Arctic Cat 450 XC 2011 User manual

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arc-
tic Cat 450 XC 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.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2011 Arctic Cat Inc. February 2011
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Manual
Table of Contents

2
011
ATV Service
Manual
450 XC
TM
SHARE OUR PASSION.
1
TABLE OF CONTENTS
General Information ........................................................ 2 Testing Oil Pump Pressure..........................................69
General Specifications.................................................. 2 Liquid Cooling System ................................................70
Torque Specifications.................................................... 2 Electric Fuel Pump/Fuel Level Sensor ........................72
Torque Conversions (ft-lb/N-m)..................................... 3 Troubleshooting ...........................................................74
Break-In Procedure ...................................................... 3 Electrical System .......................................................... 75
Gasoline - Oil - Lubricant.............................................. 3 Specifications ..............................................................75
Genuine Parts............................................................... 4 Electrical Connections.................................................75
Preparation For Storage ............................................... 4 Battery.........................................................................75
Preparation After Storage ............................................. 5 RPM Limiter ................................................................76
Periodic Maintenance...................................................... 6 Testing Electrical Components ....................................76
Periodic Maintenance Chart ......................................... 6 Accessory Receptacle/Connector ...............................76
Lubrication Points ......................................................... 7 Brakelight Switch (Pressure) .......................................76
Air Filter ........................................................................ 7 Engine Coolant Temperature (ECT) Sensor................77
Valve/Tappet Clearance................................................ 8 Fan Motor ....................................................................77
Testing Engine Compression ........................................ 9 Power Distribution Module (PDM) ...............................78
Spark Plug .................................................................... 9 Ignition Coil .................................................................78
Liquid Cooling System................................................ 10 Speed Sensor .............................................................79
Muffler/Spark Arrester ................................................ 10 Ignition Switch .............................................................79
Adjusting Throttle Cable ............................................. 11 Handlebar Control Switches........................................80
Adjusting Engine RPM (Idle)....................................... 11 Front Drive Selector Switch.........................................80
Engine/Transmission Oil - Filter ................................. 11 Front Drive Selector Actuator ......................................81
Front Differential/Rear Drive Lubricant ....................... 12 Stator Coil ...................................................................81
Tires............................................................................ 12 Starter Relay ...............................................................82
Driveshaft/Coupling .................................................... 13 Starter Motor ...............................................................82
Nuts/Bolts/Cap Screws ............................................... 13 Electronic Control Unit (ECU)......................................83
Ignition Timing ............................................................ 13 Regulator/Rectifier ......................................................83
Lights .......................................................................... 13 Lights...........................................................................83
Shift Lever................................................................... 15 Ignition Timing.............................................................85
Frame/Welds............................................................... 16 Diagnostic Trouble Codes (DTC).................................85
Hydraulic Brake Systems............................................ 16 Tilt Sensor ...................................................................86
Burnishing Brake Pads ............................................... 17 Throttle Position Sensor (TPS)....................................87
Checking/Replacing V-Belt ........................................ 17 Troubleshooting ...........................................................89
Engine/Transmission .................................................... 21 Drive System ................................................................. 91
Specifications ............................................................. 21 Front Drive Actuator ....................................................91
Troubleshooting .......................................................... 22 Front Differential ..........................................................92
Removing Engine/Transmission ................................. 25 Drive Axles ................................................................103
Top-Side Components ................................................ 27 Rear Gear Case ........................................................104
Removing Top-Side Components ............................... 27 Hub............................................................................104
Servicing Top-Side Components ................................ 30 Hand Brake Lever/Master Cylinder Assembly ...........105
Installing Top-Side Components ................................. 37 Hydraulic Brake Caliper.............................................106
Left-Side Components................................................ 41 Troubleshooting Drive System...................................109
Removing Left-Side Components............................... 41 Troubleshooting Brake System..................................109
Servicing Left-Side Components ................................ 43 Suspension.................................................................. 110
Installing Left-Side Components................................. 45 Shock Absorbers .......................................................110
Right-Side Components ............................................. 47 Front A-Arms .............................................................110
Removing Right-Side Components ............................ 47 Rear A-Arms .............................................................111
Servicing Right-Side Components.............................. 50 Wheels and Tires ......................................................112
Installing Right-Side Components .............................. 51 Troubleshooting .........................................................113
Center Crankcase Components ................................. 54 Steering/Frame............................................................ 114
Separating Crankcase Halves .................................... 54 Steering Post/Tie Rods .............................................114
Disassembling Crankcase Half................................... 55 Speedometer/LCD Gauge.........................................115
Servicing Center Crankcase Components ................. 57 Handlebar Grip..........................................................116
Assembling Crankcase Half........................................ 61 Throttle Control .........................................................116
Joining Crankcase Halves .......................................... 64 Steering Knuckles .....................................................117
Installing Engine/Transmission ................................... 65 Measuring/Adjusting Toe-Out....................................118
Fuel/Lubrication/Cooling .............................................. 67 Front Bumper Assembly............................................119
Electronic Fuel Injection ............................................. 67 Front Body Panel/Fender...........................................119
Throttle Body .............................................................. 67 Exhaust System ........................................................120
Throttle Cable Free-Play............................................. 68 Rear Body Panel .......................................................120
Gas Tank..................................................................... 68 Seat...........................................................................121
Oil Filter/Oil Pump....................................................... 69 Troubleshooting .........................................................122

2
General Information
NOTE: Some photographs and illustrations used in
this section are used for clarity purposes only and
are not designed to depict actual conditions.
