I have a 98 Warrior. I had to put in a new piston and had the head bored. I went for a ride through the trail afterwards and after about a hour of riding it overheated. I was told to up the main jet. The stock jet is a 145 and put a 150 in it. It has been doing fine until tonight. I went again and road for about 2 hours. Taking breaks every now and then. ALOT OF MUD. Anyway on the last trial we went through my bro in law got suck in a puddle, while helping him get out of that i left mine ideling for about 10 min. Did fine when i got back on it and made it through the mud. Went a little farther in the trail and it overheated again and shut off. Had someone pull me out and let is sit about 30 min and it cranked right back up. Got out of the woods and put back on the trailer and come home. Went to pull it off the trailor and it will not crank again. Turns over just fine. I do know that something is wrong with the throtle cable, it is broke or something but still want crank. Can anyone tell me what might be wrong and how can i make it not overheat? I am lost and dont know what else to do. Please help

Doug

 

so you rebuild it and didnt let it break in? also i think a 150 might be a little to big but its hard to say since im sure your elevation is different then mine. ive heard of guys running just a 147.5 with just a few mods, if yours doesnt have a pipe or good intake you might not even need a bigger jet, the stock one might work fine. warriors love to run a bit hot but, yours probaly just needs the right jet in it or maybe a better oil or even valves adjusted if they havent ben done recently.most likely i think you main jet is too fat, go back to stock size then see how it runs. having a new piston and the cylinder bored out wont require a bigger mainjet if you still run a stock pipe and intake. try out the 145 then how it runs.

 

i have a 152 in my 2003 with a pipe, filter, cam, 10.25 weisco. it runs good! it is a tad rich but it doesnt over heat on long trail rides!