ARCTIC CAT ATV 2010 450cc Service Repair Manual [IMPROVED]

FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2010 Arc- tic Cat 450 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 photographs 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. © 2009 Arctic Cat Inc. November 2009 ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

450 TM SHARE OUR PASSION. ATV ATV Service Manual Service Manual TABLE OF CONTENTS Foreword 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/Indicators 1 2 3 4 5 6 7 8 9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

1-1 1 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 Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

1-2 General Specifications* * Specifications subject to change without notice. ** One inch below plug threads. *** At the plug threads. Torque Specification * w/Blue Loctite #243 *** w/Green Loctite #609 ** w/Red Loctite #271 ****w/Patch-Lock CHASSIS Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) MISCELLANY Gas Tank Capacity 21.6 L (5.7 U.S. gal.) Coolant Capacity 2.9 L (3.0 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil Capacity 2.85 L (3.0 U.S. qt) - Overhaul 2.5 L (2.6 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 28.5 mm (1.12 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (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 ELECTRICAL COMPONENTS Ground Cable Cap Screw Crankcase 8 11 Coil Air Filter Housing 7 10 Fuel Injector Intake Pipe 8 11 STEERING COMPONENTS Steering Post Bearing Housing Frame 20 27 Steering Post Bearing Flange Frame 20 27 Lower Steering Bearing Washer Cap Screw*** Steering Post 40 54 Tie Rod End Knuckle/Steering Post 30 41 BRAKE COMPONENTS Brake Disc* Hub 15 20 Brake Hose Caliper 20 27 Brake Hose Master Cylinder 20 27 Brake Hose Auxiliary Brake Cylinder 20 27 Master Cylinder (Rear) Frame 12 16 Brake Caliper**** Knuckle/Axle Housing 20 27 Master Cylinder Clamp Master Cylinder 6 8 Brake Pedal Brake Pedal Axle 25 34 CHASSIS COMPONENTS Footrest Frame (8 mm) 20 27 Footrest Frame (10 mm) 40 54 SUSPENSION COMPONENTS (Front) Part Part Bolted To Torque ft-lb N-m A-Arm Frame 50 68 Shock Absorber Frame 50 68 Shock Absorber (Lower) Upper A-Arm 50 68 Knuckle A-Arm 50 68 SUSPENSION COMPONENTS (Rear) Shock Absorber (Upper) Frame 50 68 Shock Absorber (Lower) Lower A-Arm 20 27 A-Arm Frame 50 68 Knuckle A-Arm 50 68 DRIVE TRAIN COMPONENTS Engine Mounting Through-Bolt Frame 35 47 Front Differential* Frame/Differential Bracket 38 52 Output Drive Flange Rear Flange Output Joint 20 27 Pinion Housing Differential Housing 23 31 Differential Housing Cover*** Differential Housing 23 31 Drive Bevel Gear Nut*** Shaft 72 98 Differential Gear Case*** Hub 19 26 Lock Collar Differential Housing 125 169 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 16 22 Rear Drive Input Shaft/Housing Differential Housing 23 31 Wheel Hub 40 54 Rear Drive Gear Case Frame 38 52 Engine Output Shaft ** Rear Gear Case Input Flange 20 27 ENGINE/TRANSMISSION Clutch Shoe** Crankshaft 147 199 Clutch Cover/Housing Assembly Crankcase 8 11 Magneto Cover Crankcase 8 11 Crankcase Half (6 mm) Crankcase Half 10 13.5 Crankcase Half (8 mm) Crankcase Half 21 28 Cylinder Head (Cap Screw) Crankcase 28 38 Cylinder Head Nut Cylinder 8 11 Cylinder Head Nut (Lower) Cylinder 20 27 Cylinder Head Cover Cylinder Head 8 11 Oil Pump Drive Gear** Crankshaft 63 86 Driven Pulley Nut** Driveshaft 147 199 Ground Cable Engine 8 11 Output Shaft Flange Nut Output Shaft 59 80 Magneto Rotor Nut Crankshaft 107 146 Cam Sprocket** Camshaft 11 15 Cam Chain Tensioner Guide Cylinder Head 11 15 Cam Chain Tensioner Cylinder 10 14 Starter Motor Crankcase 8 11 V-Belt Cover Crankcase 8 11 Valve Adjuster Jam Nut Valve Adjuster 7 9.5 Oil Pump** Crankcase 8 11 Movable Drive Face Nut** Clutch Shaft 147 199 Oil Cooler Hose Clamps Engine/Oil Cooler 30 in.-lb 3.4 Valve Cover (Three Bond) Cylinder Head 8 11 Tappet Cover Crankcase 8 11 Water Pump Cover/Housing Magneto Cover 8 11 Water Pump Drive Gear** Crankshaft 28 38 Next Section Table of Contents Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

