JasonP:

Refreshing feedback. As far as whether or not it is electrical or carb, I "tend" to lean towards electrical issues, for the fact that it is not throttle-position dependant, but rather more RPM related. In lower gears it starts surging and sputtering at a lower throttle position, whereas in 4th or 5th I can crack it open a bit before it starts crapping out on me. I am unsure how to "check" the CDI; it either produces current to the coil or not, but is it not true that it limits the revolutions? I am wondering if it is defective somehow and has altered the rev limit. Just a wild guess at this point.

I will check the coil. As far as the brake/clutch switch, it is still there but I cannot for all the tea in the world figure out what it does. How would that cause these problems? It seems to be non-functional at this point. I read somewhere else in a forum that it can cause electrical problems. Should I smoke-check the thing? If so, should I bridge the wire connection or not? (is there a wire connection?)

Thanks for your input.

SnakeDoctor out

 

I have the exact same problem and similar mods. I have rebuilt the motor which was tired anyway, replaced the cdi, stator, intake boot and rebuilt the carb. I still think it is the carb. My ebrake was already removed when i bought the bike and the problem is at a higher RPM than the brake limit is.

 

Wow, Mate! It is good to hear (sort of), that someone else has had similar problems. So you say that you are still experiencing the problems? I bored the cylinder, tried different jet configurations more times than Clinton had girls in the Oval Office, and even rebuilt the card twice. Tried Dyno-Jet (which works very poorly for this quad), have totally modified the intake, changed baffles on the pipe, replaced the stator, uptake, and source coils, tried high octane fuel, new plugs, new plug wire, and so on. The ONLY thing I have yet to do is: 1) change the carb to a $Million Edelbrock, 2) change the CDI, and 3) remove the clutch thingy-ma-jigger-for-the whatcha-ma-call-it. I am not sure what the latter component does actually, but JasonP suggested that I remove it. Sounds quite logical.

One problem I have with testing it though, is I broke 3 vertebrae in a helo crash and I am NOT supposed to ride. I suppose what the dear Doc doesn't know won't hurt me.

Let me know if you have any more thoughts, and what other things you have tried with your quad. At what throttle/rpm point does it puke on you? Describe to me exactly what it does so I can determine if we have the same issue going on.

Thanks much for the thread.

 

All I did was to get rid of the clutch safety switch and park brake was to disconnect them from the harness under the plastic hood by the steering stem. I did this when I switched clutch perches and handlebars. Sometimes it would would come on when I was riding hard and the bike would stutter (parking brake switch). There really isn't a rev limit in the warrior other then this. This was a while ago that I checked the switch but I believe all I did was have the bike runing and press the switch on and off and then the bike would start to stutter while about half rpm. It's been awhle though.
I know you have dinked with your carb a lot, have you checked float bowl height? I believe this will cause a rich condtion as well.
I would ohm out the coil both hot and cold and check your readings to spec.

 

JasonP:

Thanks for the reply. I will tinker with the clutch switch and see if that makes a difference. As far as the float bowl, the height is spot on, measured with digital calipers.

Thanks for the thread. I will disconnect the clutch switch this week sometime and give it a go. Let me know if anything else occurs to you.

Best Regards,
SnakeDoctor out

 

Mine acts like a rev limiter at upper RPM's. I would guess about 5000. It does it in all gears and will act like a surge. In high gear at WOT it seems to be at 3/4 throttle that it starts.

 

That is EXACTLY what mine does. This deepens the mystery. I guess that rules out electronic problems, since it is very unlikely that your quad has the exact same set of conditions as mine. You are probably right - high likelihood of it being the carburator. Probably the model / design rather than a malfunction issue. The question that comes to mind however, is why is this performance issue not present in all other modified Warriors as well? Possibly a unique set of circumstances concerning the particular setup which leads to this problem. I am still stumped, but this new information offers hope.

What type of exhaust are you running? I have a White Brothers with 12 modular baffles installed.

Let me know. Thanks!

 

I believe you guys are overlooking what some of the others have said about the parking brake switch. Of all the post of yours I've read here, that would be the first place I'd check. Next place would be the reverse lever, and the electrical conections there. Both can cause all the problems that you keep refering to. I don't believe its your carb. (Not until you are certain that the switchs are either jumped out, or are indeed good)

 

Asfasasa3:

Thanks! I will definitely investigate the switch ASAP. The reverse switch on my quad sporadically does not work, so that is another good point made. I will thoroughly check both.

Thanks for the reminder!

 

i HAVE A 91 warrior thats totaly stock that had electrical problems with the reverse switch and the parking brake switch also would make the bike stutter at certain RPM's