Baja Warrior "build" thread

[Panhead5496]

So added the seat and an $8 throttle cable to cart.

Ends up being $44.69 shipped to me. About the same price as the eBay ones, so the cable would be "free"

I'm going to poke around site and see if I need anything else and order from there I guess

 

[Hellion]

When in doubt, measure the quantity of oil you put in. The Baja Warriors don't sit level on the ground--the front of the bike is high and therefore puts the engine on an angle, leading to erroneous readings if you're using the add-oil-until-it-dribbles-out method. It would be best to level the bike out with a jack, a ramp, or some blocks of wood and then add the oil.

Furthermore, if it's resting on its kickstand, it'll also give you false readings on the dipstick.

Needless to say, if you overfill the crankcase the excess oil is going to be blown out of the engine.... creating smoke.



I have no idea what's wrong with the pull start. Is it totally kaput? Can you fix it?
That seems to be a good price for the new one. It just doesn't match.

You sure are throwing a lot of money at this thing; but it's a gift, I know, and it's turning into a labor of love. All good. Again, can you fix the recoil starter? At least dissect the old one and find the cause, take pics and share the gory details for all...

You must learn, Daniel-san.

 

[Panhead5496]

When in doubt, measure the quantity of oil you put in. The Baja Warriors don't sit level on the ground--the front of the bike is high and therefore puts the engine on an angle, leading to erroneous readings if you're using the add-oil-until-it-dribbles-out method. It would be best to level the bike out with a jack, a ramp, or some blocks of wood and then add the oil.

Good points...I will try to level it

Furthermore, if it's resting on its kickstand, it'll also give you false readings on the dipstick.

I usually just do it that way on mine and it works fine.

Needless to say, if you overfill the crankcase the excess oil is going to be blown out of the engine.... creating smoke.

I guess that's what's happening

I have no idea what's wrong with the pull start. Is it totally kaput? Can you fix it?
That seems to be a good price for the new one. It just doesn't match.

Ok, I just looked at it. Seems the spring in it is missing? Ie when I pull out the cord it doesn't wind back up. I just took it apart and that's the issue.
You sure are throwing a lot of money at this thing; but it's a gift, I know, and it's turning into a labor of love. All good. Again, can you fix the recoil starter? At least dissect the old one and find the cause, take pics and share the gory details for all...

You must learn, Daniel-san.

As for throwing money at it, that wasn't the plan it isn't that much I don't think. I'll list everything I've spend so far.

Baja...$50

Engine work $65

Oil...$3.xx

Throttle/brake assembly...$10

Carb...$9

Total so far: about $140

That isn't too bad I don't think, since I've never seen one for sale even remotely locally for under $250 that had a good frame/tires

I think by the time I'm done (need a seat, brake handle, few small other things) I should be right around $200 give or take, which isn't too bad

 

[KingCobra]

That isn't too bad I don't think, since I've never seen one for sale even remotely locally for under $250 that had a good frame/tires

NOT bad at all considering they are $500 to $600 new!!!! I also doubt you could fill that crank case up enough to make it smoke as when they are full of oil, they are right near the oil plug anyway. Anymore oil and it would be pouring out before you could install the plug. Just how level does your Baja sit with the kick stand? My Warrior sat really level to me. Do you have the original tires etc. on it? Nothing oversize front or rear?? I know that it might lean a tad to the side but that won't cause an extra large dose of oil. I think you would have to have two quarts in there to get it to blow through your piston rings. I have heard of people getting their two cycle gas mixed up sometimes w/ their regular gas and pour it in a four cycle engine....... My neighbor did that with his riding lawn mower BAHAHAHA!!!!!!!! ........

 

[Panhead5496]

It's pretty level. I'm trying to look up some stuff on it. It's the same tires as well

I know it was regular gas too. The part this is throwing me is at idle no smoke, rev it up and it starts smoking.

Ok so pull start issue is the spring is gone on the inside. Weird. If I had cool spring I could fix but it's gone. Guess I'll order a new one ugh. May try to paint it

 

[KingCobra]

It's pretty level. I'm trying to look up some stuff on it. It's the same tires as well

I know it was regular gas too. The part this is throwing me is at idle no smoke, rev it up and it starts smoking.

Ok so pull start issue is the spring is gone on the inside. Weird. If I had cool spring I could fix but it's gone. Guess I'll order a new one ugh. May try to paint it

Well, make sure it is sitting level by leaning it against a wall or something nearly straight and level if the kick stand can't accomplish that. Then unscrew the oil plug over newspapers or something cause I believe oil will run over the frame. THEN you will know that if none trickles out, you are fine. Check the breather hoses from the valve cover to the air cleaner box etc. Maybe the carb is pulling something in through it. When you REV the engine, you are creating much vacuum.

Lawn mower shops have recoil springs etc. I had to buy from them once for a pull start thingy . They should be able to rebuild your pull starter.

 

[Panhead5496]

Ok! I will try that.

I will see about getting it fixed as well.

Where is the cheapest place to get some chain? The one on it is beyond saving I'm afraid

 

[KingCobra]

Try a motorcycle shop or a lawn mower repair shop as lawnmowers can have chain drives too. Maybe for those huge walk behinds or ride-ons. Try ace hardware?

