I have a 03 Raptor that I was riding and everything was going good. I pulled it into the driveway and washed it. I then dried it off and started it up and rode it into the garage. A couple of days later I took it out and fired it up. It starts and idles fine and has great low end. When I hit mid range it sputters out like it is hitting a rev limiter almost. I then tore the carbs apart and they were spotless and everything worked the way they were supposed to. I then checked the connections of the coil and spark plug and everything looked good. Tried it out again and the same thing is happening. Does anyone know what else I should look at? The air filter is clean and unubstructed.
Thanks Crazyotto

 

hmmm.....

Is the plug fouled? Could be a tiny spec of dirt somewhere. Unless you are revving it out too much in one gear and it actually is hitting the rev limiter. Always a thought.

What gear is this happening in? Approximately how fast can you gauge you are going ?

 

It happens in all gears. I am probally going about 10 miles per hour when it happens. Like I said it feels great on bottom and revs fine in neutral unless I rev it real high. It seems to do it under a load. Hope this helps.
Someone said it might be the reverse switch as they are governed not to go too fast in reverse. The reverse light hasn't worked since i bought the thing. Does anyone know where the reverse switch is?

 

well...

it does sound like an electrical problem, considering it didn't start happening until after you washed it. I don't know that the reverse limiter would play a part, though. I haven't heard of the reverse limiter having an effect on forward gears, unless the reverse switch, located underneath the right front fender, is jammed or stuck on and activiting the limiter.

Look and see if the switch is jammed or moves freely. Take the machine in and out of reverse a couple times and make sure it is freed up.

I would also re-check all your electrical connections from the battery to the engine to the case to the harness, etc.

 

OK, as soon as I get home I will check it. The switch on the front fender only pulls the cable and doesn't activate the rev limiter. I think the electrical part is on the tranny somewhere and could be shorted or have an open, depending on the switch type. I will also check the CDI to see if any water reached that but I doubt it. I will also put a new spark plug in it just to rule out the fouled plug possibility.

 

My 01' Raptor did the same thing but when it spuddered it would sometimes back fire i took my carb in and Dyno Jetted it... then in ran great!
But he's right it could eaisly be the spark plug or something else

 

check the parking brake if it is on there is a 3000 rpm rev limit. check the switch on the park brake up top near the clutch lever.

 

I have just started havin the same problem. Someone told me that there was a recall on the parking break switch that could be faulty. But mine did the same after I washed it is when it all started.

 

OK, I've figured it out. It was the switch by the clutch lever for the rear brake. What made mine different was that the guy I got the bike from had removed the rear parking brkae and just had the wires cut instead of removed and the grounded od from the water. All fixed and runs like a champ now.
Thanks for your help,
Crazyotto