Engine rebuild

[NoFearMx19]

First off, hello to everyone. I am new to the blaster forum although I've read here for years. So here's my story..I recently acquired a 2003 blaster, traded a ttr125 for it. The blaster has an LRD pipe and silencer, k&n air filter with no airbox lid, I have deleted the oil pump semi properly(removed pump gear, capped carb inlet and pump lines) I have yet to do the TORS delete. The poor blaster was muddy and abused when I got it, so I cleaned it immeadiatley and removed the carb, just as I suspected, full of trash. Proceeded with the carb cleaning ritual and re-installed. Boom fires right up and purrs like a sexy kitten. I ride it for a few days to get aquatinted with it. I find out the float valve is bad in the carb so I replaced it. The idle was off and would do as described by another thread on here and hang at a higher idle for a few seconds before dropping low or dying completely. So I adjusted the idle on the tors unit atop the carb, also the air screw on the left side of the carb. Fixed! ...or so I thought. It snowed here today and I thought i would get the blaster out to play. It fired right up. I let it warm up 7-8 mins, took it around the backyard twice. I left it idling as I went Inside to get goggles. Hopped back on and proceeded to ride. I got out of the driveway, hit it hard from 2nd to 3rd. All the sudden it Boggs and dies. Kick start won't budge so I kick it in neutral and push it home. Now here come the questions....
1) what's the worst case scenario?head, cylinder, piston, rod?
2) 240 or not 240?

 

[harley1-5]

sounds like you need to pull the top end first and see what the piston looks like

 

[NoFearMx19]

I will be doing just that when I get the chance. Thanks for the quick reply.

 

[harley1-5]

sounds like it ran lean and blew.when you get it fixed leak test before running

 

[Quadman1]

What jets are you running?

 

[dirtysquared]

I'd do a leak down test first before you rip the head and cylinder off. See if you had an airleak that contributed to your locking up.

That hanging idle could have been caused by a hidden air leak.

Good Luck!

 

[NoFearMx19]

Thanks guys. I had suspected just that. I'm not sure as to the jet size, I should have written it down. What size jet would you guys recommend for a mildly modded blaster such as mine? Also, I'm itching for some opinions on the 240 kit.

 

[warmeck]

sounds like it ran lean and blew.when you get it fixed leak test before running

x2 on that definatelly seems like a lean condition either by a leak or by improper jetting. to narrow it down perform a leak test if there are no leaks then it was ur jetting. Then i would start to take of head and inspect damage. You should always leak test a new bike as the PO are probably assholes and abused there blaster!

 

[warmeck]

Thanks guys. I had suspected just that. I'm not sure as to the jet size, I should have written it down. What size jet would you guys recommend for a mildly modded blaster such as mine? Also, I'm itching for some opinions on the 240 kit.

you would need to list the mods that are done to the quad such as air filter,pipe, engine mods, etc. as for the 240 kit hey if you have the money for it and you wanna make ur engine merk then by all means go for it I:I

 

[NoFearMx19]

Mods: LRD pipe and silencer, k&n(no lid). Unsure of the jetting. Will post exact jet size tomorrow.

 

[NoFearMx19]

Gonna hit the Home Depot tomorrow to build a pressure tester.

 

[dirtysquared]

I'm not sure as to the jet size, I should have written it down. What size jet would you guys recommend for a mildly modded blaster such as mine? .

Throwing a jetting # out now isn't really going to help you much. Alot can and probably will change by the time you have it back up and ready to start.

The best advise I can give you is take it one step at a time, do what the members are suggesting, and report back with your findings. It will save you alot of headaches in the long run. Then get a good game plan together for what you want/plan on doing, and " Don't put too many Irons in the fire."

 

[NoFearMx19]

Okay pressure test was good. Proceeded to remove head and cylinder to find tiny pieces of piston sitting on top of the darn thing... Removing the cylinder I find the root of the problem, shattered piston skirt. Probably due to the last owner only ringing when it needed bored, honed, and new piston/rings/bearing. Now I'm left with a mess. I found two small cracks on the bottom side of the case from the rod beating the pieces of piston against the bottom of the crankcase. New motor time. Rebuilding this one wouldn't be cost effective I believe... Any opinions?

 

[NoFearMx19]

Oh yeah, I'd like to mention that it wasn't a lean condition.

 

[harley1-5]

might be a set of cases on ebay

 

[Herpderplol]

Time for a hybrid swap I:I

 

[NoFearMx19]

Actually, I may be able to save it! For a little while at least. Now I realize how this is going to sound but bear with me... ((JB Weld)). The cracked areas aren't so bad after cleaning with gas and a wire brush.. Pictures would be infinatley better than me describing it, but for the life of me can't get them to load.. So, opinions?

 

[Blaaster]

Aaagh the dreaded JB weld.

Providing you get the parent metal super clean it may work.

Pics would be nice to comment on, I have seen so many Epoxy failures.

You are going to have to split the cases, to remove debris and clean/replace bearings, take some pics for some one to comment on.

 

[NoFearMx19]

What's funny is I HAVE pictures of the entire process, for the sole purpose of posting for you guys to comment on... For some reason I can't get them to load. (I never said I was computer savvy) haha. But for sure, as soon as I am able. I will be posting pics for your enjoyment

 

[Blaaster]

Greatly looking forward to the entertainment.

Would love to post a link on how to post pics, but I am in hospital and the laptop with the files on is at home.