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Discussion Starter #1
Well I'm a bit crushed!


Had a ATV/UTV camping trip in a couple weeks and the Prowler is blowing through oil. Topped it off Monday for a 4 hour ride and came back with no oil on the dipstick. It has no smell of burning oil and no blue smoke.


Any suggestions?


Or is it rebuild time?


Thanks in advance!
 

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Seems to be too new new of a rig to need a rebuild, have you notice any loss of power or belt slipping? Some have had oil leaking into the clutch area.
 

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Discussion Starter #3
Seems to be too new new of a rig to need a rebuild, have you notice any loss of power or belt slipping? Some have had oil leaking into the clutch area.


We bought the Prowler used with about 3,200mi on it last year. No idea on prior maintenance schedule. Only power loss I noticed was when the machine warmed up. Shut it off toward the end of the ride Monday and sat a while when the rest of the group played in a sand pit. Then when I started it back up it felt a bit peppier like it did in the beginning but then dropped off a tad shortly after when it warmed up again.


Been a frustrating week. Our 335 seized tonight when my daughter was out riding it. Had an oil leak and think it is toast. The Prowler is probably the final straw on our upcoming ATV/UTV and fishing camping trip in a couple weeks. Probably going to have to cancel the trip since were would be down to one machine.


Well that is if our other Sportsman is OK, left it outside this winter and chipmunks filled the Airbox with acorns and the Intake hose split so I need to cleanout the box and replace the throttle body hose. So basically all three machines have issues. :( Was really looking forward to this outing since about February. :(


Just crushed now.
 

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No blue smoke, so I agree with Mike on oil in the clutch cover. There is a drain plug on the bottom of the cover, so pull that and check for oil. You can also check the air out duct on your clutch for any signs of oil. My oil seal failed around 3,000 miles, they due take a beating! High Heat, High RPM, wonder they last as long as they do.
 

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Discussion Starter #5
Whew so it may NOT be an issue with the engine directly! WOOT WOOT

I also don't have anything to do a compression test just to make sure but I may have to pick one up just to make sure!

So if it is the seal that failed in the clutch cover area, how complicated is replacing it?

Have a new belt so I can swap that also while I'm in there.
 

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Whew so it may NOT be an issue with the engine directly! WOOT WOOT

I also don't have anything to do a compression test just to make sure but I may have to pick one up just to make sure!

So if it is the seal that failed in the clutch cover area, how complicated is replacing it?

Have a new belt so I can swap that also while I'm in there.
No that complicated. Ive been in there when I had a leak at my primery clutch. You need a quite solid impact wrench for the primery an secondary, and then the rest is torx size 20, if i remember right. Beware of some of the torx screws are different lengths. Use a rubber mallet to tap the covers. If I where you I would wait for fairmot to conferme this ;)

Edit: if the leak is in the cover where the belt is, then you dont need to think of the impact wrench. That said, I also had a leak there, from the primary. To me it sounds strange if your belt isnt slippin if there is an oil leak in that area. Again, dont trist a guy from norway who writes bad english. Just my thoughts on this one...
 

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Whew so it may NOT be an issue with the engine directly! WOOT WOOT

I also don't have anything to do a compression test just to make sure but I may have to pick one up just to make sure!

So if it is the seal that failed in the clutch cover area, how complicated is replacing it?

Have a new belt so I can swap that also while I'm in there.
Did you find oil in the clutch area?
 

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Discussion Starter #8
Did you find oil in the clutch area?

Just got home from work and have to first get a large file downloaded and burned to disk for a side job tomorrow working on a server.


Then I have to clean up some garage space to tear her down since our Sportsman is currently taking up the open stall. Parts for the 700 Sportsman arrive Tuesday, I hate Chipmunks! LOL


Then the Prowler followed by the 335 Sportsman.


