I have 99 Warrior with a White Brothers E-Series, 155 main jet, K&N air filter, 4 one inch holes in airbox lid and a 45 pilot jet. My Warrior use to run really well no problems what so ever. Now all of the sudden it idles wierd. After you run it for awhile it will idle really slowly and if you hit the gas really hard it will shut off. And when you are run full throttle you can hear the exhaust make a loud crack when you hit full speed in any gear. What the heck is the problem? My guess is I need to repack my silencer since I haven't did that since I got the E-Series about 1 year ago.

 

Well, you shouldn't really need to replace the packing yet. (I don't think) Check the nuts on the headpipe to make sure they arent loose and letting air in, sometimes that happens and causes a backfire like you are stating. Also check the connection from the headpipe to the silencer and see if that is loose at all. Another problem is with the grounding wire that goes to the reverse lever, sometimes when it doesnt make contact with the frame, it will cause the machine to spit and sputter. I would check those out first and then tear down your carb and clean it really good. Try these out and let me know what happens.

 

The idling wierd thing do you think that could be the pilot jet I went one size larger on it awhile back. Do you think running a 45 instead of 42.5 is what is causing the idling problem?

 

It is possible. I have never changed that jet, it is still the stock jet. I have all these mods below and have not had the need to change it. The plug coloring shows I am right on. Give it a try, it is possible but I am willing to bet the idling problem is a dirty carb. Also check the throttle cable is not sticking.

 

Hey man since you have yours setup that way how many discs do you run on your E-Series exhaust? Cause let me tell ya something I run 12 discs I it doesn't seem like my Warrior is running at its full potential when your at full throttle.

 

Whatever you do, dont run all those disks. It seemed to rob power from mine. I run 0 and no spark arrestor plate. If you ride trails, I would recommend about 6 or 7. Just keep playing with it until it feels like you have the best power for it.

 

I put the stock pilot back in and now my Warrior idles great no prob. I put 18 discs on my exhaust and it seems fine. I will experiment more I wish someone had their Warrior exactly like mine so I could get a good start on how many I should use.