Hi all. I am hoping for a little help here as I cannot figure this out and am close to just getting rid of my ride.
I have a 2000 or 2001 Polaris Xpedition 425 manual. My girlfriend has the same exact quad. Hers has about 400 miles and mine prob 2500-3000 miles.
Hers runs perfect. When I got mine, it was missing stuff and took me a little bit of time to purchase the parts to get it back to speed.
So here is my issue. At low RPMs it has a really bad sputter. Once the RPMs get up, she goes great. It is really difficult when I am in the hills. I need to keep RPMs really high or I can't climb for crap. I can't imagine that is great for engine.
Reason I mentioned my girlfriend quad is because I have copied everything she has and all settings are the same. Ive taken my carb apart many many times. Put in a full rebuild kit.

So where should I look next? Anyone know what causes this sputter at low RPMs?
As I write this, I think the best thing to do is remove her carb and put it on mine to try to rule that out, but....I don't think she wants her quad touched because she loves it as is. Haha
Could this be electrical? Valve issue? Too much fuel?
I just remembered that I have messed with that carb a lot and still can't get the carb to not drip out the bottom when it is not moving. Float issue?

Sorry for the long thread post. Trying to give as much info as I can.
Any help is greatly appreciated

 

I don't work on Polaris, my boss hates them after his days of working on Diesel Dingbats. However, the first thing is to try a new plug. As your carb isn't right anyway, get it right. Either the float level is wrong or the needle leaking, fix that and you may cure the fault. Check inlet manifold for air leaks too, that would cause a fault at low revs. If that doesn't work then the substitution of bits from her machine onto yours is quite a good idea. When all else fails I have done this. Doubles the work but avoids buying bits you don't need in the hope they "fix" the fault.

 

Hello and good afternoon.

I had issues with my 700 Sportsman EFI sputtering/backfiring/dying at low RPMs. Ran perfectly fine at high RPMs. Found the culprit to be a cracked intake boot. This connects the filter housing to the engine. Check out the last few posts of this thread. Worth checking to see if it's something involving too much air at low RPMs because it doesn't need that much airflow.