Arctic Cat XC 450 2016 User Manual

www.arcticcat.com
SERVICE MANUAL
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Arctic Cat XC 450 2016 Specifications

General

Brand	Arctic Cat
Model	XC 450 2016
Category	Offroad Vehicle
Language	English

Summary

General Information and Specifications

General Information and Foreword

Introduction to the service manual and its purpose for the 2015 Arctic Cat XC 450 ATV.

Specifications Overview

Key technical specifications for the ATV, including chassis, engine, and electrical systems.

Torque Specifications and Fluid Recommendations

Torque Specifications Breakdown

Detailed torque values for various ATV components across multiple systems.

Torque Conversions

Converts torque values between foot-pounds (ft-lb) and Newton-meters (N-m).

Fluid Recommendations

Recommended gasoline, engine oil, and differential/rear drive lubricants for the ATV.

Storage and Preparation Procedures

Preparation for Storage

Procedure for properly preparing the ATV for extended storage to prevent damage.

Preparation After Storage

Procedure for correctly preparing the ATV after it has been in storage.

Periodic Maintenance and Tune-Up

Periodic Maintenance Overview

Routine maintenance and tune-up procedures, including tightening and lubrication.

Air Filter Cleaning and Inspection

Step-by-step guide for cleaning and inspecting the air filter element.

Valve and Tappet Clearance Adjustment

Procedure for checking and adjusting valve/tappet clearance for optimal engine performance.

Engine Testing and Component Service

Engine Compression Testing

Procedure for testing engine compression using a compression tester.

Spark Plug Inspection and Gap

Information on spark plug condition and proper gap setting for ignition.

Muffler and Spark Arrester Maintenance

Procedure for cleaning the muffler and spark arrester assembly.

Throttle Cable Adjustment

Steps to adjust the throttle cable free-play for proper throttle response.

Fluid Service and Driveshaft Inspection

Engine and Transmission Oil Change

Procedure for changing the engine/transmission oil and filter.

Differential and Drive Lubricant Service

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

Driveshaft and Coupling Inspection

Periodic inspection of driveshaft and coupling for proper operation.

Shift Lever Adjustment and Brake System

Shift Lever Adjustment Procedure

Checking and adjusting the shift lever linkage for correct gear indication.

Hydraulic Brake System Checks

Procedure for checking fluid levels and bleeding the hydraulic brake system.

Brake Pad Inspection and Replacement

How to check and replace brake pads based on thickness.

Brake Pad Burnishing and V-Belt Service

Brake Pad Burnishing Procedure

Procedure for burnishing new brake pads to ensure full braking effectiveness.

V-Belt Checking and Replacement

Procedure for removing, checking, and installing the V-belt.

Steering, Body, and Fender Service

Steering and Body Component Inspection

Periodic inspection of steering and body components for safe operation.

Front Body Panel and Fender Service

Procedure for removing, cleaning, inspecting, and installing the front body panel.

Body Panel and Steering Post Service

Rear Body Panel Service

Procedure for removing, cleaning, inspecting, and installing the rear body panel.

Steering Post and Tie Rod Service

Procedure for removing, cleaning, inspecting, and installing the steering post and tie rods.

Handlebar Grip and Gauge Replacement

Handlebar Grip Service

Procedure for removing and installing handlebar grips.

Speedometer and LCD Gauge Replacement

Procedure for replacing the speedometer or LCD gauge unit.

Throttle Control and Steering Knuckles

Throttle Control Service

Procedure for removing and installing the throttle control assembly.

Steering Knuckle Service

Procedure for removing, disassembling, cleaning, inspecting, and installing steering knuckles.

Front Wheel Alignment and Bumper

Front Wheel Alignment Procedure

Procedure for checking and adjusting the front wheel alignment (toe-out).

Front Bumper Assembly Service

Procedure for removing and installing the front bumper support tubes.

