Hi everyone, long time lurker of this thread.. it contains a lot of valuable information. I don't know if I've ever posted on this forum actually.
I have a 97 4x4 Bearcat. I have had long term problems with the stock carb. It did not have the upgrade/recall add-on primer pump on the carb. I read this thread a lot and followed the plan used by OP raven437.
I don't have pics right now but I will post them up some time, showing how I installed the DVX 400 carb. My machine came to me kind of beat up and had years old gas in it, probably why I couldn't get it to start right no matter what I did.
The installation was pretty straight forward and if you can clean a carb you can install this thing. I removed the stock carburetor and boot, and loosened the 4 screws for the air filter box. The diameters of the carb inlet was different, but it would fit the factory manifold on the outlet with a small amount of silicone spray.
I used a 2004 DVX carb without the special intake pipe and without the TPS sensor. I bought it on ebay for $100. I also had to purchase a 2004 DVX thumb throttle and cable as the attachment is different and on the opposite side of the carb. The fuel line is larger so I replaced the line from the tank and installed an inline filter.
The tricky part was the intake boot on the carb. The stock boot will work, and so far this has worked for me. I trimmed the inside lip of the larger diameter hole on the boot with a razor so it would fit flush and tighten down nicely. On the intake side of the boot, I trimmed off the lip some so it would slide inside of the opening on the intake. I am using a small amount in clear RTV to seal that, along with with a clamp tightened slightly on the plastic lip of the intake box. It seems to be holding thus far.
It starts very nicely now and I have noticed a big improvement in drivability and acceleration. Top speed may have jumped also.
The throttle cable change to the DVX 400 setup was also a trick. The cable for some reason was slightly too short, so I had to remove the adjuster nut on the throttle cable input on the carb. Fully extended on the throttle adjuster and the carb.
So far so good, I will post pics if anyone is interested. I'm going to see how my intake setup holds up over time, but if OP is still around, it would be great to see how that boot is setup on yours.
EDIT: here are a few pics of my machine and the carb setup. Forgot to put the side panels on, oops.