The Banzai Build....

[BanzaiBlaster]

Some rear hub comparison
YFZ450R to stock hub

Thought..... are the 450r hubs forged? They're much thinner and the finish is smoother....

 

[BanzaiBlaster]

A little diagram...
The bushings are just barely inserted into holes. They will be pressed in flush during final assembly.

This'll keep that booty from twerking
Honda 450R rear shock...MINT

 

[BanzaiBlaster]

I found the likely cause, or at least a contributing factor to the counter shaft seal popping out... SMH

Thought.... someone's attempt to block a hose off with 1 little zip-tie contributed to, through a series of events and circumstances, the eventual degradation of the machine.... and my coming into possession if it... for free....NICE!

This is the gearcase vent tube....

 

[BanzaiBlaster]

Nice work. Keep it up and the photos coming.

Thanks Mark, I'm thoroughly enjoying the process.

I'm trying to share as much info as I can on all products and processes used. If I miss something or anyone has questions, please, chime in.

 

[BanzaiBlaster]

Up late last night. Finished stripping rear end and got workspace reorganized and clean. Today's schedule is cleaning parts and getting the motor in the frame.

My current plan is to source and fit all the parts now. Get 5-10 days of riding in before the season ends to work out any bugs. Then completely strip the bike and get the frame and other parts blasted and coated over the winter.

On a side note I spent some time talking with Darren at ishock. I purchased a set of prototype 400ex shocks they're going to set up for me. They don't have much Blaster experience but he's gonna take a shot at the setup and worst case I'll have to send them back to be reworked. He's confident in the valving but spring rate choice is a bit of voodoo. He said when I get them on to set full weight sag and go from there. As long as i dont ride with the shocks it'll only cost for the round trip to get them reworked.

I'll be running ASR LONG travel arms in the front.

I found the shocks on Ebay NOS for $350 setup and shipped. 16.5" eye to eye, FAT shafts, dual rate springs and compression adjust.

 

[BanzaiBlaster]

Today was a good day...mission accomplished!

 

[BanzaiBlaster]

Here are the parts you will need to mount the Swingarm Shop swinger.

The weld around the pivot tube is just a little too beefy.

I'll have to file the chain "roller" sleeve down about 1mm. It currently measures 14.75mm. After taking some measurements i found there is about 3.3mm of wiggle room before the "roller" starts to bind.

 

[Markblaster]

Here are the parts you will need to mount the Swingarm Shop swinger.

View attachment 31069

The weld around the pivot tube is just a little too beefy.

View attachment 31070

I'll have to file the chain "roller" sleeve down about 1mm. It currently measures 14.75mm. After taking some measurements i found there is about 3.3mm of wiggle room before the "roller" starts to bind.

View attachment 31071

Or do away with that roller and do a chain slider.

 

[BanzaiBlaster]

Or do away with that roller and do a chain slider.

I thought about going that route but I'd already ordered the stock replacement roller before the sickness set in....lol

 

[Markblaster]

I thought about going that route but I'd already ordered the stock replacement roller before the sickness set in....lol

I did the same thing. I brought the roller but blaster mode kicked in and I changed it.

You need some nice frame plugs.
http://www.blasterforum.com/threads/hpm-blaster-bling.62415/

 

[BanzaiBlaster]

Thanks for the referral! I'll definitely be getting a few of his products.

 

[Markblaster]

Don't know what your budget is but here is another link to a nice product.
http://www.blasterforum.com/threads/aluminum-stator-cover-yamaha-blaster-for-sale.61038/

 

[BanzaiBlaster]

Don't know what your budget is but here is another link to a nice product.
http://www.blasterforum.com/threads/aluminum-stator-cover-yamaha-blaster-for-sale.61038/

We've already talked....he's out of them until he gets some available time.

 

[Markblaster]

We've already talked....he's out of them until he gets some available time.

HPM may still have covers. he had machined ones out of aluminum.

 

[BanzaiBlaster]

Thanks, I'll hit him up...

I've had a few good weeks at work and the parts are rolling in! I have today off so I'm gonna bear down and get some assembly done. About to head to fastener supply store and get some misc. bolts and aluminum to make heel guard (GYTR Raptor 250) upper mount brackets.

 

[Markblaster]

http://www.blasterforum.com/threads/frame-guard-idea.63580/

 

[BanzaiBlaster]

I got the Swingarm ready to install. I used a Wendy's plastic knife that's been shaved down small enough to fit in the lower front arm bushings. I used it to pack the recess between the bushing and bearing in each pivot tube.

THE Lucas Red "N" Tacky seems to be an excellent product....and yes, it's very "tacky" LOL.... I hate messing with grease...

 

[BanzaiBlaster]

http://www.blasterforum.com/threads/frame-guard-idea.63580/

I'd like to get a set of those too... great job on fitting them!

 

[BanzaiBlaster]

I spent most of yesterday getting the front end tore down, of course, attacking any remaining dirt I found with a toothbrush. I also got the front arms and shocks mocked up. ASR forgot to send the spacer tubes for the upper arms so buttoning it up has to wait. That gives me time to get the rest of the hard parts on the bike so I can set and adjust the sag. I hope it sags a lot because right now it doesn't budge....lol... suspension at full extension.

Before I removed the old arms etc. I sat the quad up on that jack stand... the tires were 2" off the ground. I had to lift it OFF the stand 4" to get the wheels back on ..... serious down travel!

 

[BanzaiBlaster]

I also got the bracket removed for fitting the 450R rear shock.