2018 Textron off Road Prowler 500 Service Manual – PDF DOWNLOAD
DESCRIPTION:
2018 Textron off Road Prowler 500 Service Manual – PDF DOWNLOAD
Foreword
This Textron Off Road Service Manual contains service, maintenance, and troubleshooting information for the 2018 Prowler 500. 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 CatMaster 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 Textron Off Road constantly refines and improves its products, no retroactive obligation is incurred.
TABLE OF CONTENTS:
2018 Textron off Road Prowler 500 Service Manual – PDF DOWNLOAD
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 14
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 35
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
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PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]