2001 Polaris Trail Boss 325 no top end - Polaris ATV Forum
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post #1 of 3 (permalink) Old 07-15-2019, 05:01 PM Thread Starter
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2001 Polaris Trail Boss 325 no top end

So I’ve been trying to figure this thing out and I think have it down to clutches or transmission.
I’ve done new carb, spark plug, air filter, new fuel lines, new fuel pump, new fuel shut off, cleaned fuel tank, cleaned screens in bottom of fuel tank, new drive belt, adjusted throttle cable play.

So it starts up perfect and idles perfect and once give it throttle in Forward gear at about 1/2 throttle it Boggs and sputters??? Today I had clutch cover off and inspected clutches. Started to watch and as it’s in Neutral, it will rev to full throttle, but not in gear?? Sound like either spring or buttons in the secondary clutch bad???
Any help will be much appreciated!!!
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post #2 of 3 (permalink) Old 07-15-2019, 06:04 PM
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Why a new carb? Did you get a new OEM carb or the cheap Chinese knock off? Too often here we see that someone got the cheap carb and can't make it work with the machine. "fits" your machine doesn't always mean it will work properly with your machine. IMO you are always much better off to rebuild the original carb if you can.

You are going to want to check the new carb inside against the original. Compare the jet sizes and the size and style of the main jet needle. Your secondary clutch can make a difference too. If the buttons inside get worn out then you will have metal on metal inside which will not let the clutch "shift" right.

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2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
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post #3 of 3 (permalink) Old 07-15-2019, 06:11 PM Thread Starter
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Yes the carb is a knock off. Was not going to spend over $130 just for a diaphragm for the original carb. So went onto to Polaris parts house and got part number for carb and search the web and found a whole carb for $80.

Just baffles me how can rev up to full throttle in neutral, but yet put in forward gear and runs perfect and sputters at 1/2 throttle.
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