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I have a 96 zr 580 that will idle and rev up to around 4000 rpms. it then bogs out and dies, i think it is because it isnt charging the battery. I have put a new voltage regulator on it (the square one) and tested the stator which tested good. Does anyone else have a idea at what might be going on? thanks
 

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It's not the battery. I had the same problem. take a look at this link:
http://www.snowmobilefanatics.com/forum/topic/80265/display.aspx
 

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is 4000 rpms the clutch engagement? If it is, what color are your spark plugs? I almost forgot - check your muffler for holes. I assume your sled is liquid cooled. If you feel ANY air coming out when you start it up, get it fixed.
 
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