Arctic Cat XC 450i 2012 Service Manual Download

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AG925

3. While holding the actuator firmly forward, tighten

the front cap screw to hold the actuator in place; then

install but do not tighten the two remaining cap

screws.

KC295A

4. Loosen the front cap screw; then tighten the cap

screw on the driveshaft side.

AG926



NOTE: It is important to tighten this cap screw while

the others are loose to ensure proper seating of the
actuator.

5. Tighten the remaining cap screws; then connect the

electrical plug to the main harness.

6. Turn the ignition switch to the ON position and

check the operation by shifting the selector switch

several times.

7. Secure the wiring harness to the frame with a nylon

cable tie.

Front Differential

REMOVING DIFFERENTIAL

1. Secure the ATV on a support stand to elevate the

wheels.

2. Remove the drain plug and drain the gear lubricant

into a drain pan; then reinstall the plug and tighten to

45 in.-lb.

ATV0082A

3. Remove the front wheels.

4. Pump up the hand brake; then engage the brake lever

lock.

5. Remove the cotter pin securing the hub nut; then

remove the nut.

6. Release the brake lever lock.

7. Remove the upper and lower ball joint cap screws

taking care not to strip the threads.

AF628D

! WARNING

Make sure the ATV is solidly supported on the support
stand to avoid injury.

CAUTION

Apply pressure to hold the ball joint firmly in the knuckle
or the threads will be stripped when the retaining cap
screws are removed.

Manual

Table of Contents

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

Summary of Contents for XC 450i 2012

Page 1: ...mbol WARNING identifies personal safety related information Be sure to follow the directive because it deals with the possibility of severe personal injury or even death A CAUTION identifies unsafe practices which may result in ATV related damage Follow the directive because it deals with the possibility of damaging part or parts of the ATV The symbol NOTE identifies supplementary information wort...

Page 2: ...mponents 56 Assembling Crankcase Half 60 Joining Crankcase Halves 63 Installing Engine Transmission 63 Fuel Lubrication Cooling 66 Electronic Fuel Injection 66 Throttle Body 66 Throttle Cable Free Play 67 Gas Tank 67 Oil Filter Oil Pump 68 Testing Oil Pump Pressure 68 Liquid Cooling System 69 Electric Fuel Pump Fuel Level Sensor 71 Troubleshooting 73 Electrical System 74 Electrical Connections 74 ...

Page 3: ... end side to side max 0 7 mm Connecting Rod small end deflection max 3 0 mm Crankshaft web to web 60 8 60 9 mm Crankshaft Runout max 0 03 mm CYLINDER PISTON AND RINGS Piston Skirt Cylinder Clearance 0 025 0 055 mm Piston Diameter 8 mm from Skirt End 88 96 88 98 mm Cylinder Bore 89 005 89 015 mm Piston Ring Free End Gap min 1st 2nd 8 0 mm 8 3 mm Bore x Stroke 89 0 x 71 2 mm Cylinder Trueness max 0 ...

Page 4: ...nkcase 8 11 Oil Fitting Engine 8 11 Oil Pump Crankcase 8 11 Movable Drive Face Nut Clutch Shaft 147 199 Output Shaft Flange Nut Output Shaft 59 80 Cam Chain Tensioner Guide Cylinder 11 15 Valve Cover Cylinder 8 11 Tappet Cover Valve Cover 8 11 Cam Chain Tensioner Cylinder 10 13 5 Magneto Cover Crankcase 8 11 Rear Driveline Output Drive Flange 20 27 Water Pump Cover Housing Magneto Cover 8 11 Water...

Page 5: ...s When using ethanol blended gasoline it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system RECOMMENDED ENGINE TRANSMISSION OIL The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil which has been specifically formulated for use in this Arctic Cat engine Although Arctic Cat ACX All Weather synthetic engin...

Page 6: ...5 Apply light oil to the upper steering post bushing and plungers of the shock absorbers 6 Tighten all nuts bolts cap screws and screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts cap screws and bolts are tightened to specifications 7 Fill the cooling system to the bottom of the stand pipe in the radiator neck with pro...

Page 7: ...olts cap screws and screws mak ing sure all calibrated nuts cap screws and bolts are tightened to specifications 9 Check tire pressure Inflate to recommended pressure as necessary 10 Make sure the steering moves freely and does not bind 11 Check the spark plug Clean or replace as necessary CAUTION The ignition switch must be in the OFF position prior to installing the battery or damage may occur t...

Page 8: ...er Break In First Mo or 100 Mi Every Day Every Month or 100 Miles Every 3 Months or 300 Miles Every 6 Months or 500 Miles EveryYear or 1500 Miles As Needed Battery I I C Fuses I R Air Filter Drain Tube I I C R Valve Tappet Clearance I I A Engine Compression I Spark Plug I I R 4000 Mi or 18 Mo Muffler Spark Arrester C R Gas Hoses I I R 2 Yrs Throttle Cable I I C L A R Engine Transmission Oil Level ...

Page 9: ... NOTE Foam Air Filter Cleaner and Foam Air Fil ter Oil are available from Arctic Cat 5 Dry the element 6 Put the element in a plastic bag then pour in air filter oil and work the oil into the element Insert the form ing spring into the element with the closely wrapped end of the spring toward the open end of the element 7 Clean any dirt or debris from inside the air filter housing 8 Place the filt...

Page 10: ...g a feeler gauge check each valve tappet clearance If clearance is not within specifications loosen the jam nut and rotate the tappet adjuster screw until the clear ance is within specifications Tighten each jam nut securely after completing the adjustment CC007DC Valve Adjuster Procedure A Place the Valve Clearance Adjuster onto the jam nut securing the tappet adjuster screw then rotate the valve...

Page 11: ...nspect the following items A Verify starter cranks engine over at normal speed approximately 400 RPM B Gauge functioning properly C Throttle lever in the full open position D Valve tappet clearance correct E Valve not bent or burned F Valve seat not burned NOTE To service valves see Engine Transmission 7 Pour approximately 30 ml 1 fl oz of oil into the spark plug hole reattach the gauge and retest...

