What's up everyone...this is my first posting. Quick question...
I currently have 2003 warrior with DynoJet jet kit (No.148) and WB E-Series exhaust. Also drilled out holes in the airbox for more airflow. After I installed the jet kit and exhaust, the wheeler ran excellant for about 2 months (even in Little Sahara, Ok) then all of the sudden while I was riding, the engine would not accelerate past a certain RPM. So I would have to stop and play with the choke or the key switch or whatever and eventually it would quit and I could ride again. I removed the switch for the parking brake and the cable because I thought that could be it but it wasn't. Later it happened again. What I am wondering is if there is a way to get rid of the rev limiter ( b/c that may be the problem) or if it's jetting? Maybe the carbureter is being over accelerated and there is a fuel meter inside that gets stuck? I just don't know....??[img]i/expressions/face-icon-small-disgusted.gif[/img]

 

The only rev. limited on the Warrior is on the parking brake. Once the brake is off, the limiter is disengaged and doesn't reactivate. If that was the source of your trouble you'd be complaining a lot louder cuz you would barely be able to move the warrior.

Do you get a lot of gassy smell from your machine when it starts balking? If so, it may be the floats sticking in your carb. What filter to you have installed and when did you clean it last? Check your plug also .. that will tell you if you are running rich, lean, or perfect.

Rich - Plug will be very black and look wet most often
Lean - Plug will be an ash grey or white color
Perfect - Plug will be a nice tan/brown color.

Sounds most to me like a plugged jet, but I think if it was that, then it would stay plugged and you wouldn't get anywhere ..

Good luck!!

 

I used the WB Powerfilter that came with the exhaust. It smells a little gassy but it also backfires. I'll look at the spark plug to see what it looks like.

Also I'll check the float...it's just odd how it acts when it happens

Thanks for the advise!!!

 

 

sorry about the previous post ..

Given what you said about back firing and such, I suggest that you check your coil. It sounds like you may be loosing your spark.

 

You shouldnt just go for a ride then after a couple hours come back and check your plug, that wont help you with your jetting. You could be lean on top, rich on bottom, just right for mid and your plug could look perfect.

Go out and buy some new plugs. Put a new one in and just go putt around, and not going over a 1/4 throttle. After a while come back and check the plug. Write down or remember your results.

Put a new plug in and do the same but ride around at 1/2, do the same again for 3/4. put in another new plug and find a nice long straight away run in wide open for about 10 seconds, pull in the clutch and shut the machine off, then check it.

Back to your problem, how high of rpm does it cut out at (w.o.t??). If so are you at wot for awhile then it cuts out. Next time it cuts out take off your gas cap and see if it fires up right away. Maybe the gas line vent is pinched or clogged???

 

Almost everytime it happens I am at wide open throttle. After it cuts out (but not engine stop; it still runs), depressing the throttle over 1/4 throttle the engine bogs and backfires for any given length of time (at least 1 minute). Like something is clogged (maybe the jet??). I will try everyones ideas and definately give feedback on the situation.

Thanks guys!!!

 

I had the same problem. It happened right after I had my pipe and jet kit installed, I took it back to the shop and they said there was small pieces of black plastic that clogged my jets. It just happens my atv is black they said sometimes there can be shreds of plastic or burres that are loose in gas tank. It has been fine ever since.

 

wildwheeler,

what did the dealership do? just clean out the gas tank? and carburetor? Funny thing is I got a black warrior also...and when this problem occurs it does seem like something is clogged b/c eventually it clears up. Thanks for the feedback!

 

The shop said the plastic had clogged the jets so they cleaned it all out, including the tank.