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Arctic Cat 2009 Prowler XT User Manual

Arctic Cat 2009 Prowler XT
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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2009 Arctic
Cat UTV (Utility Terrain Vehicle) models (see cover). The complete manual is designed to aid service personnel in ser-
vice-oriented applications.
Arctic Cat offers an additional publication (when it becomes available) to aid in servicing the other UTV model. To ser-
vice the model not included in this manual, please refer to the following publication:
2009 UTV Service Manual - Prowler XTZ
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 fol-
low the directive because it deals with the possibility of severe personal injury or even death. The symbol
!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.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2008 Arctic Cat Inc. September 2008
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Back to TOC

Table of Contents

Questions and Answers:

Arctic Cat 2009 Prowler XT Specifications

General IconGeneral
BrandArctic Cat
Model2009 Prowler XT
CategoryUtility Vehicle
LanguageEnglish

Summary

FOREWORD

SECTION 1 - GENERAL INFORMATION

General Specifications

Details general specifications for the vehicle, including weight, dimensions, and capacities.

Torque Specifications

Lists torque values for various components, crucial for proper assembly and safety.

Break-In Procedure

Outlines the recommended procedure for breaking in a new vehicle or overhauled engine.

Gasoline - Oil - Lubricant

Specifies recommended types of gasoline, engine oil, and lubricants for optimal performance.

Genuine Parts

Emphasizes using genuine Arctic Cat parts for quality and correct fit.

Preparation For Storage

Provides steps for properly preparing the vehicle for storage to prevent damage and deterioration.

Preparation After Storage

Details the procedure for preparing the vehicle after it has been stored.

SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP

Periodic Maintenance Chart

Provides a schedule for routine maintenance tasks based on time or mileage intervals.

Periodic Maintenance

Outlines common maintenance procedures for the Arctic Cat UTV.

Lubrication Points

Lists specific points on the vehicle that require periodic lubrication.

Air Filter

Details the procedure for cleaning and inspecting the air filter element.

Valve/Tappet Clearance (Feeler Gauge Procedure)

Explains how to check and adjust valve clearance using a feeler gauge.

Valve/Tappet Clearance (Valve Adjuster Procedure)

Details the process of adjusting valve clearance using a specialized tool.

Testing Engine Compression

Explains how to test the engine's compression to diagnose potential issues.

Spark Plug

Covers the inspection, gapping, and replacement of the spark plug.

Muffler/Spark Arrester

Details the cleaning procedure for the spark arrester.

Engine/Transmission Oil - Filter

Outlines the procedure for changing engine and transmission oil and the oil filter.

Front Differential - Rear Drive/Differential Lubricant

Explains how to check and change the lubricant in the front and rear differentials.

Driveshaft/Coupling

Describes the periodic inspection of driveshaft and coupling components.

Nuts/Bolts/Cap Screws

Emphasizes the importance of checking and tightening all fasteners.

Headlight/Taillight-Brakelight

Covers the procedure for replacing headlight and taillight bulbs.

Checking/Adjusting Headlight Aim

Explains how to check and adjust headlight aim for optimal visibility.

Shift Lever (Prowler/XTX)

Covers checking and adjusting the shift lever cable for proper gear selection.

Shift Lever (XT)

Details the procedure for checking and adjusting the shift lever linkage.

Hydraulic Brake System

Covers checking, bleeding, and inspecting the hydraulic brake system.

Parking Brake

Explains how to check and adjust the parking brake for proper function.

Burnishing Brake Pads

Details the procedure for burnishing new brake pads for optimal effectiveness.

Checking/Replacing V-Belt

Outlines the process for checking and replacing the V-belt.

SECTION 3 - ENGINE/TRANSMISSION

Engine/Transmission

Provides an overview of engine and transmission servicing procedures.

Specifications

Lists detailed specifications and tolerances for engine and transmission components.

Removing Engine/Transmission

Top-Side Components

Removing Top-Side Components

Details the process of removing components from the top of the engine.

Valve Cover

Explains how to remove and service the engine's valve cover.

Cylinder Head

Outlines the procedure for removing and servicing the cylinder head.

Cylinder

Piston

Servicing Top-Side Components

VALVE ASSEMBLY

Covers inspection and servicing of the valve assembly, including seats and stems.

Cleaning/Inspecting Valve Cover

Details the cleaning and inspection process for the valve cover.

