Ok, first off I'll mention everything I've tried (from a thorough search of past threads).
1) bypassed parking brake switch (connected to plugs at harness, removed switch)
2) grounded out reverse lever
3) disconnected reverse lever switch
4) removed carb, pulled jets and cleaned
5) stuck thin wire down pilot jet hole (saw cleaner going through 3 holes in carb throat, so I assume its clear)
6) kicked cussed and threw tools

None of these had any effect.

Symptoms: It starts ok, a little bit of hesitation. Idles pretty good, maybe a slight miss/stumble but nothing serious. The main problem is right off idle (25% throttle), it sputters/bogs/misses/hesitates like a rev limiter.

Any suggestions on what to try next, short of paying the dealer to figure it out?

A million thanks in advance!

Colby

'95 Warrior
'96 ZX-6R
'84 Porsche 911
'93 Jeep Grand Cherokee

 

We seem to have a problem like this all the time on our Wolverine.... luckely not on the warrior yet.
1. I would check the Acclerator pump
a. sticking
b. torn boot
c. weak spring
2. Also make sure there are no vaccum leaks
a. Carb parts are torqued down
b. inspect the intake manifold for cracks
c. check for intake manifold sealing (to head and to carb)

 

check the gas cap vent hose i know it may be stupid but my warrior did the same thing and come to find out some put somthing down the vent house...never found out who it was

 

I thought the accelerator pump only kicked in over 3/4 throttle. Since my problems are from about 25% throttle up, could the accelerator pump be the problem?

How do I access the accelerator pump; is it behind the black plastic side cover?

Thanks.

Colby

 

Does it ever get above 25% throttle? I forget but on mine I left the wires for the parking brake disconnected, not connected together. On my raptor I just unplugged the thing and left it hang, the warrior has the same switch so....

Since it starts and idles ok I would think the compression, spark and carb are ok, do you have alot of black smoke when you hit that 25%? usually carb problems you will be able to work the motor up in rpm but if its hitting a brick wall I would double check that brake connector and try it disconnected altogether. If not can you find another warrior with known good electrics like cdi?

 

The accelerator pump is in the carb bowl and works off the linkage under the black side cover (little plastic thingy sticking up from the bowl) I will tell you that mine didnt even touch the linkage (didnt work at all) and I never had a problem like yours.

 

Ok, I'm running out to the garage and trying things as you guys suggest them.

1) Vent tube to the gas tank is clear.
2) I tried leaving the parking brake switch wires disconnected, does the same thing either way.
3) At idle and low rpm's, there is no smoke. As it hits the sputter range, light gray smoke does start to come out, not a lot, just a little
4) It does creep up in RPMS, but sputters the whole way up, getting worse as the rpm's get higher. The RPM's never really get that high though because the sputter gets so bad.

Thanks guys, keep em coming!

Colby

 

try some gas treatment do u live where its cold out.. sometimes it helps

 

Did this just start happening out of the blue?

Im sure you were into the float bowl but it could be that the main jet came unscrewed and is laying there in the float bowl. It could also be the needle in the slide came out somehow and is stuck up. These wouldnt affect the bike until off idle. Or possibly the float level is so high and the overflow is blocked so it floods the motor out.

Just throwing things out there, I also had a plug mess up on me but it was a little more sporatic and only after it was way hot.

I went and looked at the schematic its not technical enough to really tell whats going on without actually using a voltmeter

 

Damn your right it could be water in the gas, it does the same thing