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2012 Arctic Cat 450 and 1000 ATV service and repair manual

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Service manual for the 2012 Arctic Cat 450 and 1000 ATVs.

Manual is broken down into the following sections:

General Information ............................................................. 2
General Specifications............................................................ 2
Torque Specifications ............................................................. 3
Torque Conversions (ft-lb/N-m)............................................... 4
Break-In Procedure ................................................................ 4
Gasoline - Oil - Lubricant........................................................ 4
Genuine Parts......................................................................... 5
Preparation For Storage ......................................................... 5
Preparation After Storage....................................................... 6
Periodic Maintenance .......................................................... 7
Periodic Maintenance Chart ................................................... 7
Lubrication Points ................................................................... 8
Air Filter .................................................................................. 8
Valve/Tappet Clearance.......................................................... 9
Testing Engine Compression................................................ 10
Spark Plug............................................................................ 10
Liquid Cooling System.......................................................... 11
Muffler/Spark Arrester .......................................................... 11
Adjusting Throttle Cable ....................................................... 11
Adjusting Engine RPM (Idle) ................................................ 12
Engine/Transmission Oil - Filter ........................................... 12
Front Differential/Rear Drive Lubricant ................................. 13
Tires...................................................................................... 13
Driveshaft/Coupling .............................................................. 14
Nuts/Bolts/Cap Screws......................................................... 14
Ignition Timing ...................................................................... 14
Lights .................................................................................... 14
Shift Lever............................................................................. 16
Frame/Welds/Racks.............................................................. 16
Hydraulic Brake Systems...................................................... 16
Burnishing Brake Pads ......................................................... 18
Checking/Replacing V-Belt .................................................. 18
Engine/Transmission.......................................................... 21
Troubleshooting .................................................................... 22
Removing Engine/Transmission ........................................... 24
Top-Side Components .......................................................... 25
Removing Top-Side Components......................................... 26
Servicing Top-Side Components .......................................... 29
Installing Top-Side Components........................................... 36
Left-Side Components.......................................................... 39
Removing Left-Side Components......................................... 40
Servicing Left-Side Components.......................................... 42
Installing Left-Side Components........................................... 44
Right-Side Components ....................................................... 46
Removing Right-Side Components ...................................... 46
Servicing Right-Side Components........................................ 49
Installing Right-Side Components ........................................ 50
Center Crankcase Components ........................................... 52
Separating Crankcase Halves .............................................. 52
Disassembling Crankcase Half............................................. 53
Servicing Center Crankcase Components ........................... 54
Assembling Crankcase Half.................................................. 59
Joining Crankcase Halves .................................................... 61
Installing Engine/Transmission ............................................. 62
Fuel/Lubrication/Cooling .................................................... 64
Electronic Fuel Injection ....................................................... 64
Throttle Body ........................................................................ 64
Throttle Cable Free-Play....................................................... 64
Gas Tank .............................................................................. 65
Oil Filter/Oil Pump ................................................................ 66
Testing Oil Pump Pressure ................................................... 66
Liquid Cooling System ..........................................................67
Electric Fuel Pump/Fuel Level Sensor ..................................69
Troubleshooting.....................................................................71
Electrical System................................................................72
Electrical Connections...........................................................72
Battery...................................................................................72
RPM Limiter ..........................................................................73
Testing Electrical Components..............................................73
Accessory Receptacle/Connector .........................................73
Brakelight Switch (Pressure) .................................................73
Fan Motor ..............................................................................74
Fuse Block/Power Distribution Module..................................75
Ignition Coil ...........................................................................75
Speed Sensor .......................................................................76
Ignition Switch.......................................................................77
Handlebar Control Switches..................................................77
Front Drive Selector Switch...................................................78
Front Drive Selector Actuator ................................................78
Gear Position Switch .............................................................78
Stator Coil .............................................................................79
Starter Relay .........................................................................79
Starter Motor .........................................................................80
Electronic Control Unit (ECU) ...............................................80
Regulator/Rectifier ................................................................80
Lights.....................................................................................81
Ignition Timing.......................................................................82
Tilt Sensor .............................................................................82
Throttle Position Sensor (TPS)..............................................83
Diagnostic Trouble Codes (DTC) ..........................................85
Troubleshooting.....................................................................87
Drive System ......................................................................88
Front Drive Actuator ..............................................................88
Front Differential....................................................................89
Drive Axles ............................................................................99
Rear Gear Case..................................................................101
Hub......................................................................................101
Hand Brake Lever/Master Cylinder Assembly.....................102
Hydraulic Brake Caliper.......................................................102
Troubleshooting Drive System.............................................105
Troubleshooting Brake System............................................106
Suspension.......................................................................107
Shock Absorbers.................................................................107
Front A-Arms.......................................................................107
Rear A-Arms .......................................................................108
Wheels and Tires ................................................................109
Troubleshooting...................................................................110
Steering/Frame/Controls ..................................................111
Steering Post/Tie Rods .......................................................111
LCD Gauge .........................................................................112
Handlebar Grip....................................................................113
Throttle Control ...................................................................113
Steering Knuckles ...............................................................114
Measuring/Adjusting Toe-Out..............................................116
Front Rack...........................................................................116
Front Bumper Assembly (acprc)................................................117
Front Body Panel/Fender ....................................................117
Exhaust System..................................................................118
Rear Body Panel/Rack ........................................................119
Seat.....................................................................................120
Troubleshooting...................................................................121


Book marked chapters for easy navigation allowing you to identify exact repair service procedures in the quickest time possible.

Notes, cautions and warnings throughout each chapter pinpoint critical service information.

Numbered instructions guide you through every repair procedure in a step-by-step fashion.

Bold figured numbers help you quickly match illustrations with instructions.

Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure.

Numbered table of contents easy to use so that you can find the information you need fast.

Manual Language: English
File Format: PDF
File Delivery: PDF (Instant Download)
Pages:210

To purchase this repair manual just click on the green instant download button at the upper right hand corner of this page. After purchasing just download it to your computer to save it and print pages from it whenever you need it.

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