Join Date: Feb 2015
Location: southern oregon
start with the clymer manual those carbs are pretty easy but most of them have been apart at one time or another and its really nice to know what it is suposed to look like.
you will need to clean and rebuild the carb. dont be tempted to buy the cheap Chinese carb they are not great and will need rejetted anyway. once you have it disassembled a bath in an ultrasonic clean is best but if you dont have access to that buy a gallon can of carb clean and soak it overnight and then wash it with soap and water. if you have to use carb cleaner make sure you get all of the plastic and rubber off first. make sure you blow all of the water out of it. when you pull the air mix screw out there should be a screw, spring, tiny metal washer and an even smaller o ring make absolute sure you get them out or that the last guy left them out. it will not run with 2 orings in there.
you dont mention any mods but almost all of the warriors out there have a modification to the air box and a slip on with out rejetting and are generally lean
either way now is the perfect time to do some mods. in general warriors are really choked up from the factory and significant gains in rideability can be made for under 200 bucks. this is the combo i have found that has the best bang for the buck cut some holes in the air box lid and cover the with screen ( anything will work but if you want to get fancy order the outter screen i have also used dry wall sanding screens) add a k&n with an outters sock and a dg slip on (100 buck on ebay)
regardless if you do the mods or not order a cheap rebuild kit for the carb off of ebay and then go to sigmas web site and order a jet kit from them. you will need to enter make, model, elevation and modifications done to the machine. they will custom build you a jet kit tailored to your machine and elevation. it also comes with a main above and below for fine tuning or if you go somewhere else to ride. every one i have installed has been spot on first time.
drain all of the fuel and replace it with ethanol free super and add a couple of table spoons of sea foam to the tank
while you have it apart pay very close attention to the intake manifold they are prone to cracks. if it is bad dont buy a knock off only use oem yamaha for this part.
the manuals are 25 bucks on ebay and i cant stress enough how much better it will make your life to have that manual. warriors are great reliable machines but they are commonly abused by shade tree mechanics and the manual will help you make it dependable again.