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Ghost420guy

96 Polaris Magnum dies with throttle

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My 96 polaris magnum 425 starts n idles teriffic. Upon giving it gas it stalls out in gear, and i cant rev it up very far or loose all power n sputters. This all started after hitting a deep mud hole and burying my quad. tried emptieing the bowl and nothing. Im aware theres no rebuild kit for the carb (w/o buying individual parts ) but iv read u can rebuild it using a sportsman 500 kit. However reading this in only 1 thread makes me leary to try it, has anyone else heard of this or tried it? I'v already changed oil filter, oil, spark plug n air filter.

Edited by Ghost420guy

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Thanks for the thread change, I'm just gettin ready to pull the carb off and go thru it to see if everything is in order in it. Hope to have it running again soon. And ill definitely check the jets ty.

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Well jets are clear as can be, had to order a new shut off assembly for the tank since it broke in disassembly. We'll see when it gets here if it helped. If not i could always put the yzf 450 motor in n fab it together =)

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If you still have problems with the quad after every thing is back together, do a compression test. If not a carb problem, your issues point toward a lack of compression or an ignition problem like a bad CDI box. I would check the valve lash before tearing into the motor if your compression is low.

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Upon further inspection of my quad i found the down tube on the exhaust is also packed full of mud. Tank part should be in this week so with any luck she'll be runnin by the weekend. Lookin at buying another machine tho jus for fun, any recomendations on a good machine that can take a ton of abuse?

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Utility for sure. My 425 is fun but lacks the umph im looking for, so i figured ill try the 500 sportsman head, air box and carb bored 1 mil n see how that goes but i still want another bigger machine.

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Sounds great, ill look around and see wat i can find. I'v heard the king quad tho rolls pretty easy n i have a tendancy not to use brakes or slow down for that matter. My motto is simple "ride it like u stole it" prolly why i found 3 cracks in my frame and busted the front motor mount. Thanks for the tips though, ill definitely look into the other machines!

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If you ride that hard, you may want to consider a sporty 4wd quad like Can-Am's Renegade. There is a 500 and an 800. Either one will be plenty powerful, and is more suited to handle the abuse of rough treatment. It is the best of both worlds, sporty hanldling, fast and still has the benefit of 4wd so you can still go anywhere. Other models of similar design are Yamaha's Wolverine 350 and 450, good quads, but they are a bit lacking in the power department. The 450 may be a little more powerful than your 425, but probably not by much. The Polaris Scrambler is also a good sporty 4x4, they made a 400cc two stroke Scrambler up until 2002. You could probably pick one of those up at a decent price and there is plenty of power potential there, I have heard of people getting up to 75hp out of those.

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I'll definitely look into a few of those, iv ridden the 650 can-am my buddy has an its a great machine accept the drive belt gets wet. I did jus buy a bmx 110 lil quad for my niece and a honda ttr 110 pit bike to play with this weekend, running outta room for toys. One question tho with the 2 stroke, how do u go about makin it put out more power, can u still bore and oversize the piston? Thanks for tall the input too, greatly appreciated!!

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You can still bore the cylinder and use oversized pistons in 2-strokes, but like any other motor, unless you are using an actuall big bore sleeve or cylinder, it will not yield a noticeable power increase. The most effective way to get big power out of a two stroke is good porting, it must be matched to a good pipe and carb setup. Bumping up compression helps alot too.

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Well i got her put back together. Fired up for about 15 seconds n died, couldnt get her to restart. Very little fuel getting to bowl n now no spark =/ Took it over to my buddys shop this afternoon to have it gone thru.

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Low fuel flow points toward a clogged petcock, and improperly adjusted float, or a sticking float valve. The lack of spark is a different problem all together, the simplest problem would be a bad connection between the plug boot and the coil wire or a bad plug. It could also be a bad pickup, coil, or CDI. I don't remember if anyone has mentioned a repair manual, or if you have one, but at this point I would recommend buying one. There are some direct resistance tests you can do to test some of the ignition components and there will be a troubleshooting guide that can help you track down your problems.

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Sounds good, i jus ordered the service manual for my machine so we'll see if it can help my situation any. Thanks for all the advice it has been helpful in direction on wat to do.

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That is what we are here for man, to help one another out. Anytime you have a question, I am always glad to offer any input that I may have. It is definately a good idea to have a service manual, there is alot of critical info in there, it will undoubtably come in handy in the future as well. If you ever need to take the motor apart, you have all the proper torque specs and sequences, as well as wear limits and so on.

Edited by DirtDemon

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Finally shes back up n running. Intake valves were to tight, t.p.s was way off, drive belts shot an my pilot jet was screwed up to name a few things. Back too running like a champ tho n i already barried her for her maiden voyage!!!

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Hey bud I had the same issue not more then a week ago. What mine was is that you have to take the carb off the wheeler. There is a spring inside the carb that came undone in mine. It was for the air intake. After I put the spring back in it worked great. So in a sence take the carb off, you will have to take the throttle cable off as well and there are 4 screw that you take off and under that cover is a rubber boot. the spring is under the rubber boot. Chek this our and see if that is what it is.

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