My girl just bought a 2002 warrior. I have been doing basic maintenance and updating to it, and im still getting a feel for the thing. It is in overall good condition, but does have a few small bugs that need to be worked out. The guy she bought it from said that he had went through and freshened it up a couple years ago. I noticed when we bought it that there was a strange clunk sound that would come from the starter/flywheel area, it sounds like something is loose. If you turn the engine over, but it doesnt start right away, when you release the starter button, you hear a clunk sound. It also happens when you shut the engine off. It only does it once. My kfx400 makes a similar sound under similar conditions, but it is muuch more noticeable on the warrior. My mechanic mentioned to me that he thought it might be an issue, but I didnt think much of it. I changed the oil about a week ago, and the oil that came out, although dirty, didnt look out of the ordinary at all. I put some fresh 5w40 castrol motorcycle oil in it. She rode it for a total of about 2 hours last week. Well I went to the shop today, started it up, and it was smoking more than what you would consider acceptable (has never smoked before). It smelled like oil. I only let it run for about 30 seconds and shut it off. I then checked the oil, and the level was good, but I could see microscopic metallic shavings in the oil. I immediately drained the oil and removed the filter. The oil, once in the pan, did not look all that bad, although it definitely did not look like oil that had less than 2 hours run time on it. I plan on removing the flywheel cover and seeing if there is anything obvious like a loose bolt, missing bolt, etc but I dont have a manual and I didnt want to get into that without knowing exactly what I was getting into. Im not sure if all of the above issues are related or not, but does anyone have any input on what I may be dealing with? I wont be able to work on it until Thursday so im hoping I can get some info before then. You should know the quad runs great, engine sounds great, very smooth, no problem shifting. All info is appreciated, and I apologize for the extremely long post.
Strange noise, metal shavings in oil.
- Thread starter tmr931
- Start date
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JonS
Well-Known Member
yep, the clunk is normal. every warrior does that.
elwood
Well-Known Member
the clunk is normal like said above. As for the smoke, if it smells like oil I'd do a compressoin test. Maybe the valves are out of adjustment, that is the easiest to fix. You'll find a turtoial on how to to it.
elwood
Well-Known Member
min compression is 114 and yes you do it the same way as a car