General Specifications
Specifications subject to change without notice.
* One inch below plug threads.
** At the plug threads.
Torque Specifications
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
****w/“Patch-Lock”
CHASSIS
Brake Type Hydraulic w/Brake Lever Lock
Tire Size 23 x 8-12 (Front); 23 x 10-12 (Rear)
Tire Inflation Pressure 40.0 kPa (5.7 psi)
MISCELLANY
Gas Tank Capacity 16.3 L (4.3 U.S. gal.)
Rear Drive Capacity 250 ml (8.5 fl oz)*
Front Differential Capacity 275 ml (9.3 fl oz)**
Coolant Capacity 1.8 L (1.9 U.S. qt)
Engine Oil Capacity 3.3 L (3.5 U.S. qt) - Overhaul
2.8 L (3.0 U.S. qt) - Change
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather
(Synthetic)
Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid
Drive Belt Width (minimum) 28.5 mm (1.12 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/21W (2)
Headlight 12V/35W (4)
Running Light 5W (2)
EXHAUST COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Exhaust Pipe Engine 20 27
Spark Arrester Muffler 48 in.-lb 5.5
BRAKE COMPONENTS
Brake Disc* Hub 15 20
Brake Hose Caliper 20 27
Brake Hose Master Cylinder 20 27
Brake Hose Brake Cylinder 20 27
Master Cylinder (Rear) Frame 811
Master Cylinder Clamp (Front) Master Cylinder 5.5 8
Hydraulic Caliper**** Knuckle 20 27
Brake Pedal Frame 20 27
ELECTRICAL COMPONENTS
Coil Frame 12 16
Starter Motor Positive Cable Starter Motor 811
Stator** Housing 811
CHASSIS COMPONENTS
Footrest Frame 20 27
Bumper Frame (8 mm) 20 27
SUSPENSION COMPONENTS (Front)
Part Part Bolted To Torque
ft-lb N-m
A-Arm Frame 35 47
Knuckle Ball Joint 35 47
Shock Absorber Frame 35 47
Shock Absorber Upper A-Arm 35 47
Knuckle A-Arm 35 47
SUSPENSION COMPONENTS (Rear)
Shock Absorber (Upper) Frame 35 47
Shock Absorber (Lower) Lower A-Arm 35 47
A-Arm Frame 35 47
Knuckle A-Arm 35 47
STEERING COMPONENTS
Steering Post Bearing Housing Frame 20 27
Handlebar Cap Steering Post 20 27
Lower Steering Post Bearing Cap
Screw
Steering Post 40 54
Tie Rod End** Steering Post Arm 30 41
ENGINE/TRANSMISSION
Clutch Shoe** Crankshaft 147 199
Clutch Cover/Housing Assembly Crankcase 811
Left-Side Cover Crankcase 811
Crankcase Half (6 mm) Crankcase Half 10 13.5
Crankcase Half (8 mm) Crankcase Half 21 28
Cylinder Nut Crankcase Half 811
Cylinder Head (Cap Screw) Crankcase 28 38
Cylinder Head Nut Cylinder 20 27
Cylinder Head Cover Cylinder Head 811
Oil Pump Drive Gear** Crankshaft 63 86
Driven Pulley Nut** Driveshaft 147 199
Ground Cable Engine 811
Magneto Rotor Flange Nut Crankshaft 107 146
One-Way Clutch** Flywheel 26 35
Cam Sprocket** Camshaft 11 15
V-Belt Cover Clutch Cover 811
Valve Adjuster Jam Nut Valve Adjuster 79.5
Starter Motor Crankcase 811
Oil Fitting Engine 811
Oil Pump** Crankcase 811
Movable Drive Face Nut** Clutch Shaft 147 199
Output Shaft Flange Nut Output Shaft 59 80
Cam Chain Tensioner Guide Cylinder 11 15
Valve Cover Cylinder 811
Tappet Cover Valve Cover 811
Cam Chain Tensioner Cylinder 10 13.5
Magneto Cover Crankcase 811
Rear Driveline Output Drive Flange 20 27
Water Pump Cover/Housing Magneto Cover 811
Water Pump Drive Gear Crankshaft 28 38
Intake Clamp Intake Boot 30 in.-lb 3.4
Manual
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3
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
Torque Conversions
(ft-lb/N-m)
Break-In Procedure
A new ATV and an overhauled ATV engine require a
“break-in” period. The first 10 hours (or 200 miles) are
most critical to the life of this ATV. Proper operation dur-
ing this break-in period will help assure maximum life
and performance from the ATV.
During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the engine
RPM during the break-in period allows the components
to “load” (aiding the mating process) and then “unload”
(allowing components to cool). Although it is essential to
place some stress on the engine components during
break-in, care should be taken not to overload the engine
too often. Do not pull a trailer or carry heavy loads dur-
ing the 10-hour break-in period.
When the engine starts, allow it to warm up properly. Idle
the engine several minutes until the engine has reached
normal operating temperature. Do not idle the engine for
excessively long periods of time.
During the break-in period, a maximum of 1/2 throttle is
recommended; however, brief full-throttle accelerations
and variations in driving speeds contribute to good
engine break-in.
After the completion of the break-in period, the engine
oil and oil filter should be changed. Other maintenance
after break-in should include checking of all prescribed
adjustments and tightening of all fasteners.
Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum octane
regular unleaded. In many areas, oxygenates (either etha-
nol or MTBE) are added to the gasoline. Oxygenated
gasolines containing up to 10% ethanol, 5% methane, or
5% MTBE are acceptable gasolines.
When using ethanol blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.
RECOMMENDED ENGINE/
TRANSMISSION OIL
DRIVE TRAIN COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Engine Mounting Through-Bolt Frame 38 52
Front Differential Frame/Differential
Bracket
38 52
Output Flange Rear Flange Output
Joint
20 27
Input Shaft Housing Differential Housing 18 25
Pinion Housing Gear Case Housing 18 25
Differential Housing Cover*** Differential Housing 18 25
Drive Bevel Gear Nut** Shaft 59 80
Driven Bevel Gear Nut** Driven Shaft 59 80
Thrust Button** Gear Case Cover 811
Hub Nut Shaft/Axle (max) 200 272
Oil Drain Plug Front Differential/Rear
Drive
45 in.-
lb
5
Oil Fill Plug Front Differential/Rear
Drive
16 22
Oil Drain Plug Engine 20 27
Rear Drive Input Shaft Housing Differential Housing 23 31
Lock Collar Differential Housing 125 169
Wheel Hub 40 54
Rear Drive Gear Case Frame 38 52
Engine Output Flange Rear Gear Case Input
Flange
20 27
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
11.4 26 35.4 51 69.4 76 103.4
22.7 27 36.7 52 70.7 77 104.7
34.1 28 38.1 53 72.1 78 106.1
45.4 29 39.4 54 73.4 79 107.4
56.8 30 40.8 55 74.8 80 108.8
68.2 31 42.2 56 76.2 81 110.2
79.5 32 43.5 57 77.5 82 111.5
810.9 33 44.9 58 78.9 83 112.9
912.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
CAUTION
Do not use white gas. Only Arctic Cat approved gaso-
line additives should be used.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.
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4
The recommended oil to use is Arctic Cat ACX All
Weather synthetic engine oil, which has been specifically
formulated for use in this Arctic Cat engine. Although
Arctic Cat ACX All Weather synthetic engine oil is the
only oil recommended for use in this engine, use of any
API certified SM 5W-50 oil is acceptable.
OILCHARTI
RECOMMENDED FRONT
DIFFERENTIAL/REAR DRIVE
LUBRICANT
The recommended lubricant is Arctic Cat Gear Lube or
an equivalent gear lube which is SAE approved 80W-90
hypoid. This lubricant meets all of the lubrication
requirements of the Arctic Cat ATV front differentials
and rear drives.
FILLING GAS TANK
Since gasoline expands as its temperature rises, the gas
tank must be filled to its rated capacity only. Expansion
room must be maintained in the tank particularly if the tank
is filled with cold gasoline and then moved to a warm area.
ATV0049B
Tighten the gas tank cap securely after filling the tank.
Genuine Parts
When replacement of parts is necessary, use only genuine
Arctic Cat ATV parts. They are precision-made to ensure
high quality and correct fit. Refer to the Illustrated Parts
Manual for the correct part number, quantity, and
description.
Preparation For Storage
1. Clean the seat cushion (cover and base) with a damp
cloth and allow it to dry.
2. Clean the ATV thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire ATV.
Allow the ATV to dry thoroughly. DO NOT get
water into any part of the engine or air intake.
3. Either drain the gas tank or add Fuel Stabilizer to the
gas in the gas tank. Remove the air filter housing
cover and air filter. Start the engine and allow it to
idle; then using Arctic Cat Engine Storage Preserver,
rapidly inject the preserver into the air filter opening
for a period of 10 to 20 seconds; then stop the
engine. Install the air filter and housing cover.
4. Plug the exhaust outlet on the muffler with a clean
cloth.
5. Apply light oil to the upper steering post bushing and
plungers of the shock absorbers.
6. Tighten all nuts, bolts, cap screws, and screws. Make
sure rivets holding components together are tight.
Replace all loose rivets. Care must be taken that all
calibrated nuts, cap screws, and bolts are tightened to
specifications.
7. Fill the cooling system to the bottom of the stand
pipe in the radiator neck with properly mixed cool-
ant.
CAUTION
Any lubricant used in place of the recommended lubri-
cant could cause serious front differential/rear drive
damage.
! WARNING
Always fill the gas tank in a well-ventilated area. Never
add fuel to the ATV gas tank near any open flames or
with the engine running. DO NOT SMOKE while filling
the gas tank.
! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the engine to
cool before filling the gas tank.
! WARNING
Do not over-fill the gas tank.
CAUTION
Prior to storing the ATV, it must be properly serviced to
prevent rusting and component deterioration.
CAUTION
If the interior of the air filter housing is dirty, clean the
area before starting the engine.
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5
8. Disconnect the battery cables; then remove the bat-
tery, clean the battery posts and cables, and store in a
clean, dry area.
9. Store the ATV indoors in a level position.
Preparation After
Storage
Taking the ATV out of storage and correctly preparing it
will assure many miles and hours of trouble-free riding.
1. Clean the ATV thoroughly.
2. Clean the engine. Remove the cloth from the muffler.
3. Check all control cables for signs of wear or fraying.
Replace if necessary.
4. Change the engine/transmission oil and filter.
5. Check the coolant level and add properly mixed
coolant as necessary.
6. Charge the battery; then install. Connect the battery
cables.