Exhaust System and Seat Service

Exhaust System Muffler Service

Procedure for removing, inspecting, and installing the muffler.

Seat Removal and Installation

Procedure for removing and installing the ATV seat.

Lighting System Service

Headlight Bulb Replacement

Procedure for replacing headlight bulbs.

Taillight and Brakelight Bulb Replacement

Procedure for replacing taillight and brakelight bulbs.

Running Light Bulb Replacement

Procedure for replacing running light bulbs.

Back-Up Light Bulb Replacement

Procedure for replacing back-up light bulbs.

Headlight Aiming and Troubleshooting

Headlight Aim Adjustment

Procedure for adjusting the aiming of the headlights.

General Troubleshooting Guide

Troubleshooting common issues related to steering, handling, and tire wear.

Engine Troubleshooting

Engine Starting Problems

Troubleshooting engine starting issues related to compression, spark, and fuel.

Engine Performance Issues

Troubleshooting engine stalling, noise, and performance problems.

Engine Overheating and Smoke

Troubleshooting engine overheating, exhaust smoke, and power loss.

Engine and Transmission Removal

Engine/Transmission Removal Procedure

Procedure for removing the engine and transmission assembly from the ATV frame.

Top-Side Component Service

Removing Top-Side Components Overview

Steps to remove top-side engine components like cylinder head cover.

Cylinder Head Cover and Rocker Arm Removal

Procedure for removing the cylinder head cover and rocker arms.

Cylinder Head and Camshaft Removal

Procedure for removing the cylinder head and camshaft assembly.

Top-Side Component Disassembly

Camshaft Tensioner and Cylinder Head Removal

Steps for removing camshaft tensioner, cylinder head cap screws, and cylinder head.

Cylinder and Piston Service

Cylinder Removal Procedure

Steps for removing the cylinder from the crankcase.

Piston Removal Procedure

Steps for removing the piston pin and piston.

Valve Assembly Service

Procedures for inspecting and servicing valve assembly components.

Cylinder Head and Piston Service Details

Cylinder Head Cover Cleaning and Inspection

Procedure for cleaning and inspecting the cylinder head cover.

Valve Removal Procedure

Steps for removing valve springs, keepers, and valves.

Valve Guide Bore Measurement

Procedure for measuring the valve guide bore diameter.

Valve, Piston, and Ring Service

Valve, Guide, and Seat Servicing

Instructions for servicing valves, guides, and seats.

Piston Inspection

Procedure for inspecting the piston for cracks, scuffing, and blowby.

Piston Ring Removal

Steps for removing piston rings from the piston.

Piston Ring End Gap Measurement

Procedure for measuring piston ring end gap.

Piston and Cylinder Measurements

Piston Pin and Connecting Rod Measurements

Procedures for measuring piston pin, connecting rod small end, and pin bore.

Piston Skirt and Cylinder Clearance

Procedure for measuring piston skirt to cylinder clearance.

Piston Ring Installation

Steps for installing piston rings onto the piston.

Cylinder Head and Cylinder Service

Cylinder Head Cleaning and Inspection

Procedure for cleaning and inspecting the cylinder head.

Cylinder Head Distortion Measurement

Procedure for measuring cylinder head distortion.

Cylinder Cleaning and Inspection

Procedure for cleaning and inspecting the cylinder.

Cylinder Service and Camshaft Inspection

Cylinder Cleaning, Inspection, and Honing

Procedure for cleaning, inspecting, and honing the cylinder bore.

Cam Chain Guide Inspection

Procedure for inspecting the cam chain guide for damage.

Camshaft Measurements and Inspection

Camshaft Runout Measurement

Procedure for measuring camshaft runout.

Camshaft Lobe Height Measurement

Procedure for measuring camshaft lobe height.

Camshaft Bearing Journal Inspection

Procedure for inspecting camshaft bearing journals.

Camshaft Spring and Drive Pin Inspection

Procedure for inspecting camshaft spring and drive pin.

