Arctic Cat 2012 Xl450I Xl 450I Service Manual-21031A320056.pdf -Bookmark created by https://wimanual.com FOREWORD TABLE OF CONTENTS General Information General Specifications Torque Specifications Torque Conversions (ft-lb Break-In Procedure Gasoline - Oil - Lubricant RECOMMENDED GASOLINE RECOMMENDED ENGINE RECOMMENDED FRONT DIFFERENTIAL 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 Feeler Gauge Procedure Valve Adjuster Procedure Testing Engine Compression Spark Plug Liquid Cooling System Checking Muffler Adjusting Throttle Cable Adjusting Engine RPM (Idle) Engine Front Differential Tires TIRE SIZES TIRE INFLATION PRESSURE Driveshaft Nuts Ignition Timing Lights HEADLIGHTS TAILLIGHTS-BRAKELIGHTS RUNNING LIGHTS BACK-UP LIGHTS CHECKING Shift Lever CHECKING ADJUSTMENT ADJUSTING Frame Hydraulic Brake Systems CHECKING INSPECTING HOSES CHECKING Burnishing Brake Pads Checking REMOVING INSTALLING Engine SPECIAL TOOLS Troubleshooting Removing Engine Top-Side Components Removing Top-Side Components A. Cylinder Head Cover C. Cylinder D. Piston Servicing Top-Side Components VALVE ASSEMBLY Cleaning Removing Valves Measuring Valve Stem Runout Measuring Valve Stem Outside Diameter Measuring Valve Face Measuring Valve Face Radial Runout Measuring Valve Guide (Inside Diameter) Servicing Valves Measuring Rocker Arm (Inside Diameter) Measuring Rocker Arm Shaft (Outside Diameter) Installing Valves PISTON ASSEMBLY Cleaning Removing Piston Rings Cleaning Measuring Piston-Ring End Gap (Installed) Measuring Piston Pin, Connecting Rod Small End, and Piston-Pin Bore Measuring Piston Skirt Installing Piston Rings CYLINDER Cleaning Measuring Cylinder Head Distortion Cleaning 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 Installing Top-Side Components A. Piston B. Cylinder C. Cylinder Head Left-Side Components Removing Left-Side Components A. Water Pump B. Speed Sensor C. Magneto Cover D. Rotor G. Shift Shaft H. Drive Gear Servicing Left-Side Components INSPECTING STARTER CLUTCH REPLACING STARTER CLUTCH ASSEMBLY REPLACING STARTER GEAR BEARING INSPECTING STATOR REPLACING STATOR COIL REPLACING MAGNETO COVER BEARINGS Installing Left-Side Components A. Starter Clutch 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 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 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 Fuel SPECIAL TOOLS Electronic Fuel Injection TROUBLESHOOTING Throttle Body REMOVING INSTALLING Throttle Cable Free-Play Gas Tank REMOVING CLEANING AND INSPECTING INSTALLING Oil Filter Testing Oil Pump Pressure Liquid Cooling System RADIATOR Removing Cleaning and Inspecting Installing THERMOSTAT Removing Inspecting Installing WATER PUMP Removing Installing Electric Fuel Pump 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 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 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 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 Backlash Ring Gear End-Play RING GEAR Removing Inspecting Installing Assembling Differential Assembly Removing Needle Bearing Installing Needle Bearing Removing 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 REMOVING INSPECTING INSTALLING Hydraulic Brake Caliper REMOVING CLEANING AND INSPECTING ASSEMBLING 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 Troubleshooting Steering Steering Post REMOVING CLEANING AND INSPECTING INSTALLING Speedometer REPLACING Handlebar Grip REMOVING INSTALLING Throttle Control REMOVING INSTALLING ADJUSTING Steering Knuckles REMOVING AND DISASSEMBLING CLEANING AND INSPECTING ASSEMBLING AND INSTALLING Measuring Front Bumper Assembly REMOVING INSTALLING Front Body Panel REMOVING CLEANING AND INSPECTING INSTALLING Exhaust System REMOVING MUFFLER INSPECTING MUFFLER INSTALLING MUFFLER Rear Body Panel REMOVING CLEANING AND INSPECTING INSTALLING Seat REMOVING Troubleshooting . 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