Thanks for the replies by all. I will attempt to answer everyones' questions:

Air Box Mod - Stock airbox was removed completely and replaced with a velocity tube and K&N filter. Problems were present before AND after mod with no change.
Carburetor boot - Purchased a brand new one. I figured that if there was a leak it would run lean, not rich.
Spark Plug - new.
Stator - new
Exhaust - White Brothers Slip-on with 12 baffles currently installed.

The machine begins to sputter, and "sputter" is the best description, just past one-half throttle / three-quarter throttle and beyond. Regardless of changes, replacements, modifications, repairs - the sputering has not stopped. Nothing has fixed the problem.

Should I take it to the dump?

 

One way to figure out if the issue is carb related or spark related...pull the choke slowly on, while its sputtering. Does it get worse...or better...or no change?

 

HondaBuster:

Very logical approach. I will attempt this diagnostic this afternoon and post my results this evening.

Thanks!

 

you are running mikuni jets right? if not, your problem could be coming from a dynojet kit....their numbering pattern is different!

 

Cals400ex, thanks for the reply. I briefly installed a DynoJet kit with awful results. The Warrior ran so poorly throughout the powerband that I immediately removed it. The DynoJet needle is designed with too narrow a taper I believe; it ran even more rich than now. I am using Mikuni brand jets throughout the carb, and I am using the stock jet needle. As I mentioned in a previous thread, I have tried all clip settings and a range of main jets from 130 to 160. NOTHING changes the symptoms.

I am considering just changing the carb. Either a Mikuni of the same model or an upgrade. But that kind of defeats the purpose of selling it for Christmas cash....

Ever been stuck in between a rock and a hard spot?

Thanks for the help.

 

boy that sucks man. i do have a stock warrior carb for sale if you are interested. i can't guarantee that will fix anything for you, but it may. does the bike have good spark? maybe that was discussed, heck i can't remember.

 

Thanks for the reply, 400. Yes, it appears to have excellent spark; however, I have not yet tested the coil. That should probably be my next step. I still do not know if this is a carburation or spark/electronic issue. I need to test it using the choke.

I will let you know if I am interested in the carb. I have rebuilt the existing carb to no avail. The best option would be to throw it on a dyno and get a fuel/air read at the same time, but last time I looked, I couldn't find a dyno laying around in my little shop.

Any other suggestions?

 

see what you figure out about the choke. i do have a coil and spark plug wire for a warrior if you are interested in that. once again, i can't guarantee anything....

 

Roger that, 400. I will yank the old dog out of the barn tomorrow (meant to do it today, but ate too many chocolate bon bons), and give it a test in the pasture. I did this test last spring before I left for overseas, but I have no recollection of what it did. All I remember is that I was confused (not uncommon), concerning the results. I will post the findings.

Thanks again, Mate!

 

I would make sure and put new gas in the bike first. This can cause so many problems. No start, missing, smoking and cause the carb to varish up to just name a few.
After reading this post I would have to guess and say it's a spark issue or electrical (did you gap the spark plug?). If it's RPM related then I would say this to be true. If it's throttle postion related then I would say carb. But I have have to rich of a mixture on the main and needle where the bike wouldn't rev past maybe 5000 rpm or so and just sit and sputter. Does your bike still have the parking brake switch or clutch switch one the handle bars? I remember that cause me some problems with the bike suttering. I would also test the coil or cdi.
Good luck.