OK I just bought this 4 wheeler for $300 just to ride around with some of my buddies. It was my father-in-laws and he traded it for an old boat. The guy he bought it from supposedly built it to race. It has FMF slip on exhaust, aftermarket carb, tires that are barely under the fenders, and who knows what else. I rode it last year once or twice and it is pretty hot but it always had a bit of clatter when you started it. Well shortly after that, my father-in-law couldn't get it started and just left it. I went up there and messed with it and when you hit the start it just clunks and when you try to pop start it, it just makes a bunch of noise and i'm not even sure that it's turning over. BUT, if you beat on the starter for a while and hit the start button it will turn over and I even got it to fire once but then it just made a loud clunk and I was back to the clunking when I hit the start button. Any idea on how I can figure out the problem? I know it has to be the starter gears and bearings or the starter clutch from the other threads and I'm going to take the starter off tonight and see what it looks like. But any ideas would be appreciated.

 

my warrior had a pull start, i replaced it for like 60 bucks or something.

 

I plan on getting a pull start for it because I don't want to be out on the trails and not be able to get it started but I'm not sure that's not really going to fix my problem right now if it wont even pop start.

 

I took the start off of it and it looked fine. I hooked it up to a car battery and drilled it until it started. Now, with some new gas and a little bit of carb adjustment it starts and runs great. There is just a small problem. It sounds like a derby car with no oil. It knocks really hard. I drained the oil and found a lot of mystery metal in it. Most of it looks like brass (maybe off of a clutch), one roller bearing, and one piece of aluminum. I took the cover off on the flywheel side and could not find anything loose or otherwise. I bought a flywheel puller so I can see what the starter clutch looks like. I was wondering if anyone had any ideas. I am going to pull the cover off of the clutch side tonight and see what it looks like. I am just hopeing that it doesn't have anything to do with the rod, piston, or head.

Every once in a while, the motor would seize up while I was starting it. I would put a wrench on the crank and turn it back about half a turn and it would free up and turn over just fine again. Is this part of my problem or something else?

Swerve

 

Its funny that you said that you wouldn't want to get stuck in the trails one day without a backup start. The same thing happened to me today except it wasn't that the battery died and i needed a pullstart. (i have one) i was out in the trails by myself, which wasn't the brightest idea. I turned the quad off to take a break and i could not get the thing started for anything. It just kept turning over when i hit the starter, and when i gave it gas it did not affect it at all. i did everything i could think of, i kept flicking the kill switch on off making sure it was on. i tried rollstarting it for the hell of it, i also tried the choke, i even took out the spark plug and wiped it down and put it back. Nothing changed it at all. I'm asking you because you seem to know what your doing with a machine. Thanks anything would be helpful.

 

I know you said you cleaned up the spark plug but you might try a new spark plug. They don't cost that much and I know I went through a couple of hours of mine not starting and the plug had went out on me. I put a new plug in it and it fired right up. I had changed the gas and even sprayed starter fluid straight in the carb. I had also pulled the plug to make sure it was sparking but when I put a new plug in, I could tell a difference in the spark and it fired right up after that.

I definitely would not say I know what I am doing with a machine though. I've done a lot of work on cars and trucks. I have a 74 Chevy pickup that is strickly a mud truck but I don't know to much about atv's and motorcycle's. The proof is in that the warrior is no more. I have only had it a couple of weeks and last night I through a rod trying to figure out what the knock was. I guess I figured it out but at a cost. Looks like the bearings connecting the rod to the crank had shelled makeing the rod slap back and forth when it was running. After I ran it for so long the rod just gave up and broke in two. Guess I'm looking for a new ride or a new motor.

 

hot rod makes an OEM replacement for about $230 bucks just buy the crank bearing for it and it would be a done deal. but your piston is prolly trashed too now becuz of the low end being worn, if you buy a new crank and rod and u use ur old piston with a worn out piston pin it will just wear and tear on your new low end. it most likely will need the crank,rod,piston, bored or maybe just honed if ur lucky.so your prolly looking at about at least 400-500+ bucks if you can do it yourself. lol i went through damn near the same thing and i just got it running again like a week ago.

 

This is what I was planning on getting right now but I'm debating bore and stroke since I'm here. Just depends on how much damage was done, may need a crank, piston, block, whole sha-bag. After looking at this kit, I'm thinking it may actually be the wrist pin bearing that went out. They look like they are about the same size as the needle bearings that I found in the oil.

http://www.bikebandit.com/product/A5307449


Swerve

 

yea that sucks lol. I had my dad take a look at it and he seems to thing its the coil. I will also try a new spark plug too. THanks for your help

 

Well, here is the long and short of it all. That motor was completely destroyed but I am back up and going again. Bought a rebuilt motor off of ebay and fired it back up last night. Ready to rock n roll.