2021 Arctic Cat Prowler 500 ATV Service Manual – PDF DOWNLOAD

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2021 Arctic Cat Prowler 500 ATV Service Manual

2021 ARCTIC CAT PROWLER 500 ATV SERVICE MANUAL – PDF DOWNLOAD:

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Table Of Contents:

2021 Arctic Cat Prowler 500 ATV Service Manual

General Information/Foreword………………………………… 2
Specifications ……………………………………………………… 2
Torque Specifications …………………………………………… 3
Torque Conversions (ft-lb/N-m)……………………………… 4
Gasoline — Oil — Lubricant ………………………………….. 4
Preparation for Storage ………………………………………… 5
Preparation after Storage ……………………………………… 6
Periodic Maintenance/Tune-Up ……………………………….. 7
Air Inlet Pre-Filter…………………………………………………. 7
Air Filter/Housing Drain…………………………………………. 7
Valve/Tappet Clearance………………………………………… 8
Testing Engine Compression…………………………………. 9
Spark Plug ………………………………………………………… 10
Muffler/Spark Arrester…………………………………………. 10
Engine/Transmission Oil — Filter …………………………. 10
Front Differential — Rear Drive Lubricant………………..11
Driveshaft/Coupling ……………………………………………. 12
Headlight — Taillight/ Brake Light — Reverse Light … 12
Shift Cable ………………………………………………………… 13
Hydraulic Brake System ……………………………………… 14
Burnishing Brake Pads ……………………………………….. 16
Checking/Replacing V-Belt ………………………………….. 16
Steering/Body/Controls ………………………………………… 19
Steering Wheel ………………………………………………….. 19
Steering System ………………………………………………… 19
Steering Knuckles………………………………………………. 23
Accelerator Pedal ………………………………………………. 25
Shift Lever ………………………………………………………… 26
Shift Cable ………………………………………………………… 26
LCD Gauge……………………………………………………….. 28
Front Wheel Alignment ……………………………………….. 28
Front Fascia/Front Bumper………………………………….. 28
Hood/Front Storage Compartment ……………………….. 30
Front Body Panel……………………………………………….. 30
Floor ………………………………………………………………… 31
Dashboard ………………………………………………………… 33
Belly Panel………………………………………………………… 35
Muffler………………………………………………………………. 35
Cargo Box…………………………………………………………. 36
Tailgate …………………………………………………………….. 36
Taillight Assembly ………………………………………………. 37
Seat …………………………………………………………………. 38
Troubleshooting …………………………………………………. 39
Engine/Transmission……………………………………………. 40
Troubleshooting…………………………………………………..41
Removing Engine/Transmission…………………………….43
Servicing Engine …………………………………………………47
Installing Engine/Transmission………………………………86
Fuel/Lubrication/Cooling………………………………………. 91
Throttle Body………………………………………………………91
Gas Tank ……………………………………………………………92
Oil Pump ……………………………………………………………94
Liquid Cooling System …………………………………………95
Troubleshooting…………………………………………………..98
Electrical System…………………………………………………. 99
Battery……………………………………………………………….99
Ignition Switch …………………………………………………..100
Ignition Coil ………………………………………………………100
Ignition Timing …………………………………………………..101
Accessory Connector …………………………………………101
Switches…………………………………………………………..102
Fan Motor…………………………………………………………104
Power Distribution Module (PDM) ………………………..104
EFI Sensors/Components …………………………………..105
RPM Limiter ……………………………………………………..110
Stator Coil ……………………………………………………….. 111
Regulator/Rectifier ……………………………………………. 111
Starter Motor ……………………………………………………. 111
Starter Relay ……………………………………………………. 112
Electronic Control Module (ECM)………………………… 112
EFI Diagnostic System………………………………………. 112
Troubleshooting………………………………………………… 117
Drive System……………………………………………………….118
Front Drive Actuator ………………………………………….. 118
Front Differential………………………………………………..120
Drive Axles ……………………………………………………….132
Rear Gear Case ………………………………………………..136
Hub………………………………………………………………….142
Hydraulic Brake Caliper………………………………………144
Troubleshooting Drive System …………………………….148
Troubleshooting Brake System……………………………148
Suspension………………………………………………………… 149
Shock Absorbers ……………………………………………….149
Front A-Arms …………………………………………………….149
Rear A-Arms……………………………………………………..152
Wheels and Tires ………………………………………………154
Troubleshooting…………………………………………………155

Description:

2021 Arctic Cat Prowler 500 ATV Service Manual

• This Service Manual contains service, maintenance, and troubleshooting information for the 2021 Prowler 500 model. The complete manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections. Each section covers a specific vehicle component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions.
• When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. This service manual is designed primarily for use by a basic level technician. The procedures found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special tools to be completed.
• The technician should use sound judgment when determining which procedures can be completed based on their skill level and access to appropriate special tools. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. When replacement of parts is necessary, use only genuine parts. They are precision-made to ensure high quality and correct fit.
• Refer to the appropriate Illustrated Parts Manual for the correct part number, quantity, and description. All publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol !WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of serious personal injury or even death.
• A CAUTION identifies unsafe practices which may result in vehicle-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the vehicle. The symbol  NOTE: identifies supplementary information worthy of particular attention. The symbol ? AT THIS POINT directs the technician to certain and specific procedures to promote efficiency and to improve clarity.
• At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because we constantly refine and improve our products, no retroactive obligation is incurred.

Please Note:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]