2012 Arctic Cat XC 450i ATV Service Manual

2012 Arctic Cat XC 450i ATV Service Manual

This OEM service manual provides complete factory-authorized procedures for the 2012 Arctic Cat XC 450i ATV. All technical content shown below is based strictly on the manual’s Table of Contents, including full engine and transmission teardown, EFI troubleshooting, fuel–lubrication–cooling system servicing, electrical diagnostics, driveline and differential repair, brake system maintenance, and complete chassis, steering, and suspension service procedures.

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2012 Arctic Cat XC 450i ATV

Note: Features full valve train inspection, piston/cylinder servicing, crankcase procedures, EFI and throttle body diagnostics, complete electrical testing (including DTC codes), differential and driveline disassembly, and detailed steering/frame/control adjustments.

File Format: PDF

Size: 36.98 MB

No. of Pages: 124

Language: English

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

📑 Included Sections:

General Information

• Specifications, torque specs, conversion charts
• Break-in procedure for new engines
• Recommended fuel, oil, and lubrication requirements
• Storage preparation and post-storage procedures
• Genuine parts and service notes

Periodic Maintenance

• Maintenance chart and special tools
• Lubrication points and service intervals
• Air filter inspection and drain cleaning
• Valve/tappet clearance measurement and adjustment
• Engine compression testing
• Spark plug inspection
• Cooling system checking and filling
• Muffler and spark arrester cleaning
• Throttle cable adjustment
• Idle RPM adjustment
• Engine–transmission oil and filter service
• Front differential and rear drive lubricant service
• Tire size, pressure, and inspection
• Driveshaft and coupling checks
• Hardware (nuts–bolts–cap screws) inspection
• Ignition timing verification
• Lighting—headlight, tail/brake, running lights, backup light; headlight aiming
• Shift-lever adjustment
• Frame and weld inspections
• Hydraulic brake bleeding, hose inspection, pad replacement
• Brake pad burnishing
• V-belt removal and installation

Engine / Transmission

• Special tools and troubleshooting
• Engine/transmission removal and installation

Top-Side Components

• Head cover, rocker arms, cylinder head, camshaft, cylinder, piston removal
• Valve assembly servicing: valve removal, measurements, guide/seat service, valve installation
• Piston assembly: ring removal, groove cleaning, end-gap measurement, clearance checks, ring installation
• Cylinder/head servicing: inspection, distortion measurement, cam chain guide, honing, camshaft inspection
• Reinstalling piston, cylinder, head, camshaft, cover, rocker arms

Left-Side Components

• Removal: water pump, speed sensor, magneto–stator, rotor–flywheel, starter clutch/gear, starter motor, shift shaft, drive gear
• Left-side servicing: starter clutch & bearing, stator–magneto cover, sensors, bearings
• Reinstallation: starter clutch–gear, rotor–flywheel, magneto cover, water pump

Right-Side Components

• Removal: V-belt cover, driven pulley, clutch cover, centrifugal clutch, oil pump gears, oil pump–strainer
• Servicing: clutch shoe, clutch housing, one-way drive, oil pump, driven pulley assembly
• Reinstallation: oil strainer–pump, clutch cover, fixed & movable drive faces

Center Crankcase

• Separating crankcase halves
• Disassembling crankcase components
• Secondary gear setup: backlash and tooth-contact checks
• Crankshaft measurement (runout, deflection, clearances)
• Countershaft disassembly and assembly
• Crankcase reassembly and joining halves

Fuel – Lubrication – Cooling

• EFI troubleshooting procedures
• Throttle body removal and installation
• Throttle cable free-play adjustment
• Fuel tank removal, cleaning–inspection, installation
• Oil filter and oil pump servicing
• Oil pump pressure testing
• Radiator removal, inspection, cleaning, installation
• Thermostat removal, inspection, installation
• Water pump servicing
• Fuel pump and fuel-level sensor testing, removal, installation
• Troubleshooting charts

Electrical System

• Special tools and electrical connection standards
• Battery charging and maintenance
• RPM limiter function
• Testing electrical components
• Main fuse 30A
• Accessory receptacle voltage testing
• Brake switch (pressure type) voltage and resistance
• ECT sensor testing
• Fan motor voltage & resistance tests
• PDM relays
• Ignition coil (primary & secondary resistance, plug-cap resistance)
• Speed sensor
• Ignition switch voltage & resistance testing
• Handlebar switches: Hi/Lo beam, stop switch, reverse override
• Drive select switch voltage/resistance
• Front drive actuator voltage tests
• Gear position switch
• Stator/CKP sensor AC output, resistance, CPS voltage
• Starter relay
• Starter motor voltage test, removal, installation
• ECU and regulator–rectifier testing
• Lighting system voltage checks (head, running, tail, brake, backup)
• Ignition timing
• DTC code list
• Tilt sensor supply/output voltage
• TPS inspection, removal, installation, adjustment
• Electrical troubleshooting

Drive System

• General information and special tools
• Front drive actuator removal/installation
• Front differential teardown: input shaft, pinion gear, shim selection, backlash, end-play
• Ring gear and thrust button servicing, differential assembly, needle bearing, axle seal
• Installing differential
• Drive axles: rear/front removal, cleaning, inspection, disassembly, installation
• Rear gear case removal and installation
• Hub removal, inspection, installation
• Hand-brake lever & master-cylinder servicing
• Brake caliper removal, disassembly, cleaning, assembly, installation
• Troubleshooting for drive and brake systems

Suspension

• Shock absorber removal and installation
• Front and rear A-arm removal, cleaning, inspection, installation
• Wheel/tire size, inflation, removal, inspection, installation
• Suspension troubleshooting

Steering – Frame – Controls

• Steering post and tie-rod removal, inspection, installation
• LCD gauge replacement
• Handlebar grip removal and installation
• Throttle control removal, installation, adjustment
• Steering knuckle teardown, inspection, assembly, installation
• Toe-out measurement and adjustment
• Front bumper removal and installation
• Front body panel and fender removal, inspection, installation
• Exhaust muffler removal, inspection, installation
• Rear body panel removal, inspection, installation
• Seat removal and installation
• Troubleshooting for steering, frame, and controls

This 2012 Arctic Cat XC 450i Service Manual provides the complete factory procedures required for accurate diagnostics, maintenance, and full mechanical overhaul.