2010 ARCTIC CAT 450 ATV * DIY (DO IT YOURSELF) FACTORY SERVICE / REPAIR / MAINTENANCE MANUAL - BEST MANUAL - DOWNLOAD (38 MB ) VERY HIGH QUALITY FACTORY SERVICE MANUAL - THIS IS THE BEST MANUAL YOU COULD GET ANYWHERE!! BOOKMARKS - INDEX - SEARCHABLE TEXT - AND WHAT NOT !! SERVICE MANUAL COVERS: ================== 2010 ARCTIC CAT 450 SECTIONS Section 1. General Information/Specifications 2. Periodic Maintenance 3. Engine/Transmission 4. Fuel/Lubrication/Cooling 5. Electrical System 6. Drive System 7. Suspension 8. Steering/Frame 9. Controls/Indicator 2010 ARCTIC CAT 450 SUB SECTIONS WITH ACTUAL PAGE NUMBERS SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS TABLE OF CONTENTS General Specifications ............................................ 1-2 Torque Specifications .............................................. 1-2 Torque Conversions (ft-lb/N-m) ............................... 1-3 Tightening Torque (General Bolts) .......................... 1-3 Break-In Procedure ................................................. 1-3 Gasoline - Oil - Lubricant ........................................ 1-3 Genuine Parts ......................................................... 1-4 Preparation For Storage.......................................... 1-4 Preparation After Storage........................................ 1-5 SECTION 2 - PERIODIC MAINTENANCE TABLE OF CONTENTS Periodic Maintenance Chart.................................... 2-2 Periodic Maintenance.............................................. 2-3 Lubrication Points.................................................... 2-3 Air Filter................................................................... 2-3 Valve/Tappet Clearance (Feeler Gauge Procedure) ................................... 2-4 Valve/Tappet Clearance (Valve Adjuster Procedure) .................................. 2-4 Testing Engine Compression .................................. 2-5 Spark Plug............................................................... 2-6 Muffler/Spark Arrester ............................................. 2-6 Engine/Transmission Oil - Filter - Strainer .............. 2-6 Front Differential/Rear Drive Lubricant .................... 2-8 Driveshaft/Coupling................................................. 2-9 Nuts/Bolts/Cap Screws............................................ 2-9 Headlights/Taillight-Brakelight ................................. 2-9 Shift Lever ............................................................. 2-10 Frame/Welds/Racks .............................................. 2-10 Hydraulic Brake Systems ...................................... 2-11 Burnishing Brake Pads.......................................... 2-13 Checking/Replacing V-Belt ................................... 2-13 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ............................................... 3-2 Specifications .......................................................... 3-2 Troubleshooting ....................................................... 3-3 450 Table of Contents ............................................. 3-6 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Fuel/Lubrication/Cooling ......................................... 4-2 Electronic Fuel Injection .......................................... 4-2 Throttle Body........................................................... 4-2 Fuel Injector ............................................................ 4-4 Throttle Cable Free-Play ......................................... 4-4 Engine RPM (Idle)................................................... 4-5 Gas Tank ................................................................. 4-5 Oil Filter/Oil Pump ................................................... 4-5 Testing Oil Pump Pressure...................................... 4-5 Liquid Cooling System ............................................ 4-6 Electric Fuel Pump/Fuel Level Sensor .................... 4-8 Troubleshooting..................................................... 4-10 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical System..................................................... 5-2 Electrical Connections............................................. 5-2 Specifications .......................................................... 5-2 Battery..................................................................... 5-2 RPM Limiter............................................................. 5-3 Testing Electrical Components ................................ 5-3 Accessory Receptacle/Connector ........................... 5-4 Brakelight Switch (Auxiliary).................................... 5-4 Brakelight Switch (Handlebar Control) .................... 5-4 Engine Coolant Temperature (ECT) Sensor............ 5-5 Fan Motor ................................................................ 5-5 Power Distribution Module (PDM) ........................... 5-6 Ignition Coil ............................................................. 5-6 EFI Sensors/Components ....................................... 