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Arctic Cat 450 2010 Service Manual

Arctic Cat 450 2010
149 pages
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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2010 Arc-
tic Cat 450 ATV. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific ATV 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.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV 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 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 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 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 products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2009 Arctic Cat Inc. November 2009
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Manual
Table of Contents
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

Table of Contents

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Arctic Cat 450 2010 Specifications

General IconGeneral
BrandArctic Cat
Model450 2010
CategoryOffroad Vehicle
LanguageEnglish

Summary

FOREWORD

Section 1 - General Information/Specifications

General Specifications

Details chassis, misc specifications, and fluid capacities for the ATV.

Torque Specification

Lists torque values for various components like exhaust, electrical, steering, and suspension parts.

Torque Conversions

Provides a conversion table for torque values from ft-lb to N-m.

Break-In Procedure

Outlines the recommended break-in period and procedures for a new or overhauled ATV.

Gasoline - Oil - Lubricant

Specifies recommended gasoline octane, engine oil type, and gear lube.

Preparation For Storage

Provides a step-by-step guide for preparing the ATV for storage.

Preparation After Storage

Details the procedure for correctly preparing the ATV after it has been stored.

SECTION 2 - PERIODIC MAINTENANCE

Periodic Maintenance Chart

A comprehensive schedule detailing maintenance tasks at various intervals.

Air Filter

Procedure for removing, cleaning, and inspecting the air filter element.

Valve/Tappet Clearance (Feeler Gauge Procedure)

Instructions for checking valve/tappet clearance using a feeler gauge.

Valve/Tappet Clearance (Valve Adjuster Procedure)

Instructions for adjusting valve/tappet clearance using a valve adjuster.

Testing Engine Compression

Procedure for testing the engine's compression using a tester kit.

Spark Plug

Guidance on spark plug inspection, gap adjustment, and installation.

Engine/Transmission Oil - Filter - Strainer

Steps for changing engine oil, filter, and inspecting the oil strainer.

Front Differential/Rear Drive Lubricant

Procedure for checking and changing lubricant in front differential and rear drive.

Headlights/Taillight-Brakelight

Procedures for replacing headlight and taillight/brakelight bulbs.

Shift Lever

Instructions for checking and adjusting the shift lever.

Frame/Welds/Racks

Inspection guidelines for the ATV frame, welds, and racks.

SECTION 3 - ENGINE/TRANSMISSION

Engine/Transmission Specifications

Detailed specifications for engine and transmission components.

Troubleshooting

Common problems and their remedies related to the engine and transmission.

Removing Engine/Transmission

Step-by-step instructions for removing the engine and transmission assembly.

Top-Side Components

Procedures for servicing top-side engine components.

Cylinder Head Cover/Rocker Arms

Steps for removing and servicing the cylinder head cover and rocker arms.

Cylinder Head/Camshaft

Procedure for removing the cylinder head and camshaft assembly.

PISTON ASSEMBLY

Details on piston and ring assembly, inspection, and measurement.

Installing Piston Rings

Correct procedure for installing piston rings onto the piston.

CYLINDER/CYLINDER HEAD ASSEMBLY

Procedures for cylinder and cylinder head cleaning, inspection, and measurement.

Measuring Cylinder Head Distortion

Method for measuring cylinder head flatness.

Measuring Camshaft Runout

Procedure for checking camshaft runout.

Servicing Valves/Valve Guides/Valve Seats

Guidance on servicing valve components, often requiring machine shop.

SECTION 4 - FUEL/LUBRICATION/COOLING

Fuel/Lubrication/Cooling

Overview of fuel, lubrication, and cooling system components.

Electronic Fuel Injection

Information on the EFI system, including troubleshooting.

Throttle Body

Details on throttle body components and the removal procedure.

Fuel Injector

Procedure for replacing the fuel injector.

Throttle Cable Free-Play

Instructions for adjusting the throttle cable free-play.

Gas Tank

Steps for removing and cleaning the gas tank and its components.

Testing Oil Pump Pressure

Procedure for testing the oil pump pressure.

Liquid Cooling System

Overview and procedures for the liquid cooling system.

RADIATOR

Instructions for removing and installing the radiator.

THERMOSTAT

Procedure for removing, inspecting, and installing the thermostat.

WATER PUMP

Instructions for removing and installing the water pump.

Electric Fuel Pump/Fuel Level Sensor

Procedure for testing and replacing the electric fuel pump and sensor.

Troubleshooting

Troubleshooting common fuel system issues.

SECTION 5 - ELECTRICAL SYSTEM

Electrical Connections

Guidance on checking electrical connections for proper function.

Battery

Procedures for battery cleaning, charging, and testing.

Testing Electrical Components

General guidelines and procedures for testing electrical components.

