Here are what the deal is....


1999 Warrior 350
DC pipe with header
KN Filter (Really bad shape, wanting to go to a UNI foam filter)
Holes drilled into the air box

My Roommate just purchased this so we don't have any history.


Bike is cutting out with 3/4 throttle really bad. It back fires when you let off of the gas.

The main jet is 147.5 - 150 right now (We have tried both).

The needle clip position is all the way at the top, it was in the middle and seemed to get better the higher we went on the needle. (if that helps)

Where can I find specs on the setup for this? Any help would be awesome guys this thing is driving us nuts.


Something I am adding and wonder if it has anything to do with it, when you put the bike in reverse it dies. It just kills right there, doing research on other threads I saw that someone mentioned this as something that might be causing it, what do you guys think?

 

check your plug, it sounds rich from what your saying. is it backfiring or is it poping? i wouldnt think you would be that rich with the mods you listed and that size of a jet. as for it dieing when you put it in reverse, there is a clutch sensor on the clutch perch. I bet it came unplugged under your plastic.

 

Ok changed the plug and still running like crap. The plug was black which means its running rich correct? I also got a new K&N for it.

 

Anyone have any more ideas?

Or

Does anyone know how long a shop would take to jet a warrior?

 

yes, you are to rich. drop your main jet down a size or two, just keep checking your plug so you dont start getting to lean

 

O/T a bit here, but my buddy just bought a 2001 Warrior, basically the same as mine, only he has a DG full pipe. Are the DG pipes any good? It's certainly loud!!

 

Its sure loud!

 

jscarbrough
If the plug was black, your running rich. This could help explain why the cutting out improved as you raised the clip on the needle. The higher the clip, the leaner the mid-range becomes.
My suggestion is this.
1) put the clip back in the center position (where it cam stock)
2) use a new, clean aitfilter
3) try the 150 main with the aircleaner lid removed ( better? if so, you need more airflow or a smaller jet.)

I use my air cleaner lid just to keep the filter in place, but have cut holes around the top webbing so that I get maximum airflow.
I would also use a NGK number 7 or 8 plug if your slightly rich or a number 9 if if slightly lean.