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Discussion Starter · #1 ·
Photos of my friends' bearcat.
28" Mudlites (28x10 front, 28x12 rear)
1" Lift, 1.5" wheel spacers
Factory carb replaced with DVX400 Carb, (professionally tuned)
KNN air Filter/Watersock
Perf. exhaust
Twist throttle/engine killswitch (lanyard)
factory headlights replaced with 12w LED lamps.
Aluminum shielding installed under fenders.
New seat cover, extra 4gallon fuel tank, in-line coolant temp gauge.
Ill post some videos and more details soon if anyone with these older cats is interested in some of the hurdles we went through regarding the carb and exhaust.
 

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Looks good bet it runs good too. I've got a 99 500 that gives me carb trouble Id like to swap the DVX carb on mine what did u have to do to get it to work ?
 

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Discussion Starter · #3 · (Edited)
This all started because we wanted 'MORE POWER' lol
We bought a Moose Racing Stage 1 kit for the quad and had it installed & tuned by a local Arctic Cat dealer. The 454 ran stronger but the stock carb had a tendency to flood and run way too rich with the Stage 1 jets. The mechanic suggested opening the exhaust up so we picked up the one you see in the photos and replaced the stock muffler. It was louder and flowed better, but would still run like crap after about 30min. No power, too rich, smoking a lot, etc.

The issue was the carburetor. In 97 they built them for reliability and thus were built de-tuned. You could tune that carb to perform well hot or cold, but not both. So if you turned it to run well hot, you could barely get it to start cold.

The mechanic told us the DVX400 and Bearcat 454 ran nearly the identical engine in those years and putting the DVX 400 carb on it would be no problem and give the engine all the fuel/air it could ever want. We found a used dvx carb on ebay for $120 and delivered it to the mechanic. A week later we had the bearcat back and now it runs like a beast. The aftermarket exhaust kindof deteriorated after a few weeks so we put the stock exhaust back on and didnt seem to lose any performance at all.

It was all in the carburetor.

Now as for your 500~

I have a '00 500 manual and it uses a totally different carburetor than the '97. The stage 1 kit was all it took. Cheap and efficient.
I would get a service manual and take a look at the parts they use. The '97 454 uses a Mikuni while the 500 uses a Keihin carburetor.
 

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your bike looks good...i also have a bearcat, and was wondering if you have any issues tuning the 28's......I also have the same carb issues you spoke about sometime....i guess i should look into the DVX carb., this is the fist info i've seen a swap for one
 

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Discussion Starter · #5 · (Edited)
It turns the 28's fairly well. Here is a video of him trying to climb a wet clay hill with them. Decent amount of wheel speed for a 454.

Clay hillside - YouTube

This video was taken before the wheel spacers, lift, and carb were replaced. Mostly just stock bearcat with 28's
 

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Discussion Starter · #6 ·
A photo taken this past summer during our adventures.
We decided to sell off the 28" mud lites and put on a set of 27" sedona ripsaws. 12"w in rear, 10"w in front. Much better tires.
 

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OK, I have a 454bearcat it idles and starts fine, but it has no top end it will only go about 25mph. Had it into the catdealer & basspro they cleaned the carb up but they are only trained on the newer models. It acts like its not getting enough air/fuel or both, there is nothing past 1/2 throttle. I looked up this dvx400 carb and found new ones for $150+/- for 2004-2008s models is this the carb you are talking about??
thanks.

This all started because we wanted 'MORE POWER' lol
We bought a Moose Racing Stage 1 kit for the quad and had it installed & tuned by a local Arctic Cat dealer. The 454 ran stronger but the stock carb had a tendency to flood and run way too rich with the Stage 1 jets. The mechanic suggested opening the exhaust up so we picked up the one you see in the photos and replaced the stock muffler. It was louder and flowed better, but would still run like crap after about 30min. No power, too rich, smoking a lot, etc.

The issue was the carburetor. In 97 they built them for reliability and thus were built de-tuned. You could tune that carb to perform well hot or cold, but not both. So if you turned it to run well hot, you could barely get it to start cold.

The mechanic told us the DVX400 and Bearcat 454 ran nearly the identical engine in those years and putting the DVX 400 carb on it would be no problem and give the engine all the fuel/air it could ever want. We found a used dvx carb on ebay for $120 and delivered it to the mechanic. A week later we had the bearcat back and now it runs like a beast. The aftermarket exhaust kindof deteriorated after a few weeks so we put the stock exhaust back on and didnt seem to lose any performance at all.

It was all in the carburetor.

Now as for your 500~

I have a '00 500 manual and it uses a totally different carburetor than the '97. The stage 1 kit was all it took. Cheap and efficient.
I would get a service manual and take a look at the parts they use. The '97 454 uses a Mikuni while the 500 uses a Keihin carburetor.
 

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Nice machine. I really like those lockable fuel tanks. I am thinking of buying one for my 2012 Sportsman 500 with the loc n ride system.
 

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Discussion Starter · #9 ·
We had that happen on this bearcat once (before upgrade) Would start & run but was worthless. No power, etc. It was the needle & seat on the carb.