6. Check the entire brake systems (fluid level, pads,
etc.), all controls, lights, and headlight aim; adjust or
replace as necessary.
7. Tighten all nuts, bolts, cap screws, and screws mak-
ing sure all calibrated nuts, cap screws, and bolts are
tightened to specifications.
8. Check tire pressure. Inflate to recommended pressure
as necessary.
9. Make sure the steering moves freely and does not
bind.
10. Check the spark plug. Clean or replace as necessary.
CAUTION
Avoid storing outside in direct sunlight and avoid using
a plastic cover as moisture will collect on the ATV caus-
ing rusting.
CAUTION
The ignition switch must be in the OFF position prior to
installing the battery or damage may occur to the igni-
tion system.
CAUTION
Connect the positive battery cable first; then the negative.
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6
Periodic Maintenance
This section has been organized into sub-sections which
show common maintenance procedures for the Arctic Cat
ATV.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appro-
priate tool description.
NOTE: Special tools are available from the Arctic
Cat Service Department.
Periodic Maintenance
Chart
A = Adjust I = Inspect C = Clean L = Lubricate R = Replace T = Tighten
* Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil.
*** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year.
Description p/n
Compression Tester Kit 0444-213
Oil Filter Wrench 0644-389
Tachometer 0644-275
Timing Light 0644-296
Valve Clearance Adjuster 0444-078
Item
Initial Service After
Break-In (First Mo
or 100 Mi)
Every
Day
Every Month
or 100 Miles
Every 3
Months or
300 Miles
Every 6
Months or
500 Miles
Every Year
or 1500
Miles
As
Needed
Battery II C
Fuses IR
Air Filter/Drain Tube IIC* R
Valve/Tappet Clearance IIA
Engine Compression I
Spark Plug I I R (4000 Mi
or 18 Mo)
Muffler/Spark Arrester CR
Gas Hoses II R(2Yrs)
Throttle Cable II C-L A-R
Engine-Transmission Oil Level IA
Engine-Transmission Oil/Filter R R*/R**/R***
Front Differential/Rear Drive Lubricant II R(4Yrs)
Tires/Air Pressure II R
Steering Components II I R
V-Belt IlR
Suspension (Ball joint boots, drive axle boots front
and rear, tie rods, differential and rear drive bellows)
II R
Nuts/Cap Screws/Screws II A
Ignition Timing I
Lights II R
Switches II R
Shift Lever IA-L
Handlebar Grips IR
Handlebar II R
Gauges/Indicators II R
Frame/Welds Il
Electrical Connections IlC
Complete Brake System II C L-R
Brake Pads II*R
Brake Fluid IIR(2Yrs)
Brake Hoses IIR(4Yrs)
Coolant/Coolant System II R(2Yrs)
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7
Lubrication Points
It is advisable to lubricate certain components periodi-
cally to ensure free movement. Apply light oil to the
throttle lever and brake lever pivots.
Air Filter
CLEANING AND INSPECTING FILTER
1. Loosen the clamp securing the front air inlet boot to
the air filter housing; then loosen the clamp securing
the rear inlet boot to the air box. Remove the inlet
pipe.
KC445A
KC446
2. Remove two reinstallable rivets from the air filter
housing mounting bracket and slide the air filter
housing rearward out of the mounting bracket.
KC447A
3. Turn and release the three locking lugs on the air fil-
ter housing and separate the air filter cover from the
housing; then remove the air filter element. Separate
the foam element from the spring.
KC143
4. Fill a wash pan larger than the element with a non-
flammable cleaning solvent; then dip the element in
the solvent and wash it.
NOTE: Foam Air Filter Cleaner and Foam Air Fil-
ter Oil are available from Arctic Cat.
5. Dry the element.
6. Put the element in a plastic bag; then pour in air filter
oil and work the oil into the element. Insert the form-
ing spring into the element with the closely wrapped
end of the spring toward the open end of the element.
7. Clean any dirt or debris from inside the air filter
housing.
8. Place the filter assembly in the air filter housing
making sure it is properly positioned and properly
seated with the filter element straight in the housing.
CAUTION
A torn air filter element can cause damage to the ATV
engine. Dirt and dust may get inside the engine if the
element is torn. Carefully examine the element for tears
before and after cleaning it. Replace the element with a
new one if it is torn.
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8
KC449
9. Install the air filter housing cover and secure with the
locking tabs.
10. Install the air filter housing assembly into the mount-
ing bracket and secure with two reinstallable rivets.
11. Install the inlet pipe onto the air box; then connect to
the air filter assembly making sure the boots are fully
engaged. Tighten the clamps securely.
KC445A
CHECKING AND CLEANING DRAIN
1. Inspect the drain on the filter housing cover and
clean out any dirt or debris.
KC397B
2. Replace any drain that is cracked or shows any signs
of hardening or deterioration.
3. Wipe any accumulation of oil or gas from the filter
housing and drain.
Valve/Tappet Clearance
To check and adjust valve/tappet clearance, use the fol-
lowing procedure.
NOTE: The seat, left-side and right-side engine
covers, and gas tank must be removed for this pro-
cedure.
1. Remove the timing inspection plug and spark plug;
then remove the tappet covers (for more detailed
information, see Engine/Transmission - Servicing
Top-Side Components).
CF005
2. Rotate the crankshaft to the TDC position on the
compression stroke.
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
Feeler Gauge Procedure
Using a feeler gauge, check each valve/tappet clearance.
