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2011 Arctic Cat 450XC ATV Service Manual – PDF DOWNLOAD
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2011 Arctic Cat 450XC ATV Service Manual
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Description
2011 Arctic Cat 450XC ATV Service Manual
DESCRIPTION:
2011 Arctic Cat 450XC ATV Service Manual
FOREWORD:
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arctic Cat 450 XC 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 photographs 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.
TABLE OF CONTENTS:
2011 Arctic Cat 450XC ATV Service Manual
FOREWORD..................................................................................... 1 TABLE OF CONTENTS ........................................................................... 2 General Information...................................................................... 3 General Specifications............................................................... 3 Torque Specifications................................................................ 3 Torque Conversions (ft-lb/N-m)....................................................... 4 Break-In Procedure................................................................... 4 Gasoline - Oil - Lubricant........................................................... 4 RECOMMENDED GASOLINE............................................................. 4 RECOMMENDED ENGINE/ TRANSMISSION OIL............................................. 4 RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT.............................. 5 FILLING GAS TANK................................................................. 5 Genuine Parts........................................................................ 5 Preparation For Storage.............................................................. 5 Preparation After Storage............................................................ 6 Periodic Maintenance..................................................................... 7 SPECIAL TOOLS........................................................................ 7 Periodic Maintenance Chart........................................................... 7 Lubrication Points................................................................... 8 Air Filter........................................................................... 8 CLEANING AND INSPECTING FILTER................................................... 8 CHECKING AND CLEANING DRAIN...................................................... 9 Valve/Tappet Clearance............................................................... 9 Feeler Gauge Procedure........................................................... 9 Valve Adjuster Procedure......................................................... 10 Testing Engine Compression........................................................... 10 Spark Plug........................................................................... 10 Liquid Cooling System................................................................ 11 Checking/Filling................................................................. 11 Muffler/Spark Arrester............................................................... 11 Adjusting Throttle Cable............................................................. 12 Adjusting Engine RPM (Idle).......................................................... 12 Engine/Transmission Oil - Filter..................................................... 12 Front Differential/Rear Drive Lubricant.............................................. 13 Tires................................................................................ 13 TIRE SIZES....................................................................... 13 TIRE INFLATION PRESSURE.......................................................... 13 Driveshaft/Coupling.................................................................. 14 Nuts/Bolts/Cap Screws................................................................ 14 Ignition Timing...................................................................... 14 Lights............................................................................... 14 HEADLIGHTS....................................................................... 14 TAILLIGHTS-BRAKELIGHTS........................................................... 14 RUNNING LIGHTS................................................................... 15 BACK-UP LIGHTS................................................................... 15 CHECKING/ADJUSTING HEADLIGHT AIM................................................. 16 Shift Lever.......................................................................... 16 CHECKING ADJUSTMENT.............................................................. 16 ADJUSTING........................................................................ 16 Frame/Welds.......................................................................... 17 Hydraulic Brake Systems.............................................................. 17 CHECKING/BLEEDING................................................................ 17 INSPECTING HOSES................................................................. 17 CHECKING/REPLACING PADS.......................................................... 18 Burnishing Brake Pads................................................................ 18 Checking/Replacing V- Belt........................................................... 18 REMOVING......................................................................... 18 INSTALLING....................................................................... 19 Engine/Transmission...................................................................... 22 SPECIAL TOOLS........................................................................ 22 Specifications....................................................................... 22 Troubleshooting...................................................................... 23 Removing Engine/ Transmission........................................................ 26 Top-Side Components.................................................................. 28 Removing Top-Side Components......................................................... 28 A. Cylinder Head Cover/ Rocker Arms B. Cylinder Head/Camshaft.................... 28 C. Cylinder D. Piston............................................................ 31 Servicing Top-Side Components........................................................ 31 VALVE ASSEMBLY................................................................... 32 Cleaning/Inspecting Cylinder Head Cover...................................... 32 Removing Valves.............................................................. 32 Measuring Valve Stem Runout.................................................. 32 Measuring Valve Stem Outside Diameter........................................ 33 Measuring Valve Face/Seat Width.............................................. 33 Measuring Valve Face Radial Runout........................................... 33 Measuring Valve Guide (Inside Diameter)...................................... 33 Servicing Valves/Valve Guides/Valve Seats.................................... 33 Measuring Rocker Arm (Inside Diameter)....................................... 33 Measuring Rocker Arm Shaft (Outside Diameter)................................ 33 Installing Valves............................................................ 33 PISTON ASSEMBLY.................................................................. 34 Cleaning/Inspecting Piston................................................... 34 Removing Piston Rings........................................................ 34 Cleaning/Inspecting Piston Ring Grooves...................................... 