Top-Side Component Installation

Piston Installation

Steps for installing the piston onto the connecting rod.

Cylinder Installation

Steps for installing the cylinder onto the crankcase.

Top-Side Component Installation Procedures

Cylinder Head and Camshaft Installation

Steps for installing the cylinder head, camshaft, and related components.

Top-Side Component Installation Details

Camshaft and Tensioner Guide Installation

Steps for installing camshaft, tensioner guides, and securing cylinder head.

Left-Side Component Service

Removing Left-Side Components Overview

Steps to remove the water pump, speed sensor, and magneto cover.

Rotor/Flywheel, Starter Clutch, and Motor Removal

Steps for removing the rotor/flywheel, starter clutch, and starter motor.

Left-Side Component Service Details

Shift Shaft and Drive Gear Removal

Procedure for removing the shift shaft and drive gear.

Starter Clutch and Gear Inspection

Procedure for inspecting the starter clutch and gear for wear or damage.

Starter Assembly and Bearing Service

Starter Clutch/Gear Inspection

Procedure for inspecting the one-way bearing.

Starter Clutch Assembly Replacement

Steps to replace the starter clutch assembly.

Starter Gear Bearing Replacement

Steps to replace the starter gear bearing.

Stator, Magneto Cover, and Bearing Service

Stator/Magneto Cover Assembly Inspection

Procedure for inspecting the stator and magneto cover assembly.

Stator Coil and Crankshaft Sensor Replacement

Steps to replace the stator coil and crankshaft position sensor.

Magneto Cover Bearing Replacement

Steps to replace the magneto cover bearings.

Left-Side Component Installation

Starter Clutch/Gear and Rotor/Flywheel Installation

Steps for installing the starter clutch gear and rotor/flywheel.

Left and Right-Side Component Installation

Magneto Cover Installation

Steps for installing the magneto cover.

Water Pump Installation

Steps for installing the water pump assembly.

Right-Side Component Removal

V-Belt Cover Removal

Steps to remove the V-belt cover.

Driven Pulley Assembly Removal

Steps to remove the driven pulley assembly.

Clutch Cover Removal

Steps to remove the clutch cover.

Right-Side Component Removal Details

Centrifugal Clutch Assembly Removal

Procedure for removing the centrifugal clutch assembly.

Oil Pump Drive and Driven Gear Removal

Procedure for removing the oil pump drive and driven gears.

Right-Side Component Inspection

Centrifugal Clutch Shoe Inspection

Procedure for inspecting the centrifugal clutch shoes.

Centrifugal Clutch Housing Inspection

Procedure for inspecting the centrifugal clutch housing.

Primary One-Way Drive Inspection

Procedure for inspecting the primary one-way drive mechanism.

Oil Pump Inspection

Procedure for inspecting the oil pump for damage.

Right-Side Component Installation

Oil Strainer and Oil Pump Installation

Steps for installing the oil strainer and oil pump.

Right-Side Component Installation Details

Clutch Cover Installation

Steps for installing the clutch cover assembly.

Drive Face Installation

Steps for installing the fixed and movable drive faces.

Center Crankcase Components Overview

Separating Crankcase Halves

Steps to separate the crankcase halves.

Disassembling Crankcase Half

Steps to disassemble the crankcase half, identifying components.

Center Crankcase Component Disassembly

Disassembling Crankshaft and Gear Assemblies

Steps to remove secondary driven shaft, reverse idler, driveshaft, and gear shift shaft.

Secondary Gear Service Procedures

Secondary Gear Backlash Checking

Procedure for measuring backlash of the secondary driven output shaft.

Secondary Gear Backlash Correction

Steps to correct backlash by adjusting shim thickness.

Secondary Gear Tooth Contact Checking

Procedure for checking tooth contact pattern of secondary driven bevel gear.

