2011 Arctic Cat 450XC Service Manual
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- 2011 Arctic Cat 450XC Service Manual
Factory repair manual for the 2011 Arctic Cat 450XC. Covers complete tear down and rebuild, pictures and part diagrams, torque specs, maintenance, troubleshooting, etc.
NO wiring diagram in this manual.
Manual is deeply indexed and searchable.
Manual chapters:
- Table of Contents
- General Information
- Periodic Maintenance
- Engine/Transmission
- Fuel/Lubrication/Cooling
- Electrical System
- Drive System
- Suspension
- Steering/Frame
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Full list of manual chapters:
Table of Contents
General Information
General Specifications
Torque Specifications
Torque Conversions (ft-lb/N-m)
Break-In Procedure
Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
RECOMMENDED ENGINE/ TRANSMISSION OIL
RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT
FILLING GAS TANK
Genuine Parts
Preparation For Storage
Preparation After Storage
Periodic Maintenance
SPECIAL TOOLS
Periodic Maintenance Chart
Lubrication Points
Air Filter
CLEANING AND INSPECTING FILTER
CHECKING AND CLEANING DRAIN
Valve/Tappet Clearance
Feeler Gauge Procedure
Valve Adjuster Procedure
Testing Engine Compression
Spark Plug
Liquid Cooling System
Checking/Filling
Muffler/Spark Arrester
Adjusting Throttle Cable
Adjusting Engine RPM (Idle)
Engine/Transmission Oil - Filter
Front Differential/Rear Drive Lubricant
Tires
TIRE SIZES
TIRE INFLATION PRESSURE
Driveshaft/Coupling
Nuts/Bolts/Cap Screws
Ignition Timing
Lights
HEADLIGHTS
TAILLIGHTS-BRAKELIGHTS
RUNNING LIGHTS
BACK-UP LIGHTS
CHECKING/ADJUSTING HEADLIGHT AIM
Shift Lever
CHECKING ADJUSTMENT
ADJUSTING
Frame/Welds
Hydraulic Brake Systems
CHECKING/BLEEDING
INSPECTING HOSES
CHECKING/REPLACING PADS
Burnishing Brake Pads
Checking/Replacing V- Belt
REMOVING
INSTALLING
Engine/Transmission
SPECIAL TOOLS
Specifications
Troubleshooting
Removing Engine/ Transmission
Top-Side Components
Removing Top-Side Components
A. Cylinder Head Cover/ Rocker Arms B. Cylinder Head/Camshaft
C. Cylinder D. Piston
Servicing Top-Side Components
VALVE ASSEMBLY
Cleaning/Inspecting Cylinder Head Cover
Removing Valves
Measuring Valve Stem Runout
Measuring Valve Stem Outside Diameter
Measuring Valve Face/Seat Width
Measuring Valve Face Radial Runout
Measuring Valve Guide (Inside Diameter)
Servicing Valves/Valve Guides/Valve Seats
Measuring Rocker Arm (Inside Diameter)
Measuring Rocker Arm Shaft (Outside Diameter)
Installing Valves
PISTON ASSEMBLY
Cleaning/Inspecting Piston
Removing Piston Rings
Cleaning/Inspecting Piston Ring Grooves
Measuring Piston-Ring End Gap (Installed)
Measuring Piston Pin, Connecting Rod Small End, and Piston-Pin Bore
Measuring Piston Skirt/ Cylinder Clearance
Installing Piston Rings
CYLINDER/CYLINDER HEAD ASSEMBLY
Cleaning/Inspecting Cylinder Head
