Arctic_cat_2012_450_1000_service_manual Arctic Cat 2012 450 1000 Service Manual

• FOREWORD
• TABLE OF CONTENTS
  • 1. GENERAL INFORMATION/ SPECIFICATIONS
    • 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
  • SECTION 2 - PERIODIC MAINTENANCE
    • Periodic Maintenance Chart
    • Periodic Maintenance
      • SPECIAL TOOLS
    • Lubrication Points
    • Air Filter
      • CHECKING AND CLEANING DRAINS
    • Valve/Tappet Clearance
      • Feeler Gauge Procedure
      • Valve Adjuster Procedure
    • Testing Engine Compression
    • Spark Plug(s)
    • Muffler/Spark Arrester
    • Engine/Transmission Oil - Filter - Strainer
      • OIL - FILTER
    • Liquid Cooling System
      • Checking/Filling
    • Front Differential/Rear Drive Lubricant
    • Nuts/Bolts/Cap Screws
    • Headlights/Taillight-Brakelight
      • CHECKING/ADJUSTING HEADLIGHT AIM
    • Shift Lever
      • CHECKING ADJUSTMENT
      • ADJUSTING SHIFT LEVER
    • Hydraulic Brake Systems
      • CHECKING/BLEEDING
      • INSPECTING HOSES
      • CHECKING/REPLACING PADS
    • Burnishing Brake Pads
    • Checking/Replacing V-Belt
      • REMOVING
      • INSTALLING
  • SECTION 3 - ENGINE/TRANSMISSION
    • Engine/Transmission
      • SPECIAL TOOLS
    • Specifications (450)
    • Specifications (1000)
    • Troubleshooting
    • Table of Contents (450)
      • 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
    • Table of Contents (1000)
      • Removing Engine/ Transmission
      • Top-Side Components
      • Removing Top-Side Components
        • A. Valve Cover/Rocker Arms B. Cylinder Head/Camshaft
        • C. Cylinders D. Pistons
      • Servicing Top-Side Components
        • VALVE ASSEMBLY
          • Cleaning/Inspecting Valve 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/Valve Stem Deflection (Wobble Method)
          • 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 Rings
          • Measuring Piston-Ring End Gap (Installed)
          • Measuring Piston Pin (Outside Diameter) 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
          • Inspecting Cylinder
          • Measuring Camshaft Runout
          • Measuring Camshaft Lobe Height
          • Inspecting Camshaft Bearing Journal
          • Measuring Camshaft to Cylinder Head Clearance
          • Inspecting Camshaft Spring/Drive Pin (Front Camshaft Only)
      • Installing Top-Side Components
        • A. Pistons B. Cylinders
        • C. Cylinder Head D. Valve Cover
      • Left-Side Components
      • Removing Left-Side Components
        • A. Magneto Cover/Stator Coils B. Water Pump C. Shifter Assembly D. Rotor/Flywheel/Starter Clutch E. Speed Sensor/ Trigger Assembly
      • Installing Left-Side Components
      • Right-Side Components
      • Removing Right-Side Components
        • A. V-Belt Cover B. Driven Pulley C. Clutch Cover D. Centrifugal Clutch
      • Servicing Right-Side Components
        • INSPECTING CENTRIFUGAL CLUTCH SHOE
        • INSPECTING CLUTCH HOUSING
        • INSPECTING PRIMARY ONE-WAY DRIVE
        • DRIVEN PULLEY ASSEMBLY
      • Installing Right-Side Components
      • Center Crankcase Components
      • Separating Crankcase Halves
      • Disassembling Crankcase Half
      • Servicing Center Crankcase Components
        • SECONDARY OUTPUT DRIVE GEARS
          • Initial Set-Up
          • Checking Backlash
          • Correcting Backlash
        • OIL PUMP ASSEMBLY
