destroyed clutch basket on the primary drive gear

[sm81]

Hi guys. Have an 06 blaster with, at the least, a broken basket on the primary drive gear and some destroyed clutch plates. I see one rogue ball bearing but everything looks good without the case cracked. Rotor puller is coming this week so I'll be able to check out the inside. It will shift every gear but at 4th-6th you have to turn the shaft back and forth a bit to get it to go into gear. Like I said, have to check in there to see whats going on.

Back to the primary drive gear. Gears are fine, riveted aluminum has no teeth left. My cheapest option to get the replacement drive gear for ~$130? Does that come just as it looks now(smaller gear on the side)? I couldn't find anything on ebay.

After I find out how the inside of the case looks I'll send the head out and get a piston. I've read that a forged piston would be the better way to go? What brand of clutch do you guys recommend?

I'm sure I'll have more questions as I go on. This is my first 2 stroke rebuild.

Thanks

 

[Blasterb0y794]

Damn that sucks. If you want I have a complete clutch Im selling. If you want PM me if your interested.

 

[brandoz28]

Wiseco for the piston, i got a PE billet clutch basket for my blaster, it was about 140 bucks and used the iron gear that the original basket is riveted to. looks like you might want to go this way for the extra protection. are the clutch boss and the pressure plate still ok?

 

[sm81]

Yes they are fine. Everything else that's visible is fine. It still ran as far as I know when It happened. It's a friends bike, said his kid power shifted every gear all the time. If I get it running I have something to ride.

 

[wolf1]

i have the gears for a blaster and all shift parts send me a picture of the gear and parts you need. they are used but in good condition..

wolfewispr@aim.com

 

[wolf1]

oh, and i prefer wiseco pistons and ebc clutch kits.

 

[sm81]

Finally got the rotor puller and split the case. (used a piece of pine and gentle taps from a rubber mallet to split the case, worked great) Everything looks good inside thankfully. So here's where I'm at.. Please bare with me

Need to clean the case and trans gears off. Carb and choke cleaner ok?

Yamabond or "right stuff" sealant I found other people using

Do I need a tool to press the case back together or can I get around that?

Is it all right to reuse the lock washers that u bend to the nuts?

I need either a used primary drive gear with the clutch basket on it (anyone got one laying around?) Or I'll go with the PE Billet basket that brando recommended.

New clutch, TBD

Send the head out and get a matching forged piston.

Medium strength threadlock strong enough?

Gasket kit

I'm also using the free online manual, is that a bad idea for reassembly?

Then hopefully it starts. There's a bunch of small things I'm missing but I've been reading these forums quite a bit so I should be ok after that.


Just a side note, the stealership wanted 1500 bucks to repair it and all they did was remove the clutch and cover. That's how I ended up with it

Thanks for all the help guys, I'm still a little nervous. Only motor I've rebuilt was a small block chevy, this is my first 2 stroke.