Page 12: ...servoir Muffler Spark Arrester At the intervals shown in the Periodic Maintenance Chart clean the spark arrester using the following procedure 1 Remove the cap screws securing the spark arrester assembly to the muffler then loosen and remove the arrester KC374A 2 Using a suitable brush clean the carbon deposits from the screen taking care not to damage the screen NOTE If the screen or gasket is da...

Page 13: ...e while the ATV is outside on level ground and allow it to idle for a few minutes 10 Turn the engine off and wait approximately one minute 11 Remove the oil level stick and wipe it with a clean cloth 12 Install the oil level into engine case NOTE The oil level stick should be threaded into the case for checking purposes 13 Remove the oil level stick the engine oil level should be above the illustr...

Page 14: ...cracked damaged or worn Nuts Bolts Cap Screws Tighten all nuts bolts and cap screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts bolts and cap screws are tightened to specifications Ignition Timing The ignition timing cannot be adjusted however verifying ignition timing can aid in troubleshooting other components To ver...

Page 15: ...Remove the headlight bulb by rotating the bulb assembly and removing from the headlight housing then spread the retaining clips and disconnect the bulb assembly from the connector KC431A KC432A 3 Install the new bulb assembly into the connector then insert the bulb assembly into the housing and rotate to lock 4 Install the access panel and secure with the screws TAILLIGHTS BRAKELIGHTS To replace a...

Page 16: ...sing making sure the gasket is in place 5 Install the housing cover CHECKING ADJUSTING HEADLIGHT AIM The headlights can be adjusted vertically and horizon tally The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming 1 Position the ATV on a level floor so the headlights are approximately 6 1 m 20 ft from an aiming sur face wall or similar aiming surface AT...

Page 17: ...ith the shift lever in the reverse position adjust the coupler B until the transmission is in reverse and the R icon appears on the LCD KC437A 3 Tighten the jam nuts securely then shift the trans mission to each position and verify correct adjust ment 4 Install the left side engine cover and seat making sure the seat locks securely in place Frame Welds The frame and welds should be checked periodi...

Page 18: ...e connections are tight the bleed screws are tight the protective caps are installed and no leakage is present INSPECTING HOSES Carefully inspect the hydraulic brake hoses for cracks or other damage If found the brake hoses must be replaced CHECKING REPLACING PADS The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear The only maintenance that is requ...

Page 19: ...r the brake pedal is depressed Checking Replacing V Belt REMOVING 1 Remove the cap screw securing the brake pedal to the frame Account for a flat washer KC149A 2 Remove the cotter pin from the brake clevis pin then slide the brake pedal away from the frame suffi ciently to remove the clevis pin KC439 3 Lower the brake pedal down to the foot wells and remove the reinstallable rivet from the CVT cut...

Page 20: ...is from the V belt housing and cover INSTALLING 1 Place the V belt onto the driven pulley making sure the arrows on the belt point in the direction of rota tion then pinch the belt together in front of the driven pulley and place it over the clutch shaft KC135 KC131 2 Install the bushing over the clutch shaft then install the movable drive face assembly on the clutch shaft KC128 KC138 3 With two d...

Page 21: ...ace install the V belt cover Using the pattern shown secure with the cap screws tightened to 8 ft lb KC142A KC153A 6 Install the clevis pin connecting the brake pedal to the master cylinder and secure with a new cotter pin then install the cap screw and flat washer securing the brake pedal to the frame and tighten to 20 ft lb KC438A Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 6...

Page 22: ...ponents when servicing the engine transmission SPECIAL TOOLS A number of special tools must be available to the techni cian when performing service procedures in this section Refer to the current Special Tools Catalog for the appro priate tool description NOTE Special tools are available from the Arctic Cat Service Department Description p n Crankcase Separator Crankshaft Remover 0444 152 Magneto ...

Page 23: ...nt 1 Clean plug 2 Replace stator assembly 3 Replace ECU 4 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance excessive 2 Valve spring s weak broken 3 Rocker arm rocker arm shaft worn 4 Camshaft worn 5 Valve tappets worn 1 Adjust clearance 2 Replace spring s 3 Replace arm shaft 4 Replace camshaft 5 Replace tappets Problem Engine noisy Noise seems to com...

Page 24: ... fuel pump Problem Exhaust smoke dirty or heavy Condition Remedy 1 Oil in the engine overfilled contaminated 2 Piston rings cylinder worn 3 Valve guides worn 4 Cylinder wall scored scuffed 5 Valve stems worn 6 Stem seals defective 1 Drain excess oil replace oil 2 Replace service rings cylinder 3 Replace cylinder head 4 Replace service cylinder 5 Replace valves 6 Replace seals Problem Engine lacks ...

Page 25: ...nto a suitable container 7 Remove the gas tank see Fuel Lubrication Cooling 8 Remove the air inlet and outlet ducts from the CVT housing 9 Remove the cap screws securing the exhaust pipe to the cylinder head then remove the springs securing the muffler to the exhaust pipe 10 Remove the muffler and exhaust pipe Account for a grafoil seal on each end of the exhaust pipe 11 Loosen the clamp securing ...

Page 26: ...connector E idle step control ISC connec tor F and throttle position sensor TPS connector G FI522A 15 From the right side disconnect the stator connector H and crankshaft position sensor connector I from the main harness then disconnect the positive cable from the starter motor and the engine ground cable from the starter mounting flange FI523A FI533A 16 Remove the spark plug cap from the spark pl...

Page 27: ...nder Head Camshaft NOTE Remove the spark plug timing inspection plug and outer magneto cover then using an appro priate wrench rotate the crankshaft to top dead cen ter of the compression stroke 1 Remove the cap screws securing the two tappet cov ers Remove the two tappet covers Account for the O rings FI603 NOTE Keep the mounting hardware with the covers for assembly purposes 2 Remove the cylinde...

