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SERVICE MANUAL

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Содержание XC 450 2016

Страница 1: ...www arcticcat com SERVICE MANUAL www arcticcat com...

Страница 2: ...44 Servicing Left Side Components 46 Installing Left Side Components 49 Right Side Components 50 Removing Right Side Components 51 Servicing Right Side Components 54 Installing Right Side Components 5...

Страница 3: ...nically correct Some photo graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions Because Arctic Cat Inc constantly refines and improves its pro...

Страница 4: ...rm Frame 35 47 Knuckle Ball Joint 35 47 Shock Absorber Frame 35 47 Shock Absorber Upper A Arm 35 47 Knuckle A Arm 35 47 DRIVE TRAIN COMPONENTS Engine Mounting Through Bolt Frame 38 52 Front Differenti...

Страница 5: ...4 51 69 4 76 103 4 2 2 7 27 36 7 52 70 7 77 104 7 3 4 1 28 38 1 53 72 1 78 106 1 4 5 4 29 39 4 54 73 4 79 107 4 5 6 8 30 40 8 55 74 8 80 108 8 6 8 2 31 42 2 56 76 2 81 110 2 7 9 5 32 43 5 57 77 5 82...

Страница 6: ...in this manual 10 Store the ATV indoors in a level position Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble free riding...

Страница 7: ...er housing then loosen the clamp securing the rear inlet boot to the air box Remove the inlet pipe KC445A KC446 2 Remove two reinstallable rivets from the air filter housing mounting bracket and slide...

Страница 8: ...ction plug and spark plug then remove the tappet covers for more detailed information see Engine Transmission Servicing Top Side Components CF005 2 Rotate the crankshaft to the TDC position on the com...

Страница 9: ...plug on the cylinder head well away from the spark plug hole 4 Attach the Compression Tester Kit NOTE The engine must be warm and the battery must be fully charged for this test 5 While holding the th...

Страница 10: ...replaced 3 Install the spark arrester assembly with gasket then secure with the cap screws Tighten to 48 in lb Adjusting Throttle Cable 1 Slide the rubber boot away then loosen the jam nut from the th...

Страница 11: ...oses 13 Remove the oil level stick the engine oil level should be above the illustrated L mark but not higher than the illustrated F mark ATV 0100AA 14 Inspect the area around the drain plug and oil f...

Страница 12: ...es not correspond to the selected gear it will be necessary to test drive the ATV to determine if the gear position switch is faulty or the shift lever needs adjustment If the ATV functions in the gea...

Страница 13: ...of brake fluid If low refill the reservoir before the bleeding procedure is continued Failure to maintain a sufficient amount of fluid in the reservoir will result in air in the system D Repeat step C...

Страница 14: ...iveness Braking distance will be extended until brake pads are properly burnished 1 Choose an area large enough to safely accelerate the ATV to 30 mph and to brake to a stop 2 Accelerate to 30 mph the...

Страница 15: ...lley pull it forward and outward off the clutch shaft then remove it from the driven pulley KC136 8 Inspect the faces of the drive and driven pulleys for scoring pitting cracks or grooving then clean...

Страница 16: ...terclockwise until the driven pulley faces are together 5 With the two alignment pins installed in the V belt housing and a new V belt cover gasket in place install the V belt cover Using the pattern...

Страница 17: ...NG 1 Remove the seat then remove four reinstallable riv ets and the side panels KC450A 2 Remove two cap screws and two reinstallable rivets then remove the gas tank cap and remove the gas tank cover R...

Страница 18: ...AND INSPECTING 1 Clean all rear body panel components with warm soap and water 2 Inspect side panels and rear body panel for cracks and loose rivets 3 Inspect threaded areas of all mounting bosses for...

Страница 19: ...unusual bends 4 Inspect all welded areas for cracks or deterioration 5 Inspect the steering post and steering post brackets for cracks bends or wear 6 Inspect the bearing halves bearing caps and beari...

Страница 20: ...ge from the pod 3 Install the new gauge and secure with the mounting nuts then plug the harness into the gauge and secure the gauge pod with the machine screws Tighten securely Handlebar Grip REMOVING...

