Arctic Cat Prowler HDX 2012 UTV Workshop Repair Service Manual

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This workshop repair service manual PDF download for the 2012 Arctic Cat Prowler HDX Utility Vehicle has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 

This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2012 Arctic Cat Prowler HDX. The complete manual is designed to aid service personnel in service-oriented applications.


APPLICABLE MODELS :

Arctic Cat Prowler HDX 2012 


TABLE OF CONTENTS :

    General Information
    Periodic Maintenance
    Engine/Transmission
    Fuel/Lubrication/Cooling
    Electrical System
    Drive System
    Suspension
    Steering/Frame/Controls

    
MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 151


This manual is divided into sections. Each section covers a specific ATV 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 givencondition. 

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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Foreword
Table of Contents
    General Information
        General Specifications
        Torque Specifications
        Torque Conversions (ft-lb/N-m)
        Break-In Procedure
        Gasoline - Oil - Lubricant
            RECOMMENDED GASOLINE
            RECOMMENDED ENGINE/ TRANSMISSION OIL
            RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT
            FILLING GAS TANK
        Genuine Parts
        Preparation For Storage
        Preparation After Storage
        
    Periodic Maintenance
        Periodic Maintenance Chart
            SPECIAL TOOLS
        Lubrication Points
        Air Filter
            CHECKING AND CLEANING DRAINS
        Valve/Tappet Clearance
            Feeler Gauge Procedure
            Valve Adjuster Procedure
        Testing Engine Compression
        Spark Plug
        Muffler/Spark Arrester
        Engine/Transmission Oil - Filter
            OIL - FILTER
        Front Differential - Rear Drive Lubricant
        Driveshaft/Coupling
        Nuts/Bolts/Cap Screws
        Headlight/Taillight- Brakelight
            HEADLIGHT
            TAILLIGHT-BRAKELIGHT
            CHECKING/ADJUSTING HEADLIGHT AIM
        Shift Lever
            CHECKING SHIFT CABLE ADJUSTMENT
            ADJUSTING SHIFT CABLE
            ADJUSTING PARK INDICATOR LIGHT
        Hydraulic Brake System
            CHECKING/BLEEDING
            INSPECTING HOSES
            CHECKING/REPLACING PADS
            BRAKE DISC
        Burnishing Brake Pads
        Checking/Replacing V- Belt
            REMOVING
            INSTALLING
        Troubleshooting Brake System
        
    Engine/Transmission
        SPECIAL TOOLS
        Troubleshooting
        Removing Engine/ Transmission
        Top-Side Components
        Removing Top-Side Components
            A. Valve Cover B. Cylinder Head
            C. Cylinder D. Piston
        Servicing Top-Side Components
            VALVE ASSEMBLY
            Cleaning/Inspecting Valve Cover
            Removing Valves
            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)
            Measuring Rocker Arm Shaft (Outside Diameter)
            Installing Valves
            PISTON ASSEMBLY
            Removing Piston Rings
            Cleaning/Inspecting Piston
            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
            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
            A. Piston B. Cylinder
            C. Cylinder Head D. Valve Cover
        Left-Side Components
        Removing Left-Side Components
            A. Water Pump B. Side Cover C. Rotor/Flywheel
        Servicing Left-Side Components
            INSPECTING STARTER CLUTCH/ GEAR
            REPLACING STARTER CLUTCH ASSEMBLY
            REPLACING STARTER GEAR BEARING
            INSPECTING STATOR/MAGNETO COVER ASSEMBLY
            REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR
        Installing Left-Side Components
        Right-Side Components
        Removing Right-Side Components
            A. V-Belt Cover B. Driven Pulley C. Clutch Cover
        Servicing Right-Side Components
            INSPECTING CENTRIFUGAL CLUTCH SHOE
            INSPECTING CLUTCH HOUSING
            INSPECTING PRIMARY ONE-WAY DRIVE
            INSPECTING OIL PUMP
            DRIVEN PULLEY
        Installing Right-Side Components
        Center Crankcase Components
        Separating Crankcase Halves
        Disassembling Crankcase Half
        Servicing Center Crankcase Components
            SECONDARY OUTPUT DRIVE GEARS
            Initial Set-Up
            Checking Backlash
            Correcting Backlash
            CRANKSHAFT ASSEMBLY
            Measuring Connecting Rod (Small End Inside Diameter)
            Measuring Connecting Rod (Small End Deflection)
            Measuring Connecting Rod (Big End Side-to-Side)
            Measuring Crankshaft (Runout)
            Measuring Crankshaft (Web-to- Web)
            COUNTERSHAFT
            Disassembling
            Assembling
        Assembling Crankcase Half
        Joining Crankcase Halves
        Installing Engine/ Transmission
        