Crankshaft and Connecting Rod Measurements

Secondary Gear Tooth Contact Correction

Steps to correct tooth contact pattern using shims.

Crankshaft Assembly Overview

Overview of crankshaft assembly and its non-serviceable nature.

Connecting Rod Measurements

Procedures for measuring connecting rod small end inside diameter.

Crankshaft and Connecting Rod Measurements

Connecting Rod Deflection and Side-to-Side Measurement

Procedures for measuring connecting rod deflection and side-to-side clearance.

Crankshaft Runout Measurement

Procedure for measuring crankshaft runout.

Crankshaft and Countershaft Measurements

Crankshaft Web-to-Web Measurement

Procedure for measuring crankshaft web-to-web distance.

Countershaft Disassembly

Steps for disassembling the countershaft components.

Countershaft Assembly and Crankcase Assembly

Countershaft Assembly

Steps for assembling the countershaft components.

Crankcase Half Assembly

Steps for assembling the crankcase half, including output shaft and crankshaft.

Crankcase Assembly and Joining

Crankcase Assembly Steps

Steps for installing crankshaft, balancer shaft, shift cam forks, and countershaft.

Joining Crankcase Halves

Steps for joining the crankcase halves after assembly.

Engine and Transmission Installation

Engine/Transmission Installation Procedure

Procedure for installing the engine assembly into the ATV frame.

Engine Installation Connections

Engine Installation Connections and Systems

Steps for connecting coolant hoses, intake, exhaust, and electrical components.

Fuel, Lubrication, and Cooling System

Fuel System Troubleshooting

Troubleshooting common issues related to the fuel system.

Throttle Body Service

Procedure for removing and installing the throttle body.

Throttle Body and Gas Tank Service

Throttle Body Installation and Synchronization

Steps for installing the throttle body and synchronizing EFI system.

Gas Tank Removal

Steps to remove the gas tank assembly from the ATV.

Gas Tank and Oil Pump Service

Gas Tank Cleaning and Installation

Instructions for cleaning and inspecting gas tank components.

Oil Pump Pressure Testing

Procedure for testing the oil pump pressure.

Liquid Cooling System Service

Cooling System Checking and Filling

Procedure for checking and filling the liquid cooling system.

Radiator Removal and Inspection

Procedure for removing and inspecting the radiator.

Cooling System, Thermostat, and Water Pump

Radiator Cleaning and Installation

Procedure for cleaning and installing the radiator assembly.

Thermostat Service

Procedure for removing, inspecting, and installing the thermostat.

Water Pump Removal and Installation

Procedure for removing and installing the water pump.

General Troubleshooting

Basic Performance Troubleshooting

Troubleshooting starting, idling, and mid-to-high speed performance issues.

Electrical System Overview

Electrical System Testing Guidelines

General guidelines for testing electrical components using meters.

Battery Maintenance and Charging

Maintenance and charging procedures for the vehicle battery.

Ignition Switch and Battery Charging

Battery Charging Procedures

Detailed charging procedures for the CTEK Multi US 800/3300 chargers.

Ignition Switch Voltage and Resistance Tests

Procedures for testing the ignition switch's voltage and resistance.

Ignition Coil and Timing Verification

Ignition Coil Resistance Test

Procedure for testing the resistance of the ignition coil primary winding.

Ignition Timing Verification

Procedure for verifying ignition timing with a timing light.

Accessory Receptacle/Connector Voltage Test

Procedure for testing voltage at the accessory receptacle or connector.

Switch Testing Procedures

Brakelight, Hi/Lo Beam, and Engine Stop Switch Tests

Testing voltage and resistance of various switches: Brakelight, Hi/Lo Beam, Engine Stop.

Reverse Override and Drive Select Switch Tests

Testing resistance and voltage for Reverse Override and Drive Select switches.

Lighting System Voltage Tests

Headlight, Running, Taillight, and Brakelight Voltage Tests

Testing voltage for headlights, running lights, taillights, and brakelights.

