project blaster

[PadGeni]

I started with a 1988 kawasaki kx125. Irode it twice and the engine blew up. My freind wanted it so i traded the kx125 for his 1998 yamaha blaster not knowing what was wrong with it. At first i had idle problems witch was resolved a day after thanks to you guys because i didn't have a clue what tors unit was. Then alot of smoking (white smoke) but i didnt care about this. Then the piston was broken but i killed it. It shattered, so i got the cylinder oversized at .090 and brand new piston+ring+top end gasket kit. after new top end rebuild and break-in I went for a little ride. On my way back to my truck the f*cking thing wont downshift! and the blaster has no brakes lol. Anyway got home safe and i said THATS IT!!! I posted an add on the internet to sell it saying it was stuck in 6th gear and no downshifting was possible. Yesterday i was tired of looking at the blaster in the driveway doing nothing so I took it apart again. Removed the engine out of the quad, removed the top end, removedpiston again, removed flywheel+stator, removed clutch and all gears and split the case myself. I have to admit that it was very easy! I discovered a bunch of metal shrapnels in the transmission and found a canadian dollar size hole in the case between the crank shaft and counter balance. I got the hole fixed(welded) for 40$ and i cleaned the case halves and tranny gears and put everything back together. today im going to see how it rips and im thinking about keeping the damn blaster.

anyway all this just to say thanks guys for all the advice and help given on this site

 

[Blaaster]

Did you find out what caused the hole in the case.

Have you done a leak down test since you got it back together?

 

[PadGeni]

The piston caused the hole. And yes it is leakproof!

 

[Blaaster]

Dont forget the break in buddy.

 

[Awk08]

glad to hear you got it all figured out. props for splittin cases and figuring out what happened
full breakin ???? that top end is as is was last time you rode it, but will require the head and base bolts to be re-torqued to set the gaskets, after a short ride, or heat cycles

let us have a ride report

 

[Larry's Shee]

The white smoke was from a bad crank seal, might want to replace both.

 

[PadGeni]

it was the crank seal and the hole in the case. and today i went for a ride and in the widdle of nowhere the quad stalled... I had a hard time strting it but managed to do it and when i took off i was going backwards i had 6 reverse gears lol. untill i called my dad to come pick me up. once at home i found that the timing key was sheared so i replaced it and it sheared 4 more keys and i found out thar the flywheel nut was stripped so i gotta get a new one and retread the crank.

 

[Larry's Shee]

Well that just sucks X(

 

[Braaaptor]

One thing at a time, buddy... That's how it always is with a project quad...ya fix one thing and it seems something else breaks. But you'll get 'er done!

You can take some valve lapping compound and use it to lap the flywheel to the crankshaft. (If the crankshaft or flywheel are damaged in any way from the sheared key.) The lapping compound trick will make a smooth surface on the crank for the flywheel to seat against, so you won't shear any more keys, even with a tight flywheel nut.

 

[PadGeni]

Thx that seems to have fixed it and i used loctite just to be sure about it

 

[Awk08]

did you use the valve grinding compound (mentioned above) to seat the flywheel to the taper of the shaft ???
thats what holds it tight, the nut just holds it in
did you torque that flywheel nut to specs, while holding the flywheel with a holder tool ???????