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Connor

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Ok guys I left off of the warrior about 5 months ago when college started and now Im going to try and finish it during Christmas break. So far, new countershaft seal, carb rebuild, repaired stripped axle threads, new gas tank peticock, and just put in brand new battery. I rebuilt the carb which essentially made it out of tune and then a bunch of other things went wrong so fixed them first and now Im back at the carb. Put in new battery last night and fired right up (SIGH OF RELIEF). However, just eyeballing with the idle and fuel mixture screws the header started getting hot and smoking alot after about 10 seconds of running. It has been sitting for 4 months so I wasnt sure why. Should I take the carb back apart and clean it? The oil is still light brown too. Maybe change that just for the sake? Going to try to tune the carb all day tomorrow. Also when I rebuilt the carb I put all new jets, except for main because it was 148 and the kit came with 145. After tons of struggle, put the old needle back in and made some progress. If I remember right, it was the 3/4 throttle mark I was having trouble with. Some guidance with this would be much appreciated guys.

Thanks
Connor
 
Replace your intake manifold. I had the same issue. My head pipe glowed red. They redesigned the new ons so go oem.
 
Frit:

Yes the oil is light brown so I feel like it is still fresh. I maybe has like an hour total on that oil. And it sputters like more bogging down. Im pretty sure this is from the carb being out of tune.

Fknboss:

It wasn't what I had thought. The header had some chemical on it, probably degreaser that was causing it to smoke. It had a foul odor and stopped after a little riding.

Could this have anything to do with the spark plug? I have a brand new one I havnt installed because the current one seemed perfect. Now I recall where I left off. I put the stock needle back in it and put the c clip back in the exact spot it was on. So basically the only thing I changed was the gaskets in the carb, the needle, and the pilot jet(which stayed the same, 42.5). At 3/4 throttle I believe was determines the sputtering is the needle and now I have stock back on it along with clip in same spot. So what could it be? Is it just the air/fuel mixture screw? Does anyone know how much give room I have before Im in the ball park. Like a quarter turn or 1/8th? I have it backed out about 2 1/4 or 2 1/3 turns. I just doesnt want to find the right spot. Any ideas?
 
Your mixture screw is ONLY for the idle air/fuel ratio and does effect the idle speed (which you correct with the idle adjustment screw). Before anyone can give you any type of advice for jetting, we need to know all of the mods you have to your engine.
 
Like Pat said and I said in the message I sent, we need to know what you have done and/or added to your engine and exhaust to really be able to help. If you do a plug chop and tell us what the plug looks like, use a new plug, we can help send you in the right direction.
 
I really appreciate the help guys! Sorry this may be a little long.

Yes I have to play with the idle screw to get it right also.

Guys, honestly I dont have a whole lot of knowledge of this quad. I traded my wolvy for it about 6 months ago and am finding out new things about it every day. As far as mods go:

-Some sort of jet kit, 148 main, 42.5 pilot
-New Uni filter along with air box holes
-The exhaust is a mess. Its sort of a custom straight pipe (no muffler) that is welded onto the header in the most hideous fashion.

These are the only mods Im aware of that have been done to the engine. One of the previous owners had some intentions of modding it but I dont think they exceeded bolt on stuff. I say this only because of the power the quad makes. Im sure I would recognize the extra power if it had and substantial mods such as stroker and cams. But, then again I have never ridden a bone stock warrior so Im not sure. I know it wouldnt keep up with a 450 of any sort.

I purchased the uni filter but it wasnt what I expected. It is like a collapsible foam filter type. I figured this would maybe affect the air consumption but it did have on a ratty K&N before.

And yes I know the exhaust sounds wack but I want you guys to know I did drive this quad when I got it and it drove perfectly. No sputtering, good power, no air leaks. So it was in good running shape when I got it. However, after I got done riding it for an hour I returned home and parked it and came back outside to see a puddle of midnight black oil underneath it. Thats when it all started. Closer inspection and I then realized it was also leaking gas from the carb (the reason I cleaned and rebuilt it).

So basically just bolt ons. Could it be the filter? Maybe the extra air is throwing it off? Sorry this is so long, thanks again you guys I really appreciate it.
 
Get a raptor 350 stock pipe and put it on its a good upgrade from stock, Sounds better, and looks wayyyy better.
 
But the exhaust was that way when I recieved it and it ran totally fine. I do have intentions of replacing but it is all one piece so I will have to find a header too. Do you guys have any thoughts on the powerbomb header?
 
Ill look around for a raptor exhaust. Is there any headers that would also fit from other quads? Maybe the raptor? Same bend and specs.
 
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