I just purchased a 2004 500 manual ac. I was adjusting the front shock settings when the tab on the shock housing broke. Has this ever happened to anyone? The adjustment tool also broke, but I have heard this always happens.

 

Have not had tabs break but agree the tool leaves alot to be desired. Some people have bought spanner wrench from tool guys(Snap-on, Mac etc...).

 

Is this problem something that would be covered under warranty if I decided I wanted it fixed? It is not a problem now, just bothers me becuase it has 10 miles on it.

 

I would sure take it back and see. I think that it should be if something is binding up.

 

yes it hapens to all of them. and yes the dealer should warrenty it they did it to mine. There fix for not having it happen again though was to lift the machine off the ground and take all weight off the shocks, then adjust. would love to see someone make a billet aluminium.

 

The adjusters are crap. They are made of cast aluminum. The stops they ride on are steel. The stops tend to wear into the adjuster over time and can make it difficult to adjust unless you compress the spring. I tore one of my front ones up trying to get it to move, even with all the weight off the wheel. The dealer I bought it from replaced it under warranty.

I bought a steel spanner that connects to a 3/8's drive ratchet. Works much better.

 

The same thing happened to me this past weekend. I bought my 04 400i last month and I had turned up the rear shocks shortly after, but I built a bumper for the front and I was going to turn up the front shocks. The first one went OK, I tried the second one, SNAP, the wrench broke. Then I tried a pipe wrench and a tab broke off. Next I made a wrench out of steel plate and broke 2 more tabs with it. Jacked the front end off the ground and it adjusted. I probablv wont adjust them again, but who knows???

 

That was exactly what happened to me. The dealer said it is not difficult to repair. I will get it repaired before my warranty runs out, but it's ok for now. Thanks

 

I found part numbers for the wrench (0441-587) $3.91 and the adjusting cam (0403-102) $4.88 at Alpha Sports.com. To replace the cam, compress the spring and slide the top retainer ring off, slide the spring off, and slide the cam off.

 

We were told that you have to get the weight of the wheels to adjust. With this done they should adjust fine if not take to the dealer and have them fix it right.