I have a 2004 Sportsman 600 that is slow. It is so slow that I loose very badly out of the hole, throught the midrange and on the top end to every 500 that I come across!! I have tried weights and springs in the clutch, carb adjustments with jetting and more air (K&N). I have tried ignition modules (Unable to check ign timing as it is a late model 600-no reference marks. Has anybody checked timing on one of these units?). I have verified compression at 150 PSI both holes. tried different spark plugs. Checked the exhaust for restriction and found nothing. The engine starts and runs great and runs good at throttle but I just can't get it to rev past 52-5300 Rpm at WOT. Does anybody have any suggestions for this unit or has anybody had a similar situation? I ride around 2500-3500 Ft and I am jetted 1 over stock. Please help!!!

 

My 700 had a similar problem. I rebuilt the bushings in both clutches and that fixed it. Mine had 4000 miles at the time.

 

Ya definitly sounds like a clutching issue to me. Pull your cover off and inspect the belt and clutches for wear.

 

Def in the clutching.Secondary clutch buttons can cause this.Along with too heavy of shift weights

 

Thanks for the input guys, but I have already done what you have suggested to no avail. I have gone inside and out with the clutches and tried various weight and spring combos and I just don't seem to be able to hit on the right combo to get this unit to rev out on the trail.

 

You think you could have a brake caliper dragging

 

Thats a good thought but everything seems to spin ok when the unit is on the jack stands.