DanPFW

I own 2 2002 ZR-500s. One has 900 miles, the other just hit 1800.

My last sled was a 2001 with over 2500 miles!

I was just made aware that APV adjustment as well as cleaning is suppose to be routine maintenance. So much for the auto-cleaning system!

Here's how I found out. On my last ride of the year, I hit a very hard drift. My sled then proceeded to stall and run like crap. At first it acted like a fowled plug, since it was close to 40 that day.

What I eventually found out is that the APV actually came into contact with the piston, causing a piece to break off and scuff the piston and cylinder. Needless to say, the motor is in the process of being rebuilt.

I know it's my fault if it is indeed routine maintenance, but I have a problem with something like this happening with less than 2000 miles on the machine! Plus how cheap are these motors built if the piece of metal that is suppose to keep the APV out of the combustion chamber is thin enough that the thing can shoot right through it with the slightest impact?

To make matters worse, my other sled has made similar clinking noise since I picked it up, and my mechanic has also noticed the similar noise on his own 500!

Has anyone heard of a recall on this item by any chance? Is this specific to 500s or is it all APV motors?

Dan

DitchPickle

I don't know about your '02 500's, but for the F6 and F7 there is a right and wrong way to install the APV. If it is installed incorrectly (upside down) the valve plate can come into contact with the piston and rings. Have your dealer check for this, and make sure he is 110% sure that they are installed correct. I know of two F7's that went to seperate dealers for a service, and came back with the valves installed wrong.

As for the clinking noise, my '98 500 did the same for two years...until the crank snapped in half and ruined the two pistons, and a cylinder. Have your crank bearings checked...

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2004 Firecat F6 EFI

michael9688

sounds like a crank on the 500 to me too. I wourk at a crank shop here as well as my dads farm.

Crank Shop
"You cant spank our crank"
just started the day b4 yesterday. Mostly sittin doen on my arse cause no one has broke nothin with the lack of snow.

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PLAY HARD, RIDE HARD, STAY HARD, DIE HARD

cj7e

My girlfriends sled ( 2002 ZL 500) is also in the Process of getting the engine rebuilt. Only 1500 miles and the power valve pin sheared and the valve hit the piston. The dealers say that they have gotten a few like this and are replacing the pins with stronger ones. They warrantied parts but not 8 hrs of labor. Big bumber. A lot cheaper to have them serviced every year. Good Luck

DanPFW

I have gotten the same answers so far. Cat finally said they'd cover the parts, but not the labor. I've even heard rumor that they do have a newer/stronger pin available now.

It's just too bad Cat is too worried about their image to let us know about this problem before the engines nuke! This would have been a very easy, inexpensive fix that I could have performed before the season even started if I just wouldn've known about it.

I don't care what kind of cool stuff any of these companies are designing, as long as they keep information like this secret. I just wish all of these big companies would share the information they know about, even if they won't cover the charges to fix the problem. I'm sure they think it would've cost too much to issue a recall, but how bad will their image be after 90% of the 500's on the snow melt down due to a very minor fix?

Dan