Page 28: ...s out of the cylinder head then remove the C ring FI613 NOTE Care should be taken not to drop the C ring down into the crankcase MD1131 6 Noting the timing marks for installing purposes drop the sprocket off the camshaft While holding the cam chain slide the sprocket and camshaft out of the cyl inder head Account for an alignment pin NOTE Loop the chain over the cylinder and secure it to keep it f...

Page 29: ...e cam sprocket are longer than the two cap screws on the left spark plug side CD211 9 Remove the cylinder head from the cylinder remove the gasket and account for two alignment pins FI623A 10 Remove the cam chain guide AT THIS POINT To service valves and cylinder head see Servicing Top Side Components sub section AT THIS POINT To inspect cam chain guide see Servicing Top Side Components sub sectio...

Page 30: ...connecting rod with rubber bands to avoid damaging the rod or install a connect ing rod holder Servicing Top Side Components NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary AT THIS POINT To service cylinder see Servicing Top Side Compo nents sub section CAUTION When removing the cylinder be sure to support the piston to prevent damage to the crankca...

Page 31: ...p all valves and valve components as a set Note the original location of each valve set for use during installation Return each valve set to its original location during installation 1 Using a valve spring compressor compress the valve springs and remove the valve keepers Account for an upper spring retainer CC132D 2 Remove the valve seal and the lower remaining spring seat Discard the valve seal ...

Page 32: ...lve guide is out of tolerance the cylinder head must be replaced Servicing Valves Valve Guides Valve Seats If valves valve guides or valve seats require servicing or replacement Arctic Cat recommends that the compo nents be taken to a qualified machine shop for servicing Measuring Rocker Arm Inside Diameter 1 Using a dial calipers measure the inside diameter of the rocker arm 2 Acceptable inside d...

Page 33: ... ring out of the ring groove CC400D 2 Remove each ring by working it toward the top of the piston while rotating it out of the groove NOTE When installing new rings install as a com plete set only Cleaning Inspecting Piston Ring Grooves 1 Take an old piston ring and snap it into two pieces then grind the end of the old ring to a 45 angle and to a sharp edge 2 Using the sharpened ring as a tool cle...

Page 34: ...r ends do not overlap Stagger the end gaps of the upper and lower thin oil rings according to the illustration NOTE Note the direction of the exhaust side of the piston 5 for correct ring end gap orientation ATV 1085B 2 Install the compression rings 1 and 2 so the letter s on the top surface of each ring faces the dome of the piston Rotate the rings until the ring end gaps are on directly opposite...

Page 35: ... the cylinder in a figure eight motion until a uniform bright metallic finish is attained CC129D Inspecting Cam Chain Guide 1 Inspect cam chain guide for cuts tears breaks or chips 2 If the chain guide is damaged it must be replaced Honing Cylinder 1 Using a slide gauge and a dial indicator or a snap gauge measure the cylinder bore diameter in three locations from top to bottom and again from top ...

Page 36: ...for scoring seizure marks or pitting 2 If excessive scoring seizure marks or pitting is found the cylinder head assembly must be replaced Measuring Camshaft to Cylinder Head Clearance 1 Loosen the jam nuts and adjuster screws CC005D 2 Place a strip of plasti gauge in each of the camshaft lands in the cylinder head 3 Place the valve cover on the cylinder head and secure with the valve cover cap scr...

Page 37: ...amaged the camshaft must be replaced Installing Top Side Components A Piston B Cylinder 1 Lubricate the piston pin connecting rod and piston pin bore with engine oil then install the piston on the con necting rod making sure there is a circlip on each side FI626 NOTE The piston should be installed so the IN points towards the intake side 2 Place the two alignment pins into position Place a new cyl...

Page 38: ...he right side of the cylinder head nearest the cam sprocket are longer than the two cap screws on the left spark plug side Tighten only until snug 8 Install the two lower nuts securing the cylinder head to the cylinder one in front and one in rear 9 In a crisscross pattern tighten the four cylinder head cap screws from step 7 to 28 ft lb Tighten the two lower cylinder head nuts from step 8 to 20 f...

Page 39: ...bearings cam lobes and the three seating journals on the cylinder head NOTE Note the position of the alignment marks on the end of the camshaft They must be parallel with the valve cover mating surface If rotating the cam shaft is necessary for alignment do not allow the chain and sprocket to rotate and be sure the cam lobes end up in the down position 15 When the camshaft assembly is seated ensur...

Page 40: ...he cap screw plug and washer and tighten securely FI608 23 Loosen the adjuster screw jam nuts then loosen the adjuster screws on the rocker arms in the valve cover 24 Apply a thin coat of Three Bond Sealant to the mat ing surface of the valve cover then place the valve cover into position Note that the two alignment pins are properly positioned NOTE At this point the rocker arms and adjuster screw...

Page 41: ...o the cylinder then remove the water pump cover FI538 2 Remove the water pump housing assembly noting the location of the longer cap screw Account for a gasket and two alignment pins FI539 FI541 3 Remove two cap screws and the oil bolt securing the oil pressure relief line to the engine Account for two crush washers and an O ring FI544 4 Remove the water pump drive gear then remove the speed senso...

Page 42: ...rotor flywheel loose from the crankshaft then remove the puller and crankshaft protector and remove the rotor flywheel FI550 9 Remove the flywheel key from the crankshaft then remove the starter clutch gear FI551A 10 Remove starter idler gears and their respective shafts then remove the starter motor Account for an O ring on the starter drive housing FI555 G Shift Shaft H Drive Gear NOTE Steps 1 1...

Page 43: ...If it moves or locks up both ways the starter clutch must be replaced 2 Inspect the starter clutch gear for chipped or missing teeth or discoloration scoring of the clutch surface Inspect the bearing for loose worn or discolored rollers If bearing is damaged it must be replaced FI569 3 Inspect the one way bearing for chipped surfaces missing rollers or discoloration If any of the above conditions ...

