Repair manual artic cat prowler

Inspect the welds of the cargo box frame for cracking 2. Disconnect the wire connector; then remove the or bending. Inspect the cargo box gate latches for smooth opera- tion. Front wheel alignment incorrect 1. Adjust alignment 2. Steering shaft binding 2. Tire inflation pressure incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5. Valve clearance out of adjustment 1. Adjust clearance 2.

Valve guides worn 2. Replace guides 3. Valves mistimed 3. Retime engine 4. Piston rings worn - broken 4. Page 39 Problem: Engine noisy Noise seems to come from secondary bevel gear and final driven shaft Condition Remedy 1. Drive - driven bevel gears damaged - worn 1.

Replace gears 2. Backlash excessive 2. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4. Closely observe the note introducing each sub-section for this important information. Page 41 8. Loosen the clamp securing the throttle body to the intake manifold boot; then remove the throttle body and set aside. From the left side, disconnect the ECT sensor con- nector, speed sensor connector, and spark plug cap.

Page 42 Remove the two exhaust springs at the muffler; then remove the exhaust pipe. Account for a grafoil seal in the cylinder head and a grafoil seal at the muffler. HDXA Remove the forward heat shield from the exhaust pipe; Page Servicing Engine Servicing Engine appropriate wrench, rotate the crankshaft to top- dead-center of the compression stroke.

Page 44 2. Remove the cylinder head cover cap screws. Note the rubber washers on the four top-side cap screws; remove the cylinder head cover. Note the orientation of the cylinder head plug and remove it. Note the location of the two alignment pins. FI 4. Page 45 MD FI 6. Noting the timing marks for installing purposes, drop the sprocket off the camshaft. While holding the cam chain, slide the sprocket and camshaft out of the cyl- inder head.

Account for an alignment pin. Remove the cylinder head from the cylinder, remove Lift the cylinder off the crankcase taking care not to the gasket, and account for two alignment pins. Account for the gasket and two alignment pins.

Always check camshaft clearance when resurfacing the cylin- der head cover. Page 48 1. Using a micrometer, measure the valve stem outside Seats diameter.

If valves, valve guides, or valve seats require servicing 2. Acceptable diameter ranges must be within specifi- or replacement, Arctic Cat recommends that the compo- cations. Page 49 4. Place a spring retainer over the valve springs; then using the valve spring compressor, compress the CAUTION valve springs and install the valve keepers.

If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced. Do not attempt to grind the valves or severe engine damage may occur. Inspect and measure the connecting rod small end inside diameter. If the measurement exceeds specifi- Grooves cations, the connecting rod must be replaced see Center Crankcase Components in this section.

Page 51 3. Place the cylinder head on the surface plate covered with grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion.

Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. If any measurement exceeds the limit, the cylinder Inspecting Cam Chain Guide must be replaced.

Measuring Camshaft Runout 1. Inspect cam chain guide for cuts, tears, breaks, or chips. Page 53 Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced. Measuring Camshaft to Cylinder Head Clearance 1. Loosen the jam nuts and adjuster screws. CCD 6. If damaged, the camshaft must be replaced. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston.

Route the cam chain up through the cylinder cam chain housing; Installing Top-Side then remove the piston holder and seat the cylinder Components Page 55 C. With the timing inspection plug removed and the cam chain held tight, rotate the crankshaft until the piston is at D. Rocker Arms Page 56 Place the tab washer onto the sprocket making sure it covers the pin in the alignment hole.

MD Place the C-ring into position in its groove in the cyl- inder head. Page Left-Side Components Rotate the crankshaft until the first cap screw from Place the two tappet covers with O-rings into posi- step 17 securing the sprocket to the camshaft can be tion; then install and tighten the cap screws to 8.

Page 58 4. Remove the water pump drive gear; then remove the speed sensor housing assembly. Account for two alignment pins, a gasket, and two seal washers. FI 2. Remove the water pump housing assembly noting the location of the longer cap screw. Account for a gasket and two alignment pins. Page 59 8. FI Remove the shift detent cam arm and spring. FI 9. Remove the flywheel key from the crankshaft; then remove the starter clutch gear.