Measuring Cylinder Head Distortion
Cleaning/Inspecting Cylinder
Inspecting Cam Chain Guide
Honing Cylinder
Measuring Camshaft Runout
Measuring Camshaft Lobe Height
Inspecting Camshaft Bearing Journal
Measuring Camshaft to Cylinder Head Clearance
Inspecting Camshaft Spring/Drive Pin
Installing Top-Side Components
A. Piston B. Cylinder
C. Cylinder Head/Camshaft D. Cylinder Head Cover/ Rocker Arms
Left-Side Components
Removing Left-Side Components
A. Water Pump B. Speed Sensor C. Magneto Cover/Stator Assembly
D. Rotor/Flywheel E. Starter Clutch/Gear F. Starter Motor
G. Shift Shaft H. Drive Gear
Servicing Left-Side Components
INSPECTING STARTER CLUTCH/ GEAR
REPLACING STARTER CLUTCH ASSEMBLY
REPLACING STARTER GEAR BEARING
INSPECTING STATOR/MAGNETO COVER ASSEMBLY
REPLACING STATOR/CRANKSHAFT POSITION SENSOR
REPLACING MAGNETO COVER BEARINGS
Installing Left-Side Components
A. Starter Clutch/Gear B. Rotor/Flywheel
C. Magneto Cover D. Water Pump
Right-Side Components
Removing Right-Side Components
A. V-Belt Cover B. Driven Pulley C. Clutch Cover
D. Centrifugal Clutch Assembly E. Oil Pump Drive Gear F. Oil Pump Driven Gear
G. Oil Pump/Oil Strainer
Servicing Right-Side Components
INSPECTING CENTRIFUGAL CLUTCH SHOE
INSPECTING CENTRIFUGAL CLUTCH HOUSING
INSPECTING PRIMARY ONE-WAY DRIVE
INSPECTING OIL PUMP
DRIVEN PULLEY ASSEMBLY
Installing Right-Side Components
A. Oil Strainer/Oil Pump
B. Clutch Cover C. Fixed Drive Face D. Movable Drive Face
Center Crankcase Components
Separating Crankcase Halves
Disassembling Crankcase Half
Servicing Center Crankcase Components
SECONDARY GEARS
Checking Backlash
Correcting Backlash
Checking Tooth Contact
Correcting Tooth Contact
CRANKSHAFT ASSEMBLY
Measuring Connecting Rod (Small End Inside Diameter)
Measuring Connecting Rod (Small End Deflection)
Measuring Connecting Rod (Big End Side-to-Side)
Measuring Crankshaft (Runout)
Measuring Crankshaft (Web-to- Web)
COUNTERSHAFT
Disassembling
ASSEMBLING
Assembling Crankcase Half
Joining Crankcase Halves
Installing Engine/ Transmission
Fuel/Lubrication/Cooling
SPECIAL TOOLS
Electronic Fuel Injection
TROUBLESHOOTING
Throttle Body
REMOVING
INSTALLING
Throttle Cable Free-Play
Gas Tank
REMOVING
CLEANING AND INSPECTING
INSTALLING
Oil Filter/Oil Pump
Testing Oil Pump Pressure
Liquid Cooling System
RADIATOR
Removing
Cleaning and Inspecting
Installing
THERMOSTAT
Removing
Inspecting
Installing
WATER PUMP
Removing
Installing
Electric Fuel Pump/Fuel Level Sensor
TESTING
REMOVING
INSPECTING
INSTALLING
Troubleshooting
Electrical System
SPECIAL TOOLS
Specifications
Electrical Connections
Battery
RPM Limiter
Testing Electrical Components
Accessory Receptacle/ Connector
VOLTAGE
Brakelight Switch (Pressure)
VOLTAGE (Wiring Harness Side)
RESISTANCE (Switch)
Engine Coolant Temperature (ECT) Sensor
Fan Motor
VOLTAGE (Main Harness Connector to Fan Motor)
RESISTANCE (Fan Motor Connector)
Power Distribution Module (PDM)