          • Disassembling and Inspecting
          • Assembling
        • 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
  • SECTION 4 - FUEL/LUBRICATION/COOLING
    • Fuel/Lubrication/Cooling
      • SPECIAL TOOLS
    • Electronic Fuel Injection
      • TROUBLESHOOTING
      • REMOVING (450)
      • REMOVING (1000)
      • INSTALLING (450)
      • INSTALLING (1000)
    • Throttle Cable Free-Play
    • Engine RPM (Idle)
    • Gas Tank
      • REMOVING
      • CLEANING AND INSPECTING
      • INSTALLING
    • Oil Filter/Oil Pump
    • Testing Oil Pump Pressure
    • Oil Cooler (1000)
      • REMOVING
      • INSTALLING
    • Liquid Cooling System
      • RADIATOR
        • Removing
        • Cleaning and Inspecting
        • Installing
      • THERMOSTAT
        • Removing (450)
        • Removing (1000)
        • Inspecting
        • Installing (450)
        • Installing (1000)
      • COOLING FAN
        • Removing
        • Installing
      • WATER PUMP (450)
        • Removing
        • Installing
      • WATER PUMP (1000)
        • Removing
        • Installing
    • Electric Fuel Pump/Fuel Level Sensor
      • TESTING
      • REMOVING
      • INSPECTING
      • INSTALLING
    • Troubleshooting
  • SECTION 5 - ELECTRICAL SYSTEM
    • Electrical System
      • SPECIAL TOOLS
    • Electrical Connections
    • Battery
      • Maintenance Charging
      • Charging
    • RPM Limiter
    • Testing Electrical Components
    • Accessory Receptacle/Connector
      • VOLTAGE
    • Brakelight Switch (Auxiliary)
      • VOLTAGE (Wiring Harness Side)
      • RESISTANCE (Switch Connector)
    • Brakelight Switch (Handlebar Control)
      • VOLTAGE (Wiring Harness Connector)
      • RESISTANCE (Switch Connector)
    • Engine Coolant Temperature (ECT) Sensor
    • Fan Motor
      • RESISTANCE (Fan Motor Connector)
    • Power Distribution Module (PDM)
      • FUSES
      • RELAYS
    • Ignition Coil
      • RESISTANCE
        • Primary Winding
        • Secondary Winding
        • Spark Plug Cap
        • Primary Voltage - ECU (1000)
    • EFI Sensors/Components
      • CRANKSHAFT POSITION (CKP) SENSOR
      • MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR (1000 Models)
      • INLET AIR TEMPERATURE (IAT) SENSOR (1000 Models)
      • MANIFOLD ABSOLUTE PRESSURE/ INLET AIR TEMPERATURE (MAP/IAT) SENSOR (450)
    • Speed Sensor
    • Electronic Power Steering (EPS)
    • Ignition Switch
      • VOLTAGE
      • RESISTANCE
    • Handlebar Control Switches
      • RESISTANCE (HI Beam)
      • RESISTANCE (LO Beam)
      • DIODE (Starter Button)
      • RESISTANCE (Engine Stop Switch)
      • RESISTANCE (Reverse Override)
    • Drive Select Switch
      • RESISTANCE
      • VOLTAGE
    • Front Drive/Differential Lock Actuator
      • VOLTAGE
    • Stator Coil/Crankshaft Position (CKP) Sensor
      • VOLTAGE (AC Generator - Regulated Output)
      • VOLTAGE (AC Generator - No Load)
      • RESISTANCE (AC Generator)
      • RESISTANCE (Crankshaft Position Sensor)
      • AC VOLTAGE
        • Crankshaft Position Sensor
    • Starter Relay
    • Starter Motor
      • TESTING VOLTAGE
      • REMOVING
      • INSTALLING
    • Electronic Control Unit (ECU)
    • Regulator/Rectifier
      • TESTING
    • Headlights
      • VOLTAGE
    • Taillight - Brakelight
      • VOLTAGE (Taillight)
      • VOLTAGE (Brakelight)
    • Ignition Timing
    • Tilt Sensor