Rotate the gear counterclockwise and it should turn freely. If it moves or locks up both ways, the starter clutch FI 2. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft position sen- sor, and one cap screw from the harness hold-down. Install the starter motor and tighten the two cap screws to 10 ft-lb.

Install the shift detent cam making sure the washer is installed. Clean the bearing bores in the housing and inspect closely for cracks or shiny areas indicating bearing movement. Install the starter clutch gear onto the crankshaft; Tighten the cap screws to 8 ft-lb. FIA 8. Page Right-Side Components Connect the coolant hoses to the water pump and secure with the hose clamps. Tighten securely.

Page 65 8. Using an impact screwdriver, remove the three Phil- lips-head cap screws holding the air intake plate. Remove the air intake plate. MD 5. Using a 6 mm cap screw threaded into the fixed driven face, spread the driven pulley by turning the cap screw clockwise; Page 66 MD FI Remove the left-hand threaded nut holding the cen- Remove the oil pump drive gear cap screw. Remove oil pump drive gear. Account for the pin. MD MD Remove oil pump driven gear.

Account for the drive pin and thrust washer. Inspect the clutch housing for burns, marks, scuffs, cracks, scratches, or uneven wear. If the housing is damaged in any way, the housing must be replaced. Page 69 MD MD 3. Place two alignment pins and the oil pump into posi- 5. Install the cam chain. Tighten to 8 ft-lb. Page 70 8.

Place the driven pulley assembly into position and secure with the nut threads coated with red Loctite Making sure the movable drive face rollers are in Remove the left-side and right-side cap screws securing the crankcase halves noting the position of the different-sized cap screws for joining purposes. Remove the gear shift shaft F noting the inner and outer washers. FIA 2. Remove the reverse idler assembly B. Account for and note the location of the inner bushing 1 , idler shaft 2 , and outer washer 3.

FIA 5. Also, always start with the original shims on the rear shaft. Place the left-side crankcase cover onto the left-side crankcase half to prevent runout of the secondary transmission output shaft.

Page 76 CCD H 3. Acceptable gap range must be within specifications. Acceptable width range must be within specifica- tions.

Place the crankshaft on a set of V blocks. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crank- When disassembling the countershaft, care must be shaft. Page 77 FI FI 3. Remove the low driven gear washer; then remove the 5.

Remove the circlip securing the high driven gear; low driven gear along with the bearing and bushing. Place the reverse driven bushing 13 onto the shaft; then install the bearing 14 , gear 15 , and splined washer Secure with a snap-ring.

Using a propane torch, heat the bearing until the to be installed. Page 80 8. Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the shift fork shaft into the locating boss in the crankcase.

FI 6. Align the shift cam fork slots with the shift fork shaft locating boss and with a washer on each end, install in the crankcase. Verify that the two alignment pins A are in place and that both case halves are clean and grease free. Apply Loctite or suitable substitute sealant to the mating surfaces.

Place the right-side half onto the left-side half. From the left side, install the remaining crankcase Servicing Right-Side Components While holding the chain, slide the sprocket and camshaft out of the cylinder head. CCD Remove the four cylinder head bolts. Cylinder D. Page Servicing Top-Side Components 1. Wash the valve cover in parts-cleaning solvent. Place the valve cover on the Surface Plate covered with grit wet-or-dry sandpaper.

Using light pressure, move the valve cover in a figure eight motion. Page 87 2. Acceptable width ranges must not exceed specifica- tions. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks. Position the dial indicator contact point on the out- side edge of the valve face; Measure the piston pin outside diameter at each end and in the center.

If measurement is not within speci- fications, the piston pin must be replaced. CCD 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. Page 91 Inspecting Cylinder 1. Page 92 2. Place a strip of plasti-gauge in each of the camshaft lands in the cylinder head. Place the valve cover on the cylinder head and secure with the valve cover cap screws.

Place the two alignment pins into position. Place the cylinder gasket into position; then place a piston holder or suitable substitute beneath the piston skirt and square the piston in respect to the crankcase. Inspect the spring and drive pin for damage. CF CFA 3. Page 94 5. Install the coolant hose onto the crankcase union and tighten the clamp. Cylinder Head D. Place the chain guide into the cylinder. Page 95 With the alignment pin installed in the camshaft, loosely A.

