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The low friction surface and shape of the polyethylene skid plate helps in mud bogs.

     Although the locking front end is the primary reason the AC did so well
in mud test, the 500 also has a few other features that contribute to
it's mudding capability. It features a full-length skid plate made out
of high-density polyethylene that wraps up around the front of the quad
without leaving any edges to catch on anything. Because of the wrap design, mud is deflected away as you glide over it with much less resistance. The other contributing factor is the large 25x10-12 Titan 489 front tires. They have a wide contact patch and an aggressive tread pattern that helps propel it through the goo, without sacrificing it's trail ability. Their impressive traction on varied terrain combined with a great ride make it our favorite stock utility tire.

    

The Titan 489's make for an excellent all-terrain stock tire.

New for 2001 are the hydraulic
disc brakes, front and rear, all controlled by a single lever. True, the single-lever attribute isn't appealing for sport-style riding in 2WD mode, but for utility work and recreational riding it's fine. The AC braking system is unique in that dual calipers are used on the rear disc effectively giving you the same stopping power as the dual disc single caliper front brakes. The hydraulic brakes work by squeezing the left hand brake lever, which applies braking pressure to both front and rear calipers making the hand brake positive four-wheel braking action. Applying the foot-brake pedal will then put braking pressure to the remaining rear caliper. This type of braking action works extremely well.

Chassis / Suspension

Click photo for detail of 2001 AC 500 upgrades.

     Just about the only criticism ever leveled at this quad has been that it felt heavy and leaned in the corners. Yep, it has some weight to it--and plenty of it. The AC500 tips the scales at 645-pounds. The third heaviest utility quad behind Bombardier's Traxter's (700+ pounds) and the Polaris Sportsman (697-pounds) So yes, it's heavy, and yes it's not a super handler, but it's not supposed to be. This quad is pure utility and as such, the weight factor is not detrimental to performance. There's nothing wrong in my opinion with a utility quad feeling heavy. Actually, solid is a better description. Other than the purring engine, there wasn't a squeak or a rattle to be heard. In my mind that's an indicator of quality construction. The entire unit is as taut and muscle bound as any machine we've tested. Another item worth mentioning is that the racks and chassis have electrostatic powdercoat painting.

    

Diagram of ACT Semi-independent rear suspension at work.

Fully independent double A-arm front suspension and patented ACT (Arctic Cat Technology)-independent rear suspension create a respectable 7.2-in. (18.3-cm) of travel at both ends. The four-link setup allows the solid axle left or right side to move up or down independently. The semi-independent axle movement provides a smoother ride and better traction than a conventional straight axle. The rear CV joints offer more efficient transfer of the power than conventional U-joints. Also allowing more suspension travel and no maintenance. The front and rear rack weight capacities of 100-lbs. and 200-lbs. respectively, are nice round increments. They are also the highest rack capacities of any quad.
     The AC drew generally high marks for comfort and lateral support with the semi-independent rear. We stormed down a rocky trail and were struck by how comfortably the suspension skimmed over the jarring bumps. As all 600+ pound 4x4 quads are at higher speeds, don't expect crisp high-speed cornering. For ordinary trail riding speeds, it's a comfortable riding quad. Overall, AC did a nice job on the suspension.

Comfort / Controls

     The display panel and controls are sensibly placed and easy to read and use. The display has an odometer, tripmeter, speedometer, high-beam indicator, reverse, neutral, overheat and gear indicator lights. We especially liked the gear position indicators.
     The easy-to-reach reverse lever on the right hand side of the fuel tank is smooth shifting. The frame is large so that just about anybody will be comfortable riding the quad on all-day excursions. The long seat is thickly padded. The floorboards with raised footpegs provide adequate boot gripping ability. An added feature is the 12V DC accessory outlet located on the left side panel.