Removing Valves

Explains how to remove valves from the cylinder head.

Measuring Valve Stem Runout

Measuring Valve Stem Outside Diameter

Measuring Valve Face/Seat Width

Measuring Valve Face Radial Runout

Measuring Valve Guide/Valve Stem Deflection (Wobble Method)

Measuring Valve Guide (Inside Diameter)

Servicing Valves/Valve Guides/Valve Seats

Measuring Rocker Arm (Inside Diameter)

Details how to measure the inside diameter of the rocker arm.

Measuring Rocker Arm Shaft (Outside Diameter)

Explains how to measure the outside diameter of the rocker arm shaft.

Installing Valves

Covers the procedure for installing valves into the cylinder head.

PISTON ASSEMBLY

Cleaning/Inspecting Piston

Details the process of cleaning and inspecting the engine piston.

Removing Piston Rings

Explains how to remove piston rings from the piston.

Cleaning/Inspecting Piston Rings

Measuring Piston-Ring End Gap (Installed)

Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore

Measuring Piston Skirt/Cylinder Clearance

Installing Piston Rings

CYLINDER/CYLINDER HEAD ASSEMBLY

Cleaning/Inspecting Cylinder Head

Details the cleaning and inspection of the cylinder head.

Measuring Cylinder Head Distortion

Cleaning/Inspecting Cylinder

Inspecting Cam Chain Guide

Honing Cylinder

Measuring Camshaft Runout

Measuring Camshaft Lobe Height

Inspecting Camshaft Bearing Journal

Measuring Camshaft to Cylinder Head Clearance

Inspecting Camshaft Spring/Drive Pin

Installing Top-Side Components

Piston

Covers the installation of the engine piston.

Cylinder

Details the installation of the engine cylinder.

Cylinder Head

Valve Cover

Explains how to install the engine valve cover.

Installing camshaft/sprocket assembly

Right-Side Components

Removing Right-Side Components

Details the process of removing components from the right side of the engine.

Water Pump

Explains how to remove the water pump.

Right-Side Cover

Details removing the right-side engine cover.

Rotor/Flywheel

Covers removing the engine's rotor and flywheel assembly.

Installing Right-Side Components

Left-Side Components

Removing Left-Side Components

Details the process of removing components from the left side of the engine.

V-Belt Cover

Explains how to remove the V-belt cover.

Driven Pulley

Details removing the driven pulley assembly.

Clutch Cover

Covers removing the engine clutch cover.

Servicing Left-Side Components

INSPECTING CENTRIFUGAL CLUTCH SHOE

Details inspection of the centrifugal clutch shoes.

INSPECTING CLUTCH HOUSING

Covers inspection of the clutch housing.

INSPECTING PRIMARY ONE-WAY DRIVE

Explains inspection of the primary one-way drive mechanism.

INSPECTING OIL PUMP

Details inspection of the engine oil pump.

Installing Left-Side Components

Center Crankcase Components

Separating Crankcase Halves

Details the process of separating the crankcase halves.

Disassembling Crankcase Half

Explains how to disassemble a crankcase half.

Servicing Center Crankcase Components

SECONDARY GEARS (Spiral)

Covers checking and correcting secondary gear backlash and tooth contact.

Checking Backlash

Explains how to check gear backlash.

Correcting Backlash

Details the procedure for correcting gear backlash.

Checking Tooth Contact

Explains how to check gear tooth contact.

Correcting Tooth Contact

SECONDARY OUTPUT DRIVE GEARS (Net-Forged)

Initial Set-Up

Outlines the initial setup for net-forged secondary output drive gears.

Checking Backlash

Correcting Backlash

CRANKSHAFT ASSEMBLY

Measuring Connecting Rod (Small End Inside Diameter)

Details measuring the connecting rod small end inside diameter.

Measuring Connecting Rod (Small End Deflection)

Explains how to measure connecting rod small end deflection.

Measuring Connecting Rod (Big End Side-to-Side)

Covers measuring connecting rod big end side-to-side clearance.

Measuring Connecting Rod (Big End Width)

Details measuring the connecting rod big end width.

Measuring Crankshaft (Runout)

Explains how to measure crankshaft runout.

Measuring Crankshaft (Web-to-Web)

COUNTERSHAFT

Disassembling

Provides step-by-step instructions for disassembling the countershaft.

