Okay I just bought my first quad, it's an 02 Warrior. While it's only 6-7 years old, those first 6 or 7 years were not easy ones. But everything seems to work and it does run and drive. No leaks, and the motor/trans is not terribly greasy. I am pretty out of my element when it comes to quads, but put me under the hood of a car or snowmobile and I can do anything and everything.

Are there any common issues or problems with these machines I should be aware of? My plan so far is to just jump in and do all the maintinance items. IE plug, wire, cap, air filter, oil filter, carb rebuild and go from there. Front and rear sprockets look so-so, still got some life left in them but not the best shape. Anything else I should do while I'm in there? Does valve lash still need to be set manually on these things? Also, what oil grade/type is suggested?

Also, I will be buying an OEM service manual for this quad. Did they ever change anything or can I buy a service manual for a Warrior of pretty much any year?

Also, my battery is shot. Should I spend the 150 bones and get the pull-start conversion or do you think I would be better off just replacing the battery and keeping it soely electric start? The electric start seems to work fine(other than the junk battery), but I have to wonder if in the long run the pull would be better...

 

i have a 99 warrior good luck with all the maintence. As for the book you can buy one that runs from the late 80's-03 i think it is. its all one book. here is a link for it though it does not have all the pages you need. ie carb specivcations but it is the same book.

http://books.google.com/books?...=8&ct=result#PPA63,M1


also yes, buy the battery. i bought one at meijer for 89 bucks it was for a moter cycle but it fit. Trying to pull start when you been riding all day sucks. Though they are nice if your starter goes out in the middle of no where.

My warrior is torn apart in my garage right now. cleaning the carb and repairing all the little things I tore up on it this summer. I think you will love it. have fun!

 

As for maintenance, don't forget to grease your bearings and bushings, check all the a-arm bushings and wheel bearings, and check the upper engine mounts. Warriors are notorious for wearing out these parts prematurely. Also get ready to replace the axle bearings if they haven't been replaced recently. Other than that the Warriors are bullett-proof.

Valves need to be set manually. You can download a FREE manual from sandwizards.com/tips & tricks............If you do buy a manual don't buy one for the late '80's /early 90's models. For the most part they are the same but the wiring has changed.

I would just replace the battery and get on with life, just make sure you strap the battery down or you will be replacing battery terminal ends on a daily basis. If you do the pull start conversion, make sure you get the exhaust compression relief to go with it or you won't be able to pull it.

 

Thanks for the link to the free manual, lots of good info in there. I'll just replace the battery and go for it. With the snowmobiles, I don't care for the electric because a good engine will start easy with a pull start. But in this case I'll stick with the electric only. Thanks for the heads up on the axle bearings, I will be sure to take a look at them.