Table Of Contents - Arctic Cat 450 XC 2011 Service Manual

Table of Contents

Table Of Contents2
Torque Specifications3
General Information3
General Specifications3
Exhaust Components3
Break-In Procedure4
Torque Conversions4
Gasoline - Oil - Lubricant4
Recommended Gasoline4
Genuine Parts5
Preparation For Storage5
Filling Gas Tank5
Preparation After Storage6
Periodic Maintenance7
Periodic Maintenance Chart7
Cleaning And Inspecting Filter8
Lubrication Points8
Air Filter8
Valve/Tappet Clearance9
Feeler Gauge Procedure9
Checking And Cleaning Drain9
Valve Adjuster Procedure10
Spark Plug10
Testing Engine Compression10
Liquid Cooling System11
Muffler/Spark Arrester11
Checking/Filling11
Adjusting Throttle Cable12
Adjusting Engine Rpm12
Engine/Transmission Oil12
Front Differential/Rear Drive Lubricant13
Tire Sizes13
Tire Inflation Pressure13
Driveshaft/Coupling14
Nuts/Bolts/Cap Screws14
Ignition Timing14
Lights14
Back-Up Lights15
Running Lights15
Shift Lever16
Checking Adjustment16
Checking/Adjusting Headlight Aim16
Frame/Welds17
Hydraulic Brake Systems17
Burnishing Brake Pads18
Checking/Replacing Pads18
Checking/Replacing V-Belt18
Engine/Transmission22
Specifications22
Special Tools22
Camshaft And Cylinder Head22
Troubleshooting23
Engine Will Not Start Or Is Hard To Start23
Engine Noisy23
Engine Idles Poorly24
Problem: Engine Runs Poorly At High Speed24
Problem: Exhaust Smoke Dirty Or Heavy24
Problem: Engine Lacks Power25
Problem: Engine Overheats25
Removing Engine/Transmission26
Removing Top-Side Components28
Top-Side Components28
Servicing Top-Side Components31
Valve Assembly32
Cleaning/Inspecting Cylinder Head Cover32
Removing Valves32
Measuring Valve Stem Runout32
Measuring Valve Guide33
Measuring Valve Stem Outside Diameter33
Measuring Valve Face/Seat Width33
Measuring Rocker Arm33
Cleaning/Inspecting Piston Ring Grooves34
Measuring Piston-Ring End Gap34
Piston Assembly34
Cleaning/Inspecting Piston34
Installing Piston Rings35
Measuring Piston Skirt35
Cylinder Clearance35
Cleaning/Inspecting Cylinder Head35
Inspecting Cam Chain Guide36
Honing Cylinder36
Measuring Cylinder Head Distortion36
Cleaning/Inspecting Cylinder36
Measuring Camshaft Runout37
Inspecting Camshaft Bearing Journal37
Measuring Camshaft Lobe Height37
Measuring Camshaft To Cylinder Head Clearance37
Installing Top-Side Components38
Inspecting Camshaft Spring/Drive Pin38
Rocker Arms39
Left-Side Components42
Removing Left-Side Components42
Servicing Left-Side Components44
Inspecting Starter Clutch/Gear44
Replacing Starter Clutch Assembly44
Inspecting Stator/Magneto Cover Assembly45
Replacing Starter Gear Bearing45
Replacing Stator/Crankshaft Position Sensor46
Replacing Magneto Cover Bearings46
Installing Left-Side Components46
Removing Right-Side Components48
Right-Side Components48
Servicing Right-Side Components51
Inspecting Centrifugal Clutch Shoe52
Installing Right-Side Components52
Inspecting Oil Pump52
Driven Pulley Assembly52
Center Crankcase Components55
Separating Crankcase Halves55
Disassembling Crankcase Half56
Correcting Backlash58
Checking Tooth Contact58
Secondary Gears58
Checking Backlash58
Measuring Connecting Rod59
Correcting Tooth Contact59
Crankshaft Assembly59
Measuring Crankshaft (Runout)59
Countershaft60
Assembling Crankcase Half62
Joining Crankcase Halves65
Installing Engine/Transmission66
Fuel/Lubrication/Cooling68
Electronic Fuel Injection68
Throttle Body68
Throttle Cable Free-Play69
Gas Tank69
Oil Filter/Oil Pump70
Testing Oil Pump Pressure70
Radiator71
Thermostat71
Water Pump72
Electric Fuel Pump/Fuel Level Sensor73
Problem: Starting Impaired75
Problem: Idling Or Low Speed Impaired75
Problem: Medium Or High Speed Impaired75
Electrical System76
Electrical Connections76
Battery76
Testing Electrical Components77
Rpm Limiter77
Brakelight Switch77
Voltage77
Fan Motor78
Resistance78
Engine Coolant Temperature (Ect) Sensor78
Ignition Coil79
Power Distribution Module (Pdm)79
Relays79
Ignition Switch80
Speed Sensor80
Handlebar Control Switches81
Front Drive Selector Switch81
Front Drive Selector Actuator82
Stator Coil82
Gear Position Switch82
Starter Motor83
Starter Relay83
Ac Generator Coil83
Testing Voltage83
Regulator/Rectifier84
Electronic Control Unit84
Headlights - Running Lights84
Voltage (Brakelights)85
Voltage (Headlights)85
Voltage (Running Lights)85
Diagnostic Trouble Codes86
Code List86
Tilt Sensor87
Supply Voltage87
Output Voltage87
Throttle Position Sensor88
Problem: Spark Absent Or Weak90
Problem: Spark Plug Fouled With Carbon90
Problem: Spark Plug Electrodes Overheat Or Burn90
Problem: Alternator Does Not Charge90
Battery "Sulfation"91
Battery Discharges Too Rapidly91
Battery Polarity Reversed91
Drive System92
Front Drive Actuator92
Front Differential93
Removing Differential93
Disassembling Input Shaft94
Assembling Input Shaft95
Disassembling Pinion Gear96
Backlash98
Shimming Procedure/Shim Selection98
Ring Gear/Thrust Button99
Ring Gear End-Play99
Assembling Differential Assembly100
Removing Needle Bearing101
Installing Needle Bearing101
Removing/Installing Axle Seal102
Installing Differential103
Drive Axles104
Removing Rear Drive Axle104
Removing Front Drive Axle104
Installing Rear Drive Axle104
Rear Gear Case105
Hub105
Hand Brake Lever/Master Cylinder Assembly106
Hydraulic Brake Caliper107
Troubleshooting Drive System110
Troubleshooting Brake System110
Power Not Transmitted From Engine To Wheels110
Braking Poor110
Suspension111
Front A-Arms111
Shock Absorbers111
Rear A-Arms112
Wheels And Tires113
Tire Size113
Suspension Too Soft114
Suspension Too Stiff114
Suspension Noisy114
Rear Wheel Oscillation114
Steering/Frame115
Steering Post/Tie Rods115
Speedometer/Lcd Gauge116
Handlebar Grip117
Throttle Control117
Steering Knuckles118
Measuring/Adjusting Toe-Out119
Front Bumper Assembly120
Front Body Panel/Fender120
Exhaust System121
Removing Muffler121
Inspecting Muffler121
Installing Muffler121
Rear Body Panel121
Seat122
Problem: Handling Too Heavy Or Stiff123
Problem: Steering Oscillation123
Problem: Steering Pulling To One Side123