I am grasping at straws... Please help!
I have a 2004 (early model) Sportsman 600 Twin that will not rev past idle. It is not backfiring and starts right up with a bit of choke. I have gone through the troubleshooting and ruled out as much as I can without tearing into the engine. Here is what I have done so far...

Replaced Speedometer (old one ate a tree branch)
Unplugged speedometer to rule out rev limiter
Checked compression - 155psi with both plugs removed and throttle open
check fuel pump, holds 5"Hg
replaced fuel filter, verified fuel flow
Rebuilt carb
Replaced carb (zoom zoom carb was only $37, easy hail mary attempt)
replaced spark plugs
Checked Throttle cable and ETC switch
Checked Air Intake, tried with & without filter, air box open & closed
Disconnected exhaust, verified no obstructions

What is left in the service manual is weak spark, Incorrect ignition timing and cam worn excessively
This model/year has the combination Ducati CDI coil, I replaced the stator a few years back as the charging side crapped out.
Any ideas? I am not looking forward to tearing into the engine to verify the cam and dont want to drop money on a replacement ignition system if I dont have to....
Thanks in advance for any help!
John

 

Can you adjust the idel speed via the carb screw?

 

Yup, it'll idle fine and I adjusted the idle to the proper range but if you try to add any throttle it dies. I'm 99.9% sure it is not carb or fuel related.

 

So you can put it at an extreme high idel?

if it just does when given gas though it sounds like too high float settings. If not you may need a new fuel pump. Also check your not vapor locking.

 

I'll double check the high idle but I don't think it'll work. I checked the float height and it seems like it's pumping plenty of fuel. I checked the tank vent and it's clear, tried with cap off as well. I put a brand new carb on and same issue.

 

You might want to check your fuel pump itself. They don't cost much.

 

Well I tried using the idle screw with no luck. A couple turns past idle and it dies. I bypass the fuel pump with an electric pump I had on hand and same results. As soon as you touch the throttle to increase it dies. Doesn't rev at all past idle.

 

Check your jet setting. If your float is good that's probably the issue. Mine slightly runs out the overflow for an unknown reason. It's not getting enough fuel somehow

 

I'm pretty sure I can rule out fuel issues at this point. I have replaced the carb with a brand new one, bypassed the fuel pump and it still does the same thing. Its like a switch, as soon as you touch the throttle to rev it dies. I've checked the throttle safety switch and its not that. Has anyone seen his with the Ducati ignition? Most of what I have found is no spark/failure to start. Would a worn out cam cause this? Those are the only things left on the service manual list I haven't ruled out.