2012 Arctic Cat XC 450i ATV Service Manual
DESCRIPTION:
2012 Arctic Cat XC 450i ATV Service Manual
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 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 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.
TABLE OF CONTENTS:
2012 Arctic Cat XC 450i ATV Service Manual
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
Liquid Cooling System 69
Electric Fuel Pump/Fuel Level Sensor 71
Troubleshooting73
Electrical System 74
Electrical Connections74
Battery74
RPM Limiter 75
Testing Electrical Components75
Main 30-Amp Fuse75
Accessory Receptacle/Connector 75
Brakelight Switch (Pressure) 76
Engine Coolant Temperature (ECT) Sensor76
Fan Motor 76
Power Distribution Module (PDM) 77
Ignition Coil 77
Speed Sensor 78
Ignition Switch 78
Handlebar Control Switches79
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
Lights82
Ignition Timing84
Diagnostic Trouble Codes (DTC)84
Tilt Sensor 86
Throttle Position Sensor (TPS)87
Troubleshooting89
Drive System 91
Front Drive Actuator 91
Front Differential 92
Drive Axles 103
Rear Gear Case 104
Hub104
Hand Brake Lever/Master Cylinder Assembly 105
Hydraulic Brake Caliper106
Troubleshooting Drive System109
Troubleshooting Brake System109
Suspension 110
Shock Absorbers 110
Front A-Arms110
Rear A-Arms 111
Wheels and Tires 112
Troubleshooting113
Steering/Frame/Controls 114
Steering Post/Tie Rods 114
Speedometer/LCD Gauge115
Handlebar Grip116
Throttle Control 116
Steering Knuckles 117
Measuring/Adjusting Toe-Out 118
Front Bumper Assembly 119
Front Body Panel/Fender119
Exhaust System 120
Rear Body Panel 120
Seat121
Troubleshooting 122
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PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]