Warrior runs like !@#$

[USMC 350]

I've worked on more 2 stroke carbs than I care to count but upon pulling the carb off my 03 warrior it is apperant that it is WAY different than anything I've worked on. Here is the current setup....

Stock
Stock
Stock

Exhaust baffle pulled out with one of those fancy spark arrestor screen tip things you can buy on flea bay in its place......

I know that the stock muffler is VERY restrictive so I'm thinking that just pulling the baffle might have allowed way more flow than stock......so I would think that the reason it runs like crap is that the jetting is off. Unfortunatly the bike was bought used and the previous owner did not provide me with the stock baffle to trouble shoot with.:argh:

So this is what she does......first I understand that its a 350 warrior and it is not known for big power....but I know what a good running bike should be.......starts fine, idles fine, cruises fine.....falls to pieces under load.

Going up a decent hill is a 3rd gear....pop pop.....to 2nd gear....and sometimes I have to go down to 1st and torque my way up. At mid to full throttle, under different conditions and different loads the thing will miss, stumble and pop. In 6th gear full throttle on a fire road it feels like its got a speed governer or like if I was pulling a trailer. Zero overrev. It should have some, not alot, but some overrev right? I pulled the carb apart and this is whats in there....

Air Screw 2 turns out
Main 145
Pilot Jet 42.5
Needle Jet 819M 0-6
And this is were I'm lost.....the book says there should be a different needle than whats in there....I cant adjust the needle because it only has one position for the clip...the needle in there is a 5J31...Is that the right needle for a 2003 yamaha warrior because the book says 5J18 in the 3rd position.:loco:

Before I buy an FMF jet kit someone please help me out. The intake boot looks good so I don't suspect and air leak....air filter is pretty clean.

 

[gawarrior]

First thing I'd try is a new plug... That'll cause all the symptoms you're describing. Then a good cleaning of the carb... It's not too difficult compared to a 2 stroke carb... Just keep all the pieces and make sure they go back in.

 

[codysisk13]

my 2001 warrior is stock and i just got done rebuilding my carb last week. I have a 140 main and the air/mixture screw is 2.5 turns out. I have a fmf megamax exhaust and a k&N and it runs great

 

[4strokerider69]

idk about ur power statementUSMC350..not that i disagree u could ride bigger things but like cody said mines a 98 with a powerbomb header n a meagamaxx to k&n airl filter n jetted and i can start a hill in second and rip it out to third like a satuday night...llike ga warrior said missing can cause major power loss ur plug probs ****...new ones like 3-5 go ngk tho no champion junk...good luckk happy rippin

 

[USMC 350]

Right one!! I have an extra brand new plug......I'll throw that in and see what happens.....All the jets and stuff are in the dip can getting a bath as of earlier today. Carb will be clean and new plug will be inserted. However does anyone have any insight on that different needle thats in there?

And to 4strokerider69......I'm not saying that the warrior is a slug or anything because I've ridden a buddies before and I know that it has its power.....My point is that although my warrior dosen't have the power of my KX500 or my CR500, it should not be falling on its face going up some of these hills. That 350 4stroke is a torque monster and should fire me up that hill with no problem......but she don't. I appriciate all of everyones help though.....you guys are awsome. I'll perform the advised steps and give everyone a report as soon as I can......If the plug is just old then I'll be happier than a fat kid finding an M&M under the couch :tup:

 

[gawarrior]

USMC, given the name, I'd assume you're a Marine... You currently serving?

 

[4strokerider69]

the needle? the one thats on ur accelerator pump? and like i said maybe u ride bigger things ...was in point to offend ya lol

 

[4strokerider69]

in no point to offend ya

 

[USMC 350]

the needle? the one thats on ur accelerator pump? and like i said maybe u ride bigger things ...was in point to offend ya lol

Not offended here.....I was afraid that I might have offended some of you!!:haha: I am refering to the needle on the slide. But now that you mention the accelerator pump.....The spring for the accelerator pump came out kinda tweaked. I wonder if the accelerator pump was not activating.

gawarrior....No longer in....did 8 years and I decided to call it good. Got out in 2007. Not bitter and I miss the Corps everyday but life decided that it was my time to get out.

 

[gawarrior]

Got out in '07 after 10 yrs also, but from the Navy...So from one vet to another, thanks for your service! Semper fi, brother...

 

[codysisk13]

I took a spring out of a golds gym pen to replace the spring from my accelerator pump. But most people say to use one out of a bic pen. a good mod believe it or not! done it to mine last week and does great!

 

[YAMAHAULER]

my 2001 warrior is stock and i just got done rebuilding my carb last week. I have a 140 main and the air/mixture screw is 2.5 turns out. I have a fmf megamax exhaust and a k&N and it runs great

you only have a 140 main? stock is 145 are you sure your not running to lean pull your spark plug and take a pic and show us

 

[4strokerider69]

yeah also make sure u tell us where the clip is on that needle theres i do belive 3 spots middle is stock...and wow cool idea with the spring mod and if u wanna see if the pump itslef is workin just take the boot from the box to the carb of and pull the throttle gas should come out of a hole u cant really see make sure u do this with it not running...

 

['00 WO-YA!]

Wouldn't hurt to check compression too.

 

[4strokerider69]

yes..just to eliminate some other issues..along the way...

 

[Gen1Pat]

Make sure the intake boot isn't ripped, or any of them for that matter. And yes, thanks for your service. My best friend, another warrior owner, was in the army for 5 years before blowing out his knee and was forced to take a medical discharge. Misses it everyday. Served in Korea for a while before serving in Afganistan with the 10th mtn for over a year.

 

[codysisk13]

yes im pretty sure it was a 140 in the rebuild kit. and my clip was on the 2nd to last notch on the needle.

 

[codysisk13]

i just got done contacting the company i bought the carb rebuild kit from and they reassured me it was a 145. but is the needle supposed to be on the 2nd to last notch?!

 

[YAMAHAULER]

i just got done contacting the company i bought the carb rebuild kit from and they reassured me it was a 145. but is the needle supposed to be on the 2nd to last notch?!

pull your spark plug out and take a pic of it and post it or send it to me and I'll see if your running to rich or lean or just right white or greyish is too lean brown or tan is perfect and black is rich

 

[codysisk13]

well the clutch is out right now, and it wont be in till tomorrow. How long do you want me to run it as it sits before i pull the plug?