Страница 21: ...actuator arm AF676D 3 Remove the cap screw lock washer and washer securing the actuator arm to the throttle control lever AF677D 4 Remove the actuator arm and account for a bushing Note the position...

Страница 22: ...ar 3 Inspect the knuckle for cracks breaks or excessive wear 4 Inspect threads for stripping or damage ASSEMBLING AND INSTALLING 1 Install the bearing then install the snap ring making sure it seats i...

Страница 23: ...he ATV with out an operator but with Arctic Cat approved acces sories 4 Measure the distance from the outside edge of each handlebar grip to equal reference points on each side 5 Adjust the handlebar...

Страница 24: ...ition slide the front of the seat into the seat retainers and push down firmly on the rear of the seat The seat should automatically lock into position Lights Rotate the ignition switch to the running...

Страница 25: ...m the housing 3 Press in and turn the bulb counterclockwise to remove Press in and turn clockwise to install the bulb 4 Insert the bulb socket assembly into the housing and turn it clockwise to secure...

Страница 26: ...tal 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 ATV 0070C NOTE There should be an average operatin...

Страница 27: ...n replace lug nuts 4 Replace bearing 5 Replace tighten tie rod ends 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts Problem Steering pulling to one side Condition Remedy 1 Tires inflated unequ...

Страница 28: ...his ATV Proper operation during this break in period will help assure maximum life and performance from the ATV Instruct the customer to follow the proper break in procedure as described in the Operat...

Страница 29: ...ective 3 ECM defective 4 Valve clearance out of adjustment 1 Clean plug 2 Replace stator assembly 3 Replace ECM 4 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve...

Страница 30: ...nition coil 7 Clean element 8 Clean or replace hose 9 Replace fuel pump Problem Exhaust smoke dirty or heavy Condition Remedy 1 Oil in the engine overfilled contaminated 2 Piston rings cylinder worn 3...

Страница 31: ...njury KC464A 4 Remove the water pump splash guard then drain the coolant into a suitable container KC463 FI530A 5 From the left side remove the gear position switch connector A and the speed sensor co...

Страница 32: ...ve the throttle body Secure the throttle body assembly clear of the work area FI695A 14 From the top side remove the engine coolant tem perature ECT sensor connector C fuel injector connector D temper...

Страница 33: ...ide Components A Cylinder Head Cover Rocker Arms B Cylinder Head Camshaft NOTE Remove the spark plug timing inspection plug and outer magneto cover then using an appro priate wrench rotate the cranksh...

Страница 34: ...Using an awl rotate the C ring in its groove until it is 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...

Страница 35: ...screws on the right side of the cylinder head nearest the 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 gask...

Страница 36: ...ing rod with rubber bands to avoid damaging the rod or install a connect ing rod holder Servicing Top Side Components VALVE ASSEMBLY When servicing valve assembly inspect valve seats valve stems valve...

Страница 37: ...e set to its origi nal 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 v...

Страница 38: ...iston 1 Inspect the piston for cracks in the piston pin boss top and skirt areas 2 Inspect the piston for seizure marks or scuffing If piston is scored or galled replace it with a new one 3 Inspect th...

Страница 39: ...27D 2 Measure the corresponding piston diameter at a point 8 mm 0 3 in above the piston skirt at a right angle to the piston pin bore Subtract this measurement from the largest measurement in step 1 T...

Страница 40: ...If marks are found repair the surface using a cylinder hone 3 Place the cylinder on the surface plate covered with 400 grit wet or dry sandpaper Using light pressure move the cylinder in a figure eigh...

Страница 41: ...ust be replaced 1 Place the camshaft on a set of V blocks then position the dial indicator contact point against the shaft and zero the indicator CC283D 2 Rotate the camshaft and note runout maximum r...

Страница 42: ...he rings and slide the cylinder over the piston Route the cam chain up through the cylinder cam chain housing then remove the piston holder and seat the cylinder firmly on the crankcase GZ142 4 Loosel...

Страница 43: ...crankshaft until the piston is at top dead center 11 While holding the cam chain to the front install the rear cam chain tensioner guide into the cylinder head Install the pivot cap screw and washer...

Страница 44: ...then install the cap screw and tab washer Tighten cap screw only until snug CC404D FI612 18 Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed the...

