new 2000 blaster need help

[BlownBlaster]

OK i picked up my blaster saturday...I have some questions...been reading alot but these things i'm wondering...clutch oil says 650 cm on case is that 650 cc?...thats 22oz...but the sight glass gets coverd with like 10-15oz's...pus only 10-15 came out like PO only filled to site glass?.......also removed oil tank cut wires....pluged carb with small vacumm cap...but i'm confuzed on pump?...if you remove pump with 2 screws....wats left is the gear sticking out engine...ive seen picks of block off plate...it looks like the engine gear needs to be gone for cover to fit?...read somepeaple just leave pump on?...others say to take pump apart and remove its gear and reinstall?...and no need for block off plate?...can someone explain this better?

 

[98blaster+4]

as far as the blockoff, i simply took the white plastic gear off and left the pump to block the hole. then i took the two lines that came out for the oil and looped them to each other, then plugged the mipple on the carb so i didnt get an airleak.
and definately do the 650 ml of oil in the trans. the sight glass fill up doesnt work, its only after everything is been run a bit and to check the level while riding.

 

[sicivicdude]

You need to put 650ml (or cubic centimeters because, technically, mL and cc's are the same volume) of transmission fluid in the fill port. It will completely cover the sight glass until the engine is started because the ring gear on the clutch basket acts as a "slinger" and throws the oil into a special area which forces it to circulate throughout the transmission. The level should even out once you start the engine.

The injection pump is turned by a delrin gear which mates to a gear on the end of the crankshaft (same gear that turns the counter-balancer shaft). The oil injection block-off kits come with a small plate which bolts in place of the oil pump and a clutch cover gasket. However, you don't actually have to purchase one unless you think that pump under that cover you cannot see is unsightly.

You can remove the clutch cover, pop the "e-clip" off of the delrin gear, remove the gear and the drive pin, and reinstall the clutch cover. If you do that, you have effectively eliminated the oil injection without having to buy a "elimination kit".

 

[BlownBlaster]

what about the rear brake caliper?...how do you check the rear breaks?

 

[Larry's Shee]

As to the brakes, hydr conversion is best option. Next best would be shorty cable and search suspension forum on how-to repair. Might have to replace plastic ratchet piece.

 

[sicivicdude]

The mechanical disc brake on the pre-'03 blasters are something to behold. They worked great when they worked and are your worst nightmare when they don't....

There was a how-to for pulling them apart and cleaning them out. The jist of it is a BUNCH of WD40 in the conical roller area and then re-grease it before assembly.