34 Measuring Piston-Ring End Gap (Installed).................................... 34 Measuring Piston Pin, Connecting Rod Small End, and Piston-Pin Bore.......... 34 Measuring Piston Skirt/ Cylinder Clearance................................... 35 Installing Piston Rings...................................................... 35 CYLINDER/CYLINDER HEAD ASSEMBLY.................................................. 35 Cleaning/Inspecting Cylinder Head............................................ 35 Measuring Cylinder Head Distortion........................................... 36 Cleaning/Inspecting Cylinder................................................. 36 Inspecting Cam Chain Guide................................................... 36 Honing Cylinder.............................................................. 36 Measuring Camshaft Runout.................................................... 37 Measuring Camshaft Lobe Height............................................... 37 Inspecting Camshaft Bearing Journal.......................................... 37 Measuring Camshaft to Cylinder Head Clearance................................ 37 Inspecting Camshaft Spring/Drive Pin......................................... 38 Installing Top-Side Components....................................................... 38 A. Piston B. Cylinder............................................................ 38 C. Cylinder Head/Camshaft D. Cylinder Head Cover/ Rocker Arms.................... 39 Left-Side Components................................................................. 42 Removing Left-Side Components........................................................ 42 A. Water Pump B. Speed Sensor C. Magneto Cover/Stator Assembly................... 42 D. Rotor/Flywheel E. Starter Clutch/Gear F. Starter Motor........................ 43 G. Shift Shaft H. Drive Gear..................................................... 43 Servicing Left-Side Components....................................................... 44 INSPECTING STARTER CLUTCH/ GEAR.................................................. 44 REPLACING STARTER CLUTCH ASSEMBLY................................................ 44 REPLACING STARTER GEAR BEARING................................................... 45 INSPECTING STATOR/MAGNETO COVER ASSEMBLY......................................... 45 REPLACING STATOR/CRANKSHAFT POSITION SENSOR...................................... 46 REPLACING MAGNETO COVER BEARINGS................................................. 46 Installing Left-Side Components...................................................... 46 A. Starter Clutch/Gear B. Rotor/Flywheel......................................... 46 C. Magneto Cover D. Water Pump................................................... 47 Right-Side Components................................................................ 48 Removing Right-Side Components....................................................... 48 A. V-Belt Cover B. Driven Pulley C. Clutch Cover................................. 48 D. Centrifugal Clutch Assembly E. Oil Pump Drive Gear F. Oil Pump Driven Gear.... 50 G. Oil Pump/Oil Strainer......................................................... 51 Servicing Right-Side Components...................................................... 51 INSPECTING CENTRIFUGAL CLUTCH SHOE............................................... 52 INSPECTING CENTRIFUGAL CLUTCH HOUSING............................................ 52 INSPECTING PRIMARY ONE-WAY DRIVE................................................. 52 INSPECTING OIL PUMP.............................................................. 52 DRIVEN PULLEY ASSEMBLY........................................................... 52 Installing Right-Side Components..................................................... 52 A. Oil Strainer/Oil Pump......................................................... 52 B. Clutch Cover C. Fixed Drive Face D. Movable Drive Face........................ 54 Center Crankcase Components.......................................................... 55 Separating Crankcase Halves.......................................................... 55 Disassembling Crankcase Half......................................................... 56 Servicing Center Crankcase Components................................................ 58 SECONDARY GEARS.................................................................. 58 Checking Backlash............................................................ 58 Correcting Backlash.......................................................... 58 Checking Tooth Contact....................................................... 58 Correcting Tooth Contact..................................................... 59 CRANKSHAFT ASSEMBLY.............................................................. 59 Measuring Connecting Rod (Small End Inside Diameter)......................... 59 Measuring Connecting Rod (Small End Deflection).............................. 59 Measuring Connecting Rod (Big End Side-to-Side).............................. 59 Measuring Crankshaft (Runout)................................................ 59 Measuring Crankshaft (Web-to- Web)........................................... 60 COUNTERSHAFT..................................................................... 60 Disassembling................................................................ 60 ASSEMBLING....................................................................... 61 Assembling Crankcase Half............................................................ 62 Joining Crankcase Halves............................................................. 65 Installing Engine/ Transmission...................................................... 66 Fuel/Lubrication/Cooling................................................................. 68 SPECIAL TOOLS........................................................................ 68 Electronic Fuel Injection............................................................ 68 TROUBLESHOOTING.................................................................. 68 Throttle Body........................................................................ 68 REMOVING......................................................................... 68 INSTALLING....................................................................... 68 Throttle Cable Free-Play............................................................. 69 Gas Tank............................................................................. 69 REMOVING......................................................................... 69 CLEANING AND INSPECTING.......................................................... 70 INSTALLING....................................................................... 70 Oil Filter/Oil Pump.................................................................. 70 Testing Oil Pump Pressure............................................................ 70 Liquid Cooling System................................................................ 71 RADIATOR......................................................................... 71 Removing..................................................................... 71 Cleaning and Inspecting...................................................... 71 Installing................................................................... 71 THERMOSTAT....................................................................... 71 Removing..................................................................... 71 Inspecting................................................................... 71 Installing................................................................... 72 WATER PUMP....................................................................... 72 Removing..................................................................... 