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1996 Polaris Magnum 425 won't go over 1/3 throttle

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I've been reading through these forums for about two weeks looking into the issue I am having with my 425 Magnum and have tried everything I have seen but nothing has fixed my issue. Basically, I picked this 4wheeler up knowing it would idle perfect but would not rev past 1/3 throttle. I figured it was a Carb issue but after looking at that realize it is not. I have replaced the Cam and Rockers, again not the problem. I finally took the air box completely off and noticed that the hose going to the airbox was wrinkle inside and possibly letting air in. I figured I would permatex it up as a temp fix before purchasing that. Well, while it was setting up over night, I decided to run the bike. It ran damn good. It would rev to full throttle even though it was sputtering which I attributed to the lack of vacuum line being connect due to the air box being off. Anywho, I put the air box back on when I got home from work thinking I found the issue and the thing is back running the way it was before. The engine doesn't completely die it just struggles to stay firing. I have also already tried disconnecting the rev limiter (black wire) but got the same results. Does anyone have any other ideas before I take this thing down the road and run it into the Quarry?!?!?!? :aargh:


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Welcome to QUADCRAZY! So you said you looked at the carb, right? You made sure the float is fully operational? Sounds like fuel flow to me or shortage of, at high rpm.

Have you checked your stator output at higher rpm?

* Added full year and manufacturer to thread title, condensed title.

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Right, I'd also lean towards the carb. Did you do a complete rebuild? Soak it over night etc...sounds fuel starved, like a filter or along that line.

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Have you checked the choke adjustment. MY Daughters quad about made me crazy and it was cracks in the fuel line at idle it was fine hit the throttle and it was like you were running out of gas.

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