Page 44: ...ss the bearing from the gear FI583 2 Thoroughly clean the gear hub then apply a drop of green Loctite 620 to the bearing outer race and press into the gear hub until even with the lower chamfer radius FI580 INSPECTING STATOR MAGNETO COVER ASSEMBLY 1 Inspect the stator for burned or discolored wiring broken or missing hold down clips or loose cap screws 2 Inspect the bearings in the magneto housing...

Page 45: ...le hold down and secure with a cap screw Tighten securely FI595A REPLACING MAGNETO COVER BEARINGS 1 Using a suitable press and proper support press the bearing from the housing as indicated one from out side and one from inside FI593 FI594 2 Clean the bearing bores in the housing and inspect closely for cracks or shiny areas indicating bearing movement Replace the housing if any of the above are e...

Page 46: ...n to 107 ft lb C Magneto Cover D Water Pump NOTE Steps 1 8 in the preceding sub section must precede this procedure 9 Install two alignment pins and place the magneto cover gasket into position Install the magneto cover Noting the different lengthed 6 mm cap screws and the location of the two internal cap screws tighten cap screws in a crisscross pattern to 8 ft lb FI596A 10 Install the water pump...

Page 47: ...ne is still in the frame remove the cap screw securing the brake pedal to the frame then slide the pedal outward KC438A 2 Remove the cap screws securing the V belt cover to the clutch cover then slide the brake pedal outward and remove the V belt cover Account for two align ment pins and a gasket KC142A 3 Mark the movable drive face and the fixed drive face for installing purposes then remove the ...

Page 48: ...g the cap screw clockwise then remove the V belt KC132 6 Remove the fixed drive face MD1094 7 Remove the nut holding the driven pulley assembly then remove the driven pulley assembly MD1068 8 Using an impact screwdriver remove the three Phil lips head cap screws holding the air intake plate Remove the air intake plate MD1092 Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9...

Page 49: ...E Steps 1 10 in the preceding sub section must precede this procedure 11 Remove the one way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes MD1286 12 Remove the left hand threaded nut holding the cen trifugal clutch assembly MD1014 MD1016 13 Remove the cam chain FI630 14 Remove the oil pump drive gear cap screw MD1018A 15 Remove oil pump drive gear Account ...

Page 50: ...worn excessively cracked damaged in any way or out of tolerance replacement is necessary INSPECTING CENTRIFUGAL CLUTCH SHOE 1 Inspect the clutch shoe for uneven wear chips cracks or discoloration 2 Inspect the depth of the grooves in the clutch shoes If any shoe is worn to the bottom of the groove replace the complete set ATV1014 INSPECTING CENTRIFUGAL CLUTCH HOUSING 1 Inspect the clutch housing f...

Page 51: ...the pump halves If the oil pump is damaged it must be replaced NOTE The oil pump is a non serviceable compo nent and must be replaced as a complete assembly DRIVEN PULLEY ASSEMBLY NOTE The driven pulley assembly is a non service able component and must be replaced as a complete assembly Installing Right Side Components A Oil Strainer Oil Pump 1 Place the oil strainer into position beneath the cran...

Page 52: ...te 271 to 63 ft lb MD1017 MD1018A 7 Install the clutch shoe assembly on the crankshaft then install the flange nut left hand threads coated with red Loctite 271 Tighten to 147 ft lb NOTE The flat side of the flange nut should be directed towards the clutch shoe 8 Install the one way clutch making sure that the green dot or the word OUTSIDE is directed away from the crankcase MD1286 B Clutch Cover ...

Page 53: ...MD1068 KC134 13 Slide the fixed drive face assembly onto the front shaft 14 Spread the faces of the driven pulley by threading a V belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V belt to drop into the pulley approximately 3 4 in KC137 NOTE The arrows on the V belt should point in direction of engine rotation 15 Making sure the movable...

Page 54: ...s to 8 ft lb KC142A Center Crankcase Components NOTE This procedure cannot be done with the engine transmission in the frame Complete Remov ing procedures for Top Side Left Side and Right Side must precede this procedure NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use disc...

Page 55: ... Half NOTE To aid in installing keep the assemblies together and in order NOTE For steps 1 6 refer to illustration FI639A FI639A 1 Remove the secondary driven shaft assembly A noting the location of the front and rear bearing locating pins and the center bearing locating ring FI660A FI659A FI661A 2 Remove the reverse idler assembly B Account for and note the location of the inner bushing 1 idler s...

Page 56: ...r shaft MD1024 7 Using Crankcase Separator Crankshaft Remover with the appropriate crankshaft protector remove the crankshaft MD1330 8 Remove the secondary drive gear secondary driven gear retaining nut From inside the crankcase using a rubber mallet drive out the output shaft assembly Account for the output shaft a shim a washer and the nut CAUTION Do not remove the remaining output shaft assembl...

Page 57: ... remove an existing shim measure it and install a new thinner shim 2 If backlash measurement is more than specified remove an existing shim measure it and install a thicker shim NOTE Continue to remove measure and install until backlash measurement is within tolerance Note the following chart Checking Tooth Contact NOTE After correcting backlash of the secondary driven bevel gear it is necessary t...

Page 58: ...ications Measuring Connecting Rod Big End Side to Side 1 Push the lower end of the connecting rod to one side of the crankshaft journal 2 Using a feeler gauge measure the gap between the connecting rod and crankshaft journal CC289D 3 Acceptable gap range must not exceed specifica tions Measuring Crankshaft Runout 1 Place the crankshaft on a set of V blocks 2 Mount a dial indicator and base on the ...

Page 59: ... the bearing and bushing FI666 FI667 4 Remove the splined washer then remove the circlip securing the high low sliding dog Remove the slid ing dog FI668 CAUTION When disassembling the countershaft care must be taken to note the direction each major component dog gear faces If a major component is installed facing the wrong direction transmission damage may occur and or the transmission will malfun...