Fan Motor Operation Test

Procedure for testing the fan motor operation.

Front Drive Actuator Voltage Test

Procedure for testing the voltage of the front drive actuator.

Lighting and Electrical System Components

Back-Up Light Voltage Test

Testing voltage for back-up lights.

Power Distribution Module (PDM) and Relays

Description of the PDM, fuses, and relays, and how to test relays.

Electrical System Protection and EFI Sensors

Main Fuse Identification

Description of the main fuse and its location.

EFI Sensors and Components Overview

Overview of testing EFI sensors and components using CATT II or multimeter.

EFI Sensor Testing Procedures

Fuel Injector and Crankshaft Position Sensor Tests

Testing procedures for Fuel Injector, Crankshaft Position Sensor, and Oxygen Sensor.

EFI Sensor Testing Procedures (Continued)

TMAP Sensor and Fuel Pump/Level Sensor Tests

Testing procedures for TMAP Sensor, Electric Fuel Pump/Fuel Level Sensor.

Speed and Tilt Sensor Testing

Speed Sensor Testing

Testing procedures for Speed Sensor.

Tilt Sensor Testing

Testing procedures for Tilt Sensor.

Tilt and Throttle Position Sensor Service

Tilt Sensor Supply and Output Voltage Tests

Testing procedures for Tilt Sensor supply and output voltage.

Throttle Position Sensor (TPS) Adjustment

Procedure for verifying and adjusting the Throttle Position Sensor.

Throttle Position Sensor Adjustment

Throttle Position Sensor (TPS) Adjustment

Procedure for verifying and adjusting the Throttle Position Sensor.

Engine Speed Limiter and Stator Coil Tests

RPM Limiter Function

Description of the RPM limiter function and its effect.

Stator Coil Voltage and Resistance Tests

Procedures for testing stator coil voltage and resistance.

Regulator/Rectifier Voltage Test

Procedure for testing the regulator/rectifier output voltage.

Starter Motor Voltage Test

Procedure for testing the starter motor voltage.

Starter Motor, Relay, and ECM

Starter Motor Removal and Installation

Procedure for removing and installing the starter motor.

Starter Relay Testing

Procedure for testing the starter relay operation.

Electronic Control Module (ECM) Description

Description of the ECM and its non-serviceable nature.

EFI Diagnostic System Guide

EFI Diagnostic System Overview

Instructions for using the digital gauge as a diagnostic tool.

Diagnostic Modes for EFI System

Coolant, Fuel, and Tachometer Diagnostic Modes

Explanation of coolant, fuel, and tachometer diagnostic modes and their readings.

Speed and TPS Diagnostic Modes

Explanation of speed and TPS diagnostic modes and their readings.

MAP, Air Temp, Battery, and DTC Information

MAP, Air Temp, and Battery Diagnostic Modes

Explanation of MAP, air temp, and battery diagnostic modes and conditions.

Diagnostic Trouble Codes (DTC) Overview

Information on Diagnostic Trouble Codes generated by the ECM.

Diagnostic Trouble Code List

List of DTC codes, fault descriptions, possible causes, and fault recovery.

General Troubleshooting Guide

Ignition and Alternator Troubleshooting

Troubleshooting steps for spark issues, alternator charging, and starter problems.

Battery and Charging System Troubleshooting

Troubleshooting battery issues like sulfation, rapid discharge, and polarity.

Drive System Overview and Actuator Service

Drive System General Information

General information, specifications, and special tools for the drive system.

Front Drive Actuator Service

Procedure for removing and installing the front drive actuator.

Front Drive Actuator Installation

Front Drive Actuator Installation Steps

Steps for installing the front drive actuator onto the ATV.

Front Differential Removal and Input Shaft Service

Front Differential Removal

Steps to remove the front differential assembly from the ATV frame.

