Warrior starting problems

88fan · 04-10-2005, 07:00 PM

I have a 89 warrior. Ever since I got it, I've had trouble getting it to turn over. It struggles to turn the engine over. I replaced the starter, battery, solonoid. All it does when I go to first start it , sounds like the starter is just sitting there zinging away, then it starts to get some resistance, then it will start to turn the motor over. Once the motor starts turning over, it doesn't have a problem. It's just by then the battery is getting low from cranking on it for so long. Thanks.

Warrior King · 04-10-2005, 07:03 PM

startor clutch? i am kinda unshure what you are discribing, but i say its in your startor....even though you said you replaced it...hmm

Quad82 · 04-10-2005, 09:15 PM

Does it sound like just the starter is turning or can you also hear it maybe turning a gear too? If the starter is turning and the motor isn't, the only thing left is the one-way driven gear. Easiest way but not the most sure is to pull the starter out and try turning the bigger gear that the starter turns by hand. If it turns both ways easy and doesn't engage you have a bad oneway. The best way to test it is to use a jackstand and prop the quad up on its side so as not to have to drain the oil. Pull the left side stator cover off. 4 Screws to pull the rewind or blanc cover off then 9 -8mm head bolts to take the stator cover off. Be careful not to missplace the 2 bushings/guides at about 10 and 2 oclock. If you are careful and use a mallet you can save the gasket. With the quad proped on its side you can turn it over like you were trying to start it. Pull the plug wire off so it doesn't start. You will see the big gear sticking out behind the flywheel. It's your oneway starter driven gear. If it's spinning with the starter but not turning the motor over, you need a new one. Need to use a flywheel puller. But that's another story. Keep us posted.

88fan · 04-11-2005, 08:54 PM

yeh, just sounds like the starter is sitting there spinning away(zinging). Then eventually it catches and sounds like it's getting resistance. Then after awhile it will turn the motor over.

**diggerzmound** · 04-11-2005, 09:20 PM

Starter clutch for sure....

88fan · 04-12-2005, 06:26 AM

starter clutch? is that part of the starter or the engine?

Ausie warior · 04-12-2005, 06:57 AM

In the starter I think.

2000 YFM350X · 04-12-2005, 07:23 AM

mine does the zinging thing every once and a while. But it will catch and start right up. I does it like once a month.

**diggerzmound** · 04-12-2005, 10:03 AM

Quote: Originally Posted by 88fan

starter clutch? is that part of the starter or the engine?

you have to pull the flywheel, the starter clutch is on a big gear behind the flywheel.

WarriorRacer#13 · 04-12-2005, 11:00 AM

The starter clutch is actually a one-way bearing that's bolted to the flywheel. The big gear that you see behind the flywheel sits inside the bearing and is what the bearing actually catches. The one-way bolts have to be drilled out to get it off the flywheel(they are shot peened on the back side to keep them from ever loosening) It's a pretty pricey part, something like $80. I had to replace the one on my first Warrior. If it's slipping like 2000 YFM350Xs, it will eventually completely fail and the quad won't start at all, much like you're experiencing 88fan.

88fan · 04-13-2005, 09:27 PM

is it possible to get a pull starter from an older warrior and put it on my 89? I just want a backup in case of a dead battery or something.

**diggerzmound** · 04-14-2005, 08:57 AM

Quote: Originally Posted by 88fan

is it possible to get a pull starter from an older warrior and put it on my 89? I just want a backup in case of a dead battery or something.

Yes, but don't forget to install the decompression setup.

Quad82 · 04-14-2005, 12:52 PM

For the pull start setup you need the pull starter case with rope, a 4flange crank adaptor. Unless you are pretty strong you also need the decompression lever on the head. I have both with and without the decompression lever. They both are useable but my kids can't pull the one over with out the lever. You can pick the recoil up off ebay for around $30 or so. I have a spare 4flage if you need it but sometimes when you buy the recoil you can get this part too if you ask.

Warrior King · 04-14-2005, 12:53 PM

I dont think you will need the decompresion, a friend runs his with nothing but pull start and hes only 5'6 140 pounds, its not that hard

88fan · 04-14-2005, 06:38 PM

Well, I took the starter off and the gear that the starter turns, I can turn it backwards(towards the rear of the quad) real easy. I can also turn it towards the front of the quad too, not as easily though. So, does that mean my one way that you referred to is bad? If so, what all is involved with replacing it. How much are the parts, cause I'm pretty mechanical and can do the work myself if I know what all's involved. Thanks, everyone.

WarriorRacer#13 · 04-14-2005, 10:54 PM

The one-way bearing is like $80. You just pull of the stator side cover, pull off the flywheel and the one-way s right there. It's actually bolted to the flywheel, but the bolts are side-punched to keep them from EVER turning out, so you canNOT get them out. You have to drill the heads off. Then put on the new bearing, put in the bolts, side-punch them and reassemble. If you can get the sidecase off without tearing the gasket, all you need is the bearing and the bolts. But I'd go on and get a gasket, just to be safe, it's only a couple bucks. Th eonly specialty tool you have to have is the flywheel puller, but if you take the quad to a shop with the side off and everything, they may do it for you for next to or nothing.