Nick's Warrior Build

A friend and I were looking for winter projects and found an ad on Pennswoods the other day and went today to pick up these machines. A 99 warrior, 2000 warrior and an Kawasaki Mojave. $750 for all 3!

"Running" warrior needs timing work, other warrior is a parts machine. Mojave needs a crank and is my buddy's project.

How it starts:





Obviously different plastics that will be changed and I'll get more pics of other projects and all the parts we got too. For the time being, here's a pic of my truck and buddy's trailer all loaded up during our trip home:



I'm open to any and all suggestions!

Other costs (I'll update as I spend):

Clymer repair manual: $26
Interstate battery: $42
Flywheel puller: $39
Front brakes: $62
Front wheelbearings: $30
Rear brakes: $30
(2) flywheel keyways: $10
Chain and Sprockets: $71
Head: $120
Total to date: $430

 

Tore off the plastics and front bumper last night. Waiting on repair manual to show up and then it'll be on with the actual work!

 

For the warrior 2 of the best mods you can do is to change out the clutch perch for one with a ball bearing in it as the stock perch is super stiff!!! The second one is to replace the shifter with a shifter off a yz250f dirt bike!! The stock shifter uses a linkage system that is sloppy and causes missed shifts, the dirt bike shifter connects directly and shortens the shift!!! By far the best mod I did to mine!!!

 

Wonderful tip and I appreciate it! I'm gonna look into that

 

Update: After about 4 nights of coming up with no solutions on the timing issue, I contacted a local warrior "expert" who advised checking the keyway under the flywheel. Low-and-behold, that little bastard was snapped! So, to this point, $40 for a flywheel puller, and a $42 Interstate battery is all I have invested. Tomorrow I gotta run to the cycle shop and grab a couple keyways, front wheelbearings, and front brakes.

 

Alright another update: Installed keyway last week, still wasn't firing. When we tried to fire the gas was blowing back through the carb. Ran a leak down test last night, heard some air pissing and yanked the head. Come to find a hell of a bent intake valve. No apparent damage to piston so I'm gonna yank the head on my parts machine tomorrow and drop it in. Hopefully have the bitch running soon!

 

Big negative update: spare head was pulled quickly and easily. Took intake valve out of both heads to swap because one of the exhaust studs was broken on spare head. Once removed from original head we noticed the valve guide was broken. So now tonight I am going to try to remove the stud from the spare head. Wish me luck lol

 

Update: Got the spare head's busted stud drilled and tapped and reinstalled the head the other night. It fired! Needs a little tuning work and a new chain and sprockets and it'll be on the trails!

Put most of the parts on just to see what it's looking like:

 

Chain and sprockets ordered. Hopefully have them by Tuesday.

 

Wow! Long time no update

Well the head I had repaired ended up stripping the threads out when I tightened down the header FUCK! So the fact summer arrived and I bought a Grizzly 700 and all I did was ride it, the warrior took a backseat. After a little push from my friend I ordered a head. It showed up Monday and is gonna be installed tomorrow night (hopefully). Gonna get a new head gasket while I'm at it. I also need to get a new set of clutch plates and springs.

 

Welp, that didn't work either. I believe it's the carb now. Either way, I'm done with it. I'm selling the warrior.