I do most of my own maintenance on the quad. I like to! So I noticed the last time out, in WV at H/M Trails, that my hand brake was very sloppy. The master cylinder's working fine but there was a lot of play/distance between the point of contact for the hand brake to master cylinder push rod. After coming home and further investigation, I noticed the tail light stays on when I release the hand brake. Looks like the problem is, the master cylinder push rod is slightly deformed from contact. It needed about another 1/16" to make full contact so I made a rubber cover for the push rod to make up the difference in play. This can only be temporary, I'll have to find a better fix before too long.
While I was looking at the first problem I just described, I noticed at the rear, right side, the shock/coil spring was rubbing on the "A" arm tubing. The spring coil actually has a wear mark on it and so does the tubing. This is a mistake! Somebody messed up. I removed the bottom bolt holding the shock in place and turned the shock 180 degrees. No more problem.
I'm gonna try to contact AC about the master cylinder brake problem but I think I'll talk to the dealer about the coil spring first. I have a very good dealer. I think they may have made the mistake when assembling from the box. They always make good on any problems.
Maybe you can look to see if you have anything like this happening before it causes you a problem.
Happy trails,
Chuck

 

Same thing with the brakes on my 2002 500 ACT. I find if you let the bike sit with the "parking brake" on you loose some leverage. Once you use the brakes for a while it seems to come back to normal. I've had people riding behind me say that there must be a short in my bike because my brake light keeps flashing on and off. I tried a spacer like your rubber cover, but it wasn't much help.
Jeepersmitty

 

my 02 375 doesthe same thing with the brake lever i was thinking the brakes need to be bled for air the brakes are soft. i also noticed that on my master cylinder the paint is come off in a streamlike partern looks like an air vent or the oring on the cover my be leaking at that point so with that happen i was thinking that had something to do with the plunger travel. does anyone know maybe i need to take it apart and clean it my have a little trash or something in it. has anyone taking there master cylinder apart yet or can even do that ?

 

Not sure if this means anything, but on Cat's snowmobiles if you leave the "parking brake" on very long it will need to be bled. Like I said not sure if this applies to the ATV's or not?

 

same thing

if you leave your parking brake on for a long period you will need to bleed it!!

Also yes i have taking my entire brake assembly apart. This was dut to me breaking mine at the braket when i hit a tree. I had to remove the plunger and all! nothing but metal. I MUST WARN YOU IT IS EXTREMLY DIFFICULT TO GET THE SEAL BACK IN, the little rubber seal that you have to remove to get the pluger out! you must ahave a small but blut edged tool to do this.

 

I've talked to the dealer and the AC Rep. The Rep is no help at all. AC wants you to talk to the dealer first. I think that sucks but again, I have a very good dealer. If I didn't, now would be the time to start thinking about another quad. Next week, I'll take the 500i to Ohio, for service. I'll let you guys know what it cost if anything.
About bleeding the master cylinder: I don't think I have the same problem but I'll try it just to satisfy my curiosity. Thanks for the help.
Chuck

 

ecorman1, I don't think the dealer did anything wrong when they put it together since all you do is fill and charge the battery, check and fill fluids, and test ride. I would think if it did any damage that they would warranty it.

 

You're right 314. The dealer didn't do it and the manufacturer wants me to take the Cat back to the dealer. Goin' Monday morning. So far, on the list of things gone wrong with the Cat, at manufacturer's cost:
*Leaking head light
*Broken speedometer
*Replaced steering knuckles (Warranty)

My 2002, AC 500i, is 15 months old and has 1,150 miles on it. That's Coal Creek, Tenn., H/M Trails, WV., Bad Lands, IN. and some of the 3,400 miles of trails in Michigan. It's a great machine. Nobody should expect less.
Now these other two problems, may be something new for AC. Both seem to be quality problems but I'll let you know how it goes.
Chuck

 

Turns out the manufacturer was responsible for the "A" arm/coil spring problem and the dealer had a fix for the brake master cylinder. They drilled a hole in the handle clamp to press on the master cylinder push rod. Cost to me? One hour service.
Chuck

 

I'll contact A/C's service rep and ask him if they have any cures for the parking brake bleeding off and get back to you ASAP. If you have any ?'s post them and I will try to get an answer from A/C for you.