Страница 45: ...n then install and tighten the cap screws to 8 ft lb FI602 29 Install the spark plug and tighten securely then install the timing inspection plug Left Side Components NOTE For efficiency it is prefera...

Страница 46: ...screws and the two longer cap screws FI596A 6 Remove the magneto cover and account for two alignment pins and the gasket D Rotor Flywheel E Starter Clutch Gear F Starter Motor NOTE Steps 1 6 in the p...

Страница 47: ...ring the output drive gear to the output shaft and remove the gear noting that the hub flange is directed toward the crankcase FI564 FI566 Servicing Left Side Components INSPECTING STARTER CLUTCH GEAR...

Страница 48: ...the cap screws after applying a drop of red Loctite 271 to the threads Tighten to 26 ft lb using a crisscross pattern Make sure the one way bearing is installed with the notches directed away from th...

Страница 49: ...crew from the harness hold down 2 Lift the rubber grommet out of the housing then remove the stator coil crankshaft position sensor Account for and note the position of the harness hold down under the...

Страница 50: ...moved place the crankshaft bearing retainer into position Apply red Loctite 271 to the three cap screws Install and tighten the three cap screws securely MD1122 2 Install the starter motor and tighten...

Страница 51: ...ly Tighten the cap screws to 8 ft lb FI541A FI539 12 Install the water pump cover with a new O ring and secure with the four cap screws Tighten to 8 ft lb FI538 13 Connect the coolant hoses to the wat...

Страница 52: ...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 nut holding the movable drive face onto t...

Страница 53: ...alling pur poses 10 Using a rubber mallet loosen the clutch cover then pull it away from the right side crankcase half Account for two alignment pins and gasket MD1115 D Centrifugal Clutch Assembly E...

Страница 54: ...w snap ring when installing the oil pump driven gear 17 Remove oil pump driven gear Account for the drive pin and thrust washer MD1020 G Oil Pump Oil Strainer NOTE Steps 1 17 in the preceding sub sect...

Страница 55: ...bly with the green dot or the word OUTSIDE directed away from the clutch shoe KC330 2 Place the clutch housing onto the clutch shoe one way clutch NOTE It will be necessary to rotate the clutch housi...

Страница 56: ...08 3 Place two alignment pins and the oil pump into posi tion on the crankcase and secure with the Phillips head screws coated with red Loctite 271 Tighten to 8 ft lb MD1060 4 Place the thrust washer...

Страница 57: ...ive Face NOTE Steps 1 8 in the preceding sub section must precede this procedure 9 Install two alignment pins and place the clutch cover gasket into position Install the clutch cover MD1115 10 Tighten...

Страница 58: ...16 Coat the threads of the nut with red Loctite 271 then making sure the splines of the clutch shaft pro trude through the cover plate secure with the nut and tighten to 147 ft lb KC138 KC141 NOTE At...

Страница 59: ...ing Crankcase Separator Crankshaft Remover and tapping lightly with a rubber mallet separate the crankcase halves Account for two alignment pins CC869 NOTE To keep the shaft gear assemblies intact for...

Страница 60: ...rk locating shaft D out of the crankcase locating boss and allow the shift forks to disengage from the gear shift shaft F FI646 FI653A 4 Remove the gear shift shaft F noting the inner and outer washer...

Страница 61: ...nge no correction is necessary 1 If backlash measurement is less than specified remove an existing shim measure it and install a new thinner shim 2 If backlash measurement is more than specified remov...

Страница 62: ...of V blocks and mount a dial indicator and base on the surface plate Position the indicator contact point against the center of the connecting rod small end journal 2 Zero the indicator and push the s...

Страница 63: ...driven gear dog then remove the circlip securing the reverse driven gear FI663 FI664 2 Remove the splined washer then remove the reverse driven gear along with the bearing and bushing FI665 3 Remove t...

Страница 64: ...ar along with the bearing and bushing and remove the high driven washer FI670 FI671 ASSEMBLING 1 With the high driven washer 1 on the countershaft install the high driven gear bushing 3 bearing 2 and...

Страница 65: ...Install the reverse dog on the shaft then place the shift forks and shift shaft into position FI663 FI662 NOTE The countershaft assembly is now ready to be installed Assembling Crankcase Half NOTE For...