Assembling

Provides step-by-step instructions for assembling the countershaft.

Assembling Crankcase Half

Joining Crankcase Halves

Installing Engine/Transmission

Troubleshooting

Problem: Engine will not start or is hard to start (Compression too low)

Addresses issues related to low engine compression affecting starting.

Problem: Engine will not start or is hard to start (No spark)

Covers troubleshooting issues related to lack of spark.

Problem: Engine will not start or is hard to start (No fuel reaching the carburetor/fuel injector)

Addresses problems with fuel delivery to the carburetor or injector.

Problem: Engine stalls easily

Lists causes and remedies for the engine stalling.

Problem: Engine noisy (Excessive valve chatter)

Details issues related to excessive valve noise.

Problem: Engine noisy (Noise seems to come from piston)

Covers noise originating from the piston area.

Problem: Engine noisy (Noise seems to come from timing chain)

Addresses noise related to the timing chain.

Problem: Engine noisy (Noise seems to come from crankshaft)

Problem: Engine noisy (Noise seems to come from transmission)

Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)

Problem: Engine idles poorly

Problem: Engine runs poorly at high speed

Problem: Exhaust smoke dirty or heavy

Problem: Engine lacks power

Problem: Engine overheats

SECTION 4 - FUEL/LUBRICATION/COOLING

Fuel/Lubrication/Cooling

Provides an overview of the fuel, lubrication, and cooling systems.

Carburetor Specifications (650 cc)

Lists detailed specifications for the 650 cc carburetor.

Electric Choke (650 cc)

Covers the electric choke system for the 650 cc model, including removal and testing.

Carburetor (650 cc)

Details the removal, inspection, and installation of the 650 cc carburetor.

Electronic Fuel Injection (550/700 cc)

Explains the EFI system for 550/700 cc models.

Engine RPM (Idle) (650 cc)

Covers adjusting idle RPM for the 650 cc model.

Gas Tank

Details the removal and installation of the gas tank.

Gas/Vent Hoses

Discusses the replacement and inspection of gas and vent hoses.

Oil Filter/Oil Pump

Covers testing, removing, and installing the oil filter and oil pump.

Oil Cooler (700 cc)

Details the removal and installation of the oil cooler for 700 cc models.

Liquid Cooling System

Explains the operation and maintenance of the liquid cooling system.

Radiator

Covers the removal and installation of the radiator.

Thermostat

Details the removal, inspection, and installation of the thermostat.

Fan

Explains the removal and installation of the cooling fan.

Water Pump

Covers the removal and installation of the water pump.

Electric Fuel Pump/Fuel Level Sensor (550/700 cc)

Details testing, removal, and installation of the electric fuel pump and sensor.

Vacuum Pulse Fuel Pump (650 cc)

Covers testing and replacing the vacuum pulse fuel pump.

Fuel Level Sensor (650 cc)

Details testing and replacing the fuel level sensor.

Troubleshooting (650 cc)

Provides troubleshooting guidance for 650 cc models.

Troubleshooting (550/700 cc)

Provides troubleshooting guidance for 550/700 cc models.

Fuel/Lubrication/Cooling

SPECIAL TOOLS

Lists special tools required for servicing fuel, lubrication, and cooling systems.

Carburetor Specifications (650 cc)

Lists detailed specifications for the 650 cc carburetor.

Electric Choke (650 cc)

Covers the electric choke system for the 650 cc model, including removal and testing.

Carburetor (650 cc)

REMOVING

Outlines the steps to remove the carburetor.

DISASSEMBLING

Provides instructions for disassembling the carburetor.

Electronic Fuel Injection (550/700 cc)

TROUBLESHOOTING

Provides troubleshooting guidance for the EFI system.

REMOVING THROTTLE BODY

Details the procedure for removing the throttle body.

INSTALLING THROTTLE BODY

Engine RPM (Idle) (650 cc)

Gas Tank

REMOVING

Outlines the steps to remove the gas tank.

CLEANING AND INSPECTING

INSTALLING

Gas/Vent Hoses

Oil Filter/Oil Pump

REMOVING/DISASSEMBLING

Details the process of removing and disassembling the oil pump.

CLEANING AND INSPECTING

Covers cleaning and inspecting oil pump components.

ASSEMBLING/INSTALLING

Provides instructions for assembling and installing the oil pump.

