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Discussion Starter · #1 ·
Happy New Year and Howdy from Southern Alberta. I have been quietly monitoring this site as it seems to be an interesting and valuable resource for Arctic Cat owners. I'm seeking opinions on a problem with my ATV. I have 2001 500 Automatic (not IRS) with 27" Mud Lights on it that stopped with bang under load. I was pulling away from a stop half way up a steep hill in low range 4WD when something went bang down below. Since then it will not turn the propeller shafts to the front or rear diffs. in any gear. The engine runs fine and I've tried rocking the machine back and forth with power on in gear to listen for grinding or chattering perhaps from the secondary drive or driven gears with no result. The belt I installed last spring is still in new condition and the moveable drive face and driven pulleys look like they function normally when I rev the engine up. Are there more diagnostic checks I can make before removing the engine transmission assembly? Suggestions? I have been studying assembly diagrams for the transmission and have the shop manusl for the machine but haven't come up with a solution yet. What do ya think?
 

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First off, welcome aboard man! Secondly, I think you're going to have to tear into that tranny. If your clutches are working properly but the driveshafts aren't spinning, then the problem lies in between those two components...that being your tranny. :( Being that you had a loud audible noise, I bet a gear broke in half or something along those lines.
 

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Yup, you should start tearing into that tranny cause that's the only thing between your clutches and your propeller shafts front and rear. Sounds like it could be a bevel gear if your not moving at all. Or a shaft in the tranny. What ever it is i'm sure it'll be expensive so if you are mechanically inclined grab up a repair manual and get to it.

P.S The manual will help out alot cause there are ways "to" and "not to" tear these things apart.
 

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Yeah I would bet that you stripped the bevel gear or that screw backed out and stripped it for you. Do a search, there is some more info on this site about it.
 

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Discussion Starter · #5 ·
I took the right side components off the crankcase and found the case is cracked around the secondary shaft. The 3 bolts holding the bearing housing backed out and it drifted out. It looks like the play introduced to the shaft by the loose housing cracked the casing and led to the premature failure of the 'bevel gears'. So suddenly I'm in the market for a crankcase. Any siezed engines for sale out there for a 01 500 Automatc? Suggestions?
 

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So what did you do with the crack?
 

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Discussion Starter · #8 ·
I'm considering taking it to a machine shop to see if I can get it welded. With the bearing housing securly in place there shouldn't be any stress on the cracked area so some JB Weld would probably be enough. I guess if I've taken it this far a weld would be more appropriate. Opinions?
 

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<div class='quotetop'>QUOTE (LandCruiser @ Feb 26 2007, 07:51 PM) <{POST_SNAPBACK}></div>
I'm considering taking it to a machine shop to see if I can get it welded. With the bearing housing securly in place there shouldn't be any stress on the cracked area so some JB Weld would probably be enough. I guess if I've taken it this far a weld would be more appropriate. Opinions?[/b]
I would have it professionally welded if you're not going to replace it. If you attempt to do it yourself, I would recommend Alumalloy before JB Weld.
 

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just out of curruosity,have you priced the new piece.I busted a cracked an axle houseing once and it was going to cost 25 to have it welded and a new piece was 80. I went new ,not wanting to have to wory about the weld holding and stranding me somewhere. Check around some atv salvage yards and you might find a piece at a resonable price.
 

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i am an experienced fabricator/welder.. you can weld this piece with a high success rate .. i myself would weld but you are the OWNER and the one that has to be comfortable with the decision.
But like i said it is weldable and im sure gonna be a whole lot cheaper than new and definetly takes away that CAN I FIND IT USED, thought also.
is my $.02 worth
 

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Discussion Starter · #12 ·
Thanks for the heads up. There is a reputable machine shop in town so I will take it there and see what they say. A new replacement case is $1400. without bearings etc., havent't found a used one yet. I did find a motor from an 03 that should bolt right in but he wants $2K. I'll let you know how it plays out.
 

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If you bought that engine for $2k, you could easily part out your other engine gear by gear by piston.

If I were you, I'd try having a professional weld it. If it doesn't work, then I'd get a newer engine (used is fine) and then part out my old one....that is if I couldn't find a used case.

Try a google search for ATV parts. You'll have to go in a few pages, but you'll find some online used ATV part dealers.
 

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Discussion Starter · #14 ·
I picked my crankcase up today and the repair looks pretty good. Certainly a much stronger fix than what I was considering originally. Thanks for the advice. I need a gear and a gasket set now and start to re-assemble my ride. Things are looking up for a change! Here are a couple photos of the repair.
 

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Discussion Starter · #15 ·
Its' all Good! I though I would provide some closure to this thread as my machine is back together now and running strong. I've put 150 hard miles on it since re-assembling it, my first ride was Saturday June 2nd. It sure is nice to have my ride back and it was an interesting project returning it to service. Out of curiosity I pulled the Rad out to have a look at it and was shocked at the mud caked in back of it. The front looked O.K. but the back side of it was plugged solid. I never had any cooling problems with it like that but it is clean now. I did the Muffler Mod and opened up the airbox a little, polished and ported the Head too. I haven't put the new jet in it yet as I didn't want to change too many things before starting it the first time. It is running great so I'll go ahead with that now. So Thanks for the help and advice when I really needed it. Here are a few more photos of the project and its completion.
 

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Good times man, I'm glad you're back in service. Where was the shot with the mountains taken?
JD
 

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Man, those are some great looking trails.
JD
 

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I agree, that looks like a great place to ride. Glad you got everything straightened out. Gotta love the feeling you get when you bolt it all back together and it runs like it should!

-Doug
 
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