I added this info to a thread I found in the technical forum, but thought I would post it here as well.
I have a 96 Magnum 425 4×4 doing same thing. Just bought it, ran fine…wide open was no problem. However the drive line was a mess. I changed sprockets and chains, few barrings and seals. Only thing I have to motor wise is new air filter, Plug and fuel lines. Well when I put it back together now from mid to full throttle it bogg’s out and back fires. New gas and I made sure no water, ran it till the carb went dry, then turned gas back on and it’s pulling fuel fine, and does same thing. Put old plug back in, checked the ETC and stuff, did the "Black wire Pull" test… everything I could think of. What could have happen in the 3 weeks I had it apart. Would the cam go bad that fast, just sitting. FYI it does this in neutral or drive with or without the over-ride. I am totally at my wits end… HELP!!!!!!!!!!!!!!!!!!!
I added this info to a thread I found in the technical forum, but thought I would post it here as well.
I have a 96 Magnum 425 4×4 doing same thing. Just bought it, ran fine…wide open was no problem. However the drive line was a mess. I changed sprockets and chains, few barrings and seals. Only thing I have to motor wise is new air filter, Plug and fuel lines. Well when I put it back together now from mid to full throttle it bogg’s out and back fires. New gas and I made sure no water, ran it till the carb went dry, then turned gas back on and it’s pulling fuel fine, and does same thing. Put old plug back in, checked the ETC and stuff, did the "Black wire Pull" test… everything I could think of. What could have happen in the 3 weeks I had it apart. Would the cam go bad that fast, just sitting. FYI it does this in neutral or drive with or without the over-ride. I am totally at my wits end… HELP!!!!!!!!!!!!!!!!!!!
I searched and found one other post of a similar nature and posted this in it also, but felt I should probably start my own thread in the Model Specific Forum.
I have a ’96 Magnum with a pin stuck in the front CV Axel end next to the front sprocket. I would like to change the front sprocket but the shaft has to come out first. Pin is flush on both sides. Tried everything posted here with no movement. I have been bathing it in liquid wrench for a few days to see if that helps. Would heating the outside up with a torch help to expand the shaft? Or will the heat damage anything?
Any help or comments are very welcome and appreciated.
Hi so I’m back with a new question about my 425 magnum 4×4 it’s cold here hovering around freezing and I’m not sure if the bike should be warming up enough for the fan to turn on or not the engine is very slow to warm up and when it does say 30 mins driving it doesn’t really come on unless I put something I front of the rad is this normal
I have a 98 425 magnum 4×4 and three of the four wheels spin in 4wd. The front left doesn’t spin. The hub fluid was at the correct level and new. I took apart the hub and everything in there looks fine. The Hilliard clutch when turned pushes out the rods in it to engage the tire. The back plate and teeth that Engage the clutch from the electromagnet is fine. When I have the quad on I can still take the plate and pull it off and slide it around when 4wd is on. It has a little magnetic pull the entire time. When I check the gray and brown wire for ohm resistance the right side has .50 and when I check the left it has 0. I tried flipping the gray and brown wires coming from the hubs on the circuit board on the side of the tank in front thinking that it would allow the left to work and the right to not but that didn’t work. The right side continued to spin with 4wd and the left didn’t. Is there something I can check electronically to see y the left side doesn’t have resistance on the wires? Could it be the magnet that went bad in the hub? I don’t see where the wire is cut but could it have busted in side the casing or silicone to where I couldn’t see it? I’m at a loss. Hopefully someone knows how to diagnose this issue.
I have a 98 425 magnum 4×4 and three of the four wheels spin in 4wd. The front left doesn’t spin. The hub fluid was at the correct level and new. I took apart the hub and everything in there looks fine. The Hilliard clutch when turned pushes out the rods in it to engage the tire. The back plate and teeth that Engage the clutch from the electromagnet is fine. When I have the quad on I can still take the plate and pull it off and slide it around when 4wd is on. It has a little magnetic pull the entire time. When I check the gray and brown wire for ohm resistance the right side has .50 and when I check the left it has 0. I tried flipping the gray and brown wires coming from the hubs on the circuit board on the side of the tank in front thinking that it would allow the left to work and the right to not but that didn’t work. The right side continued to spin with 4wd and the left didn’t. Is there something I can check electronically to see y the left side doesn’t have resistance on the wires? Could it be the magnet that went bad in the hub? I don’t see where the wire is cut but could it have busted in side the casing or silicone to where I couldn’t see it? I’m at a loss. Hopefully someone knows how to diagnose this issue.
When I put the quad into four wheel drive only three out of the four tires will spin under power the front left is limp as its out of four wheel drive. What would cause this? Any info is appreciated. Thanks for all the help before I got the motor and alignment issues taken care of.
Hi all so I have a couple questions about my bike just want to make sure things are alright so for my first question is the bikes top end is 30 mph is that all they have or should it be faster second where I am it’s cold out now when I start the bike it won’t go above 10 mph with alittle backfire and as it gets warmer it gets faster until it completely warmed up then it will do 30 mph without any backfires or issues at all now I should mention the muffler is rotten and and needs to be replaced the top end is new and the carb is new as well
Does anyone know of what other polaris atv rims will fit. I’m buying new rear tires(24×11-12) soon. I contacted a couple polaris dealers and they didn’t have a set of rims for this atv. I would like to keep these tires on the rims just to bring one when I go riding and have it for a spare.
I’ve found a lot of useful information on this site so thanks to all.
I just rebuild the carburetor on my 2004 Magnum 330 and set the pilot screw at 2 turns and it seemed to idle poorly. So I turned it in a quarter turn and it idles better. My problem is I have to pull the carb out and rotate it to make the adjustments. Id like to tweak it while running but its too tight for my right angle motorcycle carb adjustment tool. Any suggestions? Im thinking of making my own from an old knurled head screw.
