Baja Warrior Rebuild

Bluethunder3320 · Dec 19, 2011

got this thing in april 2011. its a 2006 warrior. i rode the poo out of it.

heres the old motor.

new engine. not done painting all of it yet. still need some parts that shipping is taking forever...

i want to redesign the front end. it looks kind of crappy and toyish(wish i had a better word) its also getting a new torque converter.

the grips are trashed. brake cable is weathered. but it has fairly new honda brake shoes. im thinking about getting a thumb throttle. ill strip the whole bike down and go from there i guess.

buckeye · Dec 19, 2011

Mine is striiped and ready for prime and paint. Just getting this one ready for resale.

joekd · Dec 19, 2011

I like the grips I used on my warrior, metal and rubber

Bluethunder3320 · Dec 19, 2011

cool grips. whered you get them? i still might want a thumb throttle though.

i spent tonight with a briggs gas tank, bench grinder with a wire wheel, to get all the paint off. taking a while! the tecumseh tank valve broke off and i dont know how it goes back. the parts are all cracked and messed up so the briggs tank seems like a better choice... just needs paint. i cleaned out the inside of the tank using electrolysis and baking soda.

here you can see the baja a little... 12/10/11 that was the last day it ran. i layed it down 2 times that day and i think the breather is shot because oil keeps coming out the intake. and the cylinder locked up tight with oil many times recently.

im riding the KTM in this vid
http://www.youtube.com/watch?v=rsXlWT8yrEo

joekd · Dec 19, 2011

You should try riding with the XR bars, it's a huge improvement over the OEM ape hangers

Bluethunder3320 · Dec 20, 2011

joekd said:

Xr as in honda xr bars? the red bike in some of my vids is my friends XR100R. slow bike (i can beat him with the baja) :laugh:

heres a pretty good comparison between the KTM200 and baja. were on our own bikes in this one... shows you how much i abuse the thing haha.

:thumbsup:

ktm 200 justin couture 12/10/11 - YouTube

joekd · Dec 20, 2011

Yes, XR bars as in Honda XR

Notice how much different they site then the ape hangers

Keep in mind these are aftermarket bars so they are lower then OEM XR bars, I also narrowed them a couple inches

Bluethunder3320 · Dec 21, 2011

i tried putting razor mx500 bars on it a while back. looked even worse and handled bad. i could try the xr...

but i dont like the front end of the warrior, in general. looks too... spacey? and thin. looks naked...:shrug:

anyone have fork ideas? i know regular MB forks wont take the big tire. but ill look around google and see what i can find...

oh and the H60 became a nightmare last night. put the flywheel on with a key that i thought would work. turns out i realized the flywheel nut wouldnt stop turning. the whole snout is stripped out. sh!t. i then took it all apart AGAIN and put the H70 crank in.. but the seal size doesnt match so it didnt work. i ended up putting the h60 crank back in, and i took the washer out to give me a little of good threads. used a different nut, and made a key more like the original out of a 3/16" keyway ground down on the bench grinder. seems to be tight and works......?

ut:

the more i look at the engine seems like the more money i put into it and the worse it gets.

joekd · Dec 21, 2011

Unless I missed something doesn't your OEM motor still work? Why not put it back in and run that so you can take your time building the new motor over the winter?

As for the front end people have swapped entire dirtbike front ends onto the warrior, gives you a skinny front tire and is pretty much every case a frnt disc brake too

I just looked at the MX500 in my garage, the bars are only 24" wide, this is probably why it felt so bad, even my shortened bars are around 32"

Bluethunder3320 · Dec 21, 2011

the whole bike is in my basement now, haha. the old motor runs but its beat.

i really like this front end. and seat.

picture found on google. photobucket.com/albums/z110/dt400rider/FatWheelMiniBike/DSCN5304.jpg

well im off to go see what i can do to that engine...

joekd · Dec 21, 2011

Look closely, that isn't a Warrior, as a matter of fact that isn't a Baja product at all

I do like that they set it up for a passenger to ride along though

C9H13NO3 · Dec 21, 2011

Bluethunder3320 said:

That is a from a member here.. I think his name is DT400 or something like that.

That isn't a baja.

joekd · Dec 21, 2011

C9H13NO3 said:

You are correct sir, dt400rider

DT400Rider Gallery - Old Mini Bikes Photo Gallery

Here is the thread where he had it for sale
http://www.oldminibikes.com/forum/c...3-balloon-tire-mini-bike-electric-roller.html

DT400Rider · Dec 22, 2011

joekd said:

Yes, it was mine. It now belongs to another member of the site. INJUNTOM

Here is a thread from him on the bike.

http://www.oldminibikes.com/forum/general-minibike-talk/43315-lil-indian-back-tracker.html

Here is a youtube video when I had it.
http://www.youtube.com/watch?v=9fRQ5ANsn24

Bluethunder3320 · Dec 22, 2011

joekd said:

yeah i know its not a baja, just saying i like the front end better than the baja's. maybe ill make one like that... i don t know

DT400Rider said:

thats cool. i tried to start my tecumseh today and it just backfired out the intake every time i pulled the rope. finally got it to run, and it revved to normal speed and went perfect for about 10 seconds. then i eased up on the throttle to a high idle. it began to die and when i opened up the throttle more it sputtered out.

i kept pulling like 100 more times and no start. just pop pop pop. some flames out the carb too. i thought maybe the spark was too early, so i pulled the flywheel and delayed the ignition all the way it could go. this made no difference at all.

it does have a sten's electronic ignition chip in it... no points. i have another coil that has points but i lost the little cam shaft thing that goes on the crankshaft to operate the breaker.

this thing seems like it will never be a good reliable engine no matter what i do to it. i just keep getting frustrated with it. (its been torn down completely at least 8 times. no joke.)

after going through that process so many times im really sick of the thing.

Bluethunder3320 · Dec 22, 2011

last ride of the baja warrior - YouTube

Bluethunder3320 · Dec 23, 2011

Bluethunder3320 · Dec 23, 2011

now onto the clone. before:

what the bike looks like with the painted tec 6hp:
http://i924.photobucket.com/albums/ad86/bluethunder3320/photo-287.jpg

http://i924.photobucket.com/albums/ad86/bluethunder3320/photo-2219.jpg

http://i924.photobucket.com/albums/ad86/bluethunder3320/photo-1779.jpg

http://i924.photobucket.com/albums/ad86/bluethunder3320/photo-713.jpg

frame taken apart

changed the oil in the forks and cleaned them. need paint
http://i924.photobucket.com/albums/ad86/bluethunder3320/photo-1587.jpg

tires washed, and i put armorall on them
http://i924.photobucket.com/albums/ad86/bluethunder3320/photo-1278.jpg

frame

Bluethunder3320 · Dec 25, 2011

im considering buying a new 10hp tec shortblock, and using tons of parts i have to make it complete. $130 and $40 shipping.

10hp of tecumseh flathead power in this bike would be so awesome.

Bluethunder3320 · Dec 26, 2011

just ordered.

Baja Warrior Rebuild

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