The Rocker Shifter

     This was our only gripe with the whole machine. We have to confess we had trouble warming up to the rocker shifter. It was by far the hardest shifting method we ever had to get accustomed to. We even solicited opinions for the best shifting procedures from other Arctic Cat owners on the forums section of our page. There were differing opinions on the best foot placement and shifting procedure. Mind you, these differing opinions were from long-time Arctic Cat owners. Shifting is an important element and its design shouldn't allow for a "whatever works best for you" functionality. A few mentioned that when wearing winter boots the rocker allows easier shifting. However, a toe shifter can be moved up a notch to compensate for larger boots as well. The shifter works fine mechanically, but sheesh, it drove us bonkers to use consistently well. It was unanimous among our testers that the rocker has no advantages over a toe shifter.-- In theory, it sounds easy--push your toe down to downshift and push your heel down to upshift. This works fine if you're always in an upright, sitting back on the seat position. But for riders who like sitting forward hugging the gas tank with their legs because of personal riding preference or when climbing hills, pushing down with your heel in the forward position becomes almost impossible. Personally, I thought it was fiendishly difficult to get used to. I want to stress that it worked great mechanically, the problem was just getting used to it. In any event, it's a moot point as Arctic Cat now sells a toe shifter version in their 2001 accessory catalog. My suggestion is that if you're having trouble getting used to the rocker, order the toe shifter for $19.95 from Arctic Cat. It's our humble opinion that AC should strongly consider making the toe shifter as standard equipment and the rocker shifter as an available option.

Odds / Ends

If memory serves us correctly, Arctic Cat is the first OEM since Honda's '88 350 Foreman to offer the same size front and rear tires. All the test riders liked the ride and traction of the Titan AT 489 25x10-12 tires. The same tires are found on Polaris ATVs and we've grown to like the traction and smooth ride they offer.
     OK, want me to get picky? The storage compartment could be bigger and needs better waterproofing, the handgrips need to be thicker, and the front end could use a little more bumper protection. When plowing through stump-filled stick-jabbing areas, I don't have a lot of faith in metal mesh protecting the radiator. A large thick bumper would add protection and enhance the front end aesthetically. We didn't experience any problems, I just prefer big thick "get outta' my way you measly rotten stump" bumpers.

Summary

     I actually had someone admonish me the other day for wanting to test our quads in a "controlled environment." But this is exactly the best way to test an unfamiliar quad. Because we are so familiar with our hillclimbs, mudbogs, fast trails and creek crossings, we know immediately if the quad is performing correctly or in a substandard manner. Trying to do a thorough review in day and a half of riding in unfamiliar riding areas or at the OEM intros is not easily accomplished. We've tested Arctic Cat's at intros, but this was the first time we had one at our own testing grounds and we thank AC for the opportunity.

     OK, here's the verdict. We were slightly astonished at how solid and vibration-free the entire machine felt. It's strong evidence of a thorough manufacturing process. Even after the beating we gave it, there's not a bolt or nut loose--nor any squeaks or rattles of any kind. Throttle response is superior and the torque is phenomenal. The steering was a little heavy at times, but no more than other 650-pound machines. This quad is our top pick for all-around utility work. We continue to recommend gears to people who will use the quad for lots of towing, so you farmers and firewood cutters should stick to the AC 500 with the rocker shifter as opposed to the 500 automatic.
     Concerning the recreational trail riding aspect. With the semi-independent rear and 7.2" of shock travel, the suspension is far more compliant (smooth riding) than most other utility quads. However, if you're the type of person who likes faster trail speeds and getting air, this quad isn't for you. This is a pure utility vehicle and a darn good one to boot. Despite the rocker shifter, the AC has so many other good qualities that all our testers rate it as a top machine. If this quad has any shortcomings we couldn't find them. Nice job AC.

Editor's Note: The AC impressd us enough that we've decided on doing a shootout with another highly regarded machine. Bombardier's Traxter XT. Look for the shootout results in a few weeks. We expect a close contest.

Specifications

Engine 493cc, liquid-cooled, 4-stroke, 4-valve overhead cam with automatic compression release
Dry Weight 645-pounds (293kg)
Ground Clearance 9.2" (23.3 cm)
Overall Height 45" (114.3 cm)
Overall Length 80.5" (204.3 cm)
Wheelbase 50" (127 cm)
Overall width 45" (114.3 cm)
Tire sizes Front 25x10-12

Rear 25x10-12

Suspension Type Front Double A-arm

Rear ACT-independent

Suspension Travel Front 7.2" (18.3 cm)

Rear 7.2" (18.3 cm)

Transmission 5-speed, constant mesh, 1-reverse, high / low range
Drive Train Front Shaft/Selectable 2WD-4WD Modes

Rear Shaft

Brake System Front Hydraulic disc

Rear Hydraulic disc

Fuel capacity 4.75-gallons (18 litres)
Alternator Output 25-amps
Rack Capacity Front 100-pounds (45 kg)

Rear 200-pounds (91 kg)

Towing Capacity 1050-pounds (477kg)
Instrumentation Standard speedometer with trip; LED gear position indicator, 12V plug front and rear
   
 
250 2x4

300 4x4 & 2x4

400 4x4 & 2x4

500 4x4

500 4x4 Automatic

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