I bought my 1991 warrior with bad rings or so I was told. I ran it this winter smokin like a train. come early spring I tore it down to find a keeper ring had come lose on the wrist pin causing the piston to chatter. There were deep half moon groves cut into the top and bottom of the cylinder wall. Cost effectiveness led me to have the can bored 40 over and buy a new wisco prolite piston w/rings. Well here is the delema even with the smoking the bike ran fine. Post repair It will idle perfectly. But when you hit the throttle it bogs holds there then dies. I have:
-checked and double checked the timing
-cleaned , cleaned, and cleaned the carb.
-bypassed the parking brake safety rev limiter switch.
-checked my compression which is at 145#
I thoought maybe it was draining the bowl but as soon as it dies i can hit the start button and it fires right back up.
I am a 20 holder of an automotive mechanics ASE certification and this 4 wheeler is making me crazy. please help me