I may need to replace the rack in my daughter's beetle before the Prowler though. LOL Yeah it has been one of those stats to the year. LOL
 

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If the seal is leaking, you will need to drain the oil, and pull both covers. The gaskets can be reused on the covers, so be careful taking them off. Keep the outer bolts separate from the inners as they are different in length. You will have to remove both the primary, and secondary clutches. I think on the HDX that the gas tank also has to be removed. I use a impact to remove mine. Be careful on the primary nut, I've found that they lose their grip after several uses even with lock-tite. New nuts are 4.00 dollars. Once you have the inner cover off, you will have to have the clutch housing pressed out, and same with the seal. There is also a O-ring that should be replaced. Check the spacer for wear, and replace if needed. Now you can make a decision on the one way bearing, you can remove it and reduce some driveline noise, or leave it in (I took mine out, and like it better!). I usually recommend taking the cover to a qualified dealer to have them replace the seal. I have a press in my shop so I'm able to do my own, but I'm lucky!
 

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Discussion Starter #10
Thanks! That will be very helpfull!

Hope to get my daughter's rack and pinion replaced this weekend and not looking forward to this job!

Then I should be able to pull in the Prowler. :)
 

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Discussion Starter #11
Well, I'm a bit angry now, was loading the Prowler up to go get the plow mounted and it was struggling to start. Figured the damn chipmunks may have chewed through the the pre-filter and filled the air box with acorns like they did our Sportsman.

Open the air box and the engine side is filthy! Then I leaned in for a closers look and saw a hole in the air box! Soon passed right now. How the heck did the previous owner Crack the rear and break a hole in the front of the airbox?

I saw the rear Crack and planned to clean and JB Weld it closed but never saw the front.

So glad the only time we took it for a ride I was the lead machine!

So now I belive it is probably burning the oil in small enough amounts I cannot smell or see it but probably going to have to rebuilt the top end. Just hope it makes it till spring because I am tapped for a bit after the plow and trailer. :(
 

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just pisses a guy off to find out he's been had don't it ... bet you would not have bought it iff'n you knew about all the preventable issues Eh
 

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Dirt in the engine sucks, my air filter is starting to look bad so I ordered a new one on eBay. It's a lot cheaper than AC but who knows about quality, I'll find out when it gets here this week.

Arctic Cat Prowler 650 Air Filter 2006 2007 | eBay
 

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Discussion Starter #14
just pisses a guy off to find out he's been had don't it ... bet you would not have bought it iff'n you knew about all the preventable issues Eh
Yes and no, I was already worried about the motor when we bought it because of the knock sound (was the exhaust heat shield being loose shaping around) but it was far enough under book that we could rebuild the engine and still save money. Had I known for sure, I would have held off on the plow and trailer!

Also would have just replaced the airbox right away instead of holding off since the only crack I could see was before the filter and were were not trail riding yet other than the one time. :(
 

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Discussion Starter #15
Dirt in the engine sucks, my air filter is starting to look bad so I ordered a new one on eBay. It's a lot cheaper than AC but who knows about quality, I'll find out when it gets here this week.

Arctic Cat Prowler 650 Air Filter 2006 2007 | eBay
It is infuriating!

Found a complete airbox and filter for $49.99 off eBay. :)

Next thing will be saving up and figuring out which direction to go with the top end.
 

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I bough a complete air box off ebay, next to nothing for the price. More than likely the previous owner used it to support him/her self! Mounting points are prone to breaking! I think I have several in my shop (bottoms only), but not sure if the HDX, and XT, XTX use the same box. I'll PM you if they do Ron! I've seen the Moose filters! Same as the stock different color, and cheaper! Does the same job!
 

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I've seen the Moose filters! Same as the stock different color, and cheaper! Does the same job!
Good to know, I was waiting to see what this one looked like before I order a second one so I can just swap out when it needs cleaned.
 

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Discussion Starter #18
I read a couple of you guys doing that so I plan to probably grab another filter down the road also. :)

FYI, even with all the hassles this Prowler as dropped on me, I still really like it. :)
 

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Discussion Starter #19
I bough a complete air box off ebay, next to nothing for the price. More than like the previous owner used it to support him/her self! Mounting points are prone to breaking!
Oh not that would not be good! Hope mine is in good condition! Will find out when it arrives Friday.

Then hurry to remove the broken one, clean and vacuum what I can (do not want any extra dirt getting sacked in than it already has), and then install the unbroken replacement. :)
 

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Discussion Starter #20
Had a chance to pull the vent tube and look into the CVT housing. Looked clean, didn't see any oil so no worries about that seal. LOL

Unfortunately I now know for sure it needs a a rebuild. LOL

Bonus, hoping to do the Big Bore for more power! *insert Tim the tool man gunt*
 
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