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Arctic Cat XC 450i 2012 User Manual

Arctic Cat XC 450i 2012
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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2012 Arc-
tic Cat XC 450i 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.
© 2011 Arctic Cat Inc. August 2011
®™ 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

Questions and Answers:

Arctic Cat XC 450i 2012 Specifications

General IconGeneral
BrandArctic Cat
ModelXC 450i 2012
CategoryOffroad Vehicle
LanguageEnglish

Summary

FOREWORD

General Information

General Specifications

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

Cylinder, Piston, and Rings Specifications

Specifications for cylinder, piston, and ring dimensions and clearances.

Valves and Guides Specifications

Specifications for valve and guide dimensions and clearances.

Camshaft and Cylinder Head Specifications

Specifications for camshaft and cylinder head dimensions.

Torque Specifications

Component Torque Values

Torque specifications for various ATV components.

Break-In Procedure

Lubricant Recommendations

Gasoline, Oil, and Lubricant Guidelines

Recommendations for fuel, engine oil, and lubricants.

Front Differential/Rear Drive Lubricant

Specifications for front differential and rear drive lubricants.

Periodic Maintenance

Special Tools for Maintenance

Required special tools for periodic maintenance procedures.

Periodic Maintenance Chart

A chart detailing maintenance tasks and intervals.

Air Filter Service

Cleaning and Inspecting Air Filter

Procedure for cleaning and inspecting the air filter element.

Checking and Cleaning Air Filter Drain

Inspecting and cleaning the air filter housing drain.

Valve/Tappet Clearance

Valve Clearance Measurement and Adjustment

Measuring and adjusting valve tappet clearance.

Testing Engine Compression

Spark Plug Service

Liquid Cooling System Overview

Checking and Filling Cooling System

Procedure for checking and filling the cooling system.

Muffler/Spark Arrester Service

Adjusting Throttle Cable

Engine/Transmission Oil and Filter Service

Front Differential/Rear Drive Lubricant Service

Tires Information

Ignition Timing Verification

Lighting System Service

Headlight and Running Light Bulb Replacement

Replacing headlight and running light bulbs.

Taillight and Brakelight Bulb Replacement

Replacing taillight and brakelight bulbs.

Back-Up Light Bulb Replacement

Replacing back-up light bulbs.

Headlight Aim Adjustment

How to check and adjust headlight aim.

Shift Lever Operation

Frame and Welds Inspection

Hydraulic Brake Systems Service

Checking and Bleeding Brake System

Procedures for checking and bleeding hydraulic brake systems.

Inspecting Hydraulic Brake Hoses

Inspecting hydraulic brake hoses for damage.

Checking and Replacing Brake Pads

Checking and replacing brake pads.

Burnishing Brake Pads Procedure

V-Belt Service

V-Belt Removal and Installation

Steps for removing and installing the V-belt.

Engine/Transmission Service

Special Tools for Engine/Transmission

Special tools required for engine/transmission service.

Engine Troubleshooting

Engine Starting and Performance Problems

Diagnosing and fixing engine starting, performance, and noise issues.

Engine Overheating and Power Loss

Troubleshooting engine overheating, power loss, and smoke issues.

Removing Engine/Transmission

Top-Side Components Service

Removing Top-Side Components

Steps to remove top-side engine components.

Cylinder Head Cover, Rocker Arms, Head, and Camshaft Service

Servicing cylinder head cover, rocker arms, head, and camshaft.

Cylinder and Piston Service

Servicing the cylinder and piston.

Valve Assembly Service

Cylinder Head Cover Cleaning and Inspection

Cleaning and inspecting the cylinder head cover.

Valve Removal and Measurement

Removing valves and measuring stem runout.

Valve Stem and Guide Measurement

Measuring valve stem diameter and guide inside diameter.

Valve Face and Rocker Arm Measurement

Measuring valve face and rocker arm dimensions.

Servicing Valves, Guides, and Seats

Servicing valves, guides, and seats.

Installing Valves

Installing valve assembly components.

Piston Assembly Service

Piston, Rings, and Grooves Service

Cleaning, inspecting, and measuring piston, rings, and grooves.

Piston Pin and Connecting Rod Measurement

Measuring piston pin and connecting rod dimensions.

Installing Piston Rings

Procedures for installing piston rings.

