FYI.... I have a 02 500i auto. I went out in the garage today to take care of my skid plate which would vibrate at certain RPM levels. Anyway when I pulled the skid plate off I noticed a small spot of oil on the area below where the front diff. is. O.K no big deal! Wiped it off. New machine, maybe it was there from the factory? So... I said better check the oil level in the front diff. WELL when I did I noticed it was down at least 1 1/4 inches Maybe more from the threads.[img]i/expressions/face-icon-small-shocked.gif[/img] (I would have a puddle under the ATV not a spot on the skid plate if it was leaking that much oil) so, I checked the 2000 service manual I had from my 2000 300 which covers all 2000 models and as I thought the oil should be level with the threads! So I checked the rear diff. Same thing down at least an inch [img]i/expressions/face-icon-small-disgusted.gif[/img]. I checked the dealer pre-delivery instructions that came with it to see if it had any differant info. (because I believe its a new type diff. on the 02 models but I'm not sure) As I thought it says that the oil should be level with the threads also. This is clearly my dealers fault but why would it ship with such low levels? I hope I didn't harm anything! I only have about 60 miles on it. My dealer is going to get an earfull tomorrow [img]i/expressions/face-icon-small-mad.gif[/img].
I WOULD INCOURAGE EVERYONE TO CHECK THERE DIFF. FLUID LEVELS. Please let me know what you find. Hopefully I'm the only one with this problem. Any info. as to wether or not you guys think any damage was done to my 500 would be appreciated.

 

The fluid level is supposed to be 1" below the threads. The ACT models rear diff has a fill plug and a level plug. The fluid level plug is down about half way on the diff. It is a 10mm bolt shiny compared to the black diff. Be careful the fill plugs are plastic, don't cross thread or overtighten them. If you added oilt to top it off to the fill plug you may want to drain some out. Otherwise you may blow a seal.

 

MudCat, thanks for your reply. Why do you say that the fluid level is supposed to be 1" below the threads? The pre-delivery instruction say Quote: Remove the front differential filler plug; the lubricant level should be at the threads of the plug.remove the rear drive inspection plug; the fluidlubricant level should be aat the threads of the plug. If low, add SAE 80W-90 hypoid gear lube as necessary. End Quote. Great instructions huh, since the don't even apply to the "i" model. I don't have the inspection plug they are refering to (cut and paste these links)

http://www.brownsleisureworld.com/Pa...SEASSEMBLY.htm

http://www.brownsleisureworld.com/Pa...SEASSEMBLY.htm

 

I don't know about the parts diagram but the service manual says. Pour recomended oil into the filler hole until the oil level reaches a point 25.4mm (1.0in.) below the oil filler hole. My ACT model has the fill level holes. Talk to your dealer he can show you where they are. Or explain why they aren't there. I've not looked for them on the i model. I thought the i rear diff was the same as my front.

 

MudCat, I do believe that yes, my front and rear diff. is simalar to your front diff. I'm glad to hear that your service manual says the fluid level should be 1" below the filler hole. I know that your rear diff. has a inspection plug. But can you give me some clue as to where I might find it on the front diff.since you say your act model has them. I thought I looked real good but it sounds like you have seen yours. Thanks

 

CrazyCat, that oil is most likly from changing your oil filter. The skidpan is the lowest point of the engine area and the way the oilfilter is positioned some of the oil is going to drip down.

The only way to be sure is to drain both diffs after a ride (warm oil) and replace with the proper amounts the manual says. 5.8 oz front and 10.1 oz rear. I consider this oil "breakin oil" anyways. My 500 non I auto is showing some oil around the area where the drive shaft enters the rear diff. I think it's only grease and not diff fluid. Too much oil will insure premature seal failure. You would almost have to run a diff dry to do any serious gear damage.

A good manual will give you oil capacity for new assembly and oil capacity when draining. You may find 10.1 oz may now fill the rear diff. to the inspection hole once replaced since it's impossible to drain all the gear oil out.

 

NewCatMan, Thanks for your reply. I have not done the first oil change yet. I have about 3 more hours breakin time left.I'm not so worried by the spot of oil on the skid plate as I am about the oil level in the front and rear diff's. I will call my dealer to see what he says the proper levels should be. I still can not find these inspection hole's on the front or rear diff's that you and mudcat keep refering to. I know that you have them on your rear diff. but did you locate one on your front diff.? I know my 2000 300 4x4 had them but I'll be darned if I see any on this 500i.I don't think there are any! Thanks Again.

 

So much for the oil change drip theory. I'm sure you are certain the bike is level and not on a jack when you check the diff. oil.
Let me know how you make out...these things aren't cheap they should be oil tight!

My annoying vibrations came from the side panels and the rear boddy panel was'nt secure. I used some foam seal tape and this did the trick.

 

Here is some general knowledge that I can tell you. Since I don't have a 02 I can't comment on it. Usually on ring gears and such the oil level should be around the center or a little below the half way point. Otherwise find the the level of where your axle comes out and it will probably be close to that.

 

Hey Guys, I checked with my dealer today he was not much help. I then called Arctic Cat and I explained the problem to the customer service rep. He put me on hold for a few so that he could speak to a factory tech. and came back to confirm that 1" below the fill hole is the proper level. He wasn't aware of any inspection hole on these diff's though, but I didn't have him confirm that with the tech. I'll keep an eye on the leak and the level in the front diff. for a while longer to see if it gets worse or if luck is with me maybe it will go away [img]i/expressions/face-icon-small-smile.gif[/img] I just hate having my equipment worked on especially when its this new. Not everybody (mechanics) take as much care as I would if I was doing the work. I'll keep you updated!