If clearance is not within specifications, loosen the jam
nut and rotate the tappet adjuster screw until the clear-
ance is within specifications. Tighten each jam nut
securely after completing the adjustment.
CAUTION
Failure to properly seat and align the filter element may
cause severe engine damage.
CAUTION
Failure to fully engage the inlet boots to the indicator
marks could result in ingestion of dirt and severe
engine damage.
CAUTION
The feeler gauge must be positioned at the same angle
as the valve and valve adjuster for an accurate measure-
ment of clearance. Failure to measure the valve clear-
ance accurately could cause valve component damage.
VALVE/TAPPET CLEARANCE
Intake 0.076-0.127 mm (0.003-0.005 in.)
Exhaust 0.152-0.203 mm (0.006-0.008 in.)
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9
CC007DC
Valve Adjuster Procedure
A. Place the Valve Clearance Adjuster onto the jam
nut securing the tappet adjuster screw; then rotate
the valve adjuster dial clockwise until the end is
seated in the tappet adjuster screw.
B. While holding the valve adjuster dial in place, use
the valve adjuster handle and loosen the jam nut;
then rotate the tappet adjuster screw clockwise
until friction is felt.
C. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
D. While holding the valve adjuster handle in place,
rotate the valve adjuster dial counterclockwise
until proper valve/tappet clearance is attained.
NOTE: Refer to the appropriate specifications in
Feeler Gauge Procedure sub-section for the proper
valve/tappet clearance.
NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.
E. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely
with the valve adjuster handle.
3. Install the timing inspection plug.
4. Place the two tappet covers with O-rings into posi-
tion; then tighten the covers securely.
5. Install the spark plug; then install the timing inspec-
tion plug.
Testing Engine
Compression
To test engine compression, use the following procedure.
1. Remove the high tension lead from the spark plug.
2. Using compressed air, blow any debris from around
the spark plug.
3. Remove the spark plug; then attach the high tension
lead to the plug and ground the plug on the cylinder
head well away from the spark plug hole.
4. Attach the Compression Tester Kit.
NOTE: The engine must be warm and the battery
must be fully charged for this test.
5. While holding the throttle lever in the full-open posi-
tion, crank the engine over with the electric starter
until the gauge shows a peak reading of 95-115 psi
(five to 10 compression strokes).
6. If compression is abnormally low, inspect the
following items.
A. Verify starter cranks engine over at normal speed
(approximately 400 RPM).
B. Gauge functioning properly.
C. Throttle lever in the full-open position.
D. Valve/tappet clearance correct.
E. Valve not bent or burned.
F. Valve seat not burned.
NOTE: To service valves, see Engine/Transmis-
sion.
7. Pour approximately 30 ml (1 fl oz) of oil into the
spark plug hole, reattach the gauge, and retest com-
pression.
8. If compression is now evident, service the piston
rings (see Engine/Transmission).
Spark Plug
A light brown insulator indicates that a plug is correct. A
white or dark insulator indicates that the engine may need
to be serviced. To maintain a hot, strong spark, keep the
plug free of carbon.
ATV-0051
Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.) for proper
ignition. Use a feeler gauge to check the gap.
! WARNING
Always wear safety glasses when using compressed
air.
CAUTION
Before removing a spark plug, be sure to clean the area
around the spark plug. Dirt could enter engine when
removing or installing the spark plug.
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ATV0052C
When installing the spark plug, be sure to tighten it
securely. A new spark plug should be tightened 1/2 turn
once the washer contacts the cylinder head. A used spark
plug should be tightened 1/8 - 1/4 turn once the washer
contacts the cylinder head.
Liquid Cooling System
NOTE: Debris in front of the engine or packed
between the cooling fins of the radiator can reduce
cooling capability. Using a garden hose, wash the
radiator to remove any debris preventing air flow.
The cooling system capacity can be found in the specifi-
cations chart. The cooling system should be inspected
daily for leakage and damage. If leakage or damage is
detected, take the ATV to an authorized Arctic Cat ATV
dealer for service. Also, the coolant level should be
checked periodically.
NOTE: High engine RPM, low vehicle speed, or
heavy load can raise engine temperature. Decreas-
ing engine RPM, reducing load, and selecting an
appropriate transmission gear can lower the tem-
perature.
When filling the cooling system, use a coolant/water
mixture which will satisfy the coldest anticipated weather
conditions of the area in accordance with the coolant
manufacturer’s recommendations. While the cooling sys-
tem is being filled, air pockets may develop; therefore,
run the engine for five minutes after the initial fill, shut
the engine off, and then fill the cooling system to the bot-
tom of the stand pipe in the radiator neck.
Checking/Filling
1. Locate the coolant reservoir on the right side behind
the radiator.
2. Remove the cap and fill with the appropriate coolant
until coolant level is between the LOW and FULL
lines. Do not overfill.
KC396A
3. Install the cap on the reservoir.
Muffler/Spark Arrester
At the intervals shown in the Periodic Maintenance
Chart, clean the spark arrester using the following proce-
dure.
1. Remove the cap screws securing the spark arrester
assembly to the muffler; then loosen and remove the
arrester.
KC374A
2. Using a suitable brush, clean the carbon deposits
from the screen taking care not to damage the screen.
NOTE: If the screen or gasket is damaged in any
way, it must be replaced.
3. Install the spark arrester assembly with gasket; then
secure with the cap screws. Tighten to 48 in.-lb.
