02 efi fuel pump problems? - Snowmobile World : Your #1 Snowmobile Forum

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post #1 of 30 (permalink) Old 01-08-2002, 10:58 AM Thread Starter
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I have had 3 friends who have had the same fuel pump problems on their 02 efi machines. Machine wont rev up with out bogging out and a whisteling noise comming from inside the gas tank. Anyone else had a problem?
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post #2 of 30 (permalink) Old 01-08-2002, 11:05 AM
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Sounds like their gas cap isn't vented too allow pressure changes, check for pin hole on cap! Just an idea, hope it helps! ???

sharkey the snowman
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post #3 of 30 (permalink) Old 01-09-2002, 08:03 PM
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I have an '02 ZR 600 efi only have 175 mi but I've noticed the whistling noise but it seems to go away after about 5-10 min of riding. The sled runs real strong,Very impressed so far
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post #4 of 30 (permalink) Old 01-09-2002, 11:42 PM
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My buddy's 02 600 efi got only 1.9 miles before the first pump dropped to 12 psi- supposed to be over 30.

1996 EXT 580 EFI (136 x 1.4)
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post #5 of 30 (permalink) Old 01-24-2002, 12:31 PM
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Arctic Cat has problems with their 02 EFI sleds. *4 of us bought ZR 800 Cross Countries this year and one of us has had the exact problem you described - Fuel Starvation problem with the noise in the tank. *In addition my friend whose sled had problems works with a guy who bought two new EFI sleds for 02 (ZL 600 and a 800 Pantera) and both of his sleds had the same problem the same day when was out riding with his wife. *Brought the sleds to the dealership, they ordered 3 new fuel pump kits to the the tune of $1000 a piece and installed them. *Dealership called them to come pick up the sleds - My buddy's sled was fixed, but the other two sleds failed before he could get them on the trailer? *Since then, the dealership said that after discussions with the factory, they believe it is the smart valves and have since ordered another new fuel pump kit and smart valves. *I live in the Twin Cities and every dealer down here has replaced at least 5 fuel pumps this year. *I believe it is the smart valves - 2 in each tank in line with the fuel pick up hoses (rumored to have been changed for 02) that are burning out the fuel pumps. *The problems seems to manifest itself between 100 and 400 miles. *Arctic Cat needs to do a recall, and if not, all you guys riding 02 EFI sleds may want to check into this before your warntees are up. *What sucks is the snow levels this year, there has really not been enough snow to seriously ride, I think that if there was more snow on the ground that more people would be seeing these problems. *I have just over 100 miles on my 800 and it has been flawless, GREAT SLED! - but I am worried - we will see what happens this weekend!
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post #6 of 30 (permalink) Old 01-24-2002, 02:32 PM
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Posted this the other day in another Cat post:

Went down to Java area(NY- south of Batavia) yesturday seeing that their trails still have a great base. *About 15 miles into a terrific ride I couldn't keep the sled(2001 ZR600EFI) over 4000 rpm's. *If I totally let of the throttle and gunned it I would get the full burst for about 2 seconds then it would bog. *Noticed that the fuel pump inside the tank was whinning a high pitch as if the tank were empty-but it was full. *Haven't taken it to the dealer yet but explained the problem, and three of the sledheads agreed that the fuel pump is probably starving for fuel(pinched line,bad fuel regulator in tank, hose off inside tank)what to you guys think. *I bought this sled form a private owner in the spring in which it was brand new. *He bought the sled by the spring 2000 snowcheck and by fall he went to a ZR 800 so the sled was never used until I bought it this past spring. *This was my second run this year in which I already had put 80 miles on the first run-no problems. *I had the extended "Aftercare" warranty transfered to me- I hope it covers this problem if not I hope AC will help me because a sled with under 100 miles should not have any problems and if so, take care of your customer. *This is my first Cat and I hope it nor the company lets me down.

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post #7 of 30 (permalink) Old 01-24-2002, 03:38 PM
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Man, this is amazing. *Exact same problem on my ZR600 EFI Cross Country. *It is in the shop right now and they are putting in a new fuel pump. *I hope it fixes the problem. *I have 325 miles now, and would like to put another 300 on this weekend up in Pittsburg NH. *This is the first problem-other than that this machine absolutely rocks. *I love it. *Any word on whether this problem can be solved? *How are the other guys who have had it fixed?

2002 ZR 600 EFI Cross Country. *Stock...so far.
2002 Z 570 ESR
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post #8 of 30 (permalink) Old 01-24-2002, 08:00 PM
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gettin my 600 efi back tomorrow. Bad fuel pump with only 35 miles on it. Sucks cuz I got it through the race program so no warranty.
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post #9 of 30 (permalink) Old 01-24-2002, 08:21 PM
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Speaking as a Catmaster Mechanic, i can tell you that it is a problem with the Smart Valves, i have fixed 2 of these machines so far this year, but the warranties are covereing it without a problem. If you have this problem, please have it checked by a good mechanic, he should spot the problem with the in line fuel guage.
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post #10 of 30 (permalink) Old 01-25-2002, 07:39 AM
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I hope if mine's going to go, it goes soon. *I've only got 160 damned miles on the sled and so far the winter season doesn't seem to be looking any better. *I'm going to be one pissed off sumbitch if this thing takes a crap first thing next season. * *

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