Arctic Cat Prowler 2010 Service Manual – XT 550, XTX 700 & XTZ 1000 (P/N 2258-588)

This Arctic Cat factory service manual (P/N 2258-588) covers the 2010 Prowler XT 550, XTX 700, and XTZ 1000 side-by-side UTVs. The engine and transmission chapter has separate procedures for the H1-powered XT and XTX and the H2-powered XTZ.

PDF Search and Chapter Bookmarks

Text search and navigation: The manual text is searchable, and bookmarks open the contents page and each of the nine chapters. The Foreword link on the contents page has no destination.

The download is one printable PDF with 226 pages, including the opening cover and contents page.

Prowler Engine, Driveline, and Electrical Service

This selection of workshop procedures includes major repairs and diagnostic tests. The manual also covers headlight aiming and spark arrester cleaning.

• Periodic maintenance: Feeler-gauge and factory-tool methods for valve adjustment, compression testing, shift-cable adjustment, parking-brake setup, and V-belt replacement.
• Engine and CVT: Engine removal and installation, cylinder-head and piston service, cam timing, and inspection of the starter clutch and centrifugal clutch.
• Crankcase and transmission: H2 crankcase procedures for both generations, plus countershaft disassembly, shift-fork indexing, crank-balancer timing, and secondary bevel-gear setup.
• Fuel and cooling: H1 and H2 EFI troubleshooting, throttle-body service, fuel-pump and fuel-level sensor work, oil-pressure tests, and cooling-system repairs.
• Electrical diagnosis: ECU fault codes, sensor and ignition tests, battery and charging checks, power distribution module relays and fuses, and starter-motor and relay service.
• Driveline and brakes: Front differential overhaul, axle and CV-boot repair, rear gear case and differential service, hub and U-joint work, caliper overhaul, bleeding, and pad burnishing.
• Chassis and controls: Shock absorber and A-arm service, steering and front-wheel alignment, and removal and installation procedures for the cargo box, pedals, shift lever, and instrument cluster.

The manual is suited to technicians equipped for internal engine measurements and dial-indicator gear checks. Arctic Cat recommends authorized ROV dealers for hydraulic brake service.

Crankcase and Driveline Differences

The XTZ chapter uses the left-side speed-sensor configuration to distinguish the two H2 crankcases, so you can identify the case before choosing a teardown procedure. Top-end and side-cover work can be done with the engine in the frame. Center-crankcase work requires removing the engine and transmission assembly.

The XT and XTX use a driveline caliper with hydraulic and cable actuation. The XTZ uses four-wheel hydraulic brakes and a cable-operated driveline parking brake. The drive chapter separates the XT/XTZ rear gear case from the XTX rear differential, including their lubricant requirements and the applicable seal and shim procedures.

Engine Measurements and Gear Setup

The engine chapters show how to inspect valves and guides, measure piston rings and cylinders, and check camshaft clearance and runout. Side-cover work includes magneto access and oil-pump inspection. The transmission instructions explain gear and dog orientation, shift-shaft timing marks, and dial-indicator backlash checks.

Reference illustrations include the XT/XTX crankcase shaft layout, the two XTZ crankcase layouts, a countershaft exploded view, secondary bevel-gear tooth-contact patterns, and a front differential shim-selection view. Tables provide component torque, fluid capacities, wear limits, and inspection clearances.

The one-way clutch has a specified installation orientation, and incomplete drive-face spline engagement can damage the shaft. The secondary bevel drive needs re-shimming after removal, and mistimed driveline yokes can damage the U-joints and gears.

EFI Tests, Cooling, and Factory Tools

The electrical chapter covers ECT, IAT, MAP, TPS, CKP, and tilt-sensor testing. It pairs drive-select and front-actuator voltage checks with wire-color tables, and shows how to read the dash indicator when adjusting the TPS. The separate 2010 wiring-chart publication is outside the scope of this download.

The cooling chapter covers radiator and fan service, separate XT/XTX and XTZ thermostat and water-pump procedures, and oil-cooler service for the XTX and XTZ.

Named tools include the Crankcase Separator/Crankshaft Remover (0444-152), Magneto Rotor Remover Set (0444-254), Secondary Drive Gear Holder (0444-253), Oil Pressure Test Kit (0644-495), Test Plug/Error Code List (0444-216), and U-Joint Separator Tool (0444-128).

Secure the vehicle before service and follow the manual’s precautions when lifting the engine and transmission, handling fuel, working around rotating parts, or compressing shock springs.

Sample Compression and Alignment Specs

For a hot XTZ engine at wide-open throttle, the compression chart gives 125–145 psi for the front cylinder and 165–185 psi for the rear. The separate ranges let you compare each cylinder against its own specification.

For front-wheel alignment with the vehicle unloaded, the manual specifies 6–12 mm (1/4–1/2 in.) of toe-out, measured as the difference between the front and rear tire measurements.