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Discussion Starter #1
I bought a fixer upper warrior 350 last month overly confident with my small engine repair skills. I am $1000 into this project and still unable to get it running and I'm starting to get frustrated. I have the service manual and have been searching google and forums non stop without luck so any advice would be appreciated.
So heres what's going on:
Battery is in spec, stator in spec, bright blue spark from new plug, motor is in time (checked flywheel, and head marks, confirmed cylinder is tdc), pulled head and piston/cylinder look good. I haven't done a compression test but compression feels strong putting finger over spark plug hole (pulls air through carb/out exhaust), starter turns motor over fine, inspected and adjusted valves, seem fine. Brand new caltric carburetor from Amazon (original damaged), carburetor inspected and adjusted. New oil, air, and fuel filters and of course new gas. All lights work and appears to shift into gears correctly.

Have tested 3 different stators and 3 different cdi boxes.
Motor occasionally putters or backfires (mostly nothing).
Have tried quick start fluid - no change.
Have tried bypassing parking brake and clutch sensors.

I will take and upload any photos requested
Thanks in advance!
 

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when you say you tried three stators were they factory? you can rule out any of the safety switches, they only prevent cranking not starting. did you confirm the flywheel key good, physically touch the rockers and make sure they are loose when you are at tdc. without more specifics on the brand of electronics my suspicion is you have a knock off stator and the pick up coil is wired backward from the factory. you can try switching the red and white wire on the pick up coil. i worked with another guy that had the same symptom, his turned out to be he tried 3 aftermarket cdis (not sure on the brand) went back to a stock one and fixed it
 

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Discussion Starter #3
Tried 2 different brands of stator/cdi both ordered from Amazon (also tried switching the red/white around probably saw that thread). Same results as original. Original stator and cdi on bike now. How loose are rockers supposed to be? I have removed valve covers and turned it over intake/exhaust valves go up and down. When i pulled the top end everything looked ok except maybe carbon build up which i cleaned up with wd40 and a plastic brillo.
 

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Also pulled flywheel replaced one way bearing (probably didn't need to) but woodruff key was good. Should still be since the 'T' still lines up with everything else in time. Right?
 

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if everything lines up and the rockers are loose at tdc you are good. there should not be much play. just a few thousands if memory serves but you should be able to rattle them. if not they are to tight and could be holding the valve open and reducing compression. you could try to dribble a very small amount of fuel in the plug hole and see what happens i have seen those aftermarket carbs with the jet holes not drilled. there is an orange wire that runs to the primary coil, it runs near the exhaust and can melt and cause spark issues. the finger test is not great for testing ring health try to get a real number if you can. have you tried pulling it with another quad or car. sometimes the starter will sound fine but drag enough to keep it from starting.
 

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Discussion Starter #6
I know I need to get a compression test, and I've been putting off trying to pop start it behind my truck but I'll give it a shot. Just can't believe it's not giving me anything.
 

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Are you sure you have the cam aligned properly and not off a tooth. Also if the valves are too tight it won't fire. Did you do a leak down test to make sure the valves aren't leaking. When I pull the head off I always poor solvent in the Chambers and make sure the valves aren't leaking by the seats.
 

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Discussion Starter #9
I'm gonna replace the piston, cylinder, and valves. Cylinder has more scratches than i initially thought and found a chip on exhaust valve.
 
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