Piston still at top-dead-center. Camshaft lobes directed down toward the pis- cam shaft lobes onto the camshaft. At this point, do not ton. Page 96 CD CD Remove the cap screw from the end of the chain ten- step 18 can be accessed; then tighten to 10 ft-lb.

Install the four top side cap screws with rubber wash- ers; then install the remaining cap screws. Tighten only until snug. CD CCD Remove the cap screws securing the left-side cover to the crankcase noting the location of the different- be removed from the frame for this procedure. This passage should be plugged prior to removing the driven gear and drive gear. Failure to do so could result in the loss of an alignment pin into the crankcase. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration.

If any of the above conditions exist, replace the starter clutch assembly. Inspect the stator coil for burned or discolored wir- ing, broken or missing hold-down clips, or loose cap screws. Install the water pump drive gear drive pin and the drive gear with the flat side of the gear facing out- ward as noted in removing ; then secure with the snap ring.

Install the shift cam stopper, spring, and two washers 8. Lubricate the magneto cover gasket with fresh thick washer closest to the nut ; then coat the engine oil; then place it into position on the two threads on the mounting stud with red Loctite alignment pins. The technician should use discretion and sound judgment. CDA 3. Remove the V-belt. Remove the nut securing the fixed driven assembly; then remove the assembly. Page Remove the cap screw securing the oil pump drive gear B. Account for a cap screw, washer, pin, and spacer.

CD CFA 9. Remove the nut left-hand threads securing the clutch CD shoe assembly C. Remove the snap ring securing the oil pump driven gear A ; then remove the gear noting the direction Servicing Right-Side of the sides of the gear for installing purposes. Account for a pin and a washer. Inspect the pump for damage. It is inadvisable to remove the screw securing the pump halves.

If the oil pump is damaged, it must be replaced. CD 3. Install the oil pump drive gear spacer onto the crank balancer shaft. Lightly grease the clutch housing seal; then insert the left fixed-drive spacer. Place the V-belt into position on the driven pulley and over the front shaft. H Place the driven pulley assembly into position and secure with the nut. Tighten to ft-lb. Page 3. Remove the shift shaft H ; then remove the two forks taking note of the direction of the tabs on the forks for assembling purposes.

Remove the gear shift shaft G noting the location of the two holes on the end of the shaft. Account for a spacer and a washer. If removed, bevel gear back- lash will have to be adjusted requiring re-shimming of the drive bevel gear shaft. Acceptable backlash range is 0. Correcting Backlash 5. Place the assembled shaft into the left crankshaft case; Page CCD H 2. Maximum diameter must not exceed specifications. Zero the indicator and rotate the crankshaft slowly.

Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate. Remove the reverse driven gear dog. Install the low driven gear locking washer; then 6. Remove the low driven gear. Account for a bearing, install the inner reverse driven gear washer. From the drive gear end, install a thrust washer, bushing, and bearing; Install the outer reverse driven washer; then secure 6. From the opposite end of the countershaft, install the the reverse driven gear assembly with a snap ring.

Using a propane torch, heat the bear- ancer until the counterweight is facing away from the ing until the oil begins to smoke; Place a washer on the end of the gear shift shaft; then Install the front and rear secondary driven shaft install the shaft assembly making sure the two holes assemblies into the left side of the crankcase making on the end of the shaft are positioned vertically.

Using a suitable lifting sling and engine hoist, lower the engine into the vehicle engaging the Install the CVT cooling ducts on the V-bolt hous- ing and secure with clamps. Install an appropriate nylon tie to secure the exhaust duct. On the left side, connect the ECT sensor connec- tor, speed sensor connector, and spark plug cap. Install the air filter assembly and secure to the frame Remove the seat, seat back, and seat base; then dis- connect the battery.

Loosen the clamp securing the throttle body to the 3. Remove the outer cap screw securing the front tank intake manifold boot and remove the throttle body hold-down; then swing the hold-down to the left. Use tape to cover and seal the intake opening. Page 5. Bend the washer tabs down and remove the two cap screws securing the sprocket to the camshaft; Remove the cylinder head from the cylinder, NOTE: Loop the chain over the cylinder and remove the gasket, and account for two alignment secure it to keep it from falling into the crankcase.

