losing power when put in gear.

[xxxBlasterxxx]

I've searched for days for anything causing this problem and have come up empty handed. Got the blaster blown up and beat up so I went over the whole thing. Put a new stock Wiesco piston 66.5 in at first. Put it back together and it had a pretty good knock in it which was piston slap so I cracked it back open and had to much movement in the rod so I put a new stock Wiesco crank, bearings, seals, and rod in. It fires right up no problem and idles and revs fine but soon as I drop it in first and let out on the clutch it dies. I went completely through the carb cleaned all the jets and anything I could remove and clean I did. Still no change. It has me stumped so if anyone can shed some light on this I'd greatly appreciate it. Tors has been removed with a kit and idle screw, oil injection completely removed and capped. No parking break wires. Not sure what year but I'd say older than 02.

I did a leak down test on the motor before installing it and it was perfect. Forgot to add that. Any help at all is greatly appreciated

 

[tbrooks]

Did you do heat cycles and torque the head and base nuts and leaktest again

 

[xxxBlasterxxx]

Couldn't do heat cycles as it wouldn't move when I put it in gear.

But I torqued everything to what it called for didn't cut any corners to avoid such problems. I just pulled the motor back off I'm going to tear it back apart and triple check everything I guess unless anyone has a suggestion? I just took the carb apart to check the needle settings. The whole bike is stock so I assumed no one has messed with it by the needle is set on the 2nd slot down from the top of the carb. Stock is the 3rd slot correct?

 

[speedyslyder]

this is the year,sounds like a clutch issue off the bat,did you try tightning cable or revving it up higher to take off? is chain sprockets ect in good shape??

 

[xxxBlasterxxx]

Both sprockets and chain are brand new. Yea didn't matter how high I revved it would just fall on its face. I thought the same thing about the clutch so I pulled the case off took the plates out and made sure they were facing the right way and everything. Clutch felt fine. When I let off the clutch it was like I was taking off in 5th.

 

[xxxBlasterxxx]

And the year of it......well I powder coated everything and thats no longer visable. A lot of the bike is new I went through the whole bike and replaced every bearing and seal and anything that looked as if it needed it.

 

[Herpderplol]

your clutch is slipping then. you will need to adjust that

 

[xxxBlasterxxx]

This is the first blaster I've cracked this deep into but I adjusted the clutch as it said to. Lined it with the mark on the case and the cable has a small amount of play before it engages. As for the plates you can feel a slight sharp edge I'm not sure how sharp it's supposed to be.

 

[Herpderplol]

if you pull the clutch lever without the cover on, do the clutch plates moved? and go back tightly?

 

[xxxBlasterxxx]

Yup. That was one of my first assumptions and it may very well be the clutch plates need replaced? How do you tell that they're bad?

 

[tbrooks]

Use a digital caliper and check they are up to spec. Also check the basket for grooves. You don't need to get it in gear to do heat cycles http://www.blasterforum.com/threads/blaster-engine-break-in.44174/ and the needle is normally good on the middle clip

 

[xxxBlasterxxx]

Sorry was thinking you meant plug chop. Yes I followed Kens build on YouTube and did everything as he explained all the way to break in. I'm putting different clutch plates in now I had from a spare motor. His video says torque the pressure plate at 7.5 lbs. Is that the standard or can they be loosened a little. That's what I did at first but like I said it fell on its face. Would it being to tight cause this?

 

[xxxBlasterxxx]

Meant 4.5

 

[xxxBlasterxxx]

So I took the motor back off cracked the cases double checked everything putting it back together one last time. Switched the clutch plates with a spare motor I have still the same problem. The tors is completely removed. Is there anything electrical that would cause this? It looses all rpm as u let out the clutch idc how high you rev it. Are both sets of clutch plates junk? That's the only conclusion I've come to. If anyone has any suggestions at all plz help.

 

[amartin_72]

Does bike move innuetral or with clutch i n engine off

 

[xxxBlasterxxx]

It moves perfect in neutral. But when dropped in first and I pull the clutch u gotta give it a little shove before it releases. But it does. Should it be as loose or close to as loose as it is in neutral?

 

[Herpderplol]

its the center rod adjustment on the clutch, not much to do with how much you torque the springs

 

[Herpderplol]

It moves perfect in neutral. But when dropped in first and I pull the clutch u gotta give it a little shove before it releases. But it does. Should it be as loose or close to as loose as it is in neutral?

there are two places for the clutch. engaged or not

what gear it is in should not matter

 

[xxxBlasterxxx]

Wasn't saying it did. Was just explaining what I did and what happend. The arrow on lever lines up with the one on the cases. So the center screw on the pressure plate is fine right? When the bike is off and in neutral it rolls smooth. When I put it in gear and hold the clutch there is a little resistance I give it a shove and you can tell the clutch releases. There's more resistance than in neutral when pushing but it's turning more gears than when in neutral. I'm guessing my plates are wore out? I couldn't find a spec to measure to so I'm going on assumption here.

 

[speedyslyder]

clutch basket is grooved/file it
get a new clutch anyways they are cheap
What kind of oil are you using and how much?