2006 Arctic Cat Prowler 650XT OEM Service Manual (P/N 2287-489)

This 190-page PDF contains the Arctic Cat factory service content for the 2006 Prowler XT 650 and carries an October 2005 issue date. Its 11 sections run from general specifications and scheduled maintenance through complete powertrain repair, drivetrain service, chassis work, electrical diagnosis, torque data, and symptom-based troubleshooting. Arctic Cat describes the manual as a shop reference for service personnel; its teardown depth, precision measurements, and special-tool requirements assume professional-level mechanical knowledge.

Major Systems and Factory Procedures

• Engine and transmission: Documents powertrain removal and installation, in-frame top-, left-, and right-side service, crankcase separation and joining, valve and piston work, cylinder and head inspection, crankshaft measurement, countershaft service, and final adjustment.
• Clutch and internal drive: Covers the centrifugal clutch, primary one-way drive, driven-pulley disassembly and reassembly, secondary bevel-gear backlash and tooth-contact correction, oil-pump inspection, and transmission component orientation.
• Fuel, lubrication, and cooling: Details the Keihin CVK36 carburetor, gas tank, vacuum-pulse fuel pump, oil-pressure testing, oil-cooler restriction checks, radiator/oil-cooler removal, thermostat inspection, fan service, and water-pump replacement.
• Electrical diagnosis: Provides voltage, resistance, peak-voltage, and output tests for the ignition coil, speed sensor, switches, front-drive actuator, magneto coils, starter circuit, CDI, regulator/rectifier, relays, and lighting.
• Final drive, brakes, and chassis: Includes front differential teardown and setup, drive-axle and CV-boot service, rear gear-case removal, hubs, hydraulic calipers, universal joints, shock absorbers, A-arms, steering, wheel alignment, master cylinder, controls, and cargo-box/body-panel removal.
• Maintenance and fault isolation: Supplies the periodic-maintenance chart, valve-clearance and compression checks, V-belt replacement, hydraulic-brake bleeding and pad burnishing, component-specific torque tables, and condition/remedy charts for engine, drive, fuel, electrical, steering, suspension, and brake faults.

Powertrain Setup, Special Tools, and Repair Cautions

The engine/transmission chapter distinguishes work that can be completed in the frame from center-crankcase service that requires powertrain removal. Inspection coverage goes well beyond routine tune-up work: valve-guide and seat service, piston and ring measurements, cylinder honing checks, camshaft and rocker-arm inspection, driven-pulley overhaul, crankshaft runout, and secondary-gear setup are all documented with the related limits and specifications.

Factory tool references are tied to the procedures that need them. Examples include the Driven Pulley Compressor (P/N 0444-121), Magneto Rotor Remover Set (P/N 0444-075), and Side Case Puller (P/N 0644-262). Differential and axle repair calls out the Pinion Gear/Shaft Removal Tool (P/N 0444-127) and Boot Clamp Pliers (P/N 0444-120). Electrical peak-voltage diagnosis specifies a Fluke Model 73 Multimeter (P/N 0644-191) with Peak Voltage Reading Adapter (P/N 0644-307).

Factory cautions identify assembly errors that can create expensive repeat work. Countershaft dogs and gears must retain their original orientation, and incorrect cam-sprocket tab-washer placement can allow the alignment pin to move and damage the engine. The installation section also flags driveline-yoke phasing because incorrect alignment can damage the universal joints and gears.

Diagrams, Diagnostics, and Scope Limits

Named visual references include the Periodic Maintenance Chart, Carburetor Schematic, Oil Flow Chart, Valve Seat/Guide Servicing Flow Chart, and the secondary-gear Backlash/Shim Correction and Tooth Contact/Shim Correction charts, along with keyed component views throughout the repair sections.

This edition is specific to the carbureted, CDI-equipped Prowler XT configuration shown in the manual. Electrical coverage is built around component tests, connector locations, and specified meter readings; it does not include a complete vehicle wiring diagram. The front-drive actuator, vacuum-pulse fuel pump, starter motor, CDI, water pump, steering assembly, hydraulic brake caliper, and master cylinder are identified as non-serviceable units that are replaced as assemblies. Parts-number lookup is outside this manual's scope and is directed to the separate Illustrated Parts Manual.

Procedures involving a raised vehicle, compressed driven-pulley spring, battery electrolyte, fuel, hot coolant, and hydraulic brakes require suitable supports, protective equipment, and qualified shop judgment.