Page 60: ... bushing 3 bearing 2 and gear 4 on the countershaft then install the washers 5 and secure with the snap ring FI671A FI670 2 Install the high low shift dog 6 on the countershaft and secure with snap ring 7 then install the splined washer 8 FI668A 3 Install the low driven bushing 10 bearing 9 and gear 11 on the countershaft then install splined washer 12 FI667A Manual Table of Contents FOR ARCTIC CA...

Page 61: ...led Assembling Crankcase Half NOTE For ease of assembly install components on the right side crankcase half NOTE If the output shaft was removed make sure that the proper shim is installed 1 Install the output shaft into the crankcase making sure the two gears shim washer and nut are in the correct order MD1199 MD1079 2 Install and tighten the output shaft flange nut to 59 ft lb Using a punch peen...

Page 62: ...r of the engine Install the crank balancer shaft MD1024 5 Install the key in the crank balancer shaft then install the gear and aligning the timing marks slide the gear into place FI658 6 Align the shift cam fork slots with the shift fork shaft locating boss and with a washer on each end install in the crankcase FI652A 7 Place the shift forks into position on the assembled countershaft and install...

Page 63: ...nstall the spacer 1 shaft 2 reverse idler gear and washer 3 FI641A FI645 11 Install the secondary output driveshaft assembly into the crankcase half making sure the front and rear bear ing alignment pins are seated in the recesses then install the center carrier bearing alignment C ring FI660A FI659A FI661A Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 498...

Page 64: ...aining crankcase cap screws then tighten only until snug NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the cap screws CC871 5 In a crisscross pattern tighten the 8 mm cap screws until the halves are correctly joined then tighten to 21 ft lb NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs 6 In a crisscross pattern tighte...

Page 65: ...to 8 ft lb 8 From the top side install the ECT sensor connector C fuel injector connector D MAP sensor con nector E ISC connector F and the TPS connector G FI522A 9 Place the air filter assembly into position and con nect the crankcase breather securing with the clamp then connect the air inlet boot to the throttle body and secure with a hose clamp 10 Install the exhaust pipe using a new seal at t...

Page 66: ...and left footwell Tighten all fasteners securely 16 Install the seat making sure it locks securely in place then start the engine and allow to warm up while checking for leaks 17 Shut engine off and inspect coolant and oil levels Add fluids as required Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 67: ...body then loosen the clamp securing the intake boot to the intake housing and slide the intake housing rearward FI691A 4 Disconnect the MAP IAT sensor connector ISC con nector and TPS connector then loosen the clamp securing the throttle body to the intake manifold boot and slide the throttle body out FI528A 5 Remove the throttle arm cover and loosen the throttle cable jam nut then disconnect the ...

Page 68: ...rivets from the gas tank cover then remove the gas tank cap and remove the cover panel Reinstall the gas tank cap KC453A KC454A 4 Using a shop towel to catch any leaking gasoline disconnect the gasline hose from the fuel pump out let then disconnect the fuel pump fuel gauge con nector from the harness KC455 KC456 5 Remove the mounting bolt at the rear of the gas tank then remove the gas tank KC457...

Page 69: ...nk cap then secure the cover with four reinstallable rivets and two cap screws 4 Install the side panels and secure with reinstallable rivets making sure the tabs on the panels engage the slots on the gas tank cover 5 Connect the negative battery cable and install the battery case access cover then install the seat Oil Filter Oil Pump NOTE Whenever internal engine components wear excessively or br...

Page 70: ...iator with water to remove any contami nants 2 Inspect the radiator for leaks and damage 3 Inspect all hoses for cracks and deterioration 4 Inspect all fasteners and grommets for damage or wear Installing 1 Position the fan fan shroud assembly on the radiator then secure with existing hardware 2 Place the radiator with grommets and collars into position on the frame then install the cap screws Tig...

Page 71: ...ain the oil from the engine transmission 3 Remove the four torx head cap screws securing the front and rear fenders to the footrest then remove the four cap screws securing the footrest to the frame Remove the footrest 4 Loosen the hose clamps and slide the clamps away from the hose ends approximately 2 in then remove the hoses from the water pump 5 Remove the four cap screws securing the water pu...

Page 72: ...over see Gas Tank in this section KC220 3 Mark the fuel pump and gas tank for proper orienta tion during assembly then disconnect the fuel pump fuel level sensor connector KC423 4 Disconnect the gasline connector from the fuel pump outlet 5 Remove the screws securing the fuel pump to the gas tank then make a reference mark on the fuel pump and tank 6 Lift out the fuel pump assembly and carefully g...

Page 73: ...ce then con nect the two wire connector A INSTALLING 1 Mark the new fuel pump with a reference mark in the same location as the removed pump then place the new gasket on the pump 2 Remove the material covering the fuel pump open ing then carefully guide the fuel pump into position taking care not to damage the float or float lever KX190 3 Rotate the fuel pump until the match marks align then insta...

Page 74: ...s Problem Idling or low speed impaired Condition Remedy 1 TPS out of adjustment 1 Adjust TPS Problem Medium or high speed impaired Condition Remedy 1 High RPM cut out against RPM limiter 1 Decrease RPM speed Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 75: ...1 When charging a battery in the vehicle be sure the ignition switch is in the OFF position 2 Clean the battery terminals with a solution of baking soda and water NOTE The sealing strip should NOT be removed and NO fluid should be added 3 Be sure the charger and battery are in a well venti lated area Be sure the charger is unplugged from the 110 volt electrical outlet 4 Connect the red terminal le...

Page 76: ...pectations bring the battery to an authorized Arctic Cat dealer for further trouble shooting RPM Limiter NOTE The ATV is equipped with an ECU that retards ignition timing when maximum RPM is approached When the RPM limiter is activated it could be misinterpreted as a high speed misfire Testing Electrical Components All of the electrical tests should be made using the Fluke Model 73 Multimeter or F...

