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 Post subject: New here and to buggy's have some question's on my buggy
PostPosted: Thu Mar 09, 2017 12:24 am 
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Hello i am new to these buggy's but have read some searches and believe this is the ste to help with my buggy issues. I have just picked up a Hammerhead 250 i am not sure of the year or model. I picked it up pretty cheap because the transmission will not engage to low range. I opened up the gearbox and did not find anything wrong with bearings or the gears. once put back together it still will not engage it shifts to low but as soon as you give it gas it pops out and grinds. My other issue is with carburetor i believe.... i have a new one that i put on and it will start right up and idle fine but when you push the accelerator it sputters and cuts out until it dies. I have pulled the carburetor apart and made sure everything was clean and it still does the same thing. If i adjust the air/fuel screw almost all the way out it will run the best but still is not right. I have also put the original carb back on and tried it because i didn't know why the previous owner had purchased a new one and it runs but has no power. I have also changed the choke with a new one with no change in how it runs. I have cleaned the tank, replaced all fuel and vacuum lines as well as the fuel filter and petcock in the tank..... still no change. I have also read and adjusted the valves and still nothing any better. I hope someone will be able to give some advice on what to try next as i am running out of ideas on my own at this point. Sorry to run on so long but figured i would list everything i have done to help narrow down my problem at this point. Any ideas would be great and thank you.


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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Thu Mar 09, 2017 8:41 am 
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It sounds like you need to replace both the driven and drive low gear. This is a common problem with these. The dogs that engage into the driven gear get rounded off and will not stay engaged. It is a good thing you got it cheap as you have to buy the whole shaft assembly these days as opposed to just the two gears you need.

As for you running issue check to see if your intake is not cracked and has a vacuum leak. You can spray some carb cleaner around it to see if it speeds up while running.

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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Thu Mar 09, 2017 9:44 am 
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Thank youfor the information....... I have checked the intake and can spray all around it with no change in the idle. I am in Montana and sit at 3300' elevation is thought it may be jet issues but it was running when the previous owner parked it so I don't think it is that. Could it be electronic issues I am going thru all the wiring at this time checking for loose connection or bad grounds. As far as low gear goes will it hurt anything to run in high gear everything works fine except low. Thanks again for your help.


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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Thu Mar 09, 2017 3:21 pm 
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Did you check the pilot jet, those are the most common jet to plug up. As for the transmission no it won't hurt to run it that way.

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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Thu Mar 09, 2017 9:15 pm 
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I did pull the newer carburetor apart and removed the rubber diaphragm and needle from both places, removed the main jet and spray carb cleaner thru all ports to be sure they were clear. I did not take the original carb apart as it does not have screw heads on it to pull it apart. I was thinking about using pliers to remove the fasteners in the original one to see if it has the same size jets in it as the new one but have not done that yet. I did test the choke thing by hooking it straight to 12 volts and it did move some but not as much as the YouTube videos I have watched. I have both the original and a new one that came with the new carburetor. That's why I am kind of confused on what I might be missing. I just don't know much about these set ups. Thanks again.


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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Mon Mar 13, 2017 11:03 pm 
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Ok just to fill in anyone who is reading this post. I decided to pull the old carburetor apart and it had the same size jets in it as the newer one does. I also did some looking and it appears the newer carb is the absolute cheapest one you can buy and the reviews on it say alot of bad luck with people who purchased it. So I have now ordered a better quality carburetor that has good reviews and comes complete with the choke in place. I also ordered a new CDI for it as I found some posts saying they have caused issues with cutting out under acceleration and backfire issues. I hope to have the new parts this week and hopefully can get it running correctly.


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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Tue Mar 21, 2017 11:59 pm 
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Ok so i received my new carb and CDI unit. I still have the same issue. The pet rooster in the fuel tank has been replaced with a normal valve that has the on or off settings. new fuel line and filter. It will start up and idle fine for a little bit but if i touch the throttle it sputters and dies. If i rev it up by hand i can manage to get it reved up to full throttle, but if it is in gear it will not even move the buggy without sputtering out and dieing. Once it is idled up to full temp it will miss and end up dieing as well. I am not sure if the vacuum lines and fuel lines are ran correctly it is how i bought it. I cannot find a diagram for the proper routing of them..... all i can find is for the original vacuum pet rooster set up. I am getting very frustrated at this point and am thinking of just doing a full engine swap to a engine from something else. Any help would be great i am beating my head against the wall at this point.


