setting up a 500m.

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setting up a 500m.

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setting up a 500m. - 5/9/2008 2:50:38 PM

GWC

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Joined: 5/7/2004
From: Kansas
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Setting up a 500m , this is all just my opinion on what needs to be done to one to spin BIG tire correctly.

1. snorkel with a 2" snorkel. and Dielectric grease every plug or connector you can get your hands on. and Move the Radiator up on the rack it will save you headacks down the road.
also seal up the pull start as it does not have a gasket on it and will fill up with water and rust up never to work again..lol

2. Need a High flow muffler, Black Magic , Super trapp Mudslinger or Speed werx muffler.

3. Dyno jet kit, with the slide mod and the spring clipped.. jet size around a 148 150 or 155 with the needle on the 4th knotch and something close to a 42 pilot 2 turn out. this is a starting point for jetting as all motors are different.

4. EPI clutch kit, well worth the money and time to do it ( about 2hrs or so) the cheap $49 kit works just fine

5. Web cam , with a pc680 battery other wise it will be hard to start.

6. 4.0 diff gears, i would do these gears first as it takes away the most stress from the bevel gears. imop

7. 18% gear reduction at the clutches.

8. anything over a 2" lift will need new axles and tie rods, and a 2" lift will try to pull the fronts out if the shocks are ran on max settings.

(I think with all this done a 500m would spin up to 32s and clear them with a 2" lift.)
from here down is just more Power..lol

9. Their is a 581bbk for it from F. S. tech.

10. Also a stroker crank for it from Turners as well..

11. NOS system dont run over a 10 shot on it. jmop

think thats it..

05 500m with a home built 3" lift...

Thumbnail Image

Attachment (1)

_____________________________

08 650H1 LE
Warn 3.0
Snorkeled,Rad relocated
Custom mounted gauges
muffler tweaked
Dynojet, slide mod, spring clipped
Custom clutch kit, 4.0 gears
HL springs, HL spacers
"G" axles
29.5 Laws on custom LE wheels
30" MLs on Black Castle Roks
05 500m
Dynojet,slide mod spring clipped
muffler tweaked
Hidden snorkel
HL temp gauge
26" 589MTs on ITP type 6s
Hard.Pack.Arctic.Cat

Post #: 1

RE: setting up a 500m. - 5/9/2008 3:44:41 PM

MUDTECHinc

Posts: 1825
Joined: 12/11/2005
Status: online

well I think that is about it short of port the head and a AMR coil. the cam, clutch kit and exhaust are crutial to get the power to the ground. stock 500's feel gutless. but once you set one up with a few mods you will soon realize they have alot of torque.

_____________________________

MUDTECHinc Custom ATV Fabrication Bog Team

2005 ARCTIC CAT 650:
29.5" Laws on Beadlocks
Web cam

2008 Arctic Cat 1000 H2
Carb slide mod

http://s226.photobucket.com/albums/dd185/MUDTECHinc/

(in reply to GWC)

Post #: 2

RE: setting up a 500m. - 5/10/2008 12:47:13 AM

Willie B

Posts: 197
Joined: 12/24/2003
From: Van Alstyne, TX
Status: offline

Don't forget to re-route the crank vent hose!

_____________________________

06' 500M
Snorkled
DJ Kit
HMF
29.5 Outlaws
ITP 7's Black
4.0 gears

www.mudmilitia.com

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Post #: 3

RE: setting up a 500m. - 5/10/2008 5:50:12 AM

MONSTERQUADMANIAC

Posts: 4522
Joined: 10/6/2004
From: Natchez,MS.
Status: online

Good Post GWC. I have wanted one of these 500M's for a while. Just scared of the bevel gear issue.

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2008 Renegade 800 "X" Edition

R.I.P. Justin Danner Price
04/03/81 - 11/17/2008

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Post #: 4

RE: setting up a 500m. - 5/10/2008 6:46:48 AM

walkingcrow

Posts: 451
Joined: 3/7/2006
Status: offline

Good write up! Thanks

I think this should be pinned.

WC

< Message edited by walkingcrow -- 5/10/2008 1:33:39 PM >

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AC 05/500 extra lighting front and back, modded muffler, 2" snorkel, purple epi clutch springs, carb slide mod, k&N, heated grips, gun racks, (dial a jet FOR SALE), WYO shock bushings, temp gauge, 27" Outlaws on T7's
rad soon to be re located.
There is no reason a 600lb machine shouldn't catwalk and drive through 6 feet of water.