Cylinder/Cylinder Head Assembly

Piston Skirt/Cylinder Clearance Measurement

Measuring clearance between piston skirt and cylinder.

Cylinder Head Cleaning and Distortion Measurement

Cleaning cylinder head and measuring distortion.

Cylinder Cleaning and Honing

Cleaning and honing the cylinder bore.

Cam Chain Guide Inspection

Inspecting the cam chain guide for damage.

Camshaft Service

Camshaft Bearing Journal and Clearance Measurement

Inspecting bearing journal and measuring camshaft clearance.

Camshaft Runout and Lobe Height Measurement

Measuring camshaft runout and lobe height.

Inspecting Camshaft Spring/Drive Pin

Inspecting camshaft spring and drive pin for damage.

Installing Top-Side Components

Piston and Cylinder Installation

Installing the piston and cylinder.

Cylinder Head/Camshaft and Cover Installation

Installing cylinder head, camshaft, and cover.

Left-Side Components Service

Removing Left-Side Components

Steps to remove left-side engine components.

Rotor, Flywheel, Starter Clutch, and Motor Removal

Removing rotor, flywheel, starter clutch, and starter motor.

Starter Clutch/Gear Inspection and Replacement

Inspecting and replacing starter clutch and gear.

Starter Gear Bearing and Stator/Magneto Cover Inspection

Inspecting starter bearing and stator/magneto cover.

Stator Coil/Crankshaft Sensor and Magneto Bearing Replacement

Replacing stator coil, crankshaft sensor, and magneto bearings.

Installing Left-Side Components

Starter Clutch/Gear and Rotor/Flywheel Installation

Installing starter clutch/gear and rotor/flywheel.

Magneto Cover and Water Pump Installation

Installing magneto cover and water pump.

Right-Side Components Service

Removing Right-Side Components

Steps to remove right-side engine components.

Clutch Assembly and Oil Pump Gears Removal

Removing centrifugal clutch and oil pump gears.

Oil Pump/Oil Strainer Service

Servicing the oil pump and oil strainer.

Centrifugal Clutch Shoe and Housing Inspection

Inspecting centrifugal clutch shoe and housing.

Primary One-Way Drive and Oil Pump Inspection

Inspecting primary one-way drive and oil pump.

Installing Right-Side Components

Oil Strainer/Oil Pump Installation

Installing the oil strainer and oil pump.

Center Crankcase Components Service

Separating Crankcase Halves

Steps to separate the crankcase halves.

Disassembling Crankcase Half

Procedures for disassembling a crankcase half.

Secondary Gears - Backlash and Tooth Contact Service

Servicing secondary gears for backlash and tooth contact.

Crankshaft Assembly Service

Connecting Rod Measurement

Measuring connecting rod dimensions and deflection.

Crankshaft Measurement

Measuring crankshaft runout and web-to-web distance.

Countershaft Service

Countershaft Disassembly and Assembly

Procedures for disassembling and assembling the countershaft.

Assembling Crankcase Half

Installing Engine/Transmission

Fuel/Lubrication/Cooling System

Special Tools for Fuel/Lubrication/Cooling

Special tools for fuel, lubrication, and cooling systems.

Electronic Fuel Injection System Troubleshooting

Troubleshooting the electronic fuel injection system.

Throttle Body Service

Steps to remove and install the throttle body.

Throttle Cable Adjustment

Adjusting throttle cable free-play.

Gas Tank Service

Steps to remove and install the gas tank.

Oil Filter and Oil Pump Service

Servicing oil filter and pump, including pressure testing.

Liquid Cooling System Service

Procedures for servicing the radiator and thermostat.

Water Pump Service

Removing and installing the water pump.

Electric Fuel Pump/Fuel Level Sensor Service

Fuel Pump/Sensor Testing, Removal, and Installation

Testing, removing, and installing the fuel pump and sensor.

Troubleshooting Fuel System

Common fuel system problems and their remedies.

Electrical System Service

Special Tools for Electrical Service

Special tools for electrical system service.

Electrical Connections Inspection

Inspecting electrical connections for proper function.

Battery Service

Procedures for battery maintenance and charging.

RPM Limiter Information

Information about the ATV's RPM limiter.

Testing Electrical Components

General guidelines for testing electrical components.