Page 77: ...1 ohm of resis tance replace the switch Engine Coolant Temperature ECT Sensor 1 Connect the meter leads selector in OHMS position to the sensor terminals 2 Suspend the sensor and a thermometer in a container of cooking oil then heat the oil NOTE Neither the sensor nor the thermometer should be allowed to touch the bottom of the con tainer or inaccurate readings will occur Use wire holders to suspe...

Page 78: ... Module PDM A number of fuses and relays are located in the power distribution module in front of the steering post under the radiator electrical access panel KC466A If there is any type of related electrical system failure always check the fuses first NOTE To remove a fuse compress the locking tabs on either end of the PDM cover and lift off then remove the applicable fuse 2411 566 RELAYS The rel...

Page 79: ... tester lead connected then connect the red tester lead to the signal lead pin S 6 Slowly move the ATV forward or backward the meter must show 0 and 5 volts alternately NOTE If the sensor tests are within specifications the speedometer LCD gauge must be replaced see Steering Frame To replace a speed sensor use the following procedure 1 Disconnect the three wire connector from the speed sensor then...

Page 80: ...Beam 1 Connect one tester lead to the brown black wire then connect the other tester lead to the white wire 2 With the dimmer switch in the LO position the meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resis tance replace the switch RESISTANCE Engine Stop Switch 1 Set the meter selector to the OHMS position 2 Connect the one lead to the brown lavender wire then connect...

Page 81: ...he ignition switch in the OFF position connect the black tester lead to the black wire in the supply harness then connect the red tester lead to either orange wire in the supply harness 3 Turn the ignition switch to the ON position The meter must show 12 DC volts 4 Connect the red tester lead to the second orange wire in the supply harness The meter must show 12 DC volts 5 Connect the red tester l...

Page 82: ... Crank the engine over using the electric starter 4 The meter reading must be within specification Starter Relay 1 Remove the battery case access cover then using the multimeter set to the DC Voltage position check the relay as follows 2 Connect the red tester lead to the positive battery ter minal then connect the black tester lead to the starter cable connection on the starter relay The meter mu...

Page 83: ...he same part number to verify the suspected one is defective Diagnostic Trouble Codes DTC can be cleared by fol lowing the procedures located in the Diagnostic Trouble Codes DTC sub section in this section Regulator Rectifier The regulator rectifier is located under the radiator elec trical access panel TESTING 1 Start engine and warm up to normal operating tempera tures then connect a multimeter ...

Page 84: ...nspect the LIGHTS fuse battery connections or trouble shoot the main wiring harness TAILLIGHTS BRAKELIGHTS Voltage Taillights NOTE Perform this test on the main harness side of the connector Also the ignition switch should be in the LIGHTS position 1 Set the meter selector to the DC Voltage position 2 Connect the black tester lead to the black wire then connect the red tester lead to the brown blu...

Page 85: ... timing cannot be adjusted however verifying ignition timing can aid in troubleshooting other compo nents To verify engine timing see Periodic Maintenance Diagnostic Trouble Codes DTC If an EFI or related chassis component fails or an out of tolerance signal is detected by the ECU a diagnostic trouble code DTC will be generated in the ECU and displayed on the LCD For the first thirty seconds the L...

Page 86: ...t Low SG Open P0500 Gauge Direct Error Code N A N A N A Vehicle Speed Sensor P0508 ON C4 D3 D4 E4 I O V Idle Air Control System Circuit Low SG P0509 ON C4 D4 I O V Idle Air Control System Circuit High Open P0562 L1 I H System Voltage Low P0563 L1 I H System Voltage High P0601 N A N A N A ECU Memory Check Sum Error P0615 1 L3 O L Starter Relay Circuit P0616 ON L3 O L Starter Relay Circuit Low P0617...

Page 87: ...ollow ing tests are made with the sensor connected 1 Connect the three wire plug to the sensor then remove the mounting screws securing the sensor to the frame KC466F 2 Install the needle adapters to the multimeter leads then select DC Voltage on the multimeter 3 Connect the red tester lead to the blue brown wire B and the black tester lead to the pink black wire A then turn the ignition switch ON...

Page 88: ... 4 Turn the ignition switch to the OFF position 5 Select the OHMS position on the meter then per form the following resistance tests on the TPS A Pin B to ground infinity open circuit B Pin A to pin B approximately 1 22k ohms throttle closed C Pin A to pin B approximately 4 5k ohms throttle full open D Pin A to pin C approximately 5 5k ohms PR535A NOTE If any meter reading is not as specified repl...

Page 89: ...LING ADJUSTING 1 Place the TPS into position on the throttle body and secure with the screw Do not tighten at this time 2 Connect the TPS Multi Analyzer Harness connector 8 to the TPS then connect the harness to the TPS Analyzer Tool FI672 3 Using a multimeter connect the black tester lead to the black socket GND on the analyzer and the red tester lead to the white socket VAR then select the Volta...

Page 90: ...l grounded open 3 Regulator rectifier defective 4 Battery defective 1 Repair wires clean connector 2 Replace stator coil 3 Replace regulator rectifier 4 Replace battery Problem Alternator overcharges Condition Remedy 1 Internal battery short circuited 2 Regulator rectifier damaged defective 3 Regulator rectifier poorly grounded 1 Replace battery 2 Replace regulator rectifier 3 Clean tighten ground...

Page 91: ... battery 2 Check alternator regulator rectifier circuit connections 3 Replace battery correct charging system 4 Replace battery Problem Battery polarity reversed Condition Remedy 1 Battery incorrectly connected 1 Reverse connections replace battery repair damage Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Page 92: ...ator runs constantly or makes squeal ing or grinding sounds the actuator must be replaced REMOVING 1 Disconnect the connector on the actuator harness 2 Remove the mounting cap screw from the driveshaft side of the actuator KC293A 3 Remove the mounting cap screw from below the actuator on the suspension side KC294A 4 Loosen but do not remove the mounting cap screw at the front of the actuator then ...

