Arctic Cat Prowler XT 650, XTX 700 & XTZ 1000 UTV 2009 Service & Repair Manual (P/N 2258-391, 2258-399)

This 344-page PDF combines Arctic Cat’s 2009 factory service information for the Prowler 550, Prowler XT 650, Prowler XTX 700, and Prowler XTZ 1000. It covers the carbureted 650 alongside the EFI 550, 700, and 1000 systems, with a dedicated manual section for the XTZ. The repair depth and the specified pullers, measuring tools, press work, and electrical test equipment make this set best suited to professional technicians and experienced owners with a properly equipped shop.

• Document scope: 344 PDF pages total — 175 pages for the Prowler/Prowler XT/Prowler XTX manual, including two wiring sheets, and 169 pages for the Prowler XTZ manual, including one wiring sheet.
• Engine and transmission work: Covers engine/transmission removal and installation, top-side and side-cover service, cylinder-head and valvetrain inspection, piston and cylinder repair, cam timing, CVT and clutch service, oil-pump testing, crankcase separation, crankshaft inspection, transmission disassembly, and gear-contact/backlash setup.
• Fuel, lubrication, and cooling variants: Separates Keihin CVK36 carburetor, electric-choke, idle-speed, and vacuum-pulse fuel-pump procedures for the 650 from EFI throttle-body, sensor, and electric-pump work for the other engines. Radiator, thermostat, fan, water-pump, oil-pressure, and model-specific oil-cooler procedures are also covered.
• Electrical diagnosis: Provides test coverage for the battery, power distribution module, switches, front-drive actuator, CDI/ECU, ignition coils, stator and crankshaft-position circuits, starter system, regulator/rectifier, ECT and tilt sensors, TPS adjustment, ignition timing, and ECU error-code retrieval, together with the required voltage, resistance, and peak-voltage specifications.
• Driveline, brakes, and chassis: Details front-differential removal and internal service, drive-axle and CV-boot repair, the Prowler/XT rear gear case, XTX rear differential, XTZ rear gear case, hubs, universal joints, hydraulic brake bleeding and pad burnishing, A-arms, shocks, steering shafts, knuckles, wheel alignment, body panels, and cargo-box service.
• Diagrams and component views: Supplies three full-color harness schematics — Prowler 550/700 drawing 0743-203, Prowler 650 drawing 0742-225, and Prowler 1000 drawing 0743-659 — plus the Keihin carburetor exploded view, countershaft component layout, and drive-bevel-gear tooth-contact and shim illustrations.
• Factory reference data: Maintenance and troubleshooting charts, component-specific torque tables, lubricant and fluid-capacity data, pressure-test procedures, valve and engine clearances, wear limits, gear-shimming data, and electrical test specifications are placed with the systems they support.

Variant-Specific Repair Coverage

The 550/650/700 manual separates the XT shift-linkage procedure from the cable-operated Prowler/XTX arrangement and distinguishes the Prowler/XT rear gear case from the XTX rear differential. Its fuel and ignition chapters likewise keep the 650 carburetor/CDI hardware separate from the 550/700 EFI/ECU system. The XTZ section follows the front and rear cylinders independently through cam-chain timing and adds its own secondary-gear, crankcase, EFI, cooling, and electrical procedures.

For top-side, left-side, and right-side engine work, the manuals identify which service can be completed with the powertrain still in the frame. Center-crankcase repair requires engine/transmission removal and completion of the preceding teardown. Several components are treated as replacement assemblies rather than rebuildable units, including the driven pulley, water pump, front-drive actuator, starter, ECU, hydraulic caliper, and master cylinder. This is not an illustrated parts catalog; the manuals direct parts-number and quantity lookup to the appropriate Illustrated Parts Manual.

Factory Tooling and Repair Cautions

Arctic Cat tool numbers are given where a procedure depends on them. Examples include the 0444-009 crankcase separator/crankshaft remover, 0444-206 magneto rotor remover set, 0444-253 secondary gear drive holder for the XTZ, 0444-216 test plug/error-code list, 0444-127 pinion gear/shaft removal tool, and 0444-128 U-joint separator.

The XTZ timing pages warn that loss of cam-chain tension or incorrect retention of the cam-sprocket alignment pin can cause severe engine damage. Countershaft dogs and gears, along with the CV-joint bearing ring, are also orientation-sensitive; reversed installation can damage the transmission or axle assembly.

For engine, driveline, brake, fuel, or electrical repair, support the vehicle securely on a suitable lift or jack stands and disconnect the battery whenever the applicable factory procedure requires it. Follow the manual’s fuel-pressure, brake-system, lifting, and electrical-isolation warnings before dismantling those systems.