1-3 1 Torque Conversions (ft-lb/N-m) Tightening Torque (General Bolts) 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 during 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 during 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 accelera- tions 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 pre- scribed adjustments and tightening of all fasteners (see Periodic Maintenance Chart in Section 2). Gasoline - Oil - Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, oxygenates (either ethanol 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. ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m 1 1.4 26 35.4 51 69.4 76 103.4 2 2.7 27 36.7 52 70.7 77 104.7 3 4.1 28 38.1 53 72.1 78 106.1 4 5.4 29 39.4 54 73.4 79 107.4 5 6.8 30 40.8 55 74.8 80 108.8 6 8.2 31 42.2 56 76.2 81 110.2 7 9.5 32 43.5 57 77.5 82 111.5 8 10.9 33 44.9 58 78.9 83 112.9 9 12.2 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 Type of Bolt Thread Diameter A (mm) Tightening Torque (Conventional or 4 Marked Bolt) 5 12-36 in.-lb 6 36-60 in.-lb 8 7-11 ft-lb 10 16-25 ft-lb (7 Marked Bolt) 5 24-48 in.-lb 6 6-8 ft-lb 8 13-20 ft-lb 10 29-43 ft-lb CAUTION Do not use white gas. Only Arctic Cat approved gasoline additives should be used. Next Back Section Table of Contents Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

1-4 RECOMMENDED ENGINE/ TRANSMISSION OIL The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil, which has been specifi- cally 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 differen- tials and rear drives. FILLING GAS TANK Since gasoline expands as its temperature rises, the gas tank must be filled to its rated capacity only. Expan- sion 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 appro- priate Illustrated Parts Manual for the correct part number, quantity, and description. Preparation For Storage Arctic Cat recommends the following procedure to prepare the ATV 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. 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 recommended are racing, vegetable, non-detergent, and cas- tor-based oils. CAUTION Any lubricant used in place of the recommended lubricant 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. Next Back Section Table of Contents Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

1-5 1 4. Plug the exhaust hole in the exhaust system 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 coolant. 8. Disconnect the battery cables; then remove the battery, 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 rid- ing. Arctic Cat recommends the following procedure to prepare the ATV. 1. Clean the ATV thoroughly. 2. Clean the engine. Remove the cloth from the exhaust system. 3. Check all control wires and 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. 7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, and headlight aim; adjust or replace as necessary. 8. Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap screws, and bolts are tightened to specifications. 9. Check tire pressure. Inflate to recommended pressure as necessary. 10. Make sure the steering moves freely and does not bind. 11. Check the spark plug. Clean or replace as necessary. CAUTION If the interior of the air filter housing is dirty, clean the area before starting the engine. CAUTION Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the ATV causing rusting. CAUTION The ignition switch must be in the OFF position prior to installing the battery or damage may occur to the ignition system. CAUTION Connect the positive battery cable first; then the nega- tive. Back Section Table of Contents Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

2-1 2 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 Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

2-2 Periodic Maintenance Chart A = Adjust I = Inspect C = Clean L = Lubricate D = Drain 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 and strainer inspection can be increased to every 1,000 miles or every year. Item Initial Service After Break-In (First Mo or 100 Mi) Every Day Every Month or Every 100 Miles Every 3 Months or Every 300 Miles Every 6 Months or Every 500 Miles Every Year or Every 1500 Miles As Needed Battery I I C Fuses I R Air Filter/Drain Tube I I C* R Valve/Tappet Clearance I I A Engine Compression I Spark Plug I I R (4000 Mi or 18 Mo) Muffler/Spark Arrester C R Gas/Vent Hoses I I R (2 Yrs) Throttle Cable I I C-L A-R Engine-Transmission Oil Level I A Engine-Transmission Oil/Filter R R*/R**/R*** R Oil Strainer I I C Front Differential/Rear Drive Lubricant I I R (4 Yrs) Tires/Air Pressure I I R Steering Components I I I R V-Belt I l R Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows) I I R Nuts/Cap Screws/Screws I I T Ignition Timing I Headlight/Taillight-Brakelight I I R Switches I I R Shift Lever I A-L Handlebar Grips I R Handlebar I I R Gauges/Indicators I I R Frame/Welds/Racks I l Electrical Connections I l C Complete Brake System (Hydraulic & Auxiliary) I I C L-R Brake Pads I I* R Brake Fluid I I R (2 Yrs) Brake Hoses I I R (4 Yrs) Coolant/Cooling System I I R (2 Yrs) Next Section Table of Contents Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

2-3 2 Periodic Maintenance This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat ATV. NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. NOTE: Critical torque specifications are located in Section 1. SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section. NOTE: Special tools are available from the Arctic Cat Service Parts Department. Lubrication Points It is advisable to lubricate certain components periodi- cally to ensure free movement. Apply light oil to the components using the following list as reference. A. Throttle Lever Pivot/Cable Ends B. Brake Lever Pivot/Cable Ends C. Auxiliary Brake Cable Ends D. Shift Lever Cable End Air Filter Use the following procedure to remove the filter and inspect and/or clean it. CLEANING AND INSPECTING FILTER 1. Remove the seat; then remove the cap screws securing the storage compartment. 2. Raise the storage compartment cover; then slide the cover forward and off the compartment. Remove the storage compartment. 3. Remove three machine screws; then remove the air filter cover. FI513A 4. Remove the air filter element/spring assembly and separate the element from the screen. FI515 5. 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. 6. Dry the element. 7. Put the element in a plastic bag; then pour in air filter oil and work the oil into the element. Attach the element to the filter screen. NOTE: Carefully squeeze excessive oil from the filter element. Do not twist foam to remove oil. Description p/n Compression Tester Kit 0444-213 Oil Filter Wrench 0644-389 Tachometer 0644-275 Timing Light 0644-296 Valve Clearance Adjuster 0444-255 Next Back Section Table of Contents Manual Table of Contents FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 www.mymowerparts.com

ARCTIC CAT ATV 2010 450cc Service Repair Manual [IMPROVED]

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