New Warrior owner w/ questions.

[Buckethead]

I just picked up a 96 Warrior that needs some work. Main problem is that the exhaust/head bolts were broken off. One had enough sticking out that I could remove it, but the other was snapped at the head. I was able to drill the bolt but an e-z out wouldn't remove it. I am to the point that I'm between a helicoil or just drill it out to the alluminum and tap that. Any suggestions?

Also, the rear shock is shot (very springy)...what are the options with this...rebuild or just replace?

 

[JonS]

helicoil will probably work for you. and pick up a banshee rear shock. they're better than warrior stockers.

 

[DeadLastRacing]

Yeah, heli-coil it. If you re-tap it, you will have to find another style of thread/bigger bolt to get in there.

You can go with a banshee (any year) rear or a 2001 Raptor 660 shock. There are multiple write ups on here about shock choices. Warrior stockers are very stiff and most riders don't like the ride.

 

[Buckethead]

Thanks for the input guys. My buddy bought the bike new and it's sat for a while, so there are a lot of little things that keep popping up on it.

Anyone know off hand what thread the exhaust studs are?

 

[hatfield44]

Go with time-serts instead of helicoils. More money, but a far superior product.

 

[Buckethead]

Thanks, I'll look into them.

BTW...I did some work not far from Gilbert on what some of the locals called Big Branch? It's a Georgia Pacific landfill off rt97. Beautifull area, but it sucks for cell phone service.

 

[tyler]

I say go with the 2001 raptor 660 shock but that personal preference just like going to the banshee rear shock it....

 

[Buckethead]

I got the hole cleaned up last night and run a 1/4-28 tap down the hole...it seems to hold pretty tight. I may give that a try and just keep an eye on it for a while.

Next is to order an exhaust gasket and intake manifold. After I hear it fire up, then I'll start ordering shocks and bearings....Between the front wheels, a-arms and rear shock link bearings, I'm going to be broke.

 

[Buckethead]

IT'S ALIVE......

Got the beast back together and she fired right up. The starter is a little noisy, but other than that, sounds good. Now to order other goodies.

Back to the starter...it makes a rather loud clank/bang if it doesn't stat and you leave off the starter, and sometimes when you shut the bike off. I pulled the starter and all looks good. I even pulled the side case and the starter gears all look good. Any guesses?

 

[tyler]

mine made a weird sound to but i would always start right up and ran fine so i say dont worry about it.

 

[oddywarrior]

thats the warriors one way starter clutch set up thats so noisy its very common, alot of warriors will make a loud clank sound when shut off also, its the little sprag type clutch on the back of the stator hub that makes alot of the sound.

 

[Buckethead]

After a few little odds and ends, I finally got to take the Warrior out for a real ride last night. Doesn't run too bad...pretty good actually. Seems to be geared a little low though. I am going to need to replace the rear sprocket soon, so I'll look at changing a tooth or 3.

It does have an annoying oil drip though...looks like it is coming from the neutral switch. Is this something common? Any fixes?

 

[DeadLastRacing]

Neutral switch oil drip? Not familiar but I'm guessing just a bad gasket/seal.

 

[Buckethead]

Maybe it isn't the neutral switch....there is a sensor (?) above the shifter...looks like that is where the oil is coming from.

 

[DeadLastRacing]

I stand corrected. Yes, that is the neutral sensor. I believe that is a bolt in type sensor, you can tighten it up.

 

[deerman2701]

What is a HELICOIL?

 

[DeadLastRacing]

It's a re thread. And thread that is hollow with a threaded inside. Its what you put in stripped out holes to be able to get the same bolt size back in it.

 

[deerman2701]

hmmm i might have to get one of them! i have a messed up thread on my engine where the carb intake boots bolts on cause the previous owner used a self tapering metal screw....whose threads were not even close to what they shouldbe