2012 Arctic Cat ATV models (450, 1000) Service Manual

2012 Arctic Cat ATV 450 & 1000 Service Manual

This factory service manual provides full OEM-level maintenance, diagnostics, overhaul, and repair procedures for the 2012 Arctic Cat 450 and 1000 ATV models. All technical content is derived exclusively from the manual’s Table of Contents, covering complete engine and transmission teardown, EFI diagnostics, lubrication and cooling systems, electrical testing workflows, driveline and differential servicing, suspension repair, chassis procedures, and control system adjustments.

Model Covers:

2012 Arctic Cat 450 ATV
2012 Arctic Cat 1000 ATV

Note: Includes detailed procedures for valve train service, crankcase disassembly, EFI troubleshooting, drive system repair, brake system servicing, chassis component replacement, and full electrical diagnostics including DTC code lists for both 450 and 1000 platforms.

File Format: PDF

Size: 65.66 MB

No. of Pages: 211

Language: English

Delivery Method: Instant Download – Access your file immediately after purchase.

📑 Included Sections:

1. General Information / Specifications

• General specifications, torque specifications, conversion charts (ft-lb / N·m)
• Break-in procedure for new engines
• Recommended gasoline, engine/transmission oil, differential and rear drive lubricants
• Fuel tank filling, lubricant requirements, and genuine parts guidelines
• Storage preparation and reactivation procedures

2. Periodic Maintenance

• Maintenance chart, required special tools, lubrication points
• Air filter service, drain inspection and cleaning
• Valve/tappet clearance adjustment and engine compression testing
• Spark plug inspection, muffler and spark arrester service
• Engine/transmission oil, filter, and strainer service
• Cooling system inspection, draining, and filling
• Differential and rear drive lubricant maintenance
• Hardware inspections: nuts, bolts, and cap screws
• Headlight, taillight, brakelight testing and aiming
• Shift lever adjustment and frame/weld inspections
• Hydraulic brake system bleeding, pad replacement, hose checks
• Brake pad burnishing and V-belt inspection/replacement

3. Engine / Transmission – 450 / 1000 Models

• Model-specific specifications, special tools, and troubleshooting charts
• Engine/transmission removal procedures for both 450 and 1000 models
• Top-side disassembly: head cover, rocker arms, camshaft, cylinder head, cylinder(s), piston(s)
• Valve assembly servicing: stem OD and runout, seat width, radial runout, guide ID, rocker arm ID/OD
• Piston assembly service: ring removal, groove cleaning, end-gap measurement, skirt clearance, pin/bore checks
• Cylinder/head servicing: distortion measurement, chain guide inspection, honing, camshaft inspection
• Left-side component removal: water pump, speed sensor, magneto/stator, flywheel, starter clutch/gear, starter motor
• Left-side servicing: clutch assembly checks, bearing replacement, CPS/stator servicing, magneto bearing replacement
• Right-side disassembly: V-belt cover, driven pulley, clutch cover, centrifugal clutch, oil pump drive/driven gears
• Right-side servicing: centrifugal clutch shoe and housing inspection, one-way drive inspection, oil pump evaluation
• Crankcase separation, internal gear servicing, crankshaft measurements (runout, deflection, web-to-web)
• Crankcase assembly, sealing, and engine/transmission installation

4. Fuel / Lubrication / Cooling

• EFI troubleshooting and component removal/installation for both 450 and 1000
• Throttle cable free-play and idle RPM adjustment
• Fuel tank removal, cleaning, inspection, and reinstallation
• Oil filter and oil pump service with pump pressure testing procedures
• Oil cooler (1000) removal and installation
• Radiator service: removal, cleaning, inspection, installation
• Thermostat removal/inspection/installation (450 / 1000)
• Cooling fan removal/installation
• Water pump servicing for both 450 and 1000 models
• EFI fuel pump and fuel level sensor testing, removal, inspection, installation
• Fuel and cooling troubleshooting workflows

5. Electrical System

• Electrical testing tools, connector standards, and battery maintenance
• RPM limiter verification and electrical component testing
• Brake light switch diagnostics, ECT sensor testing, fan motor resistance checks
• PDM fuses and relays, ignition coil voltage/resistance testing
• EFI sensors (CKP, MAP, IAT) for both 450 and 1000 models
• Speed sensor and electronic power steering (EPS) diagnostics
• Ignition switch and handlebar control switch evaluations
• Drive select switch, differential lock actuator voltage checks
• Stator and CKP testing: AC regulated output, generator resistance, trigger voltage
• Starter relay and starter motor tests
• ECU, regulator-rectifier testing, headlight and taillight voltage verification
• Tilt sensor and TPS inspection, adjustment, and installation (450 and 1000 variants)
• DTC lists for 450 / 1000 FIS / Cruiser / Mud Pro models
• Electrical troubleshooting charts

6. Drive System / Brake System

• Front drive actuator and differential lock removal/installation
• Differential disassembly: input shaft, pinion gear, differential assembly, shim selection, backlash, ring gear end-play
• Front/rear axle removal, cleaning, inspection, service, and reinstallation
• Rear gear case servicing: ring gear, thrust button, and input shaft (1000)
• Hub inspection and servicing
• Hand brake lever/master cylinder servicing
• Hydraulic brake caliper teardown, inspection, and assembly
• Drive and brake system troubleshooting

7. Suspension

• Shock absorber removal, inspection, installation
• Front and rear A-arm servicing
• Tire specifications, inflation, wheel removal, inspection, and installation
• Suspension troubleshooting

8. Steering / Frame / Controls

• LCD gauge replacement
• Steering post and tie-rod removal/inspection/installation (EPS and non-EPS)
• Handlebar grip service and throttle control adjustments
• Knuckle disassembly, inspection, assembly
• Toe-out measurement and adjustment
• Shift lever servicing
• Front rack, bumper, body panels, side panels, belly panel, footrest removal/inspection/installation
• Exhaust system removal, inspection, and installation
• Rear body panel, rack, taillight and seat service
• Chassis and control system troubleshooting

This 2012 Arctic Cat ATV Service Manual is a complete technical reference for professional repair, diagnostics, and maintenance of the 450 and 1000 models.