Arctic Cat XC 450 (2011) - Workshop Manual, Repair Manual
Arctic Cat XC 450 (2011)
ARCTIC CAT XC 450 (2011) - WORKSHOP MANUAL - REPAIR MANUAL
ARCTIC CAT XC 450 (2011) - WORKSHOP MANUAL - REPAIR MANUAL - English Workshop 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
Arctic Cat XC 450 (2011) - Workshop Manual, Repair Manual
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