Hello to everyone! I am new to the forum. I have two questions and I am hoping the members can help.

I just picked up a (very gently used; as in barely used) 2002 Arctic Cat 500 Automatic 4x4. Everything is in great shape except for two issues. First, it appears that there is an issue with the fuel valve, in that the motor breaks up and pops when revved low to high when set at the “on” position. When set at the “res” position, it runs fine. From research on the forum, it looks like I need to pull the tank and clean it out. My question is really a double: is my assessment correct and if so, how do you pull the tank?

My other “issue” is whether or not there are 12v accessory plugs on the machine? I have not found them as of yet, since the bike came with full camo covering and I have not yet pulled it all off.

I guess a third question would be the best place to get a repair manual for the machine, assuming one is available 8 or 9 years later?

Thanks in advance!

 

are you sure your turning the fuel valve in the correct direction/position? You maybe looking at it backwards as some have done. I personally can not remember which direction to turn it to make sure its on the "on" position. You may have it in the right position when it runs fine and it may be in the reserve position when it runs badly. there is a 12 volt outlet yes, i believe its on the right front fender. someone should correct me if im wrong.(I had a 2002 500 for 6 years,you'd think i'd remember)

 

Hey Mud, I think I am setting the valve correctly. If you are sitting on the bike, looking forward, the valve is on the right side, below the tank. It is in a round recess, and the valve is black with a “bar” that bisects the circle. The 12 o’clock position says “RES”, the 3 o’clock position says “OFF” and the 6 o’clock says “ON”. The black bar has no markings painted on it, but it does have an arrow head on one end. When moving the valve, I am pointing the arrow at the “ON” or “RES” positions. The valve will not turn past either the “RES” or “ON” positions.

No matter what, I am resigned to the fact I will have to pull the tank and clean the carburetor. Even if the “RES” and “ON” are getting switched, it starts to run badly on the one position after about 20 seconds, so if it is the reserve, it is not doing me any good.

Thanks for your input.

 

it isnt a bad idea to just pull the tank and clean the carb on your atv as you dont know when the last time if ever the carb was cleaned.

 

i just remembered!! the 12v outlet is on the right side but near the gas valve .

 

OK, thanks for your advice. I finally got 10 minutes to play with bike. I pulled the camo cover off. I made a mistake. This is a 2000 500 Automatic, not a 2002. The AC outlet is on the left fender! So clean, it looks like it was never used.

Anyway, I have another problem. When trying to start the machine, I snapped the choke lever on the left handle grip. I found the part on line and ordered it. I am concerned that I will not be able to put the new one on. Are there any things I should know before I try this? I am assuming that I need to take the whole assembly off to swap the broken for the new?

Hunting season opens this Saturday; guess I will be walking up the mountain!

 

Ive never had all that off before so i can not help. I usually tear into things and get my info from that,but sometimes i create a bigger problem.

 

I'm not super mechanical, so I guess this will be a learning experience. Probably will not get to it for at least two weeks, as this weekend starts hunting season.

I will give it my best shot. Thanks.

 

Dave there is a screen type fuel filter on the petcock where it goes into the fuel tank , the reserve position doesn't have a filter screen i would do as mudslingfool stated and remove the tank and carb and give them a good cleaning ; and once you get the fuel tank off pour the fuel from the into a glass jar or clear plastic container then remove the petcock and clean the filter screen.

After you do this and put it back together install a clear inline fuel filter between the petcock and Carb you can get this filter at any auto parts store , and while you're there get a can of Sea Foam to mix in the new fuel just pour some of the Sea Foam in your fuel tank ; then fill the tank with the gas and Sea Foam mix and run a tankfull of the mixed fuel and this should get it back running as it should !

If that doesn't do it the next thing i would try is check the valve clearance , i think the valve Spec's are 0.006 " for both Intake and Exhaust valve's ; i hope this help's !

williebee......

 

Thanks Willie! I may not be the shapest tool in the shed, but when guys like you and Mud give me direction, with your experience, I will listen. Might take me a few weeks to get to it, but I will give it a go. I'll let you know how it ends up.