(in reply to MONSTERQUADMANIAC)

Post #: 5

RE: setting up a 500m. - 5/10/2008 9:36:19 AM

Super Cat

Posts: 207
Joined: 3/4/2008
From: Jacksonville, Arkansas
Status: offline

would it be the same for a 500 auto?

_____________________________

2006 AC 500 Auto
2" HL kit
EPI Clutch springs
secondary mod
lightend rollers
warn 2500lb winch
28" mudlites
12" SS 108 black
2" full snorkle
Dynojet kit
Speedwerx pipe
K&N filter
slide modded
clipped

(in reply to walkingcrow)

Post #: 6

RE: setting up a 500m. - 5/10/2008 4:37:04 PM

GWC

Posts: 21535
Joined: 5/7/2004
From: Kansas
Status: offline

yes it is pinned and most stuff listed will work for the auto, the 18% reduction is the mani thing that wont work for the auto..

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Post #: 7

RE: setting up a 500m. - 5/10/2008 7:05:00 PM

TeamMudd

Posts: 2321
Joined: 5/6/2007
From: Dry Prong, LA
Status: online

good write up man!! i'm taking more notes as we speak!! i think my wife is going to stop letting me in the AC forum..... the old suzuki forum doesn't focus on many 500m stuff, lol!

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Jason
Team Mudd Racing Pres.
WWW.TEAM-MUDD-RACING.COM
MINE: '07 Vinson *29.5 Laws/28 mudlites *"TEAM MUDD" snorkel (my design)*Lift kit*18% Gear reduction*reverse lights*aux head lights*Moose cargo seat*EPI clutch kit*HMF*UNI filter*Jetted
HERS: '07 Vinson *26 XTR's *"TEAM MUDD" snorkel*reverse lights*custom seat back*UNI filter

(in reply to GWC)

Post #: 8

RE: setting up a 500m. - 5/10/2008 9:57:09 PM

sodbuster

Posts: 1337
Joined: 11/4/2004
From: "Show me state"
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O yea... great right up there GWC!!!

I just cant get enough of my little 500m tractor

.

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0==}==>TeAm GeT YoU SoMe<=={==0
06 ARCTIC CAT 500M N.O.S.
Rad relocated, fully snorkeled
29.5 Laws on Type 4s
18% reduction & 4.0 gears
EPI clutch kit
POWERED BY ETHANOL
06 650H1N.O.S.
Rad relocated, fully snorkeled
29.5 Laws on Type 6s
4.0 Gears
Dalton clutch kit

(in reply to TeamMudd)

Post #: 9

RE: setting up a 500m. - 5/10/2008 10:08:33 PM

TeamMudd

Posts: 2321
Joined: 5/6/2007
From: Dry Prong, LA
Status: online

i like

"500m TANK" better

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Post #: 10

RE: setting up a 500m. - 5/10/2008 11:12:53 PM

Super Cat

Posts: 207
Joined: 3/4/2008
From: Jacksonville, Arkansas
Status: offline

will the epi clutch kit work on a auto too? is it also hard to install?

_____________________________

2006 AC 500 Auto
2" HL kit
EPI Clutch springs
secondary mod
lightend rollers
warn 2500lb winch
28" mudlites
12" SS 108 black
2" full snorkle
Dynojet kit
Speedwerx pipe
K&N filter
slide modded
clipped

(in reply to TeamMudd)

Post #: 11

RE: setting up a 500m. - 5/10/2008 11:13:57 PM

squeak12

Posts: 3122
Joined: 9/8/2003
From: Thomaston/Statesboro GA
Status: offline

Add some axle spacers with the 2" lift fromi 700Blaze, and it seems to be trouble free if you won the bevel gear lottery.

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2005 AC 500M
- Snorkeled - Rad Relocated - K&N - FMF - Clutch Kit - 6" Lift - 31" Outlaws - 14" Type 7's -
http://s18.photobucket.com/albums/b132/squeak12/AC500M/

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Post #: 12

RE: setting up a 500m. - 5/10/2008 11:18:46 PM

GWC

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Joined: 5/7/2004
From: Kansas
Status: offline

quote:

ORIGINAL: Super Cat

will the epi clutch kit work on a auto too? is it also hard to install?

yes you can use the EPI kit for it as well, but i would go ahead and get the full kit from them, Secondary spring (thinks its yellow) new rollers and the new wet clutch springs.

