I think I know why AC has such competitive pricing. The quality of some parts are questionable at best. My friend and I both have 2001 400 4x4's and we've experienced a number of minor annoyances which left us shaking our heads. For example, the "metal" clip which holds the break lever down when parked has broken in half twice on my friends AC. I've seen plastic that was harder than this "metal". He finally went to a machine shop and had one made out of a block of aluminum.

I mentioned in a prior thread that I had a leak in my rear differential coming from the filler plug. Well, I purchased a new rubber o-ring and inserted it on the plug. While re-installing the bolt, the head snapped completely off leaving the threaded portion in the hole. I wasn't even applying heavy pressure. Upon inspection of the bolt, I noticed that it was the same mystery "metal" as the brake clip. What type of garbage is this? It is very light and obviously has low density. Has anyone else had similar experiences? The brake fluid reservoir appears to be made of the same substance. One impact from a twig or bug and say goodbye!

Incidently, can anyone tell me how much gear oil should be in the rear differential? There are three plugs: filler, drain and a small inspection plug located half way up. The owners manual says to fill the rear diff to the bottom of the filler plug. Is this correct? Then why is there a small inspection plug in the center of the diff? Any help on this would be appreciated.

Thanks

Rob

 

TheCount-
I'm wondering if for '01 they didn't change a few of the parts to that material you're describing for weight issues??? The parts you mention on my 'Cat are solid material, and all the bolts on the diff. are a normal bolt steel-not sure what grade, but I tend to "overtorque" my stuff a lot, have never broke them off like that. Does anybody know if they did indeed change out a few parts here and there for lighter weight, or maybe less dollar cost to produce??? Those pieces are definately different on my machine.

As for the capacity of the rear diff-DO NOT FILL TO LOWER PART OF FILLER PLUG! Way too much fluid there. Pull the "inspection plug", fill till it just starts seeping out of that, then cap everything off, do not install any more than that. The supplement manual to the 500 auto states the capacity of the rear diff. to be 10.1 fluid ounces. The front diff. is 5.8 ounces-this will be the same on your machine as well.

As for the sheared off bolt, I'd try to do a small tack weld on the bolt itself to the head, then back it out. You could drill it out, then re-tap it, but at the expense of risking some possible shavings in the diff itself. I'd try the welding trick first, then do the re-taping bit as a last resort. When you go to get the new bolt-take your old one to the dealer, show him what had happened and see if they did indeed switch to a lesser grade material. Your post has me really questioning that now, I'm wondering what will be on the new '02 models. 'Cat has had a good reputation for building "rock solid" equipment, if indeed they have switched to a lesser grade bolt material and such, maybe a few letters from 'Cat owners are in order to ask them to keep high quality parts on their machines. 'Cats are probably the most durable utility machine-I know I really work the hell out of mine, moreso than other machines are capable of. If the new machines are not as strong as my current machine, I'd be more than dissappointed to say the least.

Best of Luck with that, let us know what you find.

Mike

 

Funny, I broke off the same exact rear diff. filler plug on my 01 AC 500 auto when checking my gear oil level. I stopped by my dealer,and he didn't have one in stock,so he took another off a 01 500 manuel. For some reason that plug was thicker,and more durable looking. My old one was very thin threaded,and of that white metal looking
material. I had some threads exposed on one that broke,so was able to screw it out. I filled my rear until I could see the oil at the top of the gear,using a flashlight. I didn't want to fill it up to the plug,seemed too much leaving no room for any heat pressure build up. which is what the tubing on top of your differential is also for. The plug is the only problem I've experienced with my Cat thus far,and have been very happy with it.

 

That "whoozit" thingy, or whatever it's called on top of the diff. is for heat gasses to expand into, not for oil overflow-or was that what you meant? Also, sounds like you have too much oil in there-it's only supposed to have about 10.1 ounces, not completely filled to the top of the gear. The gear dips down into the oil, pulls it up to the top for lubrication, and doesn't need to be in a "complete bath" for proper oiling. As soon as it comes out the "inspection hole", it's full enough.

Sorry for the confusion, hope that helps.

Mike

 

This mystery material is certainly lighter than metal. Also, the threaded portion of the filler bolt on the 01's are hollow down the center! I was surprised to note this when I first removed the bolt. It's probably because the filler hole is so wide. When the head of the bolt snapped off, I inserted my finger into the hollow opening and backed the threaded portion out. Fortunately, nothing fell into the diff.

I called my dealer and had him order a new plug. Said he'll have it for Saturday morning so I can ride. In the meantime, I'm going to take the broken bolt to NAPA and try to get a replacement that's better quality.

Cowboy - the supplement manual you have seems to be very helpful. I was looking for a manual on my particular model but I couldn't find anything. Could it be they're not out yet? I also noticed that there is generally not much available for AC. I visited bikebandit.com which seems to be popular in the different forums, but they do not carry any parts for AC. The owners manual that came with the quad isn't worth %#%@$! (e.g. the instructions in the owners manual are to fill the diff to the bottom of the filler plug)

Arctic Cat is now a big enough player that they should have a technical support number for their customers.

Anyway, thanks for the help. Good riding.

Robert

 

Oh, the "supplement manual" is available from your dealer-it is a standard "shop manual" that he himself uses to fix YOUR quad! The main manual cost is around $50-the auto "supplement" is $29.95 I THINK. You'll have to go to your dealer to get one-that's the only place I know of to buy them. Just tell him what machine you have exactly, and you want the shop manual for it. If he doesn't have it, he should be able to order it in within the week. If your machine is still under warranty, I have heard of a few dealers that will not sell you the shop manual till it is out of warranty-that way they cover their own butts, should something go wrong and you try to fix it with the manual, then screw up and have to take it in for them to re-repair, fixing both the original problem, and whatever you may have screwed up in the meantime. I can see their point with that.

As far as your plug being hollow-DAMN, THEY ARE DIFFERENT! All of mine are solid, and heavy. I wonder if they switched them all to that new cheap style, or if maybe they just ran out that particular day and made due with what they had???? Interested to hear what other '01 400 owners have in their units. I'm sure glad I don't have that style on my machine, as I tend to "over torque" bolts all too often. I'd surely snap every single on of those off in a heartbeat! Sorry to hear what you're dealing with there-I'd definately get some better bolts. Did you dealer say those hollow ones are standard?

As for stuff available for AC-what kind of stuff? It is true there aren't nearly as many things available for AC as there are for Yammy, Pol. and Honda, but there is still quite a bit of stuff out there. You can get jets, filters, pipes, lifts, spacers, all kinds of things like that. If that is the type of stuff you're looking for, go to www.highlifter.com, www.cabelas.com, www.rockymountainatv.com, www.hi-per.com, www.mooseutilities.com to name a few. Those will surely keep you busy for a day or two! heh heh heh [img]i/expressions/face-icon-small-wink.gif[/img]

Best of Luck,

Mike