    Fuel/Lubrication/Cooling
        SPECIAL TOOLS
        Electronic Fuel Injection
            TROUBLESHOOTING
            REMOVING THROTTLE BODY
            INSTALLING THROTTLE BODY
        Gas Tank
            REMOVING
            CLEANING AND INSPECTING
            INSTALLING
        Gas/Vent Hoses
        Oil Filter/Oil Pump
            TESTING OIL PUMP PRESSURE
            REMOVING/DISASSEMBLING
            CLEANING AND INSPECTING
            ASSEMBLING/INSTALLING
        Liquid Cooling System
        Radiator
            REMOVING
            CLEANING AND INSPECTING
            INSTALLING
        Thermostat
            REMOVING
            INSPECTING
            INSTALLING
        Fan
            REMOVING
            INSTALLING
        Water Pump
            REMOVING
            INSTALLING
        Electric Fuel Pump/Fuel Level Sensor
            TESTING
            REMOVING
            INSPECTING
            INSTALLING
        Troubleshooting
        
    Electrical System
        SPECIAL TOOLS
        Battery
            Maintenance Charging
            Charging
        RPM Limiter
        Testing Electrical Components
        Switches
        Electrical Connections
        Accessory Receptacle/ Connector
            VOLTAGE
        Brakelight Switch
            VOLTAGE (Wiring Harness Connector)
            RESISTANCE (Switch Connector)
        Engine Coolant Temperature (ECT) Sensor
        Fan Motor
            RESISTANCE (Fan Motor Connector)
        Power Distribution Module (PDM)
            RELAYS
        Ignition Coil
            VOLTAGE (Primary Side)
            RESISTANCE
            Primary Winding
            Secondary Winding
            Spark Plug Cap
            VOLTAGE
            Primary Coil
        EFI Sensors/Components
            CRANKSHAFT POSITION (CKP) SENSOR
            MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
        Speed Sensor
        Electronic Power Steering (EPS)
        Ignition Switch
            VOLTAGE
        Headlight Switch
            VOLTAGE
        Drive Select Switch
            RESISTANCE
            VOLTAGE
        Reverse Override Switch
            VOLTAGE
        Front Drive Actuator
            VOLTAGE
        Stator Coil/Crankshaft Position (CKP) Sensor
            VOLTAGE (AC Generator - Regulated Output)
            VOLTAGE (AC Generator - No Load)
            RESISTANCE (AC Generator)
            RESISTANCE (Crankshaft Position Sensor)
            AC VOLTAGE
            Crankshaft Position Sensor
        Starter Motor
            REMOVING
            INSTALLING
            TESTING VOLTAGE
        Starter Relay
        Electronic Control Unit (ECU)
        Regulator/Rectifier
            TESTING VOLTAGE
        Headlights
            VOLTAGE
        Taillight-Brakelight
            VOLTAGE (Taillight)
            VOLTAGE (Brakelight)
        Ignition Timing
        ECU Error Codes
            ECU Error Code List
        Tilt Sensor
            SUPPLY VOLTAGE
            OUTPUT VOLTAGE
        Throttle Position Sensor (TPS)
            INSPECTING
            REMOVING
            INSTALLING/ADJUSTING
        Troubleshooting
        
