Over-compressed suspension/ drivetrain?

TCW_400 · 2023-05-12

Hi all, I tried to use my 2003 AC 400 quad this wknd to pull a pipe out of the ground. I parked above it and tried to winch it straight up - Of course the suspension began compressing and I think I let it go too far (!) In 4-wheel it has a churning sound and intermittent buzz through the handlebars as if something is bent or was over-stressed. In 2-wheel it goes away, but I have a light "clink" somewhere between the motor to the front gearbox - potentially driveshaft or other running gear. Any ideas on what might go wrong if you over-compress the suspension and so-on? Shocks did not blow, but I bet I bottomed it all out and more... Help me figure out what stupid thing I may have done! This is my 1st quad and I have not done any repairs yet, so don't know how it all works just yet. Thanks!

doorfx

· #2 · 16 d ago

Check your a-arm bushings. You may have squished one out. Check your drive axles for play

2013 700 XT TRV EPS :
28" Bighorns on bed linered 08 Prowler rims , Wireless winch remote, 3000LB. Warn winch, Heated front and rear grips, Cat relay wiring harness for accessories, LED light bar, 08 650 trv LTD rear box, Heated rear seat, Elka stage 3 shocks all 4 corners, Aftermarket A-arm bushings, aftermarket sway bar bushings(prototype), Deluxe brush guard bumpers front and rear, Red anodized Hause fairlead, beverage opener winch hook, Synthetic winch rope, RTR motor mount bushings, Dynojet PC5 programmer, Dynojet Autotune, [/B]

07 500 Gone but not forgotten;
Dynojet/142m/45p/3rd/3turns--Clipped and drilled--Unifilter--Easy adjust PMS--L.C.V. mod--AC Swaybar--Exhaust mod--2"Snorkels--Sanny shock bushings-- Airdam stage 1--PSC phase 2--21/ 23gr rollers--Dalton yellow spring--.7mm shim--Sanny Steerlites--RTR Flex Bracket--2 up seat / pegs--Tach--AC handguards--28" Outlaw mst's--Skull tailight--Skull shifter--Self Resetting Breakers--1" Wheel spacers--Customcncparts Steering Damper--AC deluxe handwarmers--6000k HID'S hi/lo--AC Deluxe Bumpers--Inline Fuel Filter-- O2 sensor \AFR guage--Black Magic Full Stainless Exhaust System--Wireless Winch Remote--29.5 Outlaws--Fox Podium X Rear Shocks--

It's mind over matter,If you don't mind,
It just doesn't matterCat happy

No Boost No Bottle
just balls and throttle

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TCW_400

Discussion Starter · #3 · 16 d ago

doorfx said:
Check your a-arm bushings. You may have squished one out. Check your drive axles for play

Thanks - Will do!

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doorfx

· #4 · 16 d ago

Jack it up off the ground when checking for play in the bushings.

2013 700 XT TRV EPS :
28" Bighorns on bed linered 08 Prowler rims , Wireless winch remote, 3000LB. Warn winch, Heated front and rear grips, Cat relay wiring harness for accessories, LED light bar, 08 650 trv LTD rear box, Heated rear seat, Elka stage 3 shocks all 4 corners, Aftermarket A-arm bushings, aftermarket sway bar bushings(prototype), Deluxe brush guard bumpers front and rear, Red anodized Hause fairlead, beverage opener winch hook, Synthetic winch rope, RTR motor mount bushings, Dynojet PC5 programmer, Dynojet Autotune, [/B]

07 500 Gone but not forgotten;
Dynojet/142m/45p/3rd/3turns--Clipped and drilled--Unifilter--Easy adjust PMS--L.C.V. mod--AC Swaybar--Exhaust mod--2"Snorkels--Sanny shock bushings-- Airdam stage 1--PSC phase 2--21/ 23gr rollers--Dalton yellow spring--.7mm shim--Sanny Steerlites--RTR Flex Bracket--2 up seat / pegs--Tach--AC handguards--28" Outlaw mst's--Skull tailight--Skull shifter--Self Resetting Breakers--1" Wheel spacers--Customcncparts Steering Damper--AC deluxe handwarmers--6000k HID'S hi/lo--AC Deluxe Bumpers--Inline Fuel Filter-- O2 sensor \AFR guage--Black Magic Full Stainless Exhaust System--Wireless Winch Remote--29.5 Outlaws--Fox Podium X Rear Shocks--

It's mind over matter,If you don't mind,
It just doesn't matterCat happy

No Boost No Bottle
just balls and throttle

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660catman

· #5 · 14 d ago

You may have broke the top aluminum spring retainer on the shock. And BTW, that’s not a 2003. Newest it would be is a 2001. As noted check your A arm bushing but yours has the old style urethane type that are not replaceable.

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TCW_400

Discussion Starter · #6 · 5 d ago

660catman said:
You may have broke the top aluminum spring retainer on the shock. And BTW, that’s not a 2003. Newest it would be is a 2001. As noted check your A arm bushing but yours has the old style urethane type that are not replaceable.

Correct, it is not a 2003 - I have it as a 2002 however. Perhaps its an '02 model, made in '01? Anyway, if the bushings aren't replaceable, what do folks do?

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660catman

· #7 · 5 d ago

TCW_400 said:
Correct, it is not a 2003 - I have it as a 2002 however. Perhaps its an '02 model, made in '01? Anyway, if the bushings aren't replaceable, what do folks do?

It’s definitely not an 02 as the headlights and panels are 02 and newer. Yours is 2001 and older. First 5 digits of serial number says it all. There was a guy on here selling replacement UHMWPE bushings for these. I changed all mine in my 2005 300 4x4. These had the old style urethane bushing too. It was a bit of work to drill out the bushing centre with a hole saw and slice the outer portion out of the control arm.

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tiggershark

· #8 · 5 d ago

looks like a 99 or 2000 to me

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