Okay, here I am. I have cleaned my carbs, checked my sparkplug(was a little black and oily),& the gap was a little off. Cleaned the air filter, changed the oil. Taken plates out, put plates back on. Unhooked the parking brake block off. Not sure what reverse wire that you were talking about, but for the most part have done everything that has been suggested, except a compression check.
Anyway, it is still cutting out on me.[img]i/expressions/face-icon-small-frown.gif[/img]It does sound like a limiter though. So the noise is kind of a missing popping noise when you full throttle in any gear.

So my next question is, could it be the valves? I know we have never adjusted them, not sure how, and does anyone know how to do this, or do I need to break down and buy a manual?

Or does anyone have any more suggestions?

look below for mods.
Thanks Again, Your Advice is much appreciated![img]i/expressions/face-icon-small-wink.gif[/img][img]i/expressions/face-icon-small-tongue.gif[/img]

 

It sounds like a problem I had with my 95 Wolverine when it was new,and since it is the same engine as yours, maybe it is the same problem. I had a bad surge and cut out at full throttle,the dealer found the stator to fire coil gap was off, it caused what is called "spark scatter",which means at high rpm,the gap made the spark so weak, it couldn't keep up with the constant load and rapid firing of high rpm use,so the engine would cut out. Have the shop check the gap on the stator to the firing coil, see if it is in spec,I was told it had to be dead on, or you could see problems.Hope this is some help. Another thing,you did mention valves never being set, one thing the Warrior engine is known for is 'floating' the valves at extended hi rpm use,the springs are not the strongest,and sometimes will start to oscillate at sustained high speed,and cause erratic valve seating,cutting back on power. Setting the valves is no big deal,a manual will be your best friend down the road if you plan on keeping the Warrior around.

 

check the intake pipe seal at the head and the hose clamp at the carb. also check the intake pipe for pinholes or tears my cousin has a 2000 warrior with alot of mods and his intake pipe had a pinhole in it . if you have any vacuum leaks between carb and head you will get a rev limiter effect at 3/4 to full throttle, any gear. valve problems wouldnt really give you that effect more likely noise (tapping) and or power loss good luck[img]i/expressions/face-icon-small-wink.gif[/img]

 

What you are describing sounds like the rev limiter to me. I hit mine quite regularly. Pops and misses. Especially when I break traction at WFO. Listen to the sound of the engine, are you winding it tight when it does this?

 

Okay, I will check all those things, Thank you for some new ideas.
Warrior Maniac, Yes I am winding at full throttle a lot. I have to ride hard to keep up with the guys I ride with. The funny thing is, is that I read an article in Dirt Wheels about the rev limiter in the Warrior. It said something to the fact that those motors were not designed to run at high rpms for a long periods of time so it has a rev limiter on it. Have you ever heard of that? I asked the owner down at the Yamaha dealership, and he said he had never heard of that before. Go Figure.
Thanks Again for the ideas, I will let you know if I figure anything out.
Michele

 

My warrior does the same thing at about 3/4 to full throttle. I didnt notice it till I put a few mods on it so from the article I read in an old dirt wheels it sounds like its valve float, I guess Warriors are known for week valve springs along with week clutch springs(clutch is a totally different topic but thought I would add it in case you dont know that already). I havent had time to look at mine yet but, my warrior also starts to sound like its ticking at idle which im pretty sure is valves out of adjustment. My warrior runs great otherwise.

 

I rejetted to 152.5 today. I did it without supervision too[img]i/expressions/face-icon-small-happy.gif[/img].(Usually hubby supervises) Getting pretty good at this.
I'll tell you right now with everything I have done to my bike, it sounds awesome, except the cutting out.

I still have not figured out what is wrong though, but I have learned a lot.
Funny thing is, everyone you ask, has a different answer![img]i/expressions/face-icon-small-wink.gif[/img]Go Figure.

Anyway, we were going to take it in tomorrow, but I talked my husband into letting me buy a manual instead. We'll see if we can find anything in there. It still sounds like it is in the carburetor.

Has anyone ever tried changing the pilot out? That hole is pretty dang small, I know my husband changed his on his Raptor. Also, there is the fuel mixture screw, has anyone tried adjusting that? That was another thing that he messed with on his Raptor.

Okay, so thanks again, for all your advice, it is nice to be able to pick other peoples brains that love there bikes.[img]i/expressions/face-icon-small-happy.gif[/img]

 

This may sound a little lame or stupid, But is your choke on or stuck on? Oh and you probably should have jetted it down if your plug was black and oily.

 

No, my choke is fine. Thanks for asking. I know what your saying, trust me, I was getting confused also. Talked to the service techs, and they said that I am running rich should try going up. I did not think it made sense either, but you know it does sound better.

 

Yeah that's weird that they told you to go up. But if I was you I would go back to the stock jet 145 and see what the plug says. What elevation are you at?