Accessory Receptacle/Connector

Testing voltage at the accessory receptacle or connector.

Brakelight Switch (Auxiliary)

Testing voltage and resistance of the auxiliary brakelight switch.

Engine Coolant Temperature (ECT) Sensor

Procedure for testing the resistance of the ECT sensor.

Power Distribution Module (PDM)

Procedure for checking fuses within the power distribution module.

Ignition Coil

Checking the resistance of the ignition coil.

EFI Sensors/Components

Overview and testing procedures for EFI sensors.

Speed Sensor

Procedure for testing speed sensor voltage and signal.

Ignition Switch

Procedure for testing the voltage of the ignition switch.

Handlebar Control Switches

Testing resistance of handlebar switches like headlight dimmer.

Drive Select Switch

Testing resistance and voltage of the drive select switch.

Front Drive/Differential Lock Actuator Power

Procedure for testing the voltage supply to the differential lock actuator.

Stator Coil/Crankshaft Position (CKP) Sensor

Testing stator coil AC generator output and CKP sensor.

Starter Relay

Procedure for testing the starter relay.

Starter Motor

Procedure for testing the starter motor voltage and operation.

Regulator/Rectifier

Procedure for testing the regulator/rectifier output voltage.

Headlights

Procedure for testing headlight voltage.

Taillight - Brakelight

Procedure for testing taillight and brakelight voltage.

Ignition Timing

Procedure for verifying ignition timing.

ECU Malfunction Codes

List and explanation of ECU malfunction codes.

Tilt Sensor

Procedure for testing the tilt sensor supply and output voltage.

Throttle Position Sensor (TPS)

Procedure for inspecting and testing the throttle position sensor.

Troubleshooting

Troubleshooting common electrical system problems.

SECTION 6 - DRIVE SYSTEM

Drive System

Overview of the drive system components.

Front Drive Actuator/Electronic Differential Lock

Procedure for removing and installing the front drive actuator.

Front Differential

Procedures for removing and servicing the front differential assembly.

Disassembling Input Shaft

Steps for disassembling the input shaft.

Assembling Input Shaft

Steps for assembling the input shaft.

Shimming Procedure/Shim Selection

Procedure for selecting and installing shims for gear cases.

Assembling Pinion Gear

Steps for assembling the pinion gear assembly.

Drive Axles

Procedures for removing and installing drive axles.

Hub

Procedures for removing and installing wheel hubs.

Hydraulic Brake Caliper

Procedure for removing, disassembling, cleaning, and installing brake calipers.

Troubleshooting Drive System

Troubleshooting common drive system issues.

SECTION 7 - SUSPENSION

Suspension

Overview of suspension system components to be inspected.

Shock Absorbers

Procedures for removing, cleaning, inspecting, and installing shock absorbers.

Front A-Arms

Procedures for removing, cleaning, inspecting, and installing front A-arms.

Rear A-Arms

Procedures for removing, cleaning, inspecting, and installing rear A-arms.

Wheels and Tires

Procedures for removing, installing, cleaning, and inspecting wheels and tires.

Troubleshooting

Troubleshooting common suspension and handling issues.

SECTION 8 - STEERING/FRAME

Steering/Frame

Overview of steering and frame components to be inspected.

Steering Post/Tie Rods

Procedures for removing, cleaning, inspecting, and installing steering post/tie rods.

Handlebar Grip

Procedure for removing and installing handlebar grips.

Steering Knuckles

Procedures for removing, disassembling, cleaning, and installing steering knuckles.

Measuring/Adjusting Toe-In

Procedure for measuring and adjusting front wheel toe-in.

Front Rack

Procedure for removing and installing the front rack.

Front Bumper Assembly

Procedure for removing and installing the front bumper assembly.

Front Body Panel/Side Panels

Procedure for removing front and side body panels.

Footrests

Procedures for removing, cleaning, inspecting, and installing footrests.

Belly Panel

Procedure for removing and installing the belly panel.

Exhaust System

Procedure for removing and inspecting the muffler.

Rear Body Panel/Rack

Procedures for removing, cleaning, inspecting, and installing rear body panel and rack.

Taillight Assembly

Procedures for removing, inspecting, and installing the taillight assembly.

Seat

Procedures for removing and installing the seat.

Troubleshooting

Troubleshooting common steering and handling issues.

SECTION 9 - CONTROLS/INDICATORS

Hand Brake Lever/Master Cylinder Assembly

Procedure for removing and inspecting the master cylinder assembly.

Throttle Control

Procedure for removing and installing the throttle control.

Shift Lever

Procedure for removing, installing, and adjusting the shift lever.

Speedometer/Tachometer/LCD

Procedure for replacing the speedometer, tachometer, and LCD.

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