      • SUPPLY VOLTAGE
      • OUTPUT VOLTAGE
    • Throttle Position Sensor (TPS) (450)
      • INSPECTING
      • REMOVING
      • INSTALLING/ADJUSTING
    • Throttle Position Sensor (TPS) (1000 FIS)
      • INSPECTING
      • REMOVING
      • INSTALLING/ADJUSTING
    • Throttle Position Sensor (TPS) (1000 TRV/1000 Cruiser/1000 Mud Pro)
      • INSPECTING
      • REMOVING
      • INSTALLING/ADJUSTING
    • Diagnostic Trouble Codes (DTC) (1000 FIS)
      • Code List
    • Diagnostic Trouble Codes (DTC) (450/1000 TRV/1000 Cruiser/1000 Mud Pro)
      • Code List
    • Troubleshooting
  • SECTION 6 - DRIVE SYSTEM/ BRAKE SYSTEM
    • Drive System/Brake System
      • GENERAL INFORMATION
      • SPECIAL TOOLS
    • Front Drive Actuator/Differential Lock
      • REMOVING
      • INSTALLING
    • Front Differential
      • REMOVING DIFFERENTIAL
        • Disassembling Input Shaft
        • Assembling Input Shaft
        • Disassembling Differential Assembly
        • Disassembling Pinion Gear
        • Assembling Pinion Gear
        • Shimming Procedure/Shim Selection
        • Backlash
        • Ring Gear End-Play
        • Assembling Differential Assembly
        • Removing/Installing Axle Seal
      • INSTALLING DIFFERENTIAL
    • Drive Axles
      • REMOVING REAR DRIVE AXLE
      • REMOVING FRONT DRIVE AXLE
      • CLEANING AND INSPECTING
      • DISASSEMBLING/INSPECTING/ASSE- MBLING AXLES
      • INSTALLING REAR DRIVE AXLE
      • INSTALLING FRONT DRIVE AXLE
    • Rear Gear Case
      • REMOVING
      • RING GEAR/THRUST BUTTON
        • Removing
        • Inspecting
        • Installing/Shimming
      • REAR DRIVE INPUT SHAFT/ HOUSING (1000)
        • Removing/Disassembling
        • Cleaning and Inspecting
        • Assembling/Installing
      • 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
  • SECTION 7 - SUSPENSION
    • Suspension
    • Shock Absorbers
      • REMOVING
      • CLEANING AND INSPECTING
      • 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
  • SECTION 8 - STEERING/FRAME/CONTROLS
    • Steering/Frame/Controls
    • LCD Gauge
      • REPLACING
    • Steering Post/Tie Rods
      • REMOVING
      • CLEANING AND INSPECTING
      • INSTALLING (Models Without Electronic Power Steering)
      • INSTALLING (Electronic Power Steering Models)
    • Handlebar Grip
      • REMOVING
      • INSPECTING
      • INSTALLING
    • Throttle Control
      • REMOVING
      • INSTALLING
      • ADJUSTING
    • Steering Knuckles
      • REMOVING AND DISASSEMBLING
      • CLEANING AND INSPECTING
      • ASSEMBLING AND INSTALLING
    • Measuring/Adjusting Toe-Out
    • Shift Lever
      • REMOVING
      • INSTALLING
    • Front Rack
      • REMOVING
      • CLEANING AND INSPECTING
      • INSTALLING
    • Front Bumper Assembly
      • REMOVING
      • CLEANING AND INSPECTING
      • INSTALLING
    • Front Body Panel/Side Panels
      • REMOVING
      • CLEANING AND INSPECTING
      • INSTALLING
    • Footrests
      • REMOVING
      • CLEANING AND INSPECTING
      • INSTALLING
    • Belly Panel
      • REMOVING/INSTALLING
    • Exhaust System
      • REMOVING MUFFLER
      • INSPECTING MUFFLER
      • INSTALLING MUFFLER
    • Rear Body Panel/Rack
      • REMOVING
      • CLEANING AND INSPECTING
      • INSTALLING
    • Taillight Assembly
      • REMOVING
      • INSPECTING
      • INSTALLING
    • Seat
      • REMOVING/INSTALLING
    • Troubleshooting