Oil Cooler (700 cc)

Liquid Cooling System

Radiator

Covers the removal and installation of the radiator.

REMOVING

Outlines the steps to remove the radiator.

CLEANING AND INSPECTING

Details cleaning and inspecting radiator components.

INSTALLING

Provides instructions for installing the radiator.

Thermostat

REMOVING

Outlines the steps to remove the thermostat.

INSPECTING

Details inspection of the thermostat.

INSTALLING

Provides instructions for installing the thermostat.

Fan

Water Pump

REMOVING

Outlines the steps to remove the water pump.

INSTALLING

Provides instructions for installing the water pump.

Electric Fuel Pump/Fuel Level Sensor (550/700 cc)

TESTING

Outlines testing procedures for the fuel pump and sensor.

REMOVING

Details the steps to remove the fuel pump.

INSTALLING

Vacuum Pulse Fuel Pump (650 cc)

TESTING

Outlines testing procedures for the vacuum pulse fuel pump.

Fuel Level Sensor (650 cc)

REMOVING

Outlines the steps to remove the fuel level sensor.

INSPECTING

Details inspection of the fuel level sensor.

INSTALLING

Troubleshooting (650 cc)

Troubleshooting (550/700 cc)

SECTION 5 - ELECTRICAL SYSTEM

Electrical System

Provides an overview of the electrical system.

Specifications

Lists detailed specifications for electrical components.

Battery

Covers battery maintenance, testing, and installation.

RPM Limiter

Explains the function of the RPM limiter.

Testing Electrical Components

Outlines general procedures for testing electrical components.

Switches

Covers the inspection of various switches on the vehicle.

Electrical Connections

Emphasizes checking electrical connections for proper function.

Accessory Receptacle/Connector

Details testing the accessory receptacle and connectors.

Brakelight Switch

Covers testing the brakelight switch for voltage and resistance.

Coolant Temperature and Cooling Fan Switches (650 cc)

Details testing the coolant temp and fan switches for 650cc models.

Engine Coolant Temperature (ECT) Sensor (550/700 cc)

Covers testing the ECT sensor for 550/700cc models.

Fan Motor

Details testing the fan motor for voltage and resistance.

Power Distribution Module (PDM)

Explains how to check fuses in the power distribution module.

FUSES

Discusses the location and checking of main fuses.

Ignition Coil

Covers testing the ignition coil for voltage and resistance.

Spark Plug Cap

Details testing the spark plug cap for resistance.

RELAYS

Discusses the interchangeability and function of relays.

EFI Sensors/Components (550/700 cc)

Covers testing various EFI sensors and components.

CRANKSHAFT POSITION (CKP) SENSOR (550/700 cc)

Details testing the CKP sensor.

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

Explains testing the MAP sensor.

Speed Sensor

Covers testing the speed sensor.

Ignition Switch

Details testing the ignition switch for voltage.

Headlight Switch

Covers testing the headlight switch for voltage.

2WD/4WD/Differential Lock Switch (Prowler/XTX)

Details testing the 2WD/4WD/Diff Lock switch.

2WD/4WD Selector Switch (XT)

Covers testing the 2WD/4WD selector switch.

Differential Lock Switch (XT)

Details testing the differential lock switch.

Reverse Override Switch

Covers testing the reverse override switch.

Front Drive Actuator

Details testing the front drive actuator.

Stator Coils (650 cc)

Covers testing stator coils for voltage and resistance.

Stator Coil/Crankshaft Position (CKP) Sensor (550/700 cc)

Details testing the stator coil and CKP sensor.

Starter Motor

Covers removing, installing, and testing the starter motor.

Starter Relay

Details testing the starter relay.

CDI Unit (650 cc)

Discusses the CDI unit and its servicing.

Electronic Control Unit (ECU) (550/700 cc)

Discusses the ECU and its servicing.

Regulator/Rectifier

Covers testing the regulator/rectifier.

Headlights

Details testing headlight voltage.

Taillight-Brakelight

Covers testing taillight and brakelight voltage.

Ignition Timing

Explains how to verify ignition timing.

ECU Error Codes (550/700 cc)

Lists and explains ECU error codes.

Tilt Sensor (550/700 cc)

Details testing the tilt sensor.

Throttle Position Sensor (TPS) (550/700 cc)

Covers testing and adjusting the TPS.

Troubleshooting

Provides troubleshooting for electrical system issues.

