Arctic Cat XC 450i 2012 Service Manual
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Arctic Cat XC 450i 2012 Service Manual

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
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
AT THIS POINT directs the technician to certain
information worthy of particular attention. The symbol
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
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  • Page 1 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.

  • Page 2: Table Of Contents

    Click on the blue text to go. TABLE OF CONTENTS FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the Table of Contents bookmarks on the left side of the screen, or click the blue text below. To return to this page,...
  • Page 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Information CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance 0.025-0.055 mm Piston Diameter 8 mm from Skirt End 88.96-88.98 mm Cylinder Bore 89.005-89.015 mm  NOTE: Some photographs and illustrations used in...
  • Page 4 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SUSPENSION COMPONENTS (Front) Torque Specifications Torque Part Part Bolted To ft-lb A-Arm Frame EXHAUST COMPONENTS Knuckle Ball Joint Torque Shock Absorber Frame Part Part Bolted To ft-lb Shock Absorber Upper A-Arm...

  • Page 5: Gasoline - Oil - Lubricant

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations Torque Conversions and variations in driving speeds contribute to good (ft-lb/N-m) engine break-in. After the completion of the break-in period, the engine oil and oil filter should be changed.

  • Page 6: Preparation For Storage

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE Preparation For Storage LUBRICANT The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 CAUTION hypoid. This lubricant meets all of the lubrication...
  • Page 7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Check all control cables for signs of wear or fraying. CAUTION Replace if necessary. Connect the positive battery cable first; then the negative. 4. Change the engine/transmission oil and filter.

  • Page 8: Periodic Maintenance

    * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year. Manual Table of Contents www.mymowerparts.com...

  • Page 9: Cleaning/Inspecting Filter

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Turn and release the three locking lugs on the air fil- ter housing and separate the air filter cover from the Lubrication Points housing; then remove the air filter element. Separate the foam element from the spring.

  • Page 10: Valve/Tappet Clearance

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Install the air filter housing assembly into the mount- ing bracket and secure with two reinstallable rivets. 11. Install the inlet pipe onto the air box; then connect to the air filter assembly making sure the boots are fully engaged.

  • Page 11: Spark Plug

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 D. While holding the valve adjuster handle in place, 8. If compression is now evident, service the piston rotate the valve adjuster dial counterclockwise rings (see Engine/Transmission). until proper valve/tappet clearance is attained.

  • Page 12: Muffler/Spark Arrester

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Remove the cap screws securing the spark arrester assembly to the muffler; then loosen and remove the CAUTION arrester. Do not use a pressure washer to clean the radiator core.
  • Page 13 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Tighten the jam nut against the throttle cable adjuster 7. Apply oil to a new filter seal ring and check to make securely; then slide the rubber boot over the adjuster.

  • Page 14: Nuts/Bolts/Cap Screws

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 To change the lubricant, use the following procedure. 1. Place the ATV on level ground. Tires 2. Remove each fill plug. TIRE SIZES The ATV is equipped with low-pressure tubeless tires of the size and type listed (see General Information).
  • Page 15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Lights Rotate the ignition switch to the running lights position; the running lights and taillights should illuminate. Test the brakelights by compressing the brake lever. The brake- lights should illuminate. Shift the Hi/Lo beam switch to the Lo position;...

  • Page 16: Running Lights

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RUNNING LIGHTS The running lights are located outboard of the headlights. To replace the running light bulbs, use the following pro- cedure. 1. Rotate the bulb socket counterclockwise to release from light housing;...

  • Page 17: Shift Lever

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Adjust each headlight by turning the adjuster screw clockwise to raise the beam or counterclockwise to lower the beam. KC437A 3. Tighten the jam nuts securely; then shift the trans- mission to each position and verify correct adjust- ment.
  • Page 18 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A. Remove the cover and fill the appropriate reser- voir with DOT 4 Brake Fluid (left hand brake/foot CAUTION pedal - rear system; right hand brake - front brake system); then install and secure the cover.

