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2012 Arctic Cat XC 450i ATV service and repair manual

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Service manual for the 2012 Arctic Cat XC 450i 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............................................. 5
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................................................ 10
Muffler/Spark Arrester ................................................ 11
Adjusting Throttle Cable ............................................. 11
Adjusting Engine RPM (Idle)....................................... 12
Engine/Transmission Oil - Filter ................................. 12
Front Differential/Rear Drive Lubricant ....................... 12
Tires............................................................................ 13
Driveshaft/Coupling .................................................... 13
Nuts/Bolts/Cap Screws............................................... 13
Ignition Timing ............................................................ 13
Lights .......................................................................... 14
Shift Lever................................................................... 16
Frame/Welds............................................................... 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 ................................................ 26
Removing Top-Side Components ............................... 26
Servicing Top-Side Components ................................ 29
Installing Top-Side Components ................................. 36
Left-Side Components................................................ 40
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 ................................. 53
Separating Crankcase Halves .................................... 53
Disassembling Crankcase Half................................... 54
Servicing Center Crankcase Components ................. 56
Assembling Crankcase Half........................................ 60
Joining Crankcase Halves .......................................... 63
Installing Engine/Transmission ................................... 63
Fuel/Lubrication/Cooling .............................................. 66
Electronic Fuel Injection ............................................. 66
Throttle Body .............................................................. 66
Throttle Cable Free-Play............................................. 67
Gas Tank..................................................................... 67
Oil Filter/Oil Pump....................................................... 68
Testing Oil Pump Pressure ......................................... 68
Electric Fuel Pump/Fuel Level Sensor ........................71
Troubleshooting...........................................................73
Electrical System.......................................................... 74
Electrical Connections.................................................74
Battery.........................................................................74
RPM Limiter ................................................................75
Testing Electrical Components....................................75
Main 30-Amp Fuse......................................................75
Accessory Receptacle/Connector ...............................75
Brakelight Switch (Pressure) .......................................76
Engine Coolant Temperature (ECT) Sensor................76
Fan Motor ....................................................................76
Power Distribution Module (PDM) ...............................77
Ignition Coil .................................................................77
Speed Sensor .............................................................78
Ignition Switch .............................................................78
Handlebar Control Switches........................................79
Drive Select Switch .....................................................79
Front Drive Actuator ....................................................80
Gear Position Switch ...................................................80
Stator Coil ...................................................................81
Starter Relay ...............................................................81
Starter Motor ...............................................................81
Electronic Control Unit (ECU)......................................82
Regulator/Rectifier ......................................................82
Lights...........................................................................82
Ignition Timing.............................................................84
Diagnostic Trouble Codes (DTC).................................84
Tilt Sensor ...................................................................86
Throttle Position Sensor (TPS)....................................87
Troubleshooting...........................................................89
Drive System................................................................. 91
Front Drive Actuator ....................................................91
Front Differential ..........................................................92
Drive Axles ................................................................103
Rear Gear Case ........................................................104
Hub............................................................................104
Hand Brake Lever/Master Cylinder Assembly ...........105
Hydraulic Brake Caliper.............................................106
Troubleshooting Drive System...................................109
Troubleshooting Brake System..................................109
Suspension.................................................................. 110
Shock Absorbers .......................................................110
Front A-Arms.............................................................110
Rear A-Arms .............................................................111
Wheels and Tires ......................................................112
Troubleshooting.........................................................113
Steering/Frame/Controls ............................................ 114
Steering Post/Tie Rods .............................................114
Speedometer/LCD Gauge.........................................115
Handlebar Grip..........................................................116
Throttle Control .........................................................116
Steering Knuckles .....................................................117
Measuring/Adjusting Toe-Out ....................................118
Front Bumper Assembly ............................................119
Front Body Panel/Fender...........................................119
Exhaust System ........................................................120
Rear Body Panel .......................................................120
Seat...........................................................................121
Troubleshooting.........................................................122

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:123

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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