Electrical System

SPECIAL TOOLS

Lists special tools required for electrical system testing.

Specifications

Lists electrical specifications for 650 cc and 550/700 cc models.

Battery

Covers battery maintenance, testing, and installation.

RPM Limiter

Testing Electrical Components

Battery Charging Chart

Switches

Brakelight Switch

Electrical Connections

Accessory Receptacle/Connector

Coolant Temperature and Cooling Fan Switches (650 cc)

Engine Coolant Temperature (ECT) Sensor (550/700 cc)

Fan Motor

Power Distribution Module (PDM)

FUSES

Ignition Coil

VOLTAGE (Primary Side)

Details testing the primary side voltage of the ignition coil.

RESISTANCE

Covers testing the resistance of the ignition coil windings.

Primary Winding

Details resistance testing of the primary winding.

Secondary Winding

Covers resistance testing of the secondary winding.

Spark Plug Cap

Details testing the spark plug cap for resistance.

RELAYS

Discusses the interchangeability and function of relays.

PEAK VOLTAGE

Primary Coil (650 cc)

Details peak voltage testing for the 650 cc primary coil.

Primary Coil (550/700 cc)

Covers peak voltage testing for the 550/700 cc primary coil.

EFI Sensors/Components (550/700 cc)

Covers testing various EFI sensors and components.

CRANKSHAFT POSITION (CKP) SENSOR (550/700 cc)

Details testing the CKP sensor.

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

Explains testing the MAP sensor.

Speed Sensor

Covers testing the speed sensor.

Ignition Switch

Headlight Switch

2WD/4WD/Differential Lock Switch (Prowler/XTX)

2WD/4WD Selector Switch (XT)

Differential Lock Switch (XT)

Reverse Override Switch

Front Drive Actuator

Stator Coils (650 cc)

VOLTAGE (Generator Regulated Output)

Details testing regulated output voltage from the stator.

VOLTAGE (Charging Coil - No Load)

Covers testing charging coil voltage without load.

RESISTANCE (AC Generator)

Details resistance testing of the AC generator coils.

RESISTANCE (Crankshaft Position Sensor)

Covers resistance testing of the CKP sensor.

AC VOLTAGE

Details AC voltage testing.

Crankshaft Position Sensor

Details testing the CKP sensor.

Starter Motor

REMOVING

Outlines the steps to remove the starter motor.

INSTALLING

Provides instructions for installing the starter motor.

TESTING VOLTAGE

Details testing the starter motor voltage.

Starter Relay

CDI Unit (650 cc)

Electronic Control Unit (ECU) (550/700 cc)

Regulator/Rectifier

Headlights

Taillight-Brakelight

Ignition Timing

ECU Error Codes (550/700 cc)

Tilt Sensor (550/700 cc)

SUPPLY VOLTAGE

OUTPUT VOLTAGE

Throttle Position Sensor (TPS) (550/700 cc)

INSTALLING/ADJUSTING

Troubleshooting

Problem: Spark absent or weak

Addresses issues related to absent or weak spark.

Problem: Spark plug fouled with carbon

Lists causes and remedies for carbon-fouled spark plugs.

Problem: Spark plug electrodes overheat or burn

Covers issues related to spark plug electrode overheating.

Problem: Battery does not charge

Addresses problems with the battery not charging.

Problem: Magneto overcharges

Addresses issues with the magneto overcharging the battery.

Problem: Charging unstable

Lists causes for unstable battery charging.

Problem: Starter button not effective

Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates)

Problem: Battery discharges too rapidly

Problem: Battery polarity reversed

SECTION 6 - DRIVE SYSTEM

Drive System

Provides an overview of the drive system.

Front Drive Actuator

Covers the front drive actuator.

Front Differential

Details the front differential system.

Drive Axles

Covers the drive axles.

Rear Gear Case (Prowler/XT)/Rear Differential (XTX)

Details the rear gear case and differential.

Hub

Covers the hub components.

Hydraulic Brake Caliper

Details the hydraulic brake caliper.

Universal Joints

Covers universal joints in the drive system.

Troubleshooting

Provides troubleshooting for drive system issues.

Drive System

GENERAL INFORMATION

Provides general information about the drive system gear cases.

SPECIAL TOOLS

Lists special tools for drive system service.

Front Drive Actuator

Covers the front drive actuator, including removal and installation.

