Found a leak!

[sam0840]

So as I thought, I have an air leak. Thanks to Awk for my leak tester! it looks like its around the reed cage and the rubber manifold. My question for you guys is 2 part. Should I get a new manifold or just get some sealer and apply that? also, since I have this apart, Is replacing the reeds with something higher performance really that great of an upgrade? if it is what would be the best ones for a stock engine?

 

[mud runner]

id just get some sealer leaks in the reed cage are common with blasters and reeds will give you better throttle response but not mutch more than that

 

[sam0840]

is there a particular type of sealer you'd use? just liquid gasket stuff?

 

[Blaaster]

Copper RTV works wonders but leave to dry over night.

Dual stage reeds are a good investment for a stock motor, no more performance but a much snappier throttle.

 

[sam0840]

who makes dual stage reeds?

 

[mud runner]

who makes dual stage reeds?

I run boysen dule stage I bought them off of ebay

 

[mud runner]

here they are Yamaha Boyesen Pro Series Reeds YFS 200 Blaster | eBay

 

[Herpderplol]

Go big or go home, VF4's

 

[Blaaster]

IMHO VF4s are a waste of money on a stock motor.

 

[sam0840]

Well thanks for advise. I just left mine on there. got the RTV all applied. will let it sit for the rest of the night and re test for leaks tomorrow afternoon. Ill keep u guys updated

 

[sam0840]

the RVT sealed up the intake but now I found another smaller leak in the case. I loses the 7psi in about 2 minutes. can I apply RVT to the outside of the case halfs to seal this up or am I going to have to send my moto out to have them split everything and reseal it up.? Thanks for your help guys

 

[Blaaster]

A leaky case usually means a split and re seal.

 

[sam0840]

I called the dealer down the stgreet to see what it would cost to reseal it and it would be over 500 dollars! so looks like I'll be doing it myself. I found a few KOR vids on assembly and tear down but i just wanted to know if there are any tips. I am assuming i'll need to buy a puller. I have the one for the flywheel but not for the center cases. whats the best way to clean the case mating surfaces?

 

[Awk08]

I called the dealer down the stgreet to see what it would cost to reseal it and it would be over 500 dollars! so looks like I'll be doing it myself. I found a few KOR vids on assembly and tear down but i just wanted to know if there are any tips. I am assuming i'll need to buy a puller. I have the one for the flywheel but not for the center cases. whats the best way to clean the case mating surfaces?

the case halves should be "lapped" on a flat surface....glass, metal, granite ect.
to insure they have a perfectly flat mating surface.
tape some medium/fine autobody wet sandpaper down, spray liberally with wd-40 and stroke those case halves on it using a figure 8 motion.

not sure if there's any youtube vids on this subject, but worth a google search

then a light coat of honda/yamaha case bond applied with a plumbing flux brush right before re-assembly to seal them up

 

[Blaaster]

There is a product called Engineers blue, it is designed to stain the mating surfaces so that when you lap, the low spots will show as they will be blue.

 

[Awk08]

There is a product called Engineers blue, it is designed to stain the mating surfaces so that when you lap, the low spots will show as they will be blue.

that /\ I:I
then lap on the flat surface until all the blueing is gone

 

[mud runner]

I called the dealer down the stgreet to see what it would cost to reseal it and it would be over 500 dollars! so looks like I'll be doing it myself. I found a few KOR vids on assembly and tear down but i just wanted to know if there are any tips. I am assuming i'll need to buy a puller. I have the one for the flywheel but not for the center cases. whats the best way to clean the case mating surfaces?

on etip of advice is take lots of pictures of tearing it down so you know how it should look when you put it tighter and if you need any tranny parts pm me iv got 2 sets of gears out of other motors iv torn appart

 

[sam0840]

awesome. next question is do I have to pull the clutch side off all completely? I was hoping I could just take minimal stuff off and lap the cases and seal it back together. but its sounding like i need to just replace everything seals gaskets etc even if they are new and take everything apart. I am sure it would be close to the same if i shipped it off the Ken. I am nervous I'll screw something up!

 

[Awk08]

only the cylinder base gasket is a must replace,
even though i don't do it, annealing and reusing the head gasket is OK
seals only need replaced if they are leaking

 

[mud runner]

only the cylinder base gasket is a must replace,
even though i don't do it, annealing and reusing the head gasket is OK
seals only need replaced if they are leaking

id go ahead and replace the crank seals while it is apart