Engine rebuilding?

[twcguy]

After my engine would no longer run, and had 0 compression, I took the head off my 2003 Blaster to find that the piston had disintegrated. The cylinder and head are pretty much hosed.

I am considering sending it out to Mark Brenny in Iowa for a rebuild. He says that he can rebuild it for $595 plus shipping.

Does this seem like a good deal? Has anybody else used his services?

Here is the Ebay link:

eBay Motors: Yamaha Blaster YFS200 Rebuilt Engine Exchange (item 370013330884 end time Apr-11-08 12:07:59 PDT)

 

[Darrell]

no..no..no!!! lol you can buy a complete 240 kit off of ebay for that price and do it yourself and gain some power!!!
but i had mine done at a local shop and i just got it back and it was $203 for a complete top end boring and piston and rings! that included parts and labor!!! but if your piston is busted up then you'll probally want to split the cases and check out the bottom end for any damage!! but i would not pay $595 + shipping for that little bit off work!!!(unless i had more money than brains) lol

 

[twcguy]

The case is filled with metallic debris from the piston. I would rather not go with a 240cc engine as the Blaster is going to be the loaner bike for friends and family who want to borrow a quad for the day, it needs to maintain stock reliability.

How difficult would it be to spilt the case and rebuild? What special tools are required?

I have the downloadable manual but it seems to be lacking many details.

 

[Darrell]

well the 240 kit should have no effect on reliability, But im not sure about the caes spliting cause i havent done mine yet, so ill let some one eles answer that! but if you know its just debris and there is no damage to the bottom end, you could probally get by with flushing it out! but if your wanting reliabilty then id split the cases and check it all out just to be sure! sorry i couldnt answer any more but i would refer you to pittboss!!! he's the blaster genius of the forum!!!

 

[twcguy]

I am having the cylinder rebored and matched to a new piston. I would like to replace the crankshaft, connecting rod and bearings while I have it apart.

As far as the splitting the case goes, what special tools are really required? The online manual (PDF) shows at least 3 specialty tools "necessary" to tear down the bottom end.

Who has done this themselves? Is there a full writeup somewhere that is more complete than the downloadable manual?

TIA

 

[Kevin full throttle Noah]

There's a vid on the forum about doing a rebuild put on a few days ago. I think you'll need a impact wrench,mallet,gasket set,flywheel puller,metric sockets,phillips or allen wrenches depending on what holds your cases on,something to knock your bearings out, torque wrench. Take some pics and lay it all out in order helps. You can do it to save you some bucks.

 

[Kevin full throttle Noah]

Ohh and rtv silicone ,can't forget that.

 

[pittboss45]

There is a case splitter and a tool that we use to pull the crank into the left side case.

Please do not use RTV silicone, get some Yamabond or Honda bond, your life will be better off.

 

[twcguy]

There is a case splitter and a tool that we use to pull the crank into the left side case.

Please do not use RTV silicone, get some Yamabond or Honda bond, your life will be better off.

I know Kragen/Autozone and the like rent out automotive tools, but where would I find a case spreader and crankshaft installation tool?

 

[Blaster_boy200]

what about ebay

 

[BLASTER POWER]

i seen a vid on you tube of a complete rebuild and tat seems like a rip off??

 

[Kevin full throttle Noah]

Isn't yamabond,hondabond,permatex gasket maker a silicone based product

 

[Kevin full throttle Noah]

Sorry about jacking your thead dude but your local dealer should have the tools you need. Check out Rocky Mountain ATV or Motion Pro if they don't have them.

 

[rix005]

I have a cylinder and head, media blasted and ready to plug and play, still in stock specs. Asking $250 I will list this item in about an hr. in the for sale forum.

 

[450killer]

The only special tool you need is the flywheel puller you can seperate the cases by hand with a little time after you get the jug off

 

[twcguy]

The only special tool you need is the flywheel puller you can seperate the cases by hand with a little time after you get the jug off

I have got a flywheel puller on order from Ebay along with a Wiseco bottom end kit with a new crankshaft, connecting rod, bearings, seals and gaskets. The cylinder is going to a machine shop to be bored and matched to a new piston.

The head is a little beat up from the metal banging around inside the cylinder, I am going to clean it up with a dremel and call it good.

Thanks to everyone for the tips.

 

[mercurysoundz]

I've currently disassembled my Blaster engine and tranny. What kind of sealer do they use to seal the case halves? I bought the gasket kit and it doesn't include anything for this part. Someone said not to use RTV, what should I use instead, and is there any special way to use it?

 

[twcguy]

I've currently disassembled my Blaster engine and tranny. What kind of sealer do they use to seal the case halves? I bought the gasket kit and it doesn't include anything for this part. Someone said not to use RTV, what should I use instead, and is there any special way to use it?

Yamabond

 

[wutsupy]

spliting it sux majorly bad, just flush it out a LOT and you and your machine well be better off
spliting it is the only thing i would have a pro. do

 

[twcguy]

spliting it sux majorly bad, just flush it out a LOT and you and your machine well be better off
spliting it is the only thing i would have a pro. do

I already have it split, awaiting the new parts. The main bearings are shot and the crankshaft is blue from the heat.