REMOVING

Outlines the steps to remove the front drive actuator.

INSTALLING

Front Differential

REMOVING

Outlines the steps to remove the front differential.

Disassembling Input Shaft

Assembling Input Shaft

Disassembling Differential Assembly

Shimming Procedure/Shim Selection

Assembling Pinion Gear

Removing Needle Bearing

Installing Needle Bearing

Removing/Installing Axle Seal

INSTALLING DIFFERENTIAL

Drive Axles

REMOVING REAR DRIVE AXLE

Outlines the steps to remove the rear drive axle.

REMOVING FRONT DRIVE AXLE

CLEANING AND INSPECTING AXLES

DISASSEMBLING AXLES

ASSEMBLING AXLES

INSTALLING REAR DRIVE AXLE

INSTALLING FRONT DRIVE AXLE

Rear Gear Case (Prowler/XT)/Rear Differential (XTX)

REMOVING

Outlines the steps to remove the rear gear case/differential.

INSTALLING

Provides instructions for installing the rear gear case/differential.

Hub

REMOVING

Outlines the steps to remove the wheel hub.

CLEANING AND INSPECTING

Details cleaning and inspecting hub components.

REPLACING WHEEL STUDS

Explains how to replace wheel studs.

INSTALLING

Hydraulic Brake Caliper

REMOVING/DISASSEMBLING

Outlines the steps to remove and disassemble the brake caliper.

CLEANING AND INSPECTING

Details cleaning and inspecting brake caliper components.

ASSEMBLING/INSTALLING

Provides instructions for assembling and installing the brake caliper.

Universal Joints

REMOVING

Outlines the steps to remove universal joints.

INSPECTING

Details inspection of universal joint components.

INSTALLING

Troubleshooting

SECTION 7 - SUSPENSION

Suspension

Provides an overview of the suspension system.

Shock Absorbers

Covers shock absorbers, including removal and inspection.

Front A-Arms

Details the front A-arms, including removal and installation.

Rear A-Arms

Covers the rear A-arms, including removal and installation.

Wheels and Tires

Details wheel and tire service.

Troubleshooting

Provides troubleshooting for suspension issues.

Suspension

Shock Absorbers

Covers shock absorbers, including removal and inspection.

REMOVING

Outlines the steps to remove shock absorbers.

CLEANING AND INSPECTING

Details cleaning and inspecting shock absorber components.

INSTALLING

Front A-Arms

REMOVING

Outlines the steps to remove the front A-arms.

CLEANING AND INSPECTING

Details cleaning and inspecting A-arm components.

INSTALLING

Provides instructions for installing the front A-arms.

Rear A-Arms

REMOVING

Outlines the steps to remove the rear A-arms.

CLEANING AND INSPECTING

Details cleaning and inspecting A-arm components.

INSTALLING

Provides instructions for installing the rear A-arms.

Wheels and Tires

REMOVING

Outlines the steps to remove wheels.

CLEANING AND INSPECTING

Details cleaning and inspecting wheels and tires.

INSTALLING

Provides instructions for installing wheels.

CHECKING/INFLATING

Covers checking and adjusting tire air pressure.

Troubleshooting

SECTION 8 - STEERING/FRAME

Steering/Frame

Provides an overview of the steering and frame components.

Steering Assembly

Covers the steering assembly, including removal and inspection.

Steering Wheel

Details the removal, inspection, and installation of the steering wheel.

Upper Steering Shaft

Covers the upper steering shaft, including removal and installation.

Lower Steering Shaft Assembly

Details the lower steering shaft assembly, including removal and installation.

Steering Knuckles

Covers steering knuckles, including removal, inspection, and assembly.

Checking/Adjusting Front Wheel Alignment

Explains how to check and adjust front wheel alignment.

Front Bumper Assembly (XT/XTX)

Details the removal and installation of the front bumper.

Hood

Covers the removal and installation of the hood.

Fenders

Explains the removal and installation of fenders.

Floor

Details the removal and installation of the floor panel.

Belly Panel

Covers the removal and installation of the belly panel.

Exhaust System

Details the removal and installation of the exhaust system muffler.

Cargo Box (XT/XTX)

Covers the removal and installation of the cargo box.

Taillight Assembly

Explains the removal and installation of the taillight assembly.

Seats

Covers the removal and installation of seats.