5-7 Speed Sensor ......................................................... 5-8 Ignition Switch ......................................................... 5-8 Handlebar Control Switches.................................... 5-9 Drive Select Switch ............................................... 5-10 Front Drive/Differential Lock Actuator Power......... 5-10 Stator Coil/Crankshaft Position (CKP) Sensor ...... 5-11 Starter Relay ......................................................... 5-11 Starter Motor ......................................................... 5-12 Electronic Control Unit (ECU)................................ 5-13 Regulator/Rectifier................................................. 5-13 Headlights ............................................................. 5-13 Taillight - Brakelight ............................................... 5-13 Ignition Timing....................................................... 5-14 ECU Malfunction Codes........................................ 5-14 Tilt Sensor ............................................................. 5-15 Throttle Position Sensor (TPS).............................. 5-16 Troubleshooting ..................................................... 5-18 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System........................................................... 6-2 Front Drive Actuator/Electronic Differential Lock..... 6-2 Front Differential ...................................................... 6-3 Drive Axles ............................................................ 6-16 Rear Gear Case .................................................... 6-21 Hub........................................................................ 6-21 Hydraulic Brake Caliper......................................... 6-22 Troubleshooting Drive System............................... 6-26 Troubleshooting Brake System.............................. 6-26 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............................................................. 7-2 Shock Absorbers ..................................................... 7-2 Front A-Arms ........................................................... 7-3 Rear A-Arms ........................................................... 7-5 Wheels and Tires .................................................... 7-7 Troubleshooting ....................................................... 7-8 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame........................................................ 8-2 Steering Post/Tie Rods ........................................... 8-2 Handlebar Grip ........................................................ 8-4 Steering Knuckles ................................................... 8-4 Measuring/Adjusting Toe-In..................................... 8-6 Front Rack ............................................................... 8-8 Front Bumper Assembly .......................................... 8-8 Front Body Panel/Side Panels................................. 8-8 Footrests ............................................................... 8-10 Belly Panel ............................................................ 8-10 Exhaust System .................................................... 8-10 Rear Body Panel/Rack .......................................... 8-11 Taillight Assembly.................................................. 8-12 Seat ....................................................................... 8-12 Troubleshooting ..................................................... 8-13 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Hand Brake Lever/Master Cylinder Assembly ......... 9-2 Throttle Control ....................................................... 9-3 Shift Lever ............................................................... 9-4 Speedometer/Tachometer/LCD............................... 9-4 -------------------------------------------------------------------------------------- File Format: PDF Compatible: All Versions of Windows & Mac Downloadable: YES Language: English Requirements: Adobe PDF Reader DESCRIPTION: ========= COVERS ALL MODELS & ALL REPAIRS A-Z THIS IS NOT SOME GENERIC REPAIR INFORMATION. IT IS A VEHICLE SPECIFIC SERVICE MANUAL! THIS HIGHLY DETAILED SERVICE REPAIR MANUAL CONTAINS EVERYTHING YOU WILL EVER NEED TO SERVICE, REPAIR, RESTORE, MAINTAIN, REFURBISH OR EVEN REBUILD YOUR VEHICLE. COMPLETE & EASY TO USE STEP-BY-STEP INSTRUCTIONS, ILLUSTRATIONS, DIAGRAMS, SPECIFICATIONS & WIRING SCHEMATICS WILL HELP ASSIST YOU TO PERFORM RIGHT FROM VERY SIMPLE REPAIRS TO COMPLEX ONES !!. CLEAR PICTURES AND ZOOMABLE ILLUSTRATIONS HELP YOU PERFORM YOUR SERVICE REPAIR WITH UTMOST EASE! NO TECHNICAL EXPERTISE REQUIRED. YOU SEE IT AND YOU DO IT (DO-IT-YOURSELF MANUAL) THIS IS THE SAME MANUAL THAT TECHNICIANS AND MECHANICS IN DEALERSHIPS & ELSEWHERE USE TO SERVICE & REPAIR YOUR VEHICLE! YOU CAN REFER THIS MANUAL RIGHT FROM YOUR PC/LAPTOP OR ONLY PRINT OFF THE PAGES THAT YOU REQUIRE FOR THE MOMENT. --------------------------------------------------------------------------------------