Страница 66: ...t can be installed using a crankshaft installer 4 Rotate the crankshaft so the counterweight is toward the rear of the engine Install the crank balancer shaft MD1024 5 Install the key in the crank bal...

Страница 67: ...the crank case FI653A FI655A 9 Install the input driveshaft FI646 10 Install the spacer 1 shaft 2 reverse idler gear and washer 3 FI641A FI645 11 Install the secondary output driveshaft assembly into...

Страница 68: ...n be installed 3 From the right side install the crankcase cap screws noting the location of the different sized cap screws then tighten only until snug NOTE Rotate the shafts back and forth to ensure...

Страница 69: ...he intake clamp to 30 in lb FI695A 6 Connect the stator connector H and crankshaft position sensor connector I to the main harness then connect the positive cable to the starter motor and tighten secu...

Страница 70: ...e left side install the gear position switch connector A and the speed sensor connector B FI525A 14 Pour the specified amount of coolant into the radiator and the specified amount and grade of oil int...

Страница 71: ...dy to the intake manifold boot and slide the throttle body out FI528C 5 Remove the throttle arm cover and loosen the throttle cable jam nut then disconnect the throttle cable and remove the throttle b...

Страница 72: ...ve battery cable and remove the seat 2 Remove the reinstallable rivets securing the side panels two on each side and remove the side pan els KC450A NOTE The reinstallable rivets may be easily released...

Страница 73: ...p outlet making sure it locks securely in place then connect the fuel pump fuel gauge connector to the harness 3 Remove the gas tank cap and place the gas tank cover over the gas tank Install the gas...

Страница 74: ...ooling system is being filled air pockets may develop therefore run the engine for five minutes after the initial fill shut the engine off and then fill the cool ing system to the bottom of the stand...

Страница 75: ...en at 80 84 C 176 183 F D If the thermostat does not open it must be replaced 3 Inspect all coolant hoses connections and clamps for deterioration cracks and wear NOTE All coolant hoses and clamps sho...

Страница 76: ...urely then tighten the remaining cap screws to 20 ft lb 4 Fill the engine transmission with the proper amount of recommended oil 5 Fill the cooling system with the proper amount of recommended coolant...

Страница 77: ...ts NOTE Refer to all warnings and cautions provided with the battery or battery maintainer charger Loss of battery charge may be caused by ambient tem perature ignition OFF current draw corroded termi...

Страница 78: ...its capacity at which time the Maintenance Charge Indicator D will illuminate NOTE For optimal charge and performance leave the charger connected to the battery for a minimum 1 hour after the Mainten...

Страница 79: ...gh ten sion lead then remove the timing inspection plug from the left side crankcase cover 2 Using the Tachometer start the engine and run at 1500 RPM ignition timing should be 10 BTDC 3 Install the t...

Страница 80: ...n 2 Connect the one lead to the brown lavender wire then connect the other tester lead to the black white wire 3 With the switch in the OFF position the meter must show an open circuit 4 With the swit...

Страница 81: ...an should operate KC270A NOTE Fan motor resistance checks are not recom mended Resistance values change with the motor commutator position Front Drive Actuator NOTE With the engine stopped and the ign...

Страница 82: ...the wiring harness side of the connectors 2 Connect the black tester lead of the meter to the black wire then with the tester in the DC Volts posi tion connect the red tester lead to the white brown...

Страница 83: ...CK UP relay ignition switch or the main wiring harness Power Distribution Module PDM A number of fuses and relays are located in the power distribution module in front of the steering post under the r...

Страница 84: ...te wire pin then con nect the red positive test lead to the other white wire pin 3 With the meter in the OHMS position the reading should be between 6 7 10 1 ohms NOTE If the meter does not read as sp...

Страница 85: ...d gas tank cover 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...

Страница 86: ...for normal oper ation Check for any fuel leaks 6 Install the side panels and gas tank cover ENGINE COOLANT TEMPERATURE ECT SENSOR NOTE Preliminary checks may be performed on this component using the d...

Страница 87: ...osition The multimeter should read approximately 5 DC volts If correct voltage is not indicated check the main relay and 10 amp ignition fuse wiring harness or the igni tion switch 3 Remove the red te...