72 Installing................................................................... 72 Electric Fuel Pump/Fuel Level Sensor................................................. 73 TESTING.......................................................................... 73 REMOVING......................................................................... 73 INSPECTING....................................................................... 74 INSTALLING....................................................................... 74 Troubleshooting...................................................................... 75 Electrical System........................................................................ 76 SPECIAL TOOLS........................................................................ 76 Specifications....................................................................... 76 Electrical Connections............................................................... 76 Battery.............................................................................. 76 RPM Limiter.......................................................................... 77 Testing Electrical Components........................................................ 77 Accessory Receptacle/ Connector...................................................... 77 VOLTAGE.......................................................................... 77 Brakelight Switch (Pressure)......................................................... 77 VOLTAGE (Wiring Harness Side).................................................... 77 RESISTANCE (Switch).............................................................. 78 Engine Coolant Temperature (ECT) Sensor.............................................. 78 Fan Motor............................................................................ 78 VOLTAGE (Main Harness Connector to Fan Motor).................................... 78 RESISTANCE (Fan Motor Connector)................................................. 78 Power Distribution Module (PDM)...................................................... 79 RELAYS........................................................................... 79 Ignition Coil........................................................................ 79 RESISTANCE....................................................................... 79 Primary Winding.............................................................. 79 Secondary Winding............................................................ 79 Spark Plug Cap............................................................... 79 Speed Sensor......................................................................... 80 Ignition Switch...................................................................... 80 VOLTAGE.......................................................................... 80 RESISTANCE....................................................................... 80 Handlebar Control Switches........................................................... 81 RESISTANCE (HI Beam)............................................................. 81 RESISTANCE (LO Beam)............................................................. 81 RESISTANCE (Emergency Stop)...................................................... 81 RESISTANCE (Reverse Override).................................................... 81 Front Drive Selector Switch.......................................................... 81 RESISTANCE....................................................................... 81 VOLTAGE.......................................................................... 81 Front Drive Selector Actuator........................................................ 82 VOLTAGE.......................................................................... 82 Gear Position Switch................................................................. 82 Stator Coil.......................................................................... 82 VOLTAGE (AC Generator - Regulated Output)........................................ 82 VOLTAGE (AC Generator Coil - No Load)............................................ 83 RESISTANCE (AC Generator Coil)................................................... 83 RESISTANCE (Crankshaft Position Sensor).......................................... 83 VOLTAGE (Crankshaft Position Sensor)............................................. 83 Starter Relay........................................................................ 83 Starter Motor........................................................................ 83 TESTING VOLTAGE.................................................................. 83 REMOVING......................................................................... 84 INSTALLING....................................................................... 84 Electronic Control Unit (ECU)........................................................ 84 Regulator/Rectifier.................................................................. 84 TESTING.......................................................................... 84 Lights............................................................................... 84 HEADLIGHTS - RUNNING LIGHTS...................................................... 84 Voltage (Headlights)......................................................... 85 Voltage (Running Lights)..................................................... 85 TAILLIGHTS - BRAKELIGHTS......................................................... 85 Voltage (Taillights)......................................................... 85 Voltage (Brakelights)........................................................ 85 BACK-UP LIGHTS................................................................... 85 Voltage...................................................................... 85 Ignition Timing...................................................................... 86 Diagnostic Trouble Codes (DTC)....................................................... 86 Code List........................................................................ 86 Tilt Sensor.......................................................................... 87 SUPPLY VOLTAGE................................................................... 87 OUTPUT VOLTAGE................................................................... 87 Throttle Position Sensor (TPS)....................................................... 88 INSPECTING....................................................................... 88 REMOVING......................................................................... 89 INSTALLING/ADJUSTING............................................................. 89 Troubleshooting...................................................................... 90 Drive System............................................................................. 92 GENERAL INFORMATION.................................................................. 92 SPECIAL TOOLS........................................................................ 92 Front Drive Actuator................................................................. 92 REMOVING......................................................................... 92 INSTALLING....................................................................... 92 Front Differential................................................................... 93 REMOVING DIFFERENTIAL............................................................ 93 Disassembling Input Shaft.................................................... 94 Assembling Input Shaft....................................................... 95 Disassembling Pinion Gear.................................................... 96 Shimming Procedure/Shim Selection............................................ 98 Backlash..................................................................... 