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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Mon Mar 27, 2017 8:32 am 
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Another update I have re gone thru all the electrical. Pulled the tank valve again made sure it was clear another new fuel filter. New high octane gas. Spark plug and still having the same issues. I can actually get it to run and drive if I play with the throttle as I try to drive. But once it gets up to operating temperature it starts to sputter and dies. After that it is all I can do to get it back to the garage. Any one have any ideas what else I should be checking? Maybe I am missing something simple. Any help is appreciated thanks.


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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Mon Mar 27, 2017 10:48 am 
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Is your air filter stock? Do you have an aftermarket filter that is too small? Is your air filter dirty or clogged? Over oiled?

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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Mon Mar 27, 2017 11:12 am 
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It still has factory air box and cleaner style on it. I pulled the air filter and tried to run it with a empty air box to see how it would run but had no change. If I loosen the air/fuel adjustment almost all the way out it will run the best but still stalls out and cuts out under acceleration.


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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Mon Mar 27, 2017 2:42 pm 
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My opinion you have a vacuum leak. Runs best when you screw out increasing fuel at idle you said. Tells me it needs more fuel. Make sure you don't have a leak at the intake. Post some pics and we'll see if we can help more

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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Mon Mar 27, 2017 4:16 pm 
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Ok I will do that. I have sprayed carb cleaner all around the intake and lines and did not have any idle movement at all. I wonder if the previous owner messed up the routing of the lines by chance. I just redid them the way they were hooked up. I might just order a new intake for it they are pretty cheap. Does anybody have a good diagram or the routing of the lines by chance? I have not been able to find one. Mine has the cf moto 250 in it. Thanks again.


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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Mon Apr 03, 2017 9:39 pm 
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Sorry it has taken me so long to get back at this project have been working 12 hour days. Anyway I pulled the carburetor again and pulled the intake off looked all around it..... it has no breaks or cracks of any kind. Made sure all hoses were tight on all connections. Still does the same thing. It starts right up idles a little high until warms up. When it reaches full temperature idles down. But from idle if I touch the gas it sputters once I get to a higher idle I can floor it and it will rev way up. After engine is all the way warmed up it will miss at idle and shut down. I have a few pictures of everything maybe it is something simple I am missing.


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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Tue Apr 04, 2017 5:56 am 
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Whats the compression cold and what is it hot?

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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Tue Apr 04, 2017 8:49 am 
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We really need a pic of the other side of the carb to see the vacuum line routing.

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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Tue Apr 04, 2017 12:12 pm 
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Judging by your pic it looks to me as though your running out of gas! There is no fuel in the filter!
Also if you are still running the stock airbox you might check the air hose coming into the box for any obstruction. Depending how long it has sat there could be a home for small critters inside it... just a thought.
Another thing,if you changed the pet rooster from the vacuum type to a manual type,you should have only 1 line going from the intake to the carb.

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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Tue Apr 04, 2017 1:30 pm 
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Still saying file to large to upload pictures.


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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Tue Apr 04, 2017 1:48 pm 
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Ok I resized the pic maybe now it will go thru.


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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Tue Apr 04, 2017 6:31 pm 
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Ok, may see a problem, you have a Y in the vacuum line. Not sure where that long hose goes to coming out of that Y. On all of mine the line coming off the intake goes to the carb. If you had a vacuum operated petcock then it might go to that but most of the 250s have manual petcocks.

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here-we-go-again-joyner-polaris-500-swap-t46499.html
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 Post subject: Re: New here and to buggy's have some question's on my buggy
PostPosted: Tue Apr 04, 2017 8:14 pm 
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Ok ..... thanks the hose off of the y connection runs back to this little canister that is zip tied to the upper rear crossbar. One large hose off of the canister is plugged and the other end is connected to a thing on the exhaust.


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