  • Page 19: Burnishing Brake Pads

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 C. Secure the caliper to the knuckle and/or axle housing with new cap screws with “patch-lock.” Tighten to 20 ft-lb. KC149A 2. Remove the cotter pin from the brake clevis pin; then slide the brake pedal away from the frame suffi- ciently to remove the clevis pin.
  • Page 20 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC128 KC135 6. Thread a cap screw from the V-belt cover into the driven pulley fixed face and push the movable face open allowing the V-belt to drop down between the pulley faces approximately 3/4 in.
  • Page 21 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC152A KC142A KC141 KC153A 4. Remove the cap screw from the fixed driven face; 6. Install the clevis pin connecting the brake pedal to then rotate the pulleys counterclockwise until the the master cylinder and secure with a new cotter pin;...

  • Page 22: Special Tools

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SPECIAL TOOLS Engine/Transmission A number of special tools must be available to the techni- cian when performing service procedures in this section. Refer to the current Special Tools Catalog for the appro- priate tool description.

  • Page 23: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Replace cylinder head 3.
  • Page 24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. Drive - driven bevel gears damaged - worn 1. Replace gears 2. Backlash excessive 2.
  • Page 25 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT ...
  • Page 26 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 12. Disconnect the crankcase breather hose from the air box; then loosen the clamp securing the air box boot to the throttle body and remove the air box. FI522A 15. From the right side, disconnect the stator connector (H) and crankshaft position sensor connector (I) from the main harness;...

  • Page 27: Rocker Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Top-Side Components A. Cylinder Head Cover/ Rocker Arms B. Cylinder Head/Camshaft  NOTE: Remove the spark plug, timing inspection plug, and outer magneto cover; then using an appro- priate wrench, rotate the crankshaft to top-dead-cen- FI530B ter of the compression stroke.
  • Page 28 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. MD1354A 3. Remove the cap screw from the tension adjuster;...
  • Page 29 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI617A FI619A 7. Remove the cam chain tensioner pivot bolt and 8. Remove the four cylinder head cap screws and wash- remove the chain tensioner; then remove the two ers. Note that the two cap screws on the right side of nuts securing the cylinder head to the cylinder.
  • Page 30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Using an awl, remove one piston-pin circlip. Take care not to drop it into the crankcase. FI621 C. Cylinder D. Piston FI625 14. Using Piston Pin Puller, remove the piston pin.
  • Page 31 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VALVE ASSEMBLY When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear.  NOTE: Whenever a valve is out of tolerance, it must be replaced.
  • Page 32 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Rotate the valve in the V blocks. 4. Maximum runout must not exceed specifications. Measuring Valve Guide (Inside Diameter) 1. Insert a snap gauge 1/2 way down into each valve guide bore;...
  • Page 33 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Install the valve springs with the painted end of the spring facing away from the cylinder head.  NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head.
  • Page 34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Piston Rings 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap.
  • Page 35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a “heli-coil” insert. 3. Place the cylinder head on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion.
  • Page 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced.

  • Page 37: Installing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC145D CF060A 6. If clearance is excessive, measure the journals of the 2. If damaged, the camshaft must be replaced. camshaft. Installing Top-Side Components A. Piston B. Cylinder 1. Lubricate the piston pin, connecting rod, and piston pin bore with engine oil;...
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing;...
  • Page 39 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD383 MD1359 12. With the alignment pin installed in the camshaft and 14. Place the C-ring into position in its groove in the cyl- the cam lobes directed down (toward the piston), inder head.
  • Page 40 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 20. Install the cylinder head plug with the cupped end facing the camshaft and the opening directed down- wards. 21. Place the cam chain tensioner assembly and gasket into the cylinder. Tighten to 10 ft-lb.

  • Page 41: Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the water pump housing assembly noting the location of the longer cap screw. Account for a gasket and two alignment pins. FI602 29. Install the spark plug and tighten securely; then install the timing inspection plug.

  • Page 42: Www.mymowerparts.com

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI543 FI550 5. Remove the cap screws securing the magneto cover 9. Remove the flywheel key from the crankshaft; then to the crankcase. Note the location of the two inter- remove the starter clutch gear.

