Hi All,

I recently rebuilt my 2 cycle xplorer engine... all new seals, gaskets, bearings, piston, Carb (etc, etc.). Its running great... Except... when I was riding on the roads in the last few snow storms, everything would work perfectly for an hour (lots of power, responsiveness, etc.). Then, the throttle began to work awkwardly... basically, it would idle rough with no pressure on the throttle... or with the slightest touch (like moving it 1/16th of an inch) it would go to max RPM. I'd work the throttle to get it back home. It would backfire at home and die. I would let it sit for a few hours or until the next day, and it would work perfectly fine again.

I thought this may be a fluke. But, it happen twice, within four days, riding again for about an hour in a driving snow storm. At first I thought it was an electrical problem. The first incident was coupled with, I believe a separate issue, where the machine would not turn off (either key or kill switch). I found the black wire from the CDI had come loose from the terminal board. However, this did not happen the second incident. I could turn the machine off with the key but I still had the throttle problem (the black wire was still connected the second incident).

Anyway, I'm at a loss. The throttle and cable are virtually brand new. Again, I can't find the source.

Has anyone else had this experience? Your thoughts/comments are greatly appreciated.

Warmest Winter Regards,

 

These older models usually had less clearance required on the thumb lever than the newer models (1/16" -1/8") Just snug for the most part.But make sure the contacts on the etc switch inside the throttle aren't touching at an idle. Even though it's a new cable,check that the binding isn't because of a sticking carb slide,carb slide spring or the oil pump sticking since its a split cable and works both.