** Brake Hose Brake Hose Master Cylinder Parking Brake Mechanism Hydraulic Caliper Holder Driveline Parking Brake Caliper Assembly Shift Lever* Front/Rear Canopy Tube Top Canopy Support Rear Canopy Tube 33 35 33 33 33 33 33 33 20 33 20 20 15 5 15 20 20 25 20 20 20 12 35 20 45 48 45 45 45 45 45 45 27 45 27 27 20 7 20 27 27 34 27 27 27 16 48 27 SUSPENSION COMPONENTS (Rear) Frame Frame Frame Lower A-Arm A-Arm Cargo Box Frame Cargo Box Frame Cargo Box Frame Cargo Box Liner MISCELLANY 31 L (8.2 U.S. gal.) 2.9 L (3.0 U.S. qt) 275 ml (9.3 fl oz)** 250 ml (8.5 fl oz)** 2.5 L (2.6 U.S. qt) - Overhaul 1.9 L (2.0 U.S. qt) - Change 87 Octane Regular Unleaded Arctic Cat ACX All Weather Synthetic SAE Approved 80W-90 Hypoid SAE Approved 80W-90 Hypoid Arctic Cat 80W-90 Hypoid Friction Modified 35.0 mm (1.38 in.) DOT 4 12V/8W/27W 12V/27W (2) Electric BRAKE COMPONENTS Hub Caliper Master Cylinder Frame Frame Knuckle Rear Drive Input Flange Rear Drive Housing Rear Driveline Brake Caliper Rear Differential/Gear Case Parking Brake Actuator Lever Caliper CHASSIS/CANOPY ASSEMBLY Shift Axle Arm Rest/Steering Post Support Front/Rear Canopy Tubes Lower Canopy Support * Specifications subject to change without notice. ** Visible at plug threads. 20 20 8 8 38 40 25 25 27 27 11 11 48 54 34 34 52 54 31 31 118 170 272 5 22 22 61 27 Torque Specifications EXHAUST COMPONENTS Part Exhaust Pipe Spark Arrester DRIVE TRAIN COMPONENTS Rear Differential/Gear Case Drive Coupler Front Engine Mounting Bracket Frame Drive Flange Mounting Stud Mounting Stud Frame/Differential Bracket Rear U-Joint Flange Part Bolted To Cylinder Head Muffler Torque ft-lb N-m Rear Engine Mounting Bracket Front Differential Rear Output Flange 20 27 48 5 in.-lb 8 8 25 36 36 50 74 30 8 11 11 34 49 49 68 100 41 11 ELECTRICAL COMPONENTS Coil* Ground Wire Steering Wheel Shaft** Steering Wheel Shaft**** Rack and Pinion Assembly Tie Rod** Tie Rod End** Jam Nut Frame Engine STEERING COMPONENTS Steering Wheel Intermediate Shaft (Upper) Frame Rack Knuckle Tie Rod End 38 40 Pinion Housing Differential Housing 23 Differential Housing Cover*** Differential Housing 23 Drive Bevel Gear Nut*** Shaft 87 Lock Collar Differential Housing 125 Hub Nut Front/Rear Shaft/Axle (min) 200 Oil Drain Plug Front Differential - Rear 45 Drive/Differential in.-lb Oil Fill Plug Front Differential - Rear 16 Drive/Differential Hub Front U-Joint Oil Drain Plug Wheel Front Input Drive Flange Engine Intermediate Shaft (Lower)**** Steering Pinion Shaft 16 45 20 * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 **** w/Green Loctite #270 1-2 Back to TOC Back to Section TOC Next ENGINE/TRANSMISSION Part Clutch Shoe** Clutch Cover/Housing Assembly Crankcase Half (6 mm) Crankcase Half (8 mm) Cylinder Head (Cap Screw) Cylinder Head Nut (6 mm) Cylinder Head Nut (8 mm) Cylinder Head Cover Driven Pulley Nut Movable Drive Face Nut** Ground Wire Magneto Cover Tappet Cover Crankshaft Spacer Oil Pump Drive Gear** Output Shaft Flange Nut Outer Magneto Cover Magneto Rotor Nut** Cam Sprocket** V-Belt Cover Output Yoke Nut Part Bolted To Crankshaft Crankcase Crankcase Half Crankcase Half Crankcase Cylinder Cylinder Cylinder Head Driveshaft Driveshaft Engine Crankcase Valve Cover Crankshaft Crank Balancer Shaft Output Shaft** Magneto Cover Crankshaft Camshaft Crankcase Secondary Driven Output Shaft Torque ft-lb N-m Torque Conversions (ft-lb/N-m) 221 8 300 11 ft-lb N-m 10 14 20 27 40 54 8 11 18 24 8.5 11.5 80 109 165 224 8 11 8 11 9 12 28 38 62 84 62 84 8 11 105 143 11 15 8 11 74 100 ft-lb N-m ft-lb N-m ft-lb N-m 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1.4 2.7 4.1 5.4 6.8 8.2 9.5 10.9 12.2 13.6 15 16.3 17.7 19 20.4 21.8 23.1 24.5 25.8 27.2 28.6 29.9 31.3 32.6 34 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 35.4 36.7 38.1 39.4 40.8 42.2 43.5 44.9 46.2 47.6 49 50.3 51.7 53 54.4 55.8 57.1 58.5 59.8 61.2 62.6 63.9 65.3 66.6 68 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 69.4 70.7 72.1 73.4 74.8 76.2 77.5 78.9 80.2 81.6 83 84.3 85.7 87 88.4 89.8 91.1 92.5 93.8 95.2 96.6 97.9 99.3 100.6 102 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 103.4 104.7 106.1 107.4 108.8 110.2 111.5 112.9 114.2 115.6 117 118.3 119.7 121 122.4 123.8 125.1 126.5 127.8 129.2 130.6 131.9 133.3 134.6 136 1 * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 Tightening Torque (General Bolts) Type of Bolt (Conventional or 4 Marked Bolt) Thread Diameter A (mm) 5 6 8 10 Tightening Torque 12-36 in.-lb 36-60 in.-lb 7-11 ft-lb 16-25 ft-lb 24-48 in.-lb 6-8 ft-lb 13-20 ft-lb 29-43 ft-lb (7 Marked Bolt) 5 6 8 10 Back Back to TOC Back to Section TOC 1-3 Next 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. 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 5W-50 oil is acceptable. OILCHARTI 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 FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT (Prowler/XT) The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of the Arctic Cat vehicle front differential and rear drive. ! CAUTION Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive damage. RECOMMENDED DIFFERENTIAL LUBRICANT (Prowler XTX) NOTE: Arctic Cat recommends the use of genuine Arctic Cat lubricants. ! CAUTION Do not use white gas. Only Arctic Cat approved gasoline additives should be used. The recommended lubricant for the front differential is SAE approved 80W-90 hypoid. This lubricant meets all of the front diffrential lubrication requirements of this vehicle. Back1-4 Back to TOC Back to Section TOC Next |
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