Just an update,gonna take it down to the dealer to let them listen to it Friday,at least that way I can stop worrying about it....I'll post what they tell me...
thanks guys!

 

HELLO JohnO.
I HAVE AN 03 500I MANUAL AND IT HAS THAT TAPPING SOUND COMING FROM THE BLACK COVER ON THE RIGHT SIDE OF THE ENGINE. YOU CAN ACTUALLY FEEL IT UNDER ACCELERATION. I HAD IT TO 3 DIFFERENT SHOPS. TWO SAID IT WAS NO ISSUE AND ONE SAID TO TAKE IT BACK TO THE ORIGINAL DEALER I BOUGHT IT FROM. WHICH HAPPENED TO 220 MILES AWAY. THEY SAID IT WAS A PRE IGNITION KNOCK AND TO RAISE MY OCTANE . WHICH I THINK IS BS. ANYONE ELSE HAVE AN OPINION. THE BIKE SEEMS TO RUN FINE. BUT IT JUST DOESN'T SOUND LIKE A FINELY TUNED JAPANESE MACHINE. IT MAINLY DOES IT IT 3RD AND 4TH GEAR UNDER LOAD/ ACCELERATION. ANY INPUT WOULD BE GREATLY APPRECIATED

BCD.

 

Yep, sounds like what my 02 does. I tried 93 octane with booster added, no difference. Doesn't seem to affect power, and happens mostly with mid engine RPM's, usually in 2nd or 3rd gear.

I have heard that some of the earlier Cat 500's do this as well. Irritating sound, though after 500 miles it seems to be quieting down.

 

I have a 2002 500i and it has the same noise sounds like really bad spark knock. So far ever body has said it is the pressure relief vavle. Sure sounds bad though. I did ask if the timeing can be adjusted maybe advanced a little they said cannot be done.[img]i/expressions/face-icon-small-disgusted.gif[/img]

 

All I know is that it did not make the knocking sound when I first bought it. It was probably around 500 miles when it started. If it is the pressure release valve, is there any way to check or adjust it?

 

This is a clutch nut problem, some one at Suzuki forgot to put lock-tite on the nut on a number of 375/400 auto's. We have fixed wheelers both in & out of warranty and Arctic has always paid for it.

 

Just got home from the dealership,it doesnt look good!They knew about the clutch nut thing,that wasnt it,they called Cat,they had them check a few more things.They ended up tearing out the centrifical (sp) clutch and the drive clutch and they said knock was still there.
They are saying it needs a new connecting rod and bearings.Just my luck!The Cat rep said he had to call TRF for authorization to cover it.
(the bike is almost 1 yr old and has 250 miles on it) Heres hoping!
This is my first Cat (sled or ATV) .Guess Arctic Cat can either be awesome or terrible on my next shopping trip eh?(1 sled and 1 atv due to be replaced in the next yr or 2)All Polaris BTW...
Anyways,thanks for your help guys.....

 

I'm not sure what that is specifically. Can you elaborate?

 

dunno for sure if you are talking to me or not, but the connecting rod is the piece connecting the piston to the crankshaft...

 

Man! did I get burned!
Got the call from the dealer today ,the bike needs a new head,cam,piston,rings,hone job and gaskets (because it was torn right down)
Bottom end is ok apparently.The Lying Bastard (PO) apparently put a stick through the oil cooler and ran the bike out of oil according to Cats records (he tried to get warranty).So he obviously KNEW there were big probs with the bike.Total estimate is $2400 plus tax!I'm going to call him first and see if he will pay for half the repair bill, if not, I think its time to talk to a lawyer....Dont suppose anyone has seen a good used 375 motor anywhere (In Canada)?Thanks!