RELAYS
Ignition Coil
RESISTANCE
Primary Winding
Secondary Winding
Spark Plug Cap
Speed Sensor
Ignition Switch
VOLTAGE
RESISTANCE
Handlebar Control Switches
RESISTANCE (HI Beam)
RESISTANCE (LO Beam)
RESISTANCE (Emergency Stop)
RESISTANCE (Reverse Override)
Front Drive Selector Switch
RESISTANCE
VOLTAGE
Front Drive Selector Actuator
VOLTAGE
Gear Position Switch
Stator Coil
VOLTAGE (AC Generator - Regulated Output)
VOLTAGE (AC Generator Coil - No Load)
RESISTANCE (AC Generator Coil)
RESISTANCE (Crankshaft Position Sensor)
VOLTAGE (Crankshaft Position Sensor)
Starter Relay
Starter Motor
TESTING VOLTAGE
REMOVING
INSTALLING
Electronic Control Unit (ECU)
Regulator/Rectifier
TESTING
Lights
HEADLIGHTS - RUNNING LIGHTS
Voltage (Headlights)
Voltage (Running Lights)
TAILLIGHTS - BRAKELIGHTS
Voltage (Taillights)
Voltage (Brakelights)
BACK-UP LIGHTS
Voltage
Ignition Timing
Diagnostic Trouble Codes (DTC)
Code List
Tilt Sensor
SUPPLY VOLTAGE
OUTPUT VOLTAGE
Throttle Position Sensor (TPS)
INSPECTING
REMOVING
INSTALLING/ADJUSTING
Troubleshooting
Drive System
GENERAL INFORMATION
SPECIAL TOOLS
Front Drive Actuator
REMOVING
INSTALLING
Front Differential
REMOVING DIFFERENTIAL
Disassembling Input Shaft
Assembling Input Shaft
Disassembling Pinion Gear
Shimming Procedure/Shim Selection
Backlash
Ring Gear End-Play
RING GEAR/THRUST BUTTON
Removing
Inspecting
Installing/Shimming
Assembling Differential Assembly
Removing Needle Bearing
Installing Needle Bearing
Removing/Installing Axle Seal
INSTALLING DIFFERENTIAL
Drive Axles
REMOVING REAR DRIVE AXLE
REMOVING FRONT DRIVE AXLE
CLEANING AND INSPECTING
DISASSEMBLING AXLES
INSTALLING REAR DRIVE AXLE
INSTALLING FRONT DRIVE AXLE
Rear Gear Case
REMOVING
INSTALLING
Hub
REMOVING
CLEANING AND INSPECTING
INSTALLING
Hand Brake Lever/Master Cylinder Assembly
REMOVING
INSPECTING
INSTALLING
Hydraulic Brake Caliper
REMOVING/DISASSEMBLING
CLEANING AND INSPECTING
ASSEMBLING/INSTALLING
Troubleshooting Drive System
Troubleshooting Brake System
Suspension
Shock Absorbers
REMOVING
INSTALLING
Front A-Arms
REMOVING
CLEANING AND INSPECTING
INSTALLING
Rear A-Arms
REMOVING
CLEANING AND INSPECTING
INSTALLING
Wheels and Tires
TIRE SIZE
TIRE INFLATION PRESSURE
REMOVING
CLEANING AND INSPECTING
INSTALLING
CHECKING/INFLATING
Troubleshooting
Steering/Frame
Steering Post/Tie Rods
REMOVING
CLEANING AND INSPECTING
INSTALLING
Speedometer/LCD Gauge
REPLACING
Handlebar Grip
REMOVING
INSTALLING
Throttle Control
REMOVING
INSTALLING
ADJUSTING
Steering Knuckles
REMOVING AND DISASSEMBLING
CLEANING AND INSPECTING
ASSEMBLING AND INSTALLING
Measuring/Adjusting Toe-Out
Front Bumper Assembly
REMOVING
INSTALLING
Front Body Panel/Fender
REMOVING
CLEANING AND INSPECTING
INSTALLING
Exhaust System
REMOVING MUFFLER
INSPECTING MUFFLER
INSTALLING MUFFLER
Rear Body Panel
REMOVING
CLEANING AND INSPECTING
INSTALLING
Seat
REMOVING/INSTALLING
Troubleshooting