Page 37 C. Cylinder D. Loosen the clamp securing the coolant hose to the union; then detach the hose. Remove the two nuts securing the cylinder to the crankcase. Page Servicing Top-Side Components 2. Using light bands to avoid damaging the rod or install the pressure, move the valve cover in a figure eight Connecting Rod Holder. Page 39 2.

Remove the valve seal and the lower remaining spring seat. Discard the valve seal. ATV 2. Acceptable width range must be within specifica- tions. Runout 3. Remove the valve springs; then invert the cylinder 1. Page 40 3. If a valve guide is out of tolerance, it must be replaced. Using the sharpened ring as a tool, clean carbon from the ring-grooves. Be sure to position the ring with its tapered side up.

NOTE: Whenever a piston, rings, or pin are out of tolerance, they must be replaced. Page 42 NOTE: Note the direction of the exhaust side of the piston 5 for correct ring end gap orientation.

The ring with the orientation mark MTOP should be installed in the second middle groove and the ring with the orientation mark M should be installed in the first top groove. Page 43! CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or dam- age to the sealing surface may result.

Remove any carbon buildup in the combustion chamber. If honing oil is not avail- able, use a lightweight petroleum-based oil. Thor- oughly clean cylinder after honing using soap and hot water.

Match the width of the plasti-gauge with the chart found on the plasti-gauge packaging to determine camshaft to cylinder head and valve cover clear- ance. CFA 2. If damaged, the camshaft must be replaced. Place the two alignment pins into position. Place NOTE: Note the direction of the exhaust side of the cylinder gasket into position; then place a pis- the piston 5 for correct ring end gap orientation.

CCD 7. Place the head gasket into position on the cylinder. Place the alignment pins into position; then place the head assembly into position on the cylinder. CCD 5. Install the coolant hose onto the crankcase union and tighten the clamp. Page 48 9. Loosely install the five cylinder head nuts. NOTE: Note the position of the alignment marks on the end of the camshaft. They must be parallel In a crisscross pattern, tighten the four cylinder with the valve cover mating surface.

If rotating the head cap screws from step 8 to 40 ft-lb; Place the C-ring into position in its groove in the! Care must be taken that the tab-washer is installed correctly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result. Page 50 CD CD Loosen the four adjuster screw jam nuts; then NOTE: The adjuster shaft will be drawn into the loosen the four adjuster screws on the rocker arms tensioner as the adjuster screw is rotated clock- in the valve cover.

Water Pump B. Right-Side Cover C. Remove the four screws securing the outer mag- neto cover to the right-side cover; then remove the cover. Account for the gasket. CCD In a crisscross pattern starting from the center and 2. Loosen the clamps securing the coolant hose to the 9. Remove the nut securing the magneto rotor to the water pump; then remove the crossover tube from crankshaft; then install the magneto rotor puller the cylinder head.

Account for an O-ring. This passage should be plugged prior to removing the driven gear and drive gear. Failure to do so could result in the loss of an alignment pin into the crankcase. Installing Right-Side Components 2.

Install the water pump drive gear drive pin and the drive gear with the flat side of the gear facing out- ward as noted in removing ; then secure with the snap ring.

Page 55 5. Install the shift cam plate onto the shift cam shaft; then coat the cap screw threads with red Loctite and tighten securely. In order on the crankshaft, install a washer, ring gear, key, and the magneto rotor. Secure with the nut threads coated with red Loctite Tighten the cap screws from step 9 to 8 ft-lb.

Place the speed sensor housing and gasket into position and secure with the two cap screws. Tighten securely. CDA 8. Lubricate the magneto cover gasket with fresh engine oil; Page Left-Side Components Left-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. Page 58 PR 7. Remove the cap screws securing the clutch cover.

Oil Pump Driven Gear D. Final Drive Carrier Bearing C. Clutch Shoe Assembly screws for installing purposes. Remove the two Allen-head screws securing the gear shift position switch; then remove the sensor. Account for two neutral contact pins and two springs. CD CD Remove the nut left-hand threads securing the clutch shoe assembly C. CD Account for a pin and a washer.

Page Installing Left-Side Components 2. Install the secondary shaft bearing housing making sure the two alignment pins are properly posi- tioned. Tighten the Allen-head screws securely. Install the oil pump onto the engine; then tighten component. Grease the driven gear pin and insert it into the oil 7. Lightly grease the clutch housing seal; then insert pump shaft; then install the driven gear noting the the left fixed drive spacer.