Page 93: ...tie Front Differential REMOVING DIFFERENTIAL 1 Secure the ATV on a support stand to elevate the wheels 2 Remove the drain plug and drain the gear lubricant into a drain pan then reinstall the plug and tighten to 45 in lb ATV0082A 3 Remove the front wheels 4 Pump up the hand brake then engage the brake lever lock 5 Remove the cotter pin securing the hub nut then remove the nut 6 Release the brake l...

Page 94: ...ng cap screws and remove the differential from the frame KC291A Disassembling Input Shaft NOTE This procedure can be performed on a rear gear case however some components may vary from model to model The technician should use dis cretion and sound judgment 1 Remove the cap screws securing the front drive actu ator and remove the actuator then remove the cap screws securing the pinion housing CD102...

Page 95: ... AF982 6 Remove the snap ring securing the input shaft bear ing then place the pinion housing in a press and remove the bearing AF983 AF984 KX219 Assembling Input Shaft 1 Place the pinion housing in a press and install the input shaft bearing Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside AF993 Manual Table of Contents FOR ARCTIC CAT...

Page 96: ...2 5 Using a new O ring lubricated with grease install the front drive actuator and secure with the cap screws 6 Place the pinion housing with new gasket onto the gear case housing then secure with the existing cap screws Tighten to 18 ft lb CD103 Disassembling Pinion Gear NOTE This procedure can be performed on a rear gear case 1 Remove the cap screws securing the pinion housing then remove the ho...

Page 97: ...g the 48 mm Inter nal Hex Socket remove the lock collar securing the pinion gear assembly NOTE On a front differential the lock collar has right hand threads On a rear gear case the lock col lar has left hand threads CC875 CC876 6 Using the Pinion Gear Shaft Removal Tool and a hammer remove the pinion gear from the gear case housing CAUTION Failure to completely remove the staked material from the...

Page 98: ...ior to any other shim ming 1 Install the existing shim or a 0 051 0 055 in shim on the gear case side of the ring gear assembly GC031A 2 Install the ring gear with shim in the gear case then while holding the pinion stationary rock the ring gear forward and back to determine if any backlash exists If no backlash exists install a thicker shim and recheck GC059A 3 Install the bearing flange onto the...

Page 99: ...ntacting the ring gear axle flange GC065 2 Zero the dial indicator then push the ring gear toward the dial indicator and release End play should be 0 004 0 008 in 3 To increase end play decrease the shim thickness To decrease end play increase the shim thickness NOTE Once proper backlash and end play are established the gear case can be assembled see Assembling Differential Assembly in this sub se...

Page 100: ...n install into gear case differential housing GC031A GC059 2 Place the selected end play shim chamfered side toward the gear onto the cover side of the ring gear GC059B NOTE The spider and ring gear assembly must be replaced as a complete unit 3 Making sure the O ring is properly positioned on the differential housing cover assembly install the cover with existing cap screws coated with green Loct...

Page 101: ...ace a 1 4 in drill bit on the inside surface of the needle bearing against the bottom side then drill through the pinion shaft needle bearing housing CC885 2 Using a propane torch heat the area surrounding the needle bearing to soften the Loctite CC886 3 Using a flat nosed punch drive the bearing out of the housing CC887 Installing Needle Bearing 1 Apply green Loctite 609 to the outside of a new b...

Page 102: ...ck collar in the oil gallery area then using a hammer stake the lock col lar to ensure that the collar will remain securely tightened CC891 5 Install the pinion housing Removing Installing Axle Seal NOTE This procedure can be performed on a rear gear case 1 Remove the seal using a seal removal tool GC066 2 Using a press remove the bearing CC900 3 Using a press install the new bearing into the hous...

Page 103: ...cap screws and nuts Tighten to 38 ft lb KC291A 2 Install the cap screws securing the flange couplers together and tighten to 20 ft lb AG925 3 Install the front axles see Drive Axles in this sec tion AF610D AF897D 4 Install the wheels and tighten to 80 ft lb 5 Pour 275 ml 9 3 fl oz of SAE 80W 90 hypoid gear lubricant into the differential and install the fill plug Tighten to 16 ft lb 6 Remove the A...

Page 104: ...place in the gear case NOTE To assure proper seating of the axle give it a light pull the axle should remain clipped in place 2 Swing the knuckle up and onto the drive axle then place the knuckle into place in the upper A arm Secure the knuckle to the A arm with a cap screw and a new lock nut Tighten to 35 ft lb 3 Place the hub into position on the axle followed by a hex nuts Tighten the hex nuts ...

Page 105: ...the frame with cap screws and lock nuts Tighten to 38 ft lb 2 Secure the engine output flange to the rear gear case input flange with four cap screws and lock nuts Tighten to 20 ft lb 3 Install the rear drive axles see Drive Axles in this section Hub REMOVING 1 Secure the ATV on a support stand to elevate the wheel then remove the wheel 2 Remove the cotter pin from the nut NOTE During assembly new...

Page 106: ...ng sure each side of the pin is flush to the hub nut KC305 7 Install the wheel and tighten to 80 ft lb 8 Remove the ATV from the support stand Hand Brake Lever Master Cylinder Assembly NOTE The master cylinder is a non serviceable component it must be replaced as an assembly REMOVING 1 Slide a piece of flexible tubing over one of the wheel bleeder valves and direct the other end into a con tainer ...

Page 107: ...ce with new DOT 4 brake fluid from an unopened container Brake fluid readily absorbs moisture from the air signifi cantly lowering the boiling point This increases the chance of vapor lock reducing braking power and increasing stopping distance 3 Remove the brake hose from the caliper and close the bleed screw then remove the caliper 4 Compress the caliper holder against the caliper opposite the O...

Page 108: ... and excessive wear NOTE For measuring brake pads see Periodic Maintenance 3 Inspect the brake caliper housings for scoring in the piston bores chipped seal ring grooves or signs of corrosion or discoloration 4 Inspect the piston surface for scoring discoloration or evidence of binding or galling 5 Inspect the caliper holder for wear or bending ASSEMBLING INSTALLING 1 Install new seals into the br...