Страница 88: ...he Test Harness must be plugged into the analyzer for testing voltage Always verify battery voltage is at least 4 9 DC volts before testing TPS Testing 1 Remove the left side engine cover then disconn...

Страница 89: ...es for a total of three tests 3 The meter reading must be within specification Regulator Rectifier The regulator rectifier is located under the radiator elec trical access panel TESTING 1 Start engine...

Страница 90: ...th the nut Tighten to 8 ft lb 3 Connect the battery 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 t...

Страница 91: ...e and Set buttons together for approximately 10 seconds after which the letters dIAg will appear on the LCD momen tarily followed by COOL EFI002A NOTE The display on the gauge will display in SAE spee...

Страница 92: ...the fuel level sensor measured in ohms DTC C1400 Usage Check output of the fuel level sensor 1 Full fuel is indicated by a reading of 86 100 ohms 2 Empty is indicated by a reading of 0 5 ohms 110 500...

Страница 93: ...cranking 10 5 11 5 VDC DIAGNOSTIC TROUBLE CODES DTC If an EFI or related chassis component fails or an out of tolerance signal is detected by the ECM a diagnostic trouble code DTC will be generated in...

Страница 94: ...ttent Erratic Sensor or interconnect harness intermittent Correct condition P0340 Camshaft Angle Sensor Synchronization Sensor or interconnect harness intermittent Correct condition P0341 Camshaft Ang...

Страница 95: ...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 reg...

Страница 96: ...an be heard each time the front drive selec tor switch is shifted If no sound is heard see Electrical System If the actuator runs constantly or makes squeal ing or grinding sounds the actuator must be...

Страница 97: ...ie 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...

Страница 98: ...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...

Страница 99: ...Remover remove the input shaft seal Account for a spacer 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 KX21...

Страница 100: ...mp and the rear boot with an appropriate boot clamp CD112 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 ne...

Страница 101: ...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...

Страница 102: ...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 exist...

Страница 103: ...him 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...

Страница 104: ...nd 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 w...

Страница 105: ...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...

Страница 106: ...hous ing CC901 NOTE Prior to installing the seal apply High Per formance 2 Molybdenum Disulfide Grease to the seal outside diameter 4 Using an appropriate seal installation tool evenly press the seal...

Страница 107: ...Remove the ATV from the support stand Drive Axles REMOVING REAR DRIVE AXLE 1 Secure the ATV on a support stand to elevate the wheels 2 Pump up the hand brake then engage the brake lever lock 3 Remove...

Страница 108: ...lever lock 5 Tighten the hub hex nuts from step 3 to 200 ft lb then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut 6 Install the wheels and using a crissc...

Страница 109: ...the nut NOTE During assembly new cotter pins should be installed 3 Remove the flange nut securing the hub 4 Remove the brake caliper KC283 5 Remove the hub assembly 6 Remove the four cap screws securi...

Страница 110: ...ll quicken the draining process AF637D 2 Place an absorbent towel around the connection to absorb brake fluid Remove the banjo fitting bolt from the master cylinder Account for two crush washers and a...

Страница 111: ...E If brake pads are to be returned to service do not allow brake fluid to contaminate them PR237A PR238 5 Remove the caliper holder from the caliper and dis card the O ring PR239B NOTE The O ring is u...

Страница 112: ...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 brake caliper housing an...

Страница 113: ...the reservoir then bleed the brake system see Periodic Maintenance Tune Up 9 Install the wheels and using a crisscross pattern tighten the wheel nuts in 20 ft lb increments to a final torque of 40 ft...

Страница 114: ...coupling 4 Replace joint 5 Replace gear s 6 Replace gears 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 fl...

Страница 115: ...hock absorber assembly must be replaced INSTALLING 1 Place 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 th...

Страница 116: ...re 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 s...

Страница 117: ...guard to the lower A arm with the two cap screws Tighten securely 12 Install the wheels and using a crisscross pattern tighten the wheel nuts in 20 ft lb increments to a final torque of 40 ft lb stee...

Страница 118: ...he smallest circumference measurement 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 damag...

Страница 119: ...118 NOTES...

Страница 120: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2260 667 Effective Date September 2015 2015 Arctic Cat Inc...

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