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Post #: 13

RE: setting up a 500m. - 5/10/2008 11:28:12 PM

Super Cat

Posts: 207
Joined: 3/4/2008
From: Jacksonville, Arkansas
Status: offline

how much is the full kit cost?

_____________________________

2006 AC 500 Auto
2" HL kit
EPI Clutch springs
secondary mod
lightend rollers
warn 2500lb winch
28" mudlites
12" SS 108 black
2" full snorkle
Dynojet kit
Speedwerx pipe
K&N filter
slide modded
clipped

(in reply to GWC)

Post #: 14

RE: setting up a 500m. - 5/10/2008 11:32:30 PM

GWC

Posts: 21535
Joined: 5/7/2004
From: Kansas
Status: offline

dunno might check the High lifters online catolog and see i think they sell the kit.. aint cheap though..

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Post #: 15

RE: setting up a 500m. - 5/10/2008 11:49:03 PM

GWC

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Joined: 5/7/2004
From: Kansas
Status: offline

http://www.highlifter.com/products.php?p_cat=4240&cname=Performance%3A+Clutch+Kits%3A+Outlaw+Clutch+Kits%3A+Arctic+Cat+Outlaw+Clutch+Kit

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Post #: 16

RE: setting up a 500m. - 5/11/2008 11:50:14 AM

grit

Posts: 477
Joined: 3/18/2006
From: yukon,canada
Status: offline

Is the bevel gears a serious issue, in that does it happen to alot of 500's with 27" tires or is it more of a concern with 29.5" rubber.

thanks

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07 canam800
ITP ss106 rims 27" mudbugs,ITP ss108 27" outlaws,27" MST's
ricochet skids, heated grips, twin air, 3000lb warn

2005 rincon
25" MST's, heated grips

07 toyota FJ cruiser
3" lift, 295-70-17 rubber
arb bumper, 9000lb warn

(in reply to GWC)

Post #: 17

RE: setting up a 500m. - 5/11/2008 12:34:05 PM

GWC

Posts: 21535
Joined: 5/7/2004
From: Kansas
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more of a 29.5 thing but most of it its from boucing tires hard, catching a root while spinning them hard, or being in pb type mud and flooring it and not moving and putting alot of stress on it..

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Post #: 18

RE: setting up a 500m. - 5/11/2008 2:53:03 PM

scaleb26

Posts: 110
Joined: 12/27/2007
From: Zephyrhills, FL
Status: offline

Where are you guys buying the 4.0 Gears from? How much?

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08 Yellow Outty 800 XT
.....2" Lift - 30" SB's on Black 212's
.....HMF / Optimizer /Skids

05 Green Brute 750i (Son's)
.....2" Snorkles / Radiator Up'd

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Post #: 19

RE: setting up a 500m. - 5/11/2008 3:00:19 PM

GWC

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Joined: 5/7/2004
From: Kansas
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Dealers have them, or they can be found on e-bay somtimes.

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Post #: 20

RE: setting up a 500m. - 5/11/2008 8:23:31 PM

TBONESGRIZZ

Posts: 2244
Joined: 4/3/2006
From: Hazlehurst, MS
Status: online

quote:

ORIGINAL: GWC

4. EPI clutch kit, well worth the money and time to do it ( about 2hrs or so) the cheap $49 kit works just fine

Thumbnail Image

GWC, what kit is this exactly? It should be the same for the 700H1 if its an auto right?

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'08 Polaris RZR... Project MonstR'
'08 Arctic Cat 700H1
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Post #: 21

RE: setting up a 500m. - 5/11/2008 9:36:46 PM

GWC

Posts: 21535
Joined: 5/7/2004
From: Kansas
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Yeap the EPI clutch kit for the 500 manual wil fit the 400s -Tc1000 not sure about the 700efi Suzk motor though.
it will raise your stall around 600 to 700 rpms but still feels like the engaugment as it comes in or to say its not harsh like some stalls can be..

iam going to put one in mine in a few weeks.

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Post #: 22

RE: setting up a 500m. - 5/11/2008 10:19:27 PM

bkane

Posts: 75
Joined: 4/24/2008
From: Detroit Lakes, MN
Status: offline

What years seem to have the bevel gear issue?