  • Page 43: Servicing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Left-Side Components INSPECTING STARTER CLUTCH/ GEAR 1. Place the starter clutch gear onto the rotor/flywheel and attempt to rotate the starter clutch gear clock- wise. It should lock up to the rotor/flywheel. Rotate the gear counterclockwise and it should turn freely.
  • Page 44 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI570 FI583 2. Thoroughly clean the rotor/flywheel; then install the 2. Thoroughly clean the gear hub; then apply a drop of new one-way clutch and secure with the cap screws...

  • Page 45: Installing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR 1. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft position sen- sor, and one cap screw from the harness hold-down.
  • Page 46 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Install the starter motor and tighten the two cap screws to 8 ft-lb. 3. Install the shift detent cam making sure the washer is installed. FI551A 8. Install the rotor/flywheel and secure with the flange nut.

  • Page 47: Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AT THIS POINT  To service any one specific component, only limited dis- assembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  NOTE: The engine/transmission does not have to be removed from the frame for this procedure.
  • Page 48 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1033 KC132 4. Remove the movable drive face and spacer. Account 6. Remove the fixed drive face. for the movable drive face rollers and outer drive face cover. MD1094 7. Remove the nut holding the driven pulley assembly;...
  • Page 49 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Remove the cap screws holding the clutch cover onto the right-side crankcase half. Note the positions of the different-lengthed cap screws for installing pur- poses. 10. Using a rubber mallet, loosen the clutch cover; then pull it away from the right-side crankcase half.
  • Page 50 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1017 MD1060 16. Remove the snap ring holding the oil pump driven 19. Remove the four cap screws securing the oil strainer gear. cap; then remove the Phillips-head screws securing the oil strainer.

  • Page 51: Installing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSPECTING OIL PUMP 2. If the housing is damaged in any way, the housing must be replaced. 1. Inspect the pump for damage. INSPECTING PRIMARY 2. It is inadvisable to remove the screw securing the ONE-WAY DRIVE pump halves.
  • Page 52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1060 MD1017 4. Place the thrust washer and drive pin into position on the oil pump shaft, install the oil pump driven gear making sure the recessed side of the gear is directed inward, and secure with a new snap ring.
  • Page 53 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Install two alignment pins and place the clutch cover gasket into position. Install the clutch cover. MD1068 MD1115 10. Tighten the clutch cover cap screws to 8 ft-lb. KC134 13.

  • Page 54: Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC127 KC142A 16. Coat the threads of the nut with red Loctite #271; then making sure the splines of the clutch shaft pro- Center Crankcase trude through the cover plate, secure with the nut and tighten to 147 ft-lb.
  • Page 55 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1012 FI639A 2. Using Crankcase Separator/Crankshaft Remover and 1. Remove the secondary driven shaft assembly (A) tapping lightly with a rubber mallet, separate the noting the location of the front and rear bearing crankcase halves.
  • Page 56 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Remove the countershaft assembly (E) along with the shift fork assembly. FI641A 3. Remove the driveshaft (C); then pull the shift fork locating shaft (D) out of the crankcase locating boss...
  • Page 57 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Checking Tooth Contact AT THIS POINT   NOTE: After correcting backlash of the secondary driven bevel gear, it is necessary to check tooth con- To service crankshaft assembly, see Servicing Center tact.
  • Page 58 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Correcting Tooth Contact Measuring Connecting Rod (Big End Side-to-Side)  NOTE: If tooth contact pattern is comparable to the 1. Push the lower end of the connecting rod to one side correct pattern illustration, no correction is neces- of the crankshaft journal.
  • Page 59 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-1017 FI665 2. Acceptable width range must be within specifica- 3. Remove the low driven gear washer; then remove the tions. low driven gear along with the bearing and bushing.
  • Page 60 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI671A FI669 5. Remove the circlip securing the high driven gear; then remove a washer, the high driven gear along with the bearing and bushing, and remove the high driven washer.
  • Page 61 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI666 FI662 4. Place the reverse driven bushing (13) onto the shaft;  NOTE: The countershaft assembly is now ready to then install the bearing (14), gear (15), and splined be installed.
  • Page 62 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1333 FI658 3. Apply a liberal amount of oil to the crankshaft bear- 6. Align the shift cam fork slots with the shift fork shaft ing. Using a propane torch, heat the bearing until the locating boss and with a washer on each end, install oil begins to smoke;...
  • Page 63 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the shift fork shaft into the locating boss in the crankcase.