 

[Panhead5496]

Good suggestion Cobra, but I was told about MFG. they have cheap parts, so ordering some stuff from there soon, chain included

 

[Panhead5496]

No time for the Baja today, going out of town tomorrow so she'll have to wait till next week.

I ordered a new throttle cable and will order chain soon as well. A new pullstart and seat and that will be all I'll need!

All that's left to do...

Put on chain

Put on clutch (found the one off my Baja, it's like new, going to use it)

Paint a few places here and there I missed

Run brake cable and get new lever (it broke...cheap eBay parts )

Run throttle cable

Get seat

I think that's all. I am still kicking myself over the engine...should have bought a predator...oh well, live and learn. Will change oil on more level ground and see if that helps smoke. If not, the engine shop has a 30-day guarantee for their work. Might take it back by if still smoking.

 

[Panhead5496]

Update time!

Got the new chain in the mail. It's on, as is the clutch, and works great! Nice chain too

The new pullstart came as well, got a red one (more on that later). Perfect fit, looks great

I found some parts from my Baja and put them on...heat shield, chain guard, and clutch cover. Helps make it look finished

Back to the red...I decided to do a UGA bulldawg theme on the bike, since Dad graduated from there and it a huge fan. I will find some decals and put them on, so the red pullstart is a nice accent color!

I still need to order a seat, brake cable, and throttle cable (the cables I have work ok, but aren't very smooth and look bad lol)

I will try to add some pics next time I get it out to work on it.

Also, the smoking seems to have stopped. I cranked it with the new pullstart and revved it and I didn't notice near as much smoke as last time, if any. Go figure

 

[Panhead5496]

Houston, we have (another) problem...front axle seems to be cross threaded. The bolt came off ok but it will not go back on! I tried the bolt on mine and it went on fine, so the axle is messed up.

I am on the search now for a new axle

 

[Hellion]

You’d be surprised what a good threading die can do for buggered threads. It’s probably metric too, but get that new axle and keep this and all your iffy parts in a box for later assessment/spares...etc.

Where’s those pics?

Talk and explain your progress all you want, but pics dispel all doubt.

 

[Panhead5496]

Hey guys, update time (yes I have a few pics!)

My axle and seat came in the mail. The axle even came with a bolt, that was a nice surprise.

I got it all painted, wheels on, throttle/brake on, etc.

I had the chain and everything on and was ready for a test ride. Spent 10 mins trying to get it to crank... dang "repair shop"!

Finally cranked it, rode around the yard for a little bit. Engine smoked. Gas cap leaked. Kept stalling. Not a good experience!

It was getting dark so I put it up till the next day. Got it out to do some tweaking and I pulled the pull start...it yanked it out of my hand, and I got frustrated with it lol. Kept pulling and it kept yanking it back.

"So great" I think. "Now the pull start is messed up"

Took it off, checked the clutch (it was fine), put starter back on, still not working.

At this point I am ready to take the engine back to the "shop" and tell them to fix it, or else...

But I figured they wouldn't believe me, might try to charge me more, etc...

After a day of mulling it over (I looked it up online and found all sorts of bad things) I realized it was

PREDATOR TIME

Today I went to the store and used a coupon and walked out with a brand new PREDATOR 212 for $106.99

It is on the Baja. It looks beautiful. I am happy. (going to let Dad call the shop and talk some sense into them lol, maybe get some money back)

So, with all that said, I now am really excited for this thing to be up and running. I need to get a clutch bolt...will this work? https://www.ebay.com/itm/Clutch-Bol...e=STRK:MEBIDX:IT&_trksid=p2060353.m2749.l2649

I will upload pics later from my computer, I just have a few. When I get it out of the basement and do the chain/oil/gas/etc I'll get better pics

I do hope that bolt will work...it's just a regular predator 212. I forgot the Baja engine has threads on the crankshaft or I would have already gotten a bolt

 

[Panhead5496]

Here are a few pics of it with the predator on it.

Tomorrow I'm going to do the chain and get it all hooked up, well except for the clutch

What do y'all think?? Looking any better??

 

[Panhead5496]

Sorry for upside down pic. It was right side up on my phone lol

 

[landuse]

Looks awesome!!

 

[ezcome-ezgo]

You can get that bolt at any hardware/home store for waaaay less than $7

 

[KartFab]

Front shocks...they seem to be stuck/rusted. Not sure the best option there yet

you can disassemble the forks, and replace seals in them allen head bolt on top for the plug to add or change oil, check springs etc allen head bolt on bottom as well. I havent disassembled the forks completely, but im pretty sure you can. I just needed to add fluid to mine.

 

[Panhead5496]

Looks awesome!!

Thank you!

You can get that bolt at any hardware/home store for waaaay less than $7

Good point. I hadn't thought of looking there lol. I can't seem to find the specific size I need. Any suggestions??

you can disassemble the forks, and replace seals in them allen head bolt on top for the plug to add or change oil, check springs etc allen head bolt on bottom as well. I havent disassembled the forks completely, but im pretty sure you can. I just needed to add fluid to mine.

I forgot about that part! I will do that today as well. With the other issues I've had I forgot to do that part

I should have some more pics up tonight, hopefully I will make some good progress.