Thanks so much. Just an update, the intake valves were slightly tight but I don't think that was the problem. I think I had a few problems going on. 1) Intake valves a bit too tight 2) Bad gas 3) A plug that was dang near fouled. After taking care of each of these issues, the thing runs awesome now! However, I still think I am running rich even though I am 99% sure I have perfect jetting. That is leading me to think I might need to replace the needle and seat - it might be slightly leaking extra fuel... maybe. The only other idea is the choke circuit may not be sealing properly and letting a bit of fuel in... stay tuned.

 

I have a 1995 polaris magnum 425 4x4 . DOes it have a 4wd light. On mine the far left is oil. neutral temp , and highbeam. Also after installing my cv joints the right wheel pulls fine. But the left one pulls but I can stop it from turning if I hold the wheel with both hands. What do I need to replace

 

The 4wd light is on the right handlebar, by the switch.

If the 4wd doesn't work right, first check the fluid in the hub, then be sure you have power to the magnet, and go from there.

 

Ok found the light and replaced it. Yes there is power to the hub. and I have oil in it . It just seems not like enough power to one side I can stop it from spinning with both hands. What kind of connector connects it the halligan clutch I was unable to tell. I was thinking about changing the springs and armature plate. Any other ideas. ?

 

Try the armature plate first. It is only like a buck or so, and sometimes even a slight groove, or the tiniest bit of warpage can cause it to not grab strong enough.

Most of the time, if the spring in the hub is bad, it won't let go, but will still grab.

Farmr

 

Make sure that the alignment (sleeve to armature plate) is correct and that the spring that holds the rollers together is not too tight. If the alignment is just right, then it can grab the armature plate more completely and keep it from spinning. And keeping the armature plate from spinning is what its gonna take to get the hub to stop and let the rollers 'ramp' up and lock into the wheel. I had to slightly decrease the spring tension on one side to help get it to go into 4wd.

 

check this out 425 too 500 conversion that is a 425 bottom end with a 500 jug an piston with 500 carb and intake