-Bob

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'03 500i Man
Dynojet kit
2" lift
27" 589MT's on C6's
Carb Slide Mod
AC-3 Tractor Muffler
Homemade Shock bushings
Bedliner'd racks/front brushguard
Was big in it's day lol

WTB: REAR BUMPER

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Post #: 23

RE: setting up a 500m. - 5/12/2008 8:11:22 AM

arcticcatisthebomb

Posts: 207
Joined: 3/12/2008
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what do u put silicone around the pull start or what?

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2006 Arctic cat 500i Snorkeled, 27" mud bugs, 2" lift, Highlifter Lift springs in the rear, Fire fighter strobe lights on the front rack and Army amo box

2004 Honda Trx450r Maxxis Razr's all the way around, Akraix Freestyle graphics, pro taper contours, 13 tooth sprocket, Alba pro elite nerfbars with heel gaurds, E-brake block off plate, Powermadd Handgaurds, baffle out with tip on....

Hard Pack Arctic Cat

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Post #: 24

RE: setting up a 500m. - 5/12/2008 8:56:13 AM

GWC

Posts: 21535
Joined: 5/7/2004
From: Kansas
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Its not just a year based thing for the bevel gears its just that there are more 05 and newer 500s out there then older ones. just like there is less Suz Vinsons breaking these gears becasue they cant fit 29.5s on them as easy most run 27s on them which makes alot less stress on the drive train..

The pull start cover does not have a gasket on it and will fil up with muddy water and rust up your pull start.

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Post #: 25

RE: setting up a 500m. - 5/13/2008 8:07:24 AM

arcticcatisthebomb

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o so i put silicone around the whole pullstar right i thought u ment around jjust were the rope came out...so i pull the cover off put silicone around it and put it back on...

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2006 Arctic cat 500i Snorkeled, 27" mud bugs, 2" lift, Highlifter Lift springs in the rear, Fire fighter strobe lights on the front rack and Army amo box

2004 Honda Trx450r Maxxis Razr's all the way around, Akraix Freestyle graphics, pro taper contours, 13 tooth sprocket, Alba pro elite nerfbars with heel gaurds, E-brake block off plate, Powermadd Handgaurds, baffle out with tip on....

Hard Pack Arctic Cat

(in reply to GWC)

Post #: 26

RE: setting up a 500m. - 5/13/2008 8:34:36 AM

GWC

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Joined: 5/7/2004
From: Kansas
Status: offline

yes pull the cover and seal it then put it back on. also seal the rope handle to the cover with sylicone and you can still use it if needed..

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Post #: 27

RE: setting up a 500m. - 5/13/2008 8:40:22 AM

arcticcatisthebomb

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ok i really appreciate it.

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2006 Arctic cat 500i Snorkeled, 27" mud bugs, 2" lift, Highlifter Lift springs in the rear, Fire fighter strobe lights on the front rack and Army amo box

2004 Honda Trx450r Maxxis Razr's all the way around, Akraix Freestyle graphics, pro taper contours, 13 tooth sprocket, Alba pro elite nerfbars with heel gaurds, E-brake block off plate, Powermadd Handgaurds, baffle out with tip on....

Hard Pack Arctic Cat

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Post #: 28

RE: setting up a 500m. - 5/13/2008 8:41:49 AM

arcticcatisthebomb

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How many plugs is there that i have to put dieelectric grease in??? The spark plug and how many others?

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2006 Arctic cat 500i Snorkeled, 27" mud bugs, 2" lift, Highlifter Lift springs in the rear, Fire fighter strobe lights on the front rack and Army amo box

2004 Honda Trx450r Maxxis Razr's all the way around, Akraix Freestyle graphics, pro taper contours, 13 tooth sprocket, Alba pro elite nerfbars with heel gaurds, E-brake block off plate, Powermadd Handgaurds, baffle out with tip on....

Hard Pack Arctic Cat

(in reply to GWC)

Post #: 29

RE: setting up a 500m. - 5/13/2008 8:43:47 AM

GWC

Posts: 21535
Joined: 5/7/2004
From: Kansas
Status: offline

everyone you can. i do them all plus i pull the fuses out one at a time and put it on them as well. also stick some all over the key and put it in to get some in there as well..

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Post #: 30

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