Page 109: ...ft lb 7 Place a new crush washer on each side of the brake hose fitting and install it on the caliper Tighten to 20 ft lb 8 Fill the reservoir then bleed the brake system see Periodic Maintenance 9 Install the wheel Tighten to 80 ft lb 10 Remove the ATV from the support stand and verify brake operation CAUTION If brake pads become contaminated with brake fluid they must be thoroughly cleaned with ...

Page 110: ...s pinions 7 Replace gear s 8 Replace axle 9 Replace axle Problem Braking poor Condition Remedy 1 Pad worn 2 Pedal free play excessive 3 Brake fluid leaking 4 Hydraulic system spongy 5 Master cylinder brake cylinder seal worn 1 Replace pads 2 Replace pads 3 Repair replace hydraulic system component s 4 Bleed hydraulic system correct or repair leaks 5 Replace master cylinder Problem Brake lever trav...

Page 111: ...ace bushings and sleeves where appropriate into shock eyelet then install shock with cap screws and nuts Tighten all nuts to 35 ft lb 2 Remove the ATV from the support stand Front A Arms REMOVING 1 Secure the ATV on a support stand to elevate the front wheels then remove the wheels 2 Remove the cotter pin from the nut Discard the cot ter pin 3 Remove the nut securing the hub 4 Remove the brake cal...

Page 112: ...plines then install the hub assembly onto the drive axle 7 Secure the hub assembly with the nut Tighten only until snug 8 Secure the brake caliper to the knuckle with the two new patch lock cap screws Tighten to 20 ft lb 9 Secure the hub nut from step 7 to the shaft axle Tighten to 200 ft lb 10 Install a new cotter pin and spread the pin to secure the nut 11 Install the wheel and tighten to 80 ft ...

Page 113: ... arm with a cap screw and new lock nut Tighten to 35 ft lb 11 Secure the boot guard to the lower A arm with the two cap screws Tighten securely 12 Install the wheel and tighten to 80 ft lb 13 Remove the ATV from the support stand Wheels and Tires TIRE SIZE The ATV is equipped with low pressure tubeless tires of the size and type listed in General Information Do not under any circumstances substitu...

Page 114: ...t until all tires are equal in circumference 6 Repeat steps 4 5 as necessary to ensure proper han dling Troubleshooting WARNING Do not operate the ATV if tire damage exists Problem Suspension too soft Condition Remedy 1 Spring s weak 2 Shock absorber damaged 3 Shock absorber preload too low 1 Replace spring s 2 Replace shock absorber 3 Adjust shock absorber preload Problem Suspension too stiff Con...

Page 115: ...caps KC0058 3 Remove the cap screws securing the upper steering post to the frame Account for the housing cap outer housing and inner housing KC307A 4 Remove the cotter pins from the inner tie rod ends then remove the nuts and disconnect the inner tie rod ends KC184A NOTE If tie rods are to be completely removed remove the outer tie rod ends from the knuckles at this time 5 Remove the cap screw se...

Page 116: ...ing post support then with the housing cap in place secure with the cap screws Tighten to 20 ft lb KC307A 3 Install the tie rod ends into the lower steering post arm and tighten to 30 ft lb then install new cotter pins KC184A 4 Place the handlebar and caps in place on the steering post and with the handlebar correctly positioned tighten the cap screws to 20 ft lb KC0058 5 Install the steering post...

Page 117: ...Slide the grip onto the handlebar until it is fully seated with the smooth part of the grip facing up NOTE A quick firm push is required to seat the grip completely on the handlebar Install while the glue is wet 3 Wipe off any excess glue then secure the grip with the plug end cap and cap screw Throttle Control REMOVING 1 Remove the two machine screws securing the throt tle control to the handleba...

Page 118: ...e the wheel cap from the hub then remove the cotter pin from the nut 3 Remove the nut securing the hub 4 Remove the brake caliper 5 Remove the hub assembly 6 Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle 7 Remove the two cap screws securing the ball joints in the knuckle 8 Tap the ball joint end out of the knuckle then remove the knuckle 9 Remove the snap r...

Page 119: ...KC305 7 Secure the brake caliper to the knuckle with two new patch lock cap screws Tighten to 20 ft lb KC283 8 Pump the hand brake lever then engage the brake lever lock 9 Secure the hub nut from step 6 to the shaft Tighten to 200 ft lb 10 Install a new cotter pin and spread the pin to secure the nut 11 Install the wheel then using a crisscross pattern tighten to 80 ft lb 12 Remove the ATV from th...

Page 120: ...nt 1 8 1 4 in more than the rear measurement 10 If the difference in the measurements is not within specifications adjust both tie rods equally until within specifications NOTE Prior to locking the jam nuts make sure the ball joints are at the center of their normal range of motion and at the correct angle 733 559A Front Bumper Assembly REMOVING Remove the four front cap screws securing the bumper...

Page 121: ...move the two exhaust springs at the muffler exhaust pipe juncture KC170 2 Slide the muffler rearward to clear the mounting lugs and remove the muffler Account for a grafoil seal INSPECTING MUFFLER NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is nec essary 1 Inspect muffler externally for cracks holes and dents 2 Inspect the muffler internally by shaking the mu...

Page 122: ...s INSTALLING 1 Place the rear body panel fender in place on the ATV then secure with the cap screws on the frame and fender supports Tighten all fasteners securely 2 Connect the light connectors and secure to the frame KC279 3 Secure the rear fenders to the footwells with the reinstallable rivets and lock 4 Install the seat Seat REMOVING INSTALLING 1 To remove the seat pull rearward on the latch r...

Page 123: ...ie rod ends 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts Problem Steering pulling to one side Condition Remedy 1 Tires inflated unequally 2 Front wheel alignment incorrect 3 Wheel hub bearings worn broken 4 Frame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Replace shock absorber Problem Tire wear rapid or uneven C...

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Arctic Cat XC 450i 2012, Service Manual

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