Arctic Cat XC 450 (2011) - Service Manual, Repair Manual

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ARCTIC CAT XC 450 (2011) - SERVICE MANUAL - REPAIR MANUAL

- English Service Manual / Repair Manual, in PDF format, to motorcycle Arctic Cat XC 450 (2011).

 

CONTENTS:


2011 XC 450

- foreword
- 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

2011 XC 450i

- foreword
- 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
-- 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 coil/ 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
-- electrical connections
-- battery
-- maintenance charging
-- charging
-- rpm limiter
-- testing electrical components
-- main 30-amp fuse
-- 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 (engine stop switch)
-- resistance (reverse override)
-- drive select switch
-- resistance
-- voltage
-- front drive 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/controls
-- 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