I have a 1999 warrior . It will crank up and idle fine.But when i ride it wants to sputter real bad at high rpms. It smokes a little. It is bone stock besides the baffle being out of the silencer. I can pull in the clutch and rev it up and it clears up.But when i take off again it does the same thing.I have replaced the spark plug, cleaned out the carb, installed a new air filter, and a new intake boot. Any answers would be appreciated.

 

Try..
new gas
Compression test
Air leak test

 

Are you sure you cleaned the main jet out real good? I have a buddie's stock Warrior over here now that did the same thing, and his MAIN jet was stopped up. I cleaned it out, it ran fine for about 15 mins, then it did it again. We checked it again and the main jet had more crap in it again. We drained the gas, put new gas in, and cleaned the main jet again, now its fine.

 

A few guesses that I have are that the removed baffle could be throwing off the jetting enough for it to act up at high rpms. Another one could be the valves being out of adjustment.

 

I thought that the baffle would throw of the jetting so i went up to a 146 main jet. didnt help. Do you know the proper adjustment for the valves?

 

Figured out what it was. The guy that had it before me had a 4 inch piece of pvc pipe hose clamped onto the air intake. Kinda like a cheap snorkel. I guess at high rpms it wasnt getting enough air. Runs fine now.

 

Sounds to me like the original "snorkel" was broken or missing so he used some pvc to replace it. There really is nowhere to attach a snorkel onto the stock airbox/intake because of the gas tank cover.

See this picture for reference, part #17 is what I'm referring to.

Warrior Airbox/Intake

 

a 146 main get is a dynojet, i think thats a very rich jet. the stock main mikuni jet is 145, with removing that baffle i would have only gone up one size, to a 147.5.i think your running way too rich. try a dynojet 138 at the most.

 

dynojets sizing method is different than mikuni. so that dynojet 146 is like a 155 + main in mikuni.

 

Right.. with a proflow K&N, no lid and no baffle in the stock pipe or most aftermarket slip ons a 147.5 or 150 is ideal. The stock warrior head pipe is pretty much the best head pipe. the others just look better.