  • Page 64: Joining Crankcase Halves

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Joining Crankcase Halves 1. Verify that the two alignment pins (A) are in place and that both case halves are clean and grease free. Apply Three Bond Sealant to the mating surfaces.
  • Page 65 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. With engine moved rearward, engage the splines of the front driveline into the front output drive yoke; then move into position and install the two through- bolts. Secure with lock nuts and tighten to 38 ft-lb.
  • Page 66 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 15. Install the water pump splash guard and left footwell. Tighten all fasteners securely. 16. Install the seat making sure it locks securely in place; then start the engine and allow to warm up while checking for leaks.

  • Page 67: Electronic Fuel Injection

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! WARNING Fuel/Lubrication/Cooling Gasoline may be under pressure. Place an absorbent towel under the connector to absorb any gasoline spray when disconnecting. SPECIAL TOOLS 3. Loosen the clamp securing the intake boot to the throttle body;...

  • Page 68: Gas Tank

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Throttle Cable Free-Play To adjust throttle cable free-play, see Periodic Maintenance. Gas Tank ! WARNING KC454A Whenever any maintenance or inspection is made on 4. Using a shop towel to catch any leaking gasoline,...

  • Page 69: Oil Filter/Oil Pump

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Remove the heat shield by reaching under the front of the shield and compressing the retainer posts to Oil Filter/Oil Pump release.  NOTE: Whenever internal engine components wear excessively or break and whenever oil is contami- nated, the oil pump should be replaced.

  • Page 70: Liquid Cooling System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Disconnect the fan wiring from the main wiring har- ness; then remove the radiator/fan assembly and account for the grommets and collars. 6. Remove the fan/fan shroud assembly from the radia- tor.

  • Page 71: Water Pump

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Inspect the thermostat for corrosion or spring damage. 2. Using the following procedure, inspect the thermo- stat for proper operation. A. Suspend the thermostat in a container filled with water.
  • Page 72 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING Electric Fuel Pump/Fuel 1. Disconnect the negative battery cable from the bat- tery. Level Sensor 2. Remove the side panels and gas tank cover (see Gas Tank in this section).
  • Page 73 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Using duct tape or other suitable means, cover the B. Engage the tabs (C) of the fuel level sensor into fuel pump opening. the mounting slot (B) and press toward the bot- tom of the fuel pump to latch in place;...
  • Page 74 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Starting impaired Condition Remedy 1. Gas contaminated 1. Drain gas tank and fill with clean gas Problem: Idling or low speed impaired Condition Remedy 1. TPS out of adjustment 1.

  • Page 75: Electrical System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Electrical System This section has been organized into sub-sections which show procedures for the complete servicing of the Arctic Cat ATV electrical system. SPECIAL TOOLS A number of special tools must be available to the techni- cian when performing service procedures in this section.

  • Page 76: Rpm Limiter

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RPM Limiter  NOTE: The ATV is equipped with an ECU that retards ignition timing when maximum RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire.

  • Page 77: Brakelight Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Brakelight Switch Engine Coolant (Pressure) Temperature (ECT) Sensor The brakelight switch is located on the top of the brake master cylinder and is pressure activated by the hand 1. Connect the meter leads (selector in OHMS position) brake or the brake pedal.

  • Page 78: Ignition Coil

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  NOTE: The ignition switch must be in the ON posi- If there is any type of related electrical system failure, always check the fuses first. tion.  NOTE: To remove a fuse, compress the locking tabs VOLTAGE (Main Harness Connector on either end of the PDM cover and lift off;...

  • Page 79: Speed Sensor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Secondary Winding 5. Leave the black tester lead connected; then connect the red tester lead to the signal lead pin (S). 1. Remove the plug cap from the high tension lead;...

  • Page 80: Drive Select Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Set the meter selector to the DC Voltage position. 3. With the dimmer switch in the HI position, the meter must show less than 1 ohm. 2. Connect the red meter lead to the red/white wire;...

  • Page 81: Gear Position Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Connect the one tester lead to the white/blue wire;  NOTE: The 4WD icon on the LCD should illuminate. then connect the other tester lead to the black wire.

