Problem with fuel flow on 1995 425 Magnum - Polaris ATV Forum
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post #1 of 9 (permalink) Old 07-12-2012, 10:31 PM Thread Starter
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Problem with fuel flow on 1995 425 Magnum

Good evening. I've got a problem with my bike and would like any ideas.

My ATV shut off on my daughter and wouldn't restart. Has spark, compression and I was thinking fuel pump problem.

After it set for a while I could get it to start but it died When I accelerated.

I tore it apart and replaced the fuel pump, filter and checked all of the lines. Even removed the intake on top of the cylinder and reseated it. Got it to run and idle, even got it up to speed and ran it for about five minutes. After running good, it suddenly sounded like it was firing back through the intake a little, lost power and died like you turned the fuel off. Had to tow it back.

I put Sea Foam in it and plan to drain the bowl on the carb. Maybe it's sediment in the carb? Or is it time for a carb rebuild? When it runs, it runs good.

For some time now, it's been hard to get to restart on reserve after running out on the main tank. I think I've got an obvious fuel flow problem.

Any advice or suggestions would be appreciated.

Big Dog.

1995 Magnum 425 4x4
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post #2 of 9 (permalink) Old 07-12-2012, 11:46 PM
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Not sure if its the same or not but my 97 500 did something similar tonight. Its been sittin for a couple years, finally got it back together, and it would not get any fuel.

The fuel shutoff/on/reserve valve is messed up. Use to, it would not shut the fuel off, now it will not flow fuel, pulled the out line off it and nothing no matter where you put the valve.

Might be totally diff. setup on the 425, but it would be a place to start.
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post #3 of 9 (permalink) Old 07-13-2012, 05:45 AM Thread Starter
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Quote:
Originally Posted by Steele3 View Post
Not sure if its the same or not but my 97 500 did something similar tonight. Its been sittin for a couple years, finally got it back together, and it would not get any fuel.

The fuel shutoff/on/reserve valve is messed up. Use to, it would not shut the fuel off, now it will not flow fuel, pulled the out line off it and nothing no matter where you put the valve.

Might be totally diff. setup on the 425, but it would be a place to start.


Yeah I changed my tank valve a couple of years ago thinking that was why i couldn't use the reserve. it's got good static flow.

Thanks though.
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post #4 of 9 (permalink) Old 07-13-2012, 02:33 PM Thread Starter
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Well I'm going to change out my needle and seat and see if that wasn't just hanging up. I'll post and let you know if that was it.

Stopped at my local dealer today to get a rebuild kit and told the parts guy what was going on. He offered to ask his tech about it, came back a few minutes later and said "the tech said to change the spark plug".

Sheesh.
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post #5 of 9 (permalink) Old 07-13-2012, 04:21 PM
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I think your pilot jet is clogged in your carb. Remove,disassemble,clean and reinstall the carb. That should cure the problem. Look at the float needle seat if it is squared off where the needle slides up and down replace it. That should fix it. I will check back 2moro. Let me know what you find. I know 425 magnums and have resources to help you fix the problem. Inspect diaphram in top of carb also. DO NOT spray carb cleaner in carb without removing the diaphram first. If you do it will desroy the $80.00 diaphram. If all of that is good check for a worn exhaust lobe on the camshaft. Check the oil and make sure the carb didn't flood the engine with gas. If it did change the oil and filter. Use 0W-40 Mobil 1 fully synthetic and a Wix filter 51358(NAPA 1358,Carquest 85358. A spark plug might cause it but I doubt it. Always use NGK spark plugs.
Maybe you will get it repaired.
Thanks
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post #6 of 9 (permalink) Old 07-13-2012, 05:04 PM Thread Starter
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Thanks for the info. I'm into the carb right now. Anyone know how to get the damned float pin out? I don't really want to use a punch and hammer for fear of breaking the supports.

Should slide out I think.
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post #7 of 9 (permalink) Old 07-14-2012, 05:21 AM
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I use a spring loaded center punch, bought from home depot, it needes a little hit with a punch to get it started then it slides out
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post #8 of 9 (permalink) Old 07-21-2012, 09:04 PM Thread Starter
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Update

Ok, I've got an update.

Tore the carb apart the other night. Finally got the Float pin out, had to drive my pocket knife under the pin head to get it to come loose. Hosed out the carb with a can of carb cleaner, installed new needle, seat and 153 main jet. Checked diaphragm (was good, thankfully), and checked throttle needle. Removed emulsion tube and cleaned, made sure all little holes were open.

Reinstalled carb and installed a K&N filter.

So far, so good. Have noticed a slight hesitation as the throttle opens, but clears up and accelerates well. Loads up a little bit at lower RPM's. I have picked up a little speed and acceleration, but not as much as I thought I would with the bigger main jet.

I left the pilot jet at 140. Any suggestions on a better combination?

Thanks for the info too.

Big Dog
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post #9 of 9 (permalink) Old 07-21-2012, 09:14 PM Thread Starter
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Tt425, thanks for all the info and numbers. They'll come in handy!
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