Secure with a snap ring. Page 63 Place the V-belt into position on the driven pulley and over the front shaft. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. Page 65 2. Remove the reverse idler gear assembly F. Using a rubber mallet, tap on the crankcase to Account for all washers, shaft, bushing, and the remove the driveshaft E. CC 7. Note the timing marks on the crank balancer gear CC 3.

Page Servicing Center Crankcase Components Remove the cap screws securing the oil strainer cap; then remove the cap. Servicing Center Remove the two cap screws securing the oil Crankcase Components strainer; then remove the strainer. NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary.

Page 68 3. Maximum deflection must not exceed specifica- 3. Zero the indicator and rotate the crankshaft slowly. Push the lower end of the connecting rod to one 4.

Page Assembling Crankcase Half 2. Install lock washer 11 , lock washer 10 , washer 6 , and bushing 9. Install bearing 8 , reverse driven gear 7 , washer 6 , and the circlip 4. Install reverse driven gear spacer 5 , circlip 4 , reverse driven gear dog 3 , and drive gear 2 2 ; then install the right drive gear washer Install the driveshaft.

Place a washer on each end of the countershaft installing tool. Apply High-Temp Sealant to the right-side mating surface. Lightly oil all bearings and grease all shafts in the left-side crankcase. Using a propane torch, heat the left-side crankshaft bearing until the oil begins to smoke; then join the CC Install the flange nuts on the rear engine mount NOTE: Arctic Cat recommends that new gaskets studs; then secure the front engine mounting and O-rings be installed whenever servicing the bracket to the front engine mount studs with two flange nuts.

Connect the lower coolant hose to the water pump! Tighten the hose clamps The drive-line yokes must be aligned timed or dam- securely. From the left-side, connect the speed sensor con- Install the carburetor and tighten the intake boot nector XT , fuel level sensor connector XT , and clamp securely; then connect the gasline hose, temperature sensor lead; then install the spark plug vacuum line, and throttle cable.

Page 75 Place the air filter assembly into position and Connect the shifter linkage to the transmission secure with the self-tapping screws; then connect shift arm placing the washer and bushing in appro- the intake boot to the carburetor and the inlet hous- priate locations; Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn - seated poorly 2. Repair - replace guides 3. Valves mistimed 3. Chain stretched 1.

Replace chain 2. Sprockets worn 2. Replace sprockets 3. Tension adjuster malfunctioning 3. Repair - replace adjuster Problem: Engine noisy Noise seems to come from crankshaft Condition Remedy 1. Page 78 Problem: Engine runs poorly at high speed Condition Remedy 1. Shift into higher gear - decrease speed 2. Valve springs weak 2. Replace springs 3. Valve timing out of adjustment 3. Adjust timing 4.

NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. Loosen the clamp securing the intake boot to the 2. Remove the vacuum piston assembly from the car- carburetor; then separate the carburetor from the buretor body. Account for a spring, spring seat, boot. Secure the needle jet holder with a wrench; then remove the main jet.

Remove the needle jet holder; then remove the needle jet, slow jet, and the starter jet. Remove the pilot screw. Account for a spring, a washer, and an O-ring. Page 83 4. Dry all components with compressed air only making sure all holes, orifices, and channels are unobstructed.

Inspect the carburetor body for cracks, nicks, stripped threads, and any other imperfections in the casting. Place the U-ring into the pump housing. Place the carburetor into position on the engine; Tighten securely. Page 85 3. While pulling forward on the upper portion of the floorboard, lift the rear panel above the seat lock studs; then insert a small wood block to hold in position.

PRD 6. Remove the outer cap screw securing the front tank hold-down; Page 86 8. Remove the joining cap screw and nut from the rear gas tank hold-down strap; then remove the inside hold-down strap. PR PRA 9. Lift and slide the tank forward raising the front of the tank first; then turn the tank and lift out the right side.

Place the gas cap filler panel into position; then if necessary, position the gas tank so the filler panel and filler neck are not binding or rubbing. PRD 7. Position the floorboard into the vehicle and secure with the appropriate hardware; then install the cen- ter console, seat-bases, and seats making sure the PR seats lock securely.

