Starter clucth went out and was replaced. Bike starts but spits and sputters when given throttle. Thought it was carburator but I disassembled and cleaned the caburator and I am still having the same problems. Others say it could be the emergency brake sensor but there is not an emergency brake. The bike will start and idle but as soons as you give it throttle, it starts spitting and sputtering.

 

i have had this same issue with my 04 660r and my 01 warrior

 

yes having the same problem with my 2002 warrior if you find the problem let me know this is driving me crazy!

 

my buddys raptor is doing the same thing and he doesnt know either. Now im just thinking here so dont take my word to heart. My dad has Honda 450Foreman 4x4 esp. His was doing the same thing, and when he took it in they said the voltage regulator was screwed up. This being screwed up it was sending too many volts into the system. So i guess i say check the voltage regulator and see if it is sending out too high of voltage or amps, i dont know the what norm is so u might have to do some digging. Another way to check i think is take a test light and check the coil and see if it is a steady blinking light or spurratic flashy. I may be completly off here and if i am please tell me because we need to help to fix it.

 

Likely that when you pulled the side cover to access the one-way, you loosened the reverse switch connection. If it's loose, the CDI thinks you're in reverse and turns on the RPM limiter which will make it sputter like an SOB when you get on the throttle.

Look for the green/white wire where it connects to the switch (just below the sprocket) on the left side. Bet you it's loose!

Good Luck