    Drive System
        GENERAL INFORMATION
        SPECIAL TOOLS
        Front Drive Actuator
            REMOVING
            INSTALLING
        Front Differential
            REMOVING
            Disassembling Input Shaft
            Assembling Input Shaft
            Disassembling Differential Assembly
            Disassembling Pinion Gear
            Assembling Pinion Gear
            Shimming Procedure/Shim Selection
            Backlash
            Ring Gear End-Play
            Assembling Differential Assembly
            Removing/Installing Axle Seal
            INSTALLING DIFFERENTIAL
        Drive Axles
            REMOVING 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
            REMOVING
            RING GEAR/THRUST BUTTON
            Removing
            Inspecting
            Installing/Shimming
            REAR DRIVE INPUT SHAFT/ HOUSING
            Removing/Disassembling
            Cleaning and Inspecting
            Assembling/Installing
            INSTALLING
        Hub
            REMOVING
            CLEANING AND INSPECTING
            REPLACING WHEEL STUDS
            INSTALLING
        Hydraulic Brake Caliper
            REMOVING/DISASSEMBLING
            CLEANING AND INSPECTING
            ASSEMBLING/INSTALLING
            MASTER CYLINDER ASSEMBLY
            Removing
            Inspecting
            Installing
        Universal Joints
            REMOVING
            INSPECTING
            INSTALLING
        Troubleshooting
        
    Suspension
        Front Shock Absorbers
            REMOVING
            CLEANING AND INSPECTING
            INSTALLING
        Rear Shock Absorbers
            REMOVING
            DISASSEMBLING
            ASSEMBLING/CHARGING
            INSTALLING
        Front A-Arms
            REMOVING
            CLEANING AND INSPECTING
            INSTALLING
        Rear A-Arms
            REMOVING
            CLEANING AND INSPECTING
            INSTALLING
        Wheels and Tires
            TIRE SIZE
            TIRE INFLATION PRESSURE
            REMOVING
            CLEANING AND INSPECTING
            INSTALLING
            CHECKING/INFLATING
        Troubleshooting
        
    Steering/Frame/Controls
        Electronic Power Steering (EPS)
            REMOVING EPS ASSEMBLY
            INSTALLING EPS ASSEMBLY
            REMOVING TIE RODS
            INSTALLING TIE RODS
        Steering Assembly
            REMOVING
            INSPECTING
            INSTALLING
        Steering Wheel
            REMOVING
            INSPECTING
            INSTALLING
        Upper Steering Shaft
            REMOVING
            INSPECTING
            INSTALLING
        Intermediate Steering Shaft Assembly
            REMOVING
            INSPECTING
            INSTALLING
        Steering Knuckles
            REMOVING AND DISASSEMBLING
            CLEANING AND INSPECTING
            ASSEMBLING AND INSTALLING
        Accelerator Pedal
            REMOVING
            INSTALLING
        Shift Lever
            REMOVING
            INSTALLING
        Shift Cable
            REMOVING
            INSTALLING
        LCD Gauge/Indicator Lights
            REPLACING
        Checking/Adjusting Front Wheel Alignment
        Front Bumper Assembly
            REMOVING
            CLEANING AND INSPECTING
            INSTALLING
        Hood
            REMOVING
            CLEANING AND INSPECTING
            INSTALLING
        Fenders
            REMOVING
            INSTALLING
        Floor
            REMOVING
            CLEANING AND INSPECTING
            INSTALLING
        Dashboard
            REMOVING
            INSTALLING
        Belly Panel
            REMOVING
            INSTALLING
        Exhaust System
            REMOVING MUFFLER
            INSPECTING MUFFLER
            INSTALLING MUFFLER
        Cargo Box
            REMOVING
            CLEANING AND INSPECTING
            INSTALLING
        Taillight Assembly
            REMOVING
            INSPECTING
            INSTALLING
        Seat
            REMOVING/INSTALLING
        Troubleshooting

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