2004 Arctic Cat 500 - Carb & Fuel Filter Questions

[wjgrange]

I am going to help a buddy with his 2004 Arctic Cat 500 TBX next week. I don't own a ATV, but am a pretty good mechanic and have been working on my own dirt bikes, road bikes, cars, trucks and small engine equipment (mowers, tractors, leaf blowers, chain saws, etc.) my whole life. I haven't brought anything to a shop for anything but tires in about 20 years. I am very confident I can do the job.

The problem is, when at idle, gas flows out of the overflow at the bottom of the carb. From my research on the internet, I know the cause is probably either;

1. (less likely) mis-adjusted float height (should be adjusted to 17mm). or

2. (more likely) debris between the needle valve and the seat.

My plan is to remove the carb, dissassemble, check the float height and give it a thorough cleaning.

My problem is my buddy lives 100 miles from me and is just going to trailer the quad to my house the day I'm going to work on it and wait while I fix it. So, I'm not going to get a chance to examine the quad before I dig in. I know, from my research that the '04 500 TBX does not have a fuel filter and it is a good idea to have one. Problem is, without being able to look at the quad ahead of time, I have no idea what size the fuel line is. The closest parts store is quite a distance from me, so I'd like to have all of the parts before he arrives.

My specific questions are:

1. When disassembling and reassembling the '04 500 TBX carb, do I need any new gaskets or O-rings or can I re-use what is on there?

2. Since the '04 500 TBX does not come with a fuel filter, could someone please give me a SPECIFIC RECOMMENDATION (i.e., Fram F5432, Purolator Z657, etc.) of a fuel filter that I can simply splice in the middle of the existing fuel line?

Keep in mind, I am asking these questions because I will not actually get to see the quad until it is time to work on it.

Any help would be appreciated.

Thanks,

Bill

[oxidized_black]

if you are careful you shouldnt need new gaskets. not sure what size fuel hose is, i looked in the service manual and it never stated a size ...

[wjgrange]

Does anyone have an '04 500 TBX that they can pull a fuel line before the carb off quickly any measure the inside diameter? Getting that dimension will allow me to buy a fuel filter before my buddy brings the ATV to my house next week.

Let me know.

Thanks,

Bill