2013 Arctic Cat 450 ATV Service Manual (P/N 0486-469)

• Covers the 2013 Arctic Cat 450 ATV with factory maintenance, repair, and troubleshooting coverage for the engine/transmission, EFI and electrical systems, drive system, hydraulic brakes, suspension, steering, frame, and controls.
• Arctic Cat factory publication P/N 2259-526, dated September 2012, with 128 pages in this PDF. The final electrical schematic is identified separately as Main Harness p/n 0486-469.
• Engine/transmission repair goes well beyond routine service: top-side, left-side, and right-side components can be serviced with the powertrain in the frame, while center-crankcase work requires engine/transmission removal and covers crankshaft, countershaft, shift forks, reverse idler, secondary gears, and balancer-shaft service.
• Includes EFI and electrical diagnosis through the LCD gauge, with COOL, FUEL, tACH, SPd, tPS, bArO, AIr, and bAtt diagnostic modes plus DTC coverage for the TPS, MAP/IAT, ECT, fuel pump relay, injector, crankshaft sensor, fan relay, starter circuit, ignition coil, system voltage, and gauge communication.
• Covers front differential, rear gear case, drive axles, and front drive actuator repair, including bevel-gear shimming, tooth-contact checks, 0.28–0.38 mm (0.011–0.015 in.) ring-gear backlash, and 0.1–0.2 mm (0.004–0.008 in.) ring-gear end play.
• Identifies factory service tools by part number, including Crankcase Separator/Crankshaft Remover 0444-152, Magneto Rotor Remover Set 0444-254, Oil Pressure Test Kit 0644-495, Peak Voltage Reading Adapter 0644-307, Backlash Measuring Tool 0544-010, and Pinion Gear/Shaft Removal Tool 0444-127.
• Chassis coverage includes hydraulic brake bleeding and caliper repair, brake-pad service, front and rear A-arms, shock absorbers, steering knuckles, steering post/tie rods, LCD gauge, and toe-out measurement and adjustment.

Procedural and Diagnostic Scope

The engine/transmission section is organized around actual repair depth rather than a simple list of maintenance items. It covers powertrain removal and installation, cylinder head and camshaft work, piston/cylinder inspection, cam-chain timing, magneto and starter-clutch service, CVT/V-belt and centrifugal-clutch work, oil-pump removal and replacement, crankcase separation, transmission countershaft disassembly, shift-fork and shift-shaft installation, crankshaft inspection, and secondary bevel-gear setup. This lets a buyer see which jobs can be performed in-frame and which require full engine removal before starting a repair.

Fuel, lubrication, cooling, and EFI sections add test procedures for oil pressure, fuel-pump pressure, fuel-level sender operation, thermostat function, throttle body service, and TPS adjustment. The electrical section covers charging-system output, stator and crankshaft-position sensor testing, starter relay and starter motor checks, ECM-related diagnosis, regulator/rectifier testing, front drive selector circuits, tilt sensor, lighting circuits, and the EFI Diagnostic System. The TPS procedure includes adjustment to 0.68 V using the specified analyzer setup, while the digital gauge can be used for both static and dynamic sensor checks and DTC diagnosis.

Drive-system repair includes front differential removal, input-shaft and pinion service, axle seals and bearings, rear gear case work, drive axles, hubs, and gear-set setup. The manual also defines serviceability limits: assemblies such as the oil pump, water pump, driven pulley, starter motor, ECM, front drive actuator, and shock absorbers are treated as non-serviceable units and replaced as assemblies when defective. Internal axle disassembly is referred to the applicable boot-kit instructions.

Several manual-specific cautions matter during major repair work. Camshaft timing depends on correct sprocket, alignment-pin, and tab-washer positioning; if the alignment pin is allowed to escape, severe engine damage can result. Countershaft dogs and gears must return in the correct facing direction, because reversed components can damage the transmission or force complete disassembly again. On the drive system, the front differential and rear gear case use different lock-collar thread directions, and the manual warns that incompletely removing the staked material can destroy the gear-case housing threads.

Because ATV service involves heavy components, pressurized gasoline, hydraulic brake fluid, and supported suspension/drivetrain assemblies, use a stable work area and follow the manual’s warnings, support requirements, fluid-handling precautions, and specified torque values.

Technical Data Preview

The manual provides concrete test values and service limits for diagnosis and rebuild work. Valve/tappet clearance is specified at 0.076–0.127 mm intake and 0.152–0.203 mm exhaust. Engine compression is 95–115 psi under the stated test conditions. Warm-engine oil pressure is 0.6–0.7 kg/cm² (8.5–10 psi) at 3000 RPM, and electric fuel-pump pressure is 3.0 kg/cm² (43 psi).

Fluid data includes 2.9 L (3.0 U.S. qt) coolant capacity, 2.8 L (3.0 U.S. qt) engine oil for a change and 3.3 L (3.5 U.S. qt) after overhaul, 275 ml (9.3 fl oz) for the front differential, and 250 ml (8.5 fl oz) for the rear drive. The drive-belt minimum width is 28.5 mm (1.12 in.), brake fluid is DOT 4, and front-wheel alignment is specified at 1/8–1/4 in. toe-out.

Reference material includes the Periodic Maintenance Chart, Torque Specifications, Backlash Measurement/Shim Correction data, secondary-gear Tooth Contact/Shim Correction views, the EFI Diagnostic Trouble Codes table, and the full-page Main Harness schematic. Together, these tables, diagnostic screens, illustrated service views, and electrical references show the actual depth of the factory repair information rather than just listing chapter titles.