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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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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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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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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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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?
 

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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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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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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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I had plans to head north for some sledding this weekend - hooked up the trailer to the truck this morning ... I am working a 1/2 day today ... When I went to start the sled (ZR 800 EFI C/C) I heard the whinning from inside the tank.  We'll be headed over to the dealer later today to drop off my "new" sled for repair?  So from the 4 sleds (all ZR 800 C/C's) that myself and three friends bought 2 have now had the same problem that you all here describe so eloquently - I understand that Arctic Cat is getting the repairs done under warantee but I can not remember seeing any coverage for a ruined weekend.  Now if I ran a business ... could I afford to have 50% of my product be defective?
 

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I do not want to sound like a know-it-all, but I have been working on this issue since the 5th of January.  At 250 miles my ZR 800 CC exhibited the same problems as discussed in previous messages.  The following Monday one of the guys who I work with that bought 02 Pantera 800 and a 02 ZL 600 came and told me that the 600 broke down on the trail because the pump was whining and the machine would bogg out under throttle.  While he was towing the wife's machine home, the Pantera developed the same problem.  Both machines had 250 miles on them.  All three of the machines went to the same dealer on the same day.  The first course of action the dealer took was to replace the fuel pumps in the machines.  They test drove them and called us and said "Come and get them, they're ready.  They guy I work with went to get them and they both developed the exact same problem as he was loading them on the trailor at the dealership.  "Hummmm", guess it's not the fuel pump.  The dealer then tried replacing the smart valves in all three machines and the fuel pumps again.  Dealer called and said "They're ready, we got'er this time!"  (This was two weeks after they were dropped off)  So end of story?  Not hardly--Read On!!   The Pantera and the ZL again died within 5 miles of eachother after about 40 miles were put on.  My Cross Country did not die during the short ride I went on.  So this guy I work with has had his sleds back at the shop still.  It seems there is the potential for the smart valves to be defective.....all of them.  I have talked to the factory and told them about the problem....first they have heard about it.  When I talked to a dealership in the Cities (MPLS/St.Paul) they say they have seen 50 so far, and every dealership around has too.  They tell me the factory is going to do a recall and they expect it anytime.  (I surmise the factory is telling the consumer, "First we've heard of it" and telling the dealerships we're going to do a recall at some point because they need to re-engineer the design of the smart valve.  (I am not sure but I believe the smart valves used in the 02 are a different design or from a different supplier that the 01 smart valves).  In fact the dealership working on our problem asked the factory if they could try a 01 smart valve in an 02 machine.)  So any way I suspect the reason the factory has not announced a recal yet is because they do not have a properly functioning replacement part to put in the machines.  O.k.  We know it is the smart valves because the dealership tested them on the bench and sure enough it locked up.  Here's what the story is now, and we're not sure if it will work.  The rear smart valve seems to be the one locking up and causing the problem.  The rear valve is vented, the front valve is not.  The dealership put a non-vented valve in the rear and wants to try that so that is this weekends test.  Will let you know if it works.  Here are a couple of tricks.  If the machine develops the problem there is air in the pump and you need to purge it out.  With the machine idleing, rock the machine side to side (Hard!!&#33
several times, then lift the ### end and slam it down like you're clearing the track.  Do this until the problem clears.  (Side to side first, then back not vice-versa)  Secondly, carry a wire coat hanger in your trunk.  The rear smart valve is middle to middle right side of the tank.  You can fish that some-##### up through the gas fill opening because she's got a long hose on it.  Bring that bad boy up and out of the tank and hit it on the tank.  This will unstick it and you can ride again.

Well, that's all I know.  Hope it helps.
 

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picked mine up at the dealer worked fine got it home and the whistleing in the tank and the bogging happened again. Another $340 and 2 weeks down the tubes. Dealer dont know whats wrong. I am so unbelievably pissed.
 

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talked to mike at cat seems the 2 valves in the fuel pump react to gas and gum up in some machines.hope that helps some of you. cat sure knows about it although most dealers sure dont.
 

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i have 02 zl600 ss efi with 400 miles on it. I have had no problems yet, runs great, is there anything I can do to in the mean time until cat has a recall? Planning trip to U.P. would hate to get there and have trouble.If I was going to have trouble would it have occured by now?
 

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2002 ZR 600 EFI no problems yet, knock on wood. I love the sled, it runs real strong. I may go for a 700 if they come out with one for next year. I haven't heard much around here in upstate ny about bad fuel pumps. I have 700+ miles on my sled. I hope all of your problems are fixed soon.
 

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Well, they fixed mine on Friday.  Said they replaced pump and baffles(?) and I out on 175 really fast hard miles in NH this weekend without a single problem.  Ran as hard as ever(now has about 500 miles), even in relatively warm temps(37 F).  Let's hope it is fixed for good.  I love the machine so much when it runs right.  I smoked a buddy's 1997 MXZ 670 on the lake, and that made me happy.  Good luck guys!
 

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Discussion Starter #20
</span><table border="0" align="center" width="95%" cellpadding="3" cellspacing="1"><tr><td>Quote (Bearcticcat @ Jan. 24 2002, 9:21pm)</td></tr><tr><td id="QUOTE">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.[/b][/quote]
Listen to this post because I learned a lot about the problem this weekend. It is definately a problem with the smart valves. I think it is the rear valve. You can take a wire and fish it out of the tank and see that it is stuck shut even when the engine is off. It seemed to me that it is a vaccume lock that is not allowing the diaphram to open back up. To temporarally fix this problem to get home, fish the rear smart valve out of the fuel tank using a wire. Open up the valve assembly using a pliers and a small flat blade screwdriver. The top half of the housing will come off of the part that the gas line is attached to. Remove the white rubber washer deal and reinstall the spring and screen. Dont run low on fuel could be a bad thing. Don't just remove the valve completely there is a lot of plastic and metal filings in the tank and you will have injector problems. Best to take it in and have your dealer fix it AC should have the answer very soon.
 
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