CAUTION
Do not use a pressure washer to clean the radiator core.
The pressure may bend or flatten the fins causing
restricted air flow, and electrical components on the
radiator could be damaged. Use only a garden hose with
spray nozzle at normal tap pressure.
CAUTION
Continued operation of the ATV with high engine tem-
perature may result in engine damage or premature
wear.
! WARNING
Wait until the muffler cools to avoid burns.
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Adjusting Throttle Cable
To adjust the throttle cable free-play, follow this proce-
dure.
1. Slide the rubber boot away; then loosen the jam nut
from the throttle cable adjuster.
AL611D
2. Turn the adjuster until the throttle cable has proper
free-play of 3-6 mm (1/8-1/4 in.) at the lever.
ATV-0047
3. Tighten the jam nut against the throttle cable adjuster
securely; then slide the rubber boot over the adjuster.
Adjusting Engine RPM
(Idle)
NOTE: Engine idle RPM is not adjustable on this
model.
Engine/Transmission Oil -
Filter
The engine should always be warm when the oil is
changed so the oil will drain easily and completely.
1. Park the ATV on level ground.
2. Remove the seat and left-side engine cover.
3. Remove the oil level stick/filler plug.
KC0051A
4. Remove the drain plug from the bottom of the engine
and drain the oil into a drain pan.
733-441A
5. Remove the oil filter plug from the filter mounting
boss (located on the front side of the transmission
case) and allow the filter to drain completely. Install
the plug and tighten securely.
6. Using the adjustable Oil Filter Wrench and a suitable
wrench, remove the old oil filter.
NOTE: Clean up any excess oil after removing
the filter.
7. Apply oil to a new filter seal ring and check to make
sure it is positioned correctly; then install the new oil
filter. Tighten securely.
8. Install the engine drain plug and tighten to 20 ft-lb.
Pour the specified amount of the recommended oil in
the filler hole. Install the oil level stick/filler plug.
9. Start the engine (while the ATV is outside on level
ground) and allow it to idle for a few minutes.
10. Turn the engine off and wait approximately one min-
ute.
11. Remove the oil level stick and wipe it with a clean
cloth.
12. Install the oil level into engine case.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.
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NOTE: The oil level stick should be threaded into
the case for checking purposes.
13. Remove the oil level stick; the engine oil level should
be above the illustrated “L” mark but not higher than
the illustrated “F” mark.
ATV-0100AA
14. Inspect the area around the drain plug and oil filter
for leaks.
15. Install the left-side engine cover and the seat.
Front Differential/Rear
Drive Lubricant
When changing the lubricant, use approved SAE 80W-90
hypoid gear lube.
To check lubricant, remove the rear drive filler plug; the
lubricant level should be 1 in. below the threads of the
plug. If low, add SAE approved 80W-90 hypoid gear
lubricant as necessary.
To change the lubricant, use the following procedure.
1. Place the ATV on level ground.
2. Remove each fill plug.
KC0077A
3. Drain the lubricant into a drain pan by removing the
drain plug from each.
ATV0082A
737-651B
4. After all the oil has been drained, install the drain
plugs and tighten to 45 in.-lb.
5. Pour the appropriate amount of approved SAE 80W-
90 hypoid gear lubricant into the filler hole.
6. Install the fill plugs and tighten to 16 ft-lb.
NOTE: If the differential/rear drive oil is contami-
nated with water, inspect the drain plug, filler plug,
and/or bladder.
Tires
TIRE SIZES
The ATV is equipped with low-pressure tubeless tires of
the size and type listed (see General Information). Do not
under any circumstances substitute tires of a different
type or size.
TIRE INFLATION PRESSURE
Front and rear tire inflation pressure should be 40.0 kPa
(5.7 psi).
CAUTION
Do not over-fill the engine with oil. Always make sure
that the oil level is above the “L” mark but not higher
than the “F” mark.
CAUTION
Water entering the outer end of the axle will not be able
to enter the rear drive unless the seals are damaged.
! WARNING
Always use the size and type of tires specified. Always
maintain proper tire inflation pressure.
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Driveshaft/Coupling
The following drive system components should be
inspected periodically to ensure proper operation.
A. Spline lateral movement (slop).
B. Coupling cracked, damaged, or worn.
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure rivets
holding components together are tight. Replace all loose
rivets. Care must be taken that all calibrated nuts, bolts,
and cap screws are tightened to specifications.
Ignition Timing
The ignition timing cannot be adjusted; however, verifying
ignition timing can aid in troubleshooting other components.
To verify ignition timing, use the following procedure.
1. Attach the Timing Light to the spark plug high ten-
sion lead; then remove the timing inspection plug
from the left-side crankcase cover.
2. Using the Tachometer, start the engine and run at
1500 RPM; ignition timing should be 10° BTDC.
3. Install the timing inspection plug.
If ignition timing cannot be verified, the rotor may be
damaged, the key may be sheared, the trigger coil bracket
may be bent or damaged, or the CDI unit/ECU may be
faulty.
Lights
Rotate the ignition switch to the running lights position;
the running lights and taillights should illuminate. Test the
brakelights by compressing the brake lever. The brake-
lights should illuminate. Shift the Hi/Lo beam switch to
the Lo position; the low beam headlights should illumi-
nate. In the Hi position, the high beam headlights should
illuminate. The running/tail lights will remain illuminated
until the ignition switch is switched to the run position.
HEADLIGHTS
NOTE: The bulb portion of a headlight is fragile.
