Help after top end rebuild

[Mario r]

Hey all first post here. So I did a top end rebuild on my 2005 blaster. Had the cylinder bored, new wiseco piston,gaskets etc and the only problem with that is I have never in my life done a top end rebuild and was able to install the new piston through help of some YouTube videos and some helpful threads in this forum.

For never doing a top end rebuild,it was pretty easy and the engine cranked right up, was running good on its own and everything was fine.turned it off to let it cool completely. Cranked it back up and same thing. I took the quad out to begin breaking it in and again everything was fine. Today, the quad left me stranded when it sputtered out all of a sudden. Now the engine will turn over but even while pressing the gas, the engine will sputter and sputter til it just dies out.

I took it apart again, made sure he piston was moving properly which it was but it continues doing the same thing. Any ideas.?. I would like to avoid taking it into be repaired by a a yamaha repair shop.

The only two things I re used was the piston bearing, and the spark plug which I'm going to get new to morrow but it seems like a long shot to me.

 

[Awk08]

where to begin ?.............
it should have been leakdown tested, heat cycled, head/base nuts retorqued, before ever being ridden,
then break in

possible causes of your current symptoms...
fried the new top end due to airleak
whats the compression ?

carb cleaned and float level set to 20 -21.5mm ?
flooded bottom end

fouled plug
reed petals cracked/chipped/broken
flywheel woodruff key sheared/missing allowing flywheel to slip out of timing
TORS disconnected ?

now you've taken it apart again...did you replace the head gasket or anneal it ?
and leakdown test again ?

 

[Mario r]

Holy wow, I appreciate the reply. To be honest I didn't do any of that.

I guess what I should be asking now is

1. With some research would I at this point be able to check out some of this you suggested or am I already sol with the new piston?

2. I want to avoid taking it to be repaired to have someone tell me I have to buy another piston or have it rebored. If I messed it up then That's my fault but would you suggest just taking it in? I have plenty of time and tools but like I said I never done it before.

 

[MURPH]

Check the compression, carburetor and reeds before you start taking it apart it might be something simple

 

[Awk08]

check for spark, try new plug
good fuel flow to carb ?

pull the carb,
check float height:
http://www.blasterforum.com/threads/float-heights-and-how-to-adjust-them.50565/

check reeds for broken petals, all 4 should be present, in 1 piece and sealing against the cage.
light coat of copper rtv on both sides of reed cage gasket, torque to spec diagonally.

torque specs:
http://www.blasterforum.com/threads/bolt-and-torque-specs.46155/

pull head off and anneal the head gasket:

torque head to spec.

leakdown test:
http://www.blasterforum.com/threads/build-and-use-a-leakdown-tester.10663/
testers 4 sale: http://www.blasterforum.com/threads/leakdown-testers.55015/

do a compression test, if it's over 110 (should be 120+ for new topend, but 110 psi should start) continue on.....

pull stator cover, flywheel nut, big washer, to see if flywheel slot is aligned with crank slot
the woodruff key in there holds the flywheel in time

3-5 heat cycles:

retorque head and base nuts.

report your findings for further assistance

 

[Larry's Shee]

Where to start II

What does the piston look like? Does it still look new?Can you post pics?
You will need new base and head gasket or anneal old H.G.

 

[bummer981]

Sounds like a parking brake or TORS issue.

03 - 06 TORS removal
http://www.blasterforum.com/threads/03-06-tors-removal-diy.41973/

For the parking brake you can simply unplug the switch at the lever.