Troubleshooting

Provides troubleshooting for steering and frame issues.

Steering/Frame

Steering Assembly

Covers the steering assembly, including removal and inspection.

REMOVING

Outlines the steps to remove the steering assembly.

INSPECTING

REPLACING TIE RODS/BOOTS

INSTALLING

Steering Wheel

REMOVING

Outlines the steps to remove the steering wheel.

INSPECTING

Details inspection of the steering wheel.

INSTALLING

Provides instructions for installing the steering wheel.

Upper Steering Shaft

REMOVING

Outlines the steps to remove the upper steering shaft.

INSTALLING

INSPECTING

Lower Steering Shaft Assembly

REMOVING

Outlines the steps to remove the lower steering shaft assembly.

INSPECTING

Details inspection of the lower steering shaft assembly.

INSTALLING

Provides instructions for installing the lower steering shaft assembly.

Steering Knuckles

REMOVING AND DISASSEMBLING

Outlines the steps to remove and disassemble steering knuckles.

CLEANING AND INSPECTING

Details cleaning and inspecting knuckle components.

ASSEMBLING AND INSTALLING

Provides instructions for assembling and installing steering knuckles.

Checking/Adjusting Front Wheel Alignment

Front Bumper Assembly (XT/XTX)

REMOVING

Outlines the steps to remove the front bumper.

CLEANING AND INSPECTING

Details cleaning and inspecting bumper components.

INSTALLING

Provides instructions for installing the front bumper.

Hood

REMOVING

Outlines the steps to remove the hood.

CLEANING AND INSPECTING

Details cleaning and inspecting hood components.

INSTALLING

Provides instructions for installing the hood.

Fenders

REMOVING

Outlines the steps to remove fenders.

INSTALLING

Provides instructions for installing fenders.

Floor

REMOVING

Outlines the steps to remove the floor panel.

INSTALLING

Provides instructions for installing the floor panel.

Belly Panel

REMOVING

Outlines the steps to remove the belly panel.

INSTALLING

Provides instructions for installing the belly panel.

Exhaust System

REMOVING MUFFLER

Outlines the steps to remove the muffler.

INSPECTING MUFFLER

Details inspection of the muffler.

INSTALLING MUFFLER

Provides instructions for installing the muffler.

Cargo Box (XT/XTX)

REMOVING

Outlines the steps to remove the cargo box.

CLEANING AND INSPECTING

Details cleaning and inspecting cargo box components.

INSTALLING

Provides instructions for installing the cargo box.

Taillight Assembly

REMOVING

Outlines the steps to remove the taillight assembly.

INSPECTING

Details inspection of the taillight assembly.

INSTALLING

Provides instructions for installing the taillight assembly.

Seats

Troubleshooting

Problem: Handling too heavy or stiff

Addresses issues related to heavy or stiff handling.

Problem: Steering oscillation

Lists causes and remedies for steering oscillation.

Problem: Steering pulling to one side

Covers issues causing the vehicle to pull to one side.

Problem: Steering impaired

Addresses general steering impairment issues.

Problem: Tire wear rapid or uneven

Lists causes for rapid or uneven tire wear.

Problem: Steering noise

Problem: Rear wheel oscillation

SECTION 9 - CONTROLS/INDICATORS

Master Cylinder Assembly

Covers the master cylinder assembly, including removal and installation.

Accelerator Pedal

Details the removal and installation of the accelerator pedal.

Front Differential Lock (XT)

Explains adjusting the front differential lock cable.

Shift Lever

Covers the removal and installation of the shift lever.

Speedometer/Tachometer/LCD/Indicator Lights

Details replacing the speedometer, tachometer, LCD, and indicator lights.

Master Cylinder Assembly

REMOVING

Outlines the steps to remove the master cylinder assembly.

INSPECTING

Details inspection of master cylinder components.

INSTALLING

Provides instructions for installing the master cylinder assembly.

Accelerator Pedal

REMOVING

Outlines the steps to remove the accelerator pedal.

Front Differential Lock (XT)

ADJUSTING CABLE

Details how to adjust the front differential lock cable.

Shift Lever

REMOVING

Outlines the steps to remove the shift lever.

INSTALLING

Provides instructions for installing the shift lever.

Speedometer/Tachometer/LCD/Indicator Lights

REPLACING

Outlines the steps to replace the gauge cluster components.

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