I would say the carb you mentioned would be the right one, however, i wasnt in on the actual purchase and we bought the model recommended to us by the AC dealer. I can find out what year it was off of specifically. I think 2004 though.

OK, I have a 454bearcat it idles and starts fine, but it has no top end it will only go about 25mph. Had it into the catdealer & basspro they cleaned the carb up but they are only trained on the newer models. It acts like its not getting enough air/fuel or both, there is nothing past 1/2 throttle. I looked up this dvx400 carb and found new ones for $150+/- for 2004-2008s models is this the carb you are talking about??
thanks.
 

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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.







 

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Discussion Starter · #11 ·
Ill see if I can get some pics within a day or two here and update this post. :)

Thanks for the input Dub!
 

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Can you remember what the exhaust was that you used on the 454?

Is it still installed?

I'd like to open up the exhaust some and see what it does
 

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carb swap from dvx400 to 96 454 bearcat

hey'all swapped a dvx400 carb to 1996 AC 454 bearcat now the damn thing wont start,when i could at least get it to start on the stock worn out carburetor. i got spark,thoroughly broke down fuel system components cleaned and reassembled so flow from tank is full flow.Pilot screw is like 2 1/8 out. opened float bowl drain screw good fuel flow and oh yeah,the gas is only 2 days old. i believe it might be a chinese carb though it came from california it was ony like 60 bucks brand new.last thing what about the vacuum nipple("that this carb wont work without") on exhaust side of carb,cap it off or ???? greatful for any help ac4fiddy4!
 

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I would cap that vacuum line. It's been a while since I did mine but I don't recall a vacuum line. Maybe it's sucking too much air to start.

What does the spark plug look like? Are you sure th carb is properly assembled and that no packing foam or any other stuff got caught in the fuel/air ports in the carb?
 

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454 dvx 400 carb swap

do you still have access to the cat that you converted? i put a piece of rubber hose on the nipple and capped it with my finger while cranking,and that seemed to make no change.my carb came shipped in a flat rate box,i think,wrapped in bubble wrap so i have no real reason to believe that there may be styrofoam or any other foreign material in the carb anywhere.if your carb has this nipple,i think it would be more or less pointed toward your left handlebar grip,and mine is only about 1/4" long as well as being brass and press fit into carb body.it will be on exhaust side of carb you could look at google images of this carb or look up dvx400 carb on ebay and look at alot of the results and someone will show which nipple im talking about. thanks for your help.look at your machine if you could and answer back,need this for plowing snow in the co.rocky mountains thanks!!!
 

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I just did this swap last week on my 98 500. I just put a hose over the vacuum port . no caps or anything. It started right up. Needs 're jetted but runs fine around the yard. Laggy on top end.
 

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carb swap from dvx400 to 96 454 bearcat

well i have done both the cap the vacuum nipple and leave it open suggestions and she wont fire up,so shes probably got timing chain issues and things are not operating at the proper time.this is all i can figure.still wont start on starting fluid either.this 454 has been sabotaged more than once or twice since we have owned it.for example,the people had unjustifiable beef against us and put OUR OWN battery acid that we had stored,into the gas tanks of two of our atvs. So this 454 doesn't smoke much(or didn't anyway)at idle,but go and give er a little hell and she smoked pretty good.i have a good old(pretty dated)compression tester but it wont fit down the bore the plug boot sits in so i cant really run a test on that aspect of it.(recommend a compression tester set for atv and dirtbike use?)thanks again guys for ideas
 

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454 dvx 400 carb swap

well i can say i got a pretty darn good jolt. i need to reexamine the spark at the plug,maybe grab a new one. now i removed the muffler and put my hand over the tail pipe and it is alternating between blowing against my hand and sucking on my hand, so i did this test to my 2002 500i but got no results because it started to fast so......does this seem normal because i would not think so.i see it was r dubya that replied back,can you tell me what you did with this vacuum nipple that is claimed it has to be there for this dvx400 carb to operate? thanks all!!my dad currently has me tearing both the 02 500i and the 96 454 apart to do an engine swap but i dont believe the engines will bolt up the same,the drive line setups are different i mean it looks as though these two quads are TOTALLY different but he dont seem to care i have to do it anyway.:wacko:I dunno
 

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454 dvx 400 carb swap

well i have a box of 10 cr6e brand new ngk spark plugs,so i put one in.(in case you fellas dont know im pretty sure i ran into some info somewhere saying the factory changed the plug number on these machines from the original cr8e to a cr6e).then i removed the exhaust and got top dead center on compression(AGAIN)and i looks like i had on of the exhaust valves a little to tight so i just backed it off a little and tightened the jamb nut back up,gave it a little shot of starting fluid,and it fired right up! i found some machine specs on the atv connection forum .i just typed 1996 bearcat 454 will not start in the google chrome search bar and he copied specs right out of the book,and put them on the forum.im going to set the valves one more time,hook up the gas tank and see what happens.talk to you guys in a while.THANKSRockerdude
 
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