Set the parking brake and start the engine. Allow the engine to warm up to operating temperature with cooling fan cycling. When filling the cooling system, use premixed Arctic Cat Antifreeze. While the cooling system is being 5. Remove six torx-head screws securing the dash assembly to the frame and one cap screw and nut from the center support. Slide the dash rearward approximately four inches. PR 4. Drain the coolant into a suitable container; then disconnect the cooling fan wire connector from the main harness.

Page Thermostat 3. Inspect all hoses for cracks and deterioration. Inspect all fasteners and grommets for damage or wear. Place the radiator into position making sure the grommets are correctly installed; then secure to the mounts with the two shoulder bolts and nuts. Page Fan 3. Inspect all coolant hoses, connections, and clamps for deterioration, cracks, and wear. Page Vacuum Pulse Fuel Pump 5.

Check the entire cooling system for leakage. CAUTION After operating the vehicle for the initial min- utes, stop the engine, allow the engine to cool down, and check the coolant level. Add coolant as neces- sary. Install the right-side seat-base; then install the cen- ter console and seats making sure the seats lock securely. Page Fuel Level Sensor Xt 2. Move the float lever and check for free movement. If there is binding or sticking, replace the fuel level sensor.

Test the fuel level sensor by connecting a multime- ter A to the fuel level sensor connector B ; Starter jet obstructed 1. Clean jet 2. Starter jet passage obstructed 2. Clean passage 3. Carburetor leaking air 3. Replace gasket Problem: Idling or low speed impaired Condition Remedy 1.

Slow jet obstructed - loose 1. Page Electrical System NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. Page Brakelight Switch Brakelight Switch The switch connector is the two-prong black connector below the master cylinder. When the lever is depressed, the meter must show 1. Set the meter selector to the DC Voltage position.

Set the meter selector to the OHMS position. Using the red tester lead, contact each end of the fuse holder connector terminals individually. The meter must show battery voltage from one side of the connector terminal ends. Always disconnect the battery when performing resistance tests to avoid damaging the multimeter.

If any other type of tester is used, readings may vary due to internal circuitry. Connect the red meter lead to the yellow wire; then select the high beam position on the headlight switch. Page Reverse Override Switch 1. The meter must show approximately 1. Depress the reverse override switch.

The meter showing should not change from step 1. Page Stator Coils 2. Connect the black lead to the black wire using a 3. NOTE: All of the peak voltage tests should be 1. Depress the starter button while observing the multimeter. Page Headlights 1. Headlights 2.

Connect the black tester lead to the black wire; then connect the red tester lead to the white wire. The meter should show battery voltage. The connectors are the four 2-prong ones secured to 3. Ignition coil defective 1. Replace ignition coil 2.

Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace magneto 4. CDI unit defective 4. Replace CDI unit 5. Pick-up coil defective 5. Page Problem: Magneto overcharges Condition Remedy 1. Internal battery short circuited 1. Replace battery 2. Replace resistor 3. Clean - tighten ground connection Problem: Charging unstable Condition Remedy 1. Lead wire intermittently shorting 1. PRA 4. Loosen but do not remove the mounting cap screw at the front of the actuator; then slide the actuator Lubricate the O-ring on the actuator; then ensure that all mounting surfaces are clean and free of 5.

Page 9. Remove two cap screws securing the differential lock cable support; then disconnect the differential lock cable at the differential. Remove the front wheels. Page Using a slide hammer, remove the front axles. PR Support the axle to not allow it to drop or hang. Remove the lower differential mounting cap! Account for a lock nut and four washers. Note the position of the washers for assembling. Page 4. Using a seal removal tool, remove the input shaft seal. Account for a spacer.

PRA 2. Using a rubber mallet, remove the housing. Remove the fork, collar, and spring. Note the location of all the components for AF 5. Page Assembling Input Shaft 1. Place the pinion housing in a press and install the input shaft bearing. Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside. KX 4. Install the input shaft into the pinion housing; then secure in the bearing with a circlip. NOTE: This procedure can be performed on a 4.

Remove the splined coupler, shifter fork, pin, and rear gear case. Page KX CC 6. Place the differential with the open side down; 8. Install the bearing onto the pinion shaft. Install the pinion shaft collar.