98 Ring Gear End-Play........................................................... 99 RING GEAR/THRUST BUTTON.......................................................... 99 Removing..................................................................... 99 Inspecting................................................................... 99 Installing/Shimming.......................................................... 99 Assembling Differential Assembly.............................................100 Removing Needle Bearing......................................................101 Installing Needle Bearing....................................................101 Removing/Installing Axle Seal................................................102 INSTALLING DIFFERENTIAL..........................................................103 Drive Axles..........................................................................104 REMOVING REAR DRIVE AXLE.........................................................104 REMOVING FRONT DRIVE AXLE........................................................104 CLEANING AND INSPECTING..........................................................104 DISASSEMBLING AXLES..............................................................104 INSTALLING REAR DRIVE AXLE.......................................................104 INSTALLING FRONT DRIVE AXLE......................................................104 Rear Gear Case.......................................................................105 REMOVING.........................................................................105 INSTALLING.......................................................................105 Hub..................................................................................105 REMOVING.........................................................................105 CLEANING AND INSPECTING..........................................................106 INSTALLING.......................................................................106 Hand Brake Lever/Master Cylinder Assembly............................................106 REMOVING.........................................................................106 INSPECTING.......................................................................107 INSTALLING.......................................................................107 Hydraulic Brake Caliper..............................................................107 REMOVING/DISASSEMBLING...........................................................107 CLEANING AND INSPECTING..........................................................108 ASSEMBLING/INSTALLING............................................................108 Troubleshooting Drive System.........................................................110 Troubleshooting Brake System.........................................................110 Suspension...............................................................................111 Shock Absorbers......................................................................111 REMOVING.........................................................................111 INSTALLING.......................................................................111 Front A-Arms.........................................................................111 REMOVING.........................................................................111 CLEANING AND INSPECTING..........................................................112 INSTALLING.......................................................................112 Rear A-Arms..........................................................................112 REMOVING.........................................................................112 CLEANING AND INSPECTING..........................................................113 INSTALLING.......................................................................113 Wheels and Tires.....................................................................113 TIRE SIZE........................................................................113 TIRE INFLATION PRESSURE..........................................................113 REMOVING.........................................................................113 CLEANING AND INSPECTING..........................................................113 INSTALLING.......................................................................113 CHECKING/INFLATING...............................................................114 Troubleshooting......................................................................114 Steering/Frame...........................................................................115 Steering Post/Tie Rods...............................................................115 REMOVING.........................................................................115 CLEANING AND INSPECTING..........................................................115 INSTALLING.......................................................................116 Speedometer/LCD Gauge................................................................116 REPLACING........................................................................116 Handlebar Grip.......................................................................117 REMOVING.........................................................................117 INSTALLING.......................................................................117 Throttle Control.....................................................................117 REMOVING.........................................................................117 INSTALLING.......................................................................118 ADJUSTING........................................................................118 Steering Knuckles....................................................................118 REMOVING AND DISASSEMBLING.......................................................118 CLEANING AND INSPECTING..........................................................119 ASSEMBLING AND INSTALLING........................................................119 Measuring/Adjusting Toe- Out.........................................................119 Front Bumper Assembly................................................................120 REMOVING.........................................................................120 INSTALLING.......................................................................120 Front Body Panel/Fender..............................................................120 REMOVING.........................................................................120 CLEANING AND INSPECTING..........................................................121 INSTALLING.......................................................................121 Exhaust System.......................................................................121 REMOVING MUFFLER.................................................................121 INSPECTING MUFFLER...............................................................121 INSTALLING MUFFLER...............................................................121 Rear Body Panel......................................................................121 REMOVING.........................................................................121 CLEANING AND INSPECTING..........................................................122 INSTALLING.......................................................................122 Seat.................................................................................122 REMOVING/INSTALLING..............................................................122 Troubleshooting......................................................................123
2011 ARCTIC CAT 450XC ATV SERVICE MANUAL – PDF DOWNLOAD:
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