Hi all, just bought a Warrior 350, runs perfectly but has a loud clunking noise when starting, also a loud thud when turned off.

Looking on YouTube it seems it could be the starter clutch?

Is this doing any damage the way it is?

Also the "puller", do I need to buy this puller specifically, or would other types work?
I'm in New Zealand so would probably be cheaper for me to purchase parts in the states and have them shipped over.

Thanks for any advice or stories!

 

A lot of this noise could be normal functions of the starter clutch. Almost all machines that have them do make a clunking noise starting and even louder noise when you kill it.Some more than others. You'll know for sure if a starter clutch goes out, all the starter will do is spin free and the engine wont turn over. All the 4 stroke dirt bikes we sold and even the $20,000 KTM 1190 RC8 we sold made this awful noise that was hard for even me to get used to.Listen to this thing start up,plus go along for the ride..

 

Yes starter clutch and gear is going bad prolly could be loose bolts that hold the clutch assy on flywheel..If let go to long could break or bust stater housing or tooth off gears an flywheel maginet will pick up broken tooth from gears an chew up stator assy which also fairly pricey.

 

personally i wouldn't worry too much about it until it freewheels. you can pull the starter out and inspect the gears on both sides but other than that.. go with it.

 

Thanks guys, my main concern is that they have the same problem as the 660 Raptor? Here in NZ the 660 Raptors are known for a similar problem to this, resulting in motor/gearbox overhauls....the quad is a 97, still paid $2200 for it here, so for another $200 or so I better fix it...few vids on Youtube. Thanks guys.

 

Actually if I can tomorrow, I'll get a vid of it so you can hear it, and throw it up on YouTube. Sounds damned loud to me....lol

 

the 01 660 raptors just flat out have bad one ways on 95% of the models.. these do not have that issue unless they break from handling it wrong.

 

Have put this quick video on YouTube, ignore the noisy tappets/valves, the motor is quiet in "real life"..just a crap mic on the camera...in fact the motor sounds TOTALLY different in real life....lol

The noisy starter does not come up on video as loud as it does here unfortubately, but you still get to hear the thud at the end.

Anyone who can say this is certainly the starter clutch I'd appreciate it. Also is this kit the same through all years up to say 1997? Mine is a 97, and want to make sure I get the right parts since they will be coming from the States...and planning on some long rides here so want reliability.


and thanks for all your advice and knowledge, much appreciated.

 

That sounds pretty normal for a Warrior. I wouldn`t worry to much about it I`ve heard a lot worse.

 

Even some brand new KTMs sound louder than this.