Lets see...

Fender flares pop lose, but this is easily fixed with sturdier screws...

Cracked plastic that I riveted back together, but this is only due to the tree's being a little tougher than the plastic...

Replaced the screws holding the exhaust sheild on, should been checking them, rider error...

Busted plastic on the speedometer, but I guess rolling it will do this...

Broken mechanical (foot) brake, guess I shouldn't have stood on the lever, eh?...

Oh...

And now I need a new bumper, left headlight, left bumper support channel and radiator, collisions are detrimental to the machine's health.



700+ miles and considering the abuse it gets it's as sturdy as a rock (well, a well beaten rock)!

 

I've had my 02'400i since last March 1500 miles later and only prob is tearing boots.But that is on any machine if you go where I go.Otherwise solid machine considering how rough I am on anything I ride.[img]i/expressions/face-icon-small-wink.gif[/img]

 

well to start bearings about every year, customer severice sucked, carb. had something wrong with it, cv boots but that was my fault, the were more but i have just forgot most of them because i got red of the thing quick.

 

We have good luck with both the 300s we have except that they are very cold blooded and very hard to start if they have been setting more than 20-30 days. Rejetting may have helped a littelbit but it is still a very big prbblem.If I cannot cure it they will be replaced with another brand.

 

well lets see...

rear axle,boot between carb and engine, front axle(my fault),brakes all the way around, shock bushings on both front shocks, headlight( the orig got water in it and washed off the reflective coating),rt rear lower fender(the black part)(My fault), upper left ball joint, neutral relay, front diff seals,and it needs to have the reverse indicator fixed as well...

all this in about 250 miles!!!

before you ask, I am a mud freek, but I do try to take care of the thing

 

Replace oil seal in rear diff. (Warranty). Had oil cooler tig welded(my fault).

 

My first one a 98 500 4x4 had the rectifier replaced under warranty, it may have been my fault since I was doing some wiring on it at the time. Had a front axle seal replaced under warranty, due to fishing line wraped around axle. I had over 3700 miles on it when I traded it off for a 2000 500 auto. All of these miles were with 27" Vampires and playing in the mud every time I went out on it. I did put 2 sets of brakes on it but it still had the original wheel bearings, tie rod ends and ball joints.
The 500 auto I only had it for about 6 months and replaced the clutch cover bearings 2 times due to getting water in the clutch cover. This is a simple and cheap repair but still on a $6000 quad it should have been better sealed. The newer ones are sealed much better.
The 01 250 4x4 has had wheel bearings replaced as well as 2 sets of brake pads. I had to rebuild the motor due to no fault of the quad. This has really been a bullet proof quad it has been ridden by my son, jumping, mudding, rolled and abused. It has close to 600 hours on it now and still going strong, no end in sight.
The first 02 500 Cat I had was replaced under a recall, yes replaced! It had 700 miles they gave me a brand new one with new warranty. They said the a-arm welds were bad, I never could see what they were talking about. The second one had about 900 miles on it and the fan went out it was replaced under warranty at 8 months.
I like the Cats and think they are the best quad going as long as you are not wanting a sporty quad. The have the best customer service I have ever seen or heard about from a quad company. The main thing is you need to get a good Cat dealer. I have one.

 

I agree with mudcat. The dealer has to be the main stream for your problems. I've had my CAT for 12 months. It has 900 miles on it. Bought it with 589's all the way round. Since the purchase, I've had it back at the dealer for warranty work:
1)Defective speedo
2)Recall for ball joints
3)Headlite taking on water

Then I did replace plastic which broke when I was in a mudhole. Not covered under warranty.
My new speedo has popped off once since replacement. Resealed it with silicon chem. When I was looking at this quad, I thought, "What a way to go! A simple speedometer that not electronic should work fine." WRONG! The speedo is a piece of trash. It needs to be redesigned. I'm sure that I will be replacing this second speedo this year.
Sorry this is so long guys...
Chuck

 

Hi, I am a long time reader and this is a VERY informative site.

I love my bike I bought it in dec and am very please with it,, I have a 2 questions about it.

1. The header pipe get realy red when I am riding it at NIGHT. It only takes a few miles till it gets red ,,is this normal? the dealer says that it is because the header pipe it thin,, it realy scares me that i could probly light a cigar on it,,, but as soon as i stop and leave the bike idle the redness goes away please help!

2. When I first start up my bike after it was sitting a long time(overnight) I hear a ticking sound that sound like a lifter is unprimed,,,, the dealer says that it is the decompression thingy that is making the noise. It only lasts till I give it a shot of gas does it go away. Whats up with this?

 

Basstoy-
the clicking you are hearing is the automatic decompression working- I believe that it works untill about 500 rpm and then stops. As for your pipe- thats kinda strange. I have had only one problem with my 01 300- I blew a headlight and thats it for the 1000 miles I have put on it this last year, however I did lean it out a bit and I adjusted the clutch a little to make it shift a little easyer. I am a mechanic at a AC dealer and I really don't see too many ATVs come in for service other than oil changes and checkovers. The most common problems I see are torn CV boots and some carb problems on the older 454s. As a whole, ACs are quite tough machines......