  • Page 82: Stator Coil

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VOLTAGE (Crankshaft Position Sensor) Stator Coil 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the green wire; then VOLTAGE connect the black tester lead to the blue wire.
  • Page 83 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Electronic Control Unit (ECU) The electronic control unit (ECU) is located above the radiator under the radiator/electrical access panel.  NOTE: The ECU is not a serviceable component. If the unit is defective, it must be replaced.
  • Page 84 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  NOTE: If the meter does not show voltage, inspect the LIGHTS fuse, battery connections, or trouble- shoot the main wiring harness. TAILLIGHTS - BRAKELIGHTS Voltage (Taillights)  NOTE: Perform this test on the main harness side of the connector.

  • Page 85: Ignition Timing

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. If the meter does not show battery voltage, inspect the LIGHTS fuse, BACK-UP relay, ignition switch, or the main wiring harness. Ignition Timing The ignition timing cannot be adjusted; however, verifying ignition timing can aid in troubleshooting other compo- nents.
  • Page 86 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Input/ Gauge DTC Wrench Icon Status ECU PIN High/Low Variable Description Output Tilt Sensor Circuit High C0063 Tilt Sensor Circuit Low/SG/Open C0064 P0107 MAP Sensor Circuit Low/SG/Open P0108 MAP Sensor Circuit High/SP...

  • Page 87: Tilt Sensor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 OUTPUT VOLTAGE Tilt Sensor  NOTE: Needle adapters or a “break-out” harness will be required on the multimeter leads as the follow- ing tests are made with the sensor connected.
  • Page 88 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC416B PR538A  NOTE: If the meter does not read as specified, check for poor connections at the ECU or open/bro- Throttle Position Sensor ken wires in the wiring harness.
  • Page 89 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Connect the TPS Multi-Analyzer Harness connector #8 to the TPS; then connect the harness to the TPS Analyzer Tool. PR546A 8. Select the DC Voltage position on the meter and turn the ignition switch to the ON position.
  • Page 90 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Alternator defective 3. Replace stator coil assembly 4.

  • Page 91: Manual

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Battery discharges too rapidly Condition Remedy 1. Battery sulfided 1. Replace battery 2. Charging system not charging 2. Check alternator - regulator/rectifier - circuit connections 3. Battery overcharged - damaged 3.

  • Page 92: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Drive System GENERAL INFORMATION Ring Gear Backlash 0.28-0.38 mm (0.011-0.015 in.) Ring Gear End Play 0.1-0.2 mm (0.004-0.008 in.) All gear cases are tagged beneath a cover bolt. This tag is marked with a production date code, sequence code, and a ratio code.

  • Page 93: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Front Differential REMOVING DIFFERENTIAL 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.

  • Page 94: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Pull the steering knuckle away from the axle taking care not to damage the seals as the axle clears the knuckle. KC291A Disassembling Input Shaft  NOTE: This procedure can be performed on a rear KC314 gear case;...

  • Page 95: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD106 AF983 3. Using a side-cutter (or suitable substitute), remove the boot clamps; then remove the boots and splined drive from the input shaft. 4. Remove the input shaft from the pinion housing.

  • Page 96: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF994 CD112 2. Install the input shaft seal making sure it is flush with 5. Using a new O-ring lubricated with grease, install the edge of the housing. the front drive actuator and secure with the cap screws.

  • Page 97: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX173 KX181 3. Using a plastic mallet, tap lightly to remove the dif- 5. Unstake the lock collar; then using the 48 mm Inter- ferential cover. Account for an O-ring and a shim.

  • Page 98: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Backlash  NOTE: Always set backlash prior to any other shim- ming. 1. Install the existing shim or a 0.051-0.055-in. shim on the gear case side of the ring gear assembly.

  • Page 99: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Secure the gear case in a holding fixture with the 5. Place the Backlash Measuring Tool into the splines cover side up; then install a dial indicator contacting of the ring gear and install a dial indicator making the ring gear axle flange.

  • Page 100: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GC057A GC059 2. Place the ring gear with selected shim into the cover 2. Place the selected (end-play) shim, chamfered side and measure the ring gear to thrust button clearance toward the gear, onto the cover side of the ring gear.

