this is moore85, yah you hit it on the dot idiot. i havent been able to get on so I had to make up a new name.

 

Another manufacturer won't satisfy you...
Some guys will cry with a tit in their mouth...
Chuck

 

where i live we have some of the hardest riding going .
from mountain climbing to mud bogging and everything inbetween.
and i dont baby my quads but i dont kill them eather.
i think you ride a bit agressively like me and if you ride them hard there gonna brake.
but like is said befor i think ac needs a stronger axel.
P.S. i was out with a friend of mine yesterday and the day befor and i notest that when hes on his quad ridind it that his axels are almost flat.
so theres hardly any angle to the cv joints.
i think his shocks are set to the second or maybe the 3rd setting.
it could be less i never looked.
i know i had mine set on the 5th setting and the axels were always the same as it was when nobody was on it.
maybe the angle of the axel was to much for all the time riding and helped them to brake prematurely.
(not enuff weight to push them down)
i liked the stiffest setting because it made it handle better on the dirt roads ( no rolling into the corners and less drift)
and i found that with them like that it still was good in the mud snow and trails.
but it probly dident help the cv joints any.
have you changed the factory setting on your shocks.
if so maybe try putting it back and see if it happens again.
i dont know what else to say other then i feel for ya man.
i had the same troubles last year that your having now and thats part of the reason why i went to a solid rear axel.
plus thay wouldent honer the warrenty after this last fix and i was tired of it always being in the shop instead of the trails.
so it was a good excuse to get a new quad.

 

Arctic Cat did up grade the axles on the 400 and 500s to the 650 axles this year (2005).

 

you keep saying that.
but that dont help anyone with an 04 or older.
unless those new axels will fit the 04s and older.

 

There is now a new part number for the axles on the 2004 which is suppose to be an upgrade assembly. The number is different for the 2004 650 and the 2005s but it is suppose to be the cure for your problem. I can't be the only guy that can find out this info. If your dealer was worth a damn he would know.

 

Also, the 2004 Cats had updated axels compared to the 2003's.

 

when i broke my axels they put 04 axels on it and the only differance was the middle of the axel was thinner, but the ends were the same thickness as the old ones. and i still broke two of them.
so unless the 05s are better then the 04s its not a fix.
because the 04 axels broke faster then the old ones.
they twisted off right where they taper down.
i got close to a thousand miles on the old axels where as i got maybe 500 miles on the new ones befor they broke.
so hopefully the 05 axels are better then the 04 ones.
for you cat owners sakes.

 

In 2004 AC made a running change in the axles and there is a break serial number that the update happens at. VIN # 225000 and up got the 650 axles.

 

mmmmmmmmmmm