HANDLE WITH CARE. When replacing a headlight
bulb, do not touch the glass portion of the bulb. If
the glass is touched, it must be cleaned with a dry
cloth before installing. Skin oil residue on the bulb
will shorten the life of the bulb.
To replace the headlight bulbs, use the following proce-
dure.
1. Remove four screws securing the headlight access
panel to the headlight housing.
KC429A
2. Remove the headlight bulb by rotating the bulb
assembly and removing from the headlight housing;
then spread the retaining clips and disconnect the
bulb assembly from the connector.
KC431A
KC432A
3. Install the new bulb assembly into the connector;
then insert the bulb assembly into the housing and
rotate to lock.
4. Install the access panel and secure with the screws.
TAILLIGHTS-BRAKELIGHTS
To replace a taillight-brakelight bulb, use the following
procedure.
1. Remove the cap screw and screw securing the tail-
light housing cover to the taillight housing; then
twist and remove the bulb socket.
! WARNING
Do not attempt to remove a bulb when it is hot. Severe
burns may result.
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KC433A
KC434A
2. Turn the bulb socket assembly counterclockwise and
remove from the housing.
3. Press in and turn the bulb counterclockwise to
remove. Press in and turn clockwise to install the
bulb.
4. Insert the bulb socket assembly into the housing and
turn it clockwise to secure.
5. Secure the housing cover with the two fasteners.
RUNNING LIGHTS
The running lights are located outboard of the headlights.
To replace the running light bulbs, use the following pro-
cedure.
1. Rotate the bulb socket counterclockwise to release
from light housing; then press in on the bulb and turn
counterclockwise to release from the socket.
KC428A
2. Install a new bulb and press in rotating clockwise to
secure; then place the socket into the light housing
and turn clockwise to secure.
KC428B
BACK-UP LIGHTS
The back-up lights are located outboard of the taillights/
brakelights. To replace the back-up light bulbs, use the
following procedure.
1. Remove the taillight housing cover (see taillights-
brakelights in this section).
2. Remove two screws securing the back-up light
socket to the taillight housing. Account for a small
gasket.
KC435A
KC436A
3. Twist the bulb counterclockwise and remove from
the socket; then press in and rotate the new bulb
clockwise.
4. Secure the socket to the housing making sure the
gasket is in place.
5. Install the housing cover.
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CHECKING/ADJUSTING HEADLIGHT
AIM
The headlights can be adjusted vertically and horizon-
tally. The geometric center of the HIGH beam light zone
is to be used for vertical and horizontal aiming.
1. Position the ATV on a level floor so the headlights
are approximately 6.1 m (20 ft) from an aiming sur-
face (wall or similar aiming surface).
ATV-0070C
NOTE: There should be an average operating
load on the ATV when adjusting the headlight aim.
2. Measure the distance from the floor to the mid-point
of each headlight.
3. Using the measurements obtained in step 2, make
horizontal marks on the aiming surface.
4. Make vertical marks which intersect the horizontal
marks on the aiming surface directly in front of the
headlights.
5. Switch on the lights. Make sure the HIGH beam is
on. DO NOT USE LOW BEAM.
6. Observe each headlight beam aim. Proper aim is
when the most intense beam is centered on the verti-
cal mark 5 cm (2 in.) below the horizontal mark on
the aiming surface.
7. Adjust each headlight by turning the adjuster screw
clockwise to raise the beam or counterclockwise to
lower the beam.
KC406A
Shift Lever
CHECKING ADJUSTMENT
KC165
With the engine stopped and the brake lever lock
engaged, turn the ignition switch to the ON position; then
shift the transmission into each of the gear positions and
note that the gear position indicated on the LCD corre-
sponds to the gear position selected by the lever.
If the indicator does not correspond to the selected gear,
it will be necessary to test drive the ATV to determine if
the gear position switch is faulty or the shift lever needs
adjustment.
If the ATV functions in the gear selected by the shift
lever, troubleshoot the gear position switch (see Electri-
cal System).
If the ATV functions but the shift lever does not corre-
spond with the gear indicated on the LCD, adjust the shift
linkage. To adjust, proceed to ADJUSTING.
ADJUSTING
1. Remove the seat; then remove the left-side engine
cover.
2. With the ignition switch in the ON position, loosen
jam nut (A) (left-hand threads); then loosen jam nut
(C) and with the shift lever in the reverse position,
adjust the coupler (B) until the transmission is in
reverse and the “R” icon appears on the LCD.
KC437A
3. Tighten the jam nuts securely; then shift the trans-
mission to each position and verify correct adjust-
ment.
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4. Install the left-side engine cover and seat making
sure the seat locks securely in place.
Frame/Welds
The frame and welds should be checked periodically for
damage, bends, cracks, deterioration, broken compo-
nents, and missing components. If replacement or repair
constitutes removal, see Steering/Frame.
Hydraulic Brake Systems
CHECKING/BLEEDING
The hydraulic brake systems have been filled and bled at
the factory. To check and/or bleed a hydraulic brake sys-
tem, use the following procedure.
1. With the master cylinders in a level position, check
the fluid level in the reservoirs. On the hand brakes if
the level in the reservoir is adequate, the sight win-
dows will appear dark. If the level is low, the sight
windows will appear clear.
KC387A
2. Compress the brake levers/pedal several times to
check for a firm brake. If the brake is not firm, the
systems must be bled.
3. To bleed the brake systems, use the following proce-
dure.