Main 30-Amp Fuse Check

Locating and checking the main 30-amp fuse.

Accessory Receptacle/Connector Test

Testing the accessory receptacle and connector.

Brakelight Switch Testing

Testing the brakelight switch for voltage and resistance.

Engine Coolant Temperature Sensor Testing

Testing the ECT sensor resistance at various temperatures.

Fan Motor Testing

Testing the fan motor for voltage and resistance.

Power Distribution Module (PDM), Relays, and Fuses

Information on the PDM, relays, and fuses.

Ignition Coil Testing

Testing the ignition coil resistance.

Spark Plug Cap Testing

Testing the spark plug cap resistance.

Speed Sensor Testing

Testing the speed sensor voltage and operation.

Ignition Switch Testing

Testing the ignition switch voltage and resistance.

Handlebar Control Switches Testing

Testing handlebar control switch resistance.

Drive Select Switch Testing

Testing drive select switch resistance and voltage.

Front Drive Actuator Service

Testing the front drive actuator voltage.

Gear Position Switch Service

Testing the gear position switch resistance.

Stator Coil Testing

Testing stator coil voltage and resistance.

Starter Relay Testing

Testing the starter relay.

Starter Motor Testing

Testing the starter motor voltage output.

ECU Service Information

Information on the Electronic Control Unit (ECU).

Regulator/Rectifier Testing

Testing the regulator/rectifier.

Lighting System Voltage Testing

Testing headlight and running lights voltage.

Ignition Timing and Diagnostic Trouble Codes

Ignition timing verification and DTC code list.

Tilt Sensor Service

Testing tilt sensor supply and output voltage.

Throttle Position Sensor (TPS) Service

Inspecting and testing TPS voltage.

Troubleshooting Electrical System

Spark, Ignition, and Plug Issues

Troubleshooting spark, ignition, and spark plug problems.

Alternator and Charging Issues

Troubleshooting alternator and charging system problems.

Starter and Battery Issues

Troubleshooting starter system and battery problems.

Drive System Service

General Information and Special Tools

General info on drive system and special tools.

Front Drive Actuator Service

Testing the front drive actuator voltage.

Front Differential Service

Removing front differential and disassembling input shaft.

Pinion Gear Service

Procedures for disassembling the pinion gear assembly.

Front Differential Service (Continued)

Servicing differential bearings and axle seals.

Drive Axles Service

Procedures for removing and installing drive axles.

Rear Gear Case Service

Steps to remove and install the rear gear case.

Hub Service

Steps to remove and install the wheel hub.

Hand Brake Lever/Master Cylinder Assembly Service

Procedures for removing and installing the hand brake lever/master cylinder.

Hydraulic Brake Caliper Service

Procedures for servicing the hydraulic brake caliper.

Troubleshooting Drive System

Troubleshooting Brake System

Suspension System Inspection

Shock Absorber Service

Procedures for removing and installing shock absorbers.

Front and Rear A-Arms Service

Procedures for removing front and rear A-arms.

Wheels and Tires Service

Wheel and Tire Inspection and Inflation

Inspecting and inflating wheels and tires.

Wheel and Tire Removal/Installation

Procedures for removing and installing wheels and tires.

Troubleshooting Suspension

Suspension Performance Issues

Diagnosing and fixing suspension stiffness or noise.

Rear Wheel Oscillation Troubleshooting

Troubleshooting rear wheel oscillation.

Steering/Frame/Controls Inspection

Steering Post and Tie Rods Service

Procedures for removing and installing steering post and tie rods.

Speedometer/LCD Gauge Service

Handlebar Grip Service

Throttle Control Service

Throttle Control Removal and Installation

Procedures for removing and installing the throttle control.

Steering Knuckles Service

Steering Knuckles Removal, Disassembly, Cleaning, and Assembly

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

Measuring/Adjusting Front Wheel Toe Out

Front Bumper Assembly Service

Front Body Panel/Fender Service

Front Body Panel/Fender Removal and Installation

Procedures for removing and installing the front body panel/fender.

Exhaust System Service

Rear Body Panel Service

Rear Body Panel Removal and Installation

Procedures for removing and installing the rear body panel/fender.

Seat Service

Troubleshooting Handling and Steering

Handling and Steering Performance Issues

Diagnosing and fixing handling, steering, tire wear, and noise problems.

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