Input Shaft Disassembly

Steps to disassemble the input shaft of the front differential.

Input Shaft and Pinion Gear Service

Input Shaft Assembly

Steps to assemble the input shaft of the front differential.

Pinion Gear Disassembly

Steps to disassemble the pinion gear from the front differential.

Differential Shimming and Backlash Adjustment

Shim Selection Procedure

Procedure for selecting and installing shims for proper gear adjustment.

Ring Gear Backlash Measurement

Procedure for measuring and adjusting ring gear backlash.

Differential Backlash and End-Play Adjustment

Backlash Adjustment Steps

Steps to adjust backlash by adding or removing shims.

Ring Gear End-Play Measurement

Procedure for measuring and adjusting ring gear end-play.

Differential Components and Assembly

Ring Gear and Thrust Button Service

Procedure for removing, inspecting, and installing the ring gear and thrust button.

Thrust Button Shimming

Steps for installing and shimming the thrust button.

Differential Assembly Procedures

Differential Assembly Steps

Steps for assembling the differential assembly with shims and components.

Differential Bearing and Seal Service

Needle Bearing Removal

Procedure for removing the needle bearing from the housing.

Needle Bearing Installation

Procedure for installing a new needle bearing into the housing.

Axle Seal Removal and Installation

Procedure for removing and installing axle seals.

Differential Installation

Differential Installation Procedure

Steps for installing the differential assembly onto the ATV frame.

Drive Axle Service

Rear Drive Axle Removal

Steps to remove the rear drive axle from the ATV.

Rear Drive Axle Installation

Steps to install the rear drive axle into the ATV.

Front Drive Axle and Hub Service

Front Drive Axle Installation

Steps to install the front drive axle into the ATV.

Hub Assembly Service

Steps to remove, clean, inspect, and install the hub assembly.

Hub Nut Tightening and Wheel Installation

Hub Nut Tightening and Wheel Installation

Steps for tightening the hub nut and installing wheels.

Hand Brake Lever and Master Cylinder Service

Hand Brake Lever/Master Cylinder Service

Procedure for removing, inspecting, and installing the hand brake lever and master cylinder.

Hydraulic Brake Caliper Service

Hydraulic Brake Caliper Removal and Disassembly

Steps to remove and disassemble the hydraulic brake caliper.

Caliper Cleaning and Inspection

Instructions for cleaning and inspecting caliper components.

Caliper Assembly and Installation

Steps to assemble and install the hydraulic brake caliper.

Hydraulic Brake Caliper Installation Details

Caliper and Brake Pad Installation

Steps for installing the caliper onto the caliper holder and securing brake pads.

Hydraulic Brake Caliper Final Steps

Brake Caliper Final Assembly and Bleeding

Steps for bleeding the brake system and installing wheels.

Drive System and Brake System Troubleshooting

Drive System Power Transmission Troubleshooting

Troubleshooting power transmission issues in the drive system.

Brake System Troubleshooting Guide

Troubleshooting common brake system problems like poor braking and leaks.

Suspension System Overview

Suspension Component Inspection

Overview of suspension system components and periodic inspection.

Shock Absorber Service

Procedure for removing and installing shock absorbers.

Front A-Arm Service

Procedure for removing and installing front A-arms.

Suspension Component Service (Continued)

Front A-Arm Service Details

Procedure for cleaning, inspecting, and installing front A-arms.

Rear A-Arm Service

Procedure for removing and installing rear A-arms.

Wheels and Tires Service

Tire Size and Inflation Pressure

Information on tire size, inflation pressure, and wheel/tire service.

Tire Checking and Inflating

Procedure for checking and inflating tire pressure.

Wheel Service and Suspension Troubleshooting

Wheel Installation and Tire Inspection

Procedure for checking tire condition and handling adjustments.

Suspension Troubleshooting Guide

Troubleshooting common suspension issues like softness, stiffness, noise, and oscillation.