A. Remove the cover and fill the appropriate reser-
voir with DOT 4 Brake Fluid (left hand brake/foot
pedal - rear system; right hand brake - front brake
system).
B. Install and secure the cover; then slowly compress
the brake lever several times.
C. Remove the protective cap, install one end of a
clear hose onto one FRONT bleeder screw, and
direct the other end into a container; then while
holding slight pressure on the right brake lever,
open the bleeder screw and watch for air bubbles.
Close the bleeder screw before releasing the brake
lever. Repeat this procedure until no air bubbles
are present.
AF637D
PR377C
NOTE: During the bleeding procedure, watch the
appropriate reservoir very closely to make sure
there is always a sufficient amount of brake fluid. If
low, refill the reservoir before the bleeding proce-
dure is continued. Failure to maintain a sufficient
amount of fluid in the reservoir will result in air in
the system.
D. Repeat step C until the brake lever is firm.
E. At this point, perform step B, C, and D on the
other FRONT bleeder screw; then move to the
REAR bleeder screw and follow the same proce-
dure using the left brake lever or foot pedal.
4. Carefully check the entire hydraulic brake system
that all hose connections are tight, the bleed screws
are tight, the protective caps are installed, and no
leakage is present.
INSPECTING HOSES
Carefully inspect the hydraulic brake hoses for cracks or
other damage. If found, the brake hoses must be replaced.
CAUTION
Brake fluid that has been drained or bled from the brake
system must NEVER be re-used or severe brake system
corrosion and damage may occur. Always discard used
brake fluid in an appropriate manner.
CAUTION
This hydraulic brake system is designed to use DOT 4
brake fluid only. If brake fluid must be added, care must be
taken as brake fluid is very corrosive to painted surfaces.
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CHECKING/REPLACING PADS
The clearance between the brake pads and brake discs is
adjusted automatically as the brake pads wear. The only
maintenance that is required is replacement of the brake
pads when they show excessive wear. Check the thick-
ness of each of the brake pads as follows.
1. Remove a front wheel.
2. Measure the thickness of each brake pad.
3. If thickness of either brake pad is less than 1.0 mm
(0.039 in.), the brake pads must be replaced.
PR376B
NOTE: The brake pads should be replaced as a
set.
4. To replace the brake pads, use the following proce-
dure.
A. Remove the cap screws securing the caliper
holder to the knuckle; then remove the pads.
PR237
B. Install the new brake pads.
C. Secure the caliper to the knuckle and/or axle
housing with the cap screws. Tighten to 20 ft-lb.
PR377B
5. Install the wheel. Tighten to 40 ft-lb.
6. Burnish the brake pads (see Burnishing Brake Pads
in this section).
Burnishing Brake Pads
Brake pads must be burnished to achieve full braking
effectiveness. Braking distance will be extended until
brake pads are properly burnished. To properly burnish
the brake pads, use the following procedure.
1. Choose an area large enough to safely accelerate the
ATV to 30 mph and to brake to a stop.
2. Accelerate to 30 mph; then compress brake levers or
brake pedal to decelerate to 0-5 mph.
3. Repeat procedure on each brake system twenty
times.
4. Verify the brakelights illuminate when the hand lever
is compressed or the brake pedal is depressed.
Checking/Replacing V-
Belt
REMOVING
1. Remove the cap screw securing the brake pedal to
the frame. Account for a flat washer.
! WARNING
Failure to properly burnish the brake pads could lead to
premature brake pad wear or brake loss. Brake loss can
result in severe injury.
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KC149A
2. Remove the cotter pin from the brake clevis pin; then
slide the brake pedal away from the frame suffi-
ciently to remove the clevis pin.
KC439
3. Lower the brake pedal down to the foot wells and
remove the reinstallable rivet from the CVT cut-out
in the foot well.
4. Remove the cap screws from the CVT cover and
remove the cover accounting for two alignment pins.
5. Remove the nut securing the movable drive face to
the clutch shaft; then remove the movable drive face
assembly being careful not to let the rollers fall out.
Account for a bushing.
KC127
KC128
6. Thread a cap screw from the V-belt cover into the
driven pulley fixed face and push the movable face
open allowing the V-belt to drop down between the
pulley faces approximately 3/4 in.
KC137
7. Pinching the V-belt together in front of the driven
pulley, pull it forward and outward off the clutch
shaft; then remove it from the driven pulley.
KC136
8. Inspect the faces of the drive and driven pulleys for
scoring, pitting, cracks, or grooving; then clean any
dirt and debris from the V-belt housing and cover.
INSTALLING
1. Place the V-belt onto the driven pulley making sure
the arrows on the belt point in the direction of rota-
tion; then pinch the belt together in front of the
driven pulley and place it over the clutch shaft.
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KC135
KC131
2. Install the bushing over the clutch shaft; then install
the movable drive face assembly on the clutch shaft.
KC128
KC138
3. With two drops of red Loctite #271 on the threads
and with the splines of the clutch shaft protruding
through the movable drive face, install the nut and
tighten to 147 ft-lb.
KC152A
KC141
4. Remove the cap screw from the fixed driven face;
then rotate the pulleys counterclockwise until the
driven pulley faces are together.
5. With the two alignment pins installed in the V-belt
housing and a new V-belt cover gasket in place,
install the V-belt cover. Using the pattern shown,
secure with the cap screws tightened to 8 ft-lb.
KC142A
KC153A
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