  • Page 101: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC893 CC885 6. Place the input shaft housing assembly onto the gear 2. Using a propane torch, heat the area surrounding the case housing; then secure with the existing cap needle bearing to soften the Loctite.

  • Page 102: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC888 CC891 2. Using a suitable driver, install the needle bearing into 5. Install the pinion housing. the gear case housing making sure the bearing is Removing/Installing Axle Seal seated.

  • Page 103: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC901 AG925 3. Install the front axles (see Drive Axles in this sec-  NOTE: Prior to installing the seal, apply High Perfor- tion). mance #2 Molybdenum Disulfide Grease to the seal outside diameter.

  • Page 104: Install The Wheel. Tighten To 80 Ft-Lb

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING FRONT DRIVE AXLE Drive Axles  NOTE: For removing a front drive axle, see Front Differential in this section. CLEANING AND INSPECTING REMOVING REAR DRIVE AXLE  NOTE: Always clean and inspect the drive axle com- 1.

  • Page 105: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC305 KC288A 5. Install the wheel and tighten to 80 ft-lb.  AT THIS POINT 6. Remove the ATV from the support stand and release For servicing the input shaft, pinion gear, needle bear- the brake lever lock.

  • Page 106: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC283 KC305 5. Remove the hub assembly. 7. Install the wheel and tighten to 80 ft-lb. 6. Remove the four cap screws securing the brake disc. 8. Remove the ATV from the support stand.

  • Page 107: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. 1. Inspect the pin securing the brake lever for wear. 2. Inspect the brake lever for elongation of the pivot hole.

  • Page 108: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING 5. Remove the caliper holder from the caliper and dis- card the O-ring. 1. Clean all caliper components (except the brake pads) with DOT 4 brake fluid. Do not wipe dry.

  • Page 109: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Making sure brake fluid does not contact the brake pads, compress the caliper holder toward the caliper and install the inner brake pad; then install the outer pad. CAUTION...

  • Page 110: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shafts serration worn - broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel...

  • Page 111: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the ATV from the support stand. Suspension Front A-Arms The following suspension system components should be inspected periodically to ensure proper operation. REMOVING A. Shock absorber rods not bent, pitted, or dam- 1.

  • Page 112: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Secure the hub assembly with the nut. Tighten only until snug. 8. Secure the brake caliper to the knuckle with the two new “patch-lock” cap screws. Tighten to 20 ft-lb.

  • Page 113: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Remove the cap screws and lock nuts securing the A- arms to the frame; then remove the A-arms. Wheels and Tires NOTE: If removing the upper right A-arm, it will be necessary to disconnect the brake hose from the A-arm.

  • Page 114: Bearings Worn

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally. NOTE: Be sure all tires are the specified size and have identical tread pattern.

  • Page 115: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent, cracked, and has equal and complete full-left and full-right capability.

  • Page 116: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect the tie rods for damaged threads or wear. 3. Inspect the tie rods for cracks or unusual bends. 4. Inspect all welded areas for cracks or deterioration. 5. Inspect the steering post and steering-post brackets for cracks, bends, or wear.

  • Page 117: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 3. Install the new gauge and secure with the mounting nuts; then plug the harness into the gauge and secure 1. Apply a liberal amount of Handlebar Grip Adhesive the gauge pod with the machine screws.

  • Page 118: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering Knuckles REMOVING AND DISASSEMBLING 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.

  • Page 119: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. 1. Clean all knuckle components. 2. Inspect the bearing for pits, gouges, rusting, or pre- mature wear.

  • Page 120: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Measure the distance from the outside edge of each handlebar grip to equal reference points on each side. Front Bumper Assembly 5. Adjust the handlebar direction until the two measure- ments are equal;...

  • Page 121: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Place the gas tank cover into position and secure with the existing hardware; then install the two cap screws securing the rear of the panel to the frame. Tighten all cap screws and fasteners securely.

  • Page 122: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Clean all rear body panel components with warm soap and water. 2. Inspect side panels and rear body panel for cracks and loose rivets. 3. Inspect threaded areas of all mounting bosses for stripping.

  • Page 123: Replace Bushing

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure low 3. Adjust pressure 4.

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