how hard is it to mod a blaster to keep up with the 400ex and z400s. will some bolt ons and a port job do the trick. or will i need a 240 kit and a race piston ?
Here's what i did for the blasters my sons ride and they more than keep up with the stock Ltz400 and the 400 ex (I have owned both the ltz400 and the 400ex)
1) Have the stock cylinder bored 40 over and put a wiseco 40 over piston kit in it. (Here it cost $180.00 to have it bored and to buy the 40 over piston kit and top end gasket set, and a new wrist pin bearing. of course that is with me doing all the labor of taking it apart and putting it back together.)
2) buy a 1 up chain and sprocket kit,
3) put either "Aktive" carbon race reeds, or "Boyeson" power reeds in it
(i prefer the Aktive carbon)
4) and put a boost bottle on it.
(a lot of people say the boost bottles don't work but my dyno machine shows 10% horse power increase after putting them on my sons blasters.)
5) get a good set of hole shot tires for the back of it and throw those old balloon tires it came with away. (they are actually left overs from the balloon tire era)
and be sure to set your suspension set up right so you don't have to slow down too much going over whoops or rough terrain.
I put my son's blasters both on my dyno machine at my shop and they came factory with 28 horsepower.
when i bored them 40 over i put them back on the dyno and they were at 32 horsepower.
i put Aktive carbon race reeds in both and put a 1 up chain and sprocket kit on them and a reed spacer from trengaracing and tested them again; they jumped up to 35 horsepower.
I put the boost bottle on and got 37 horsepower total.
(and that's all without a 240 big bore kit.)
I then took the airbox cover off them and removed the baffles from the exhaust, i drilled a 1/2 inch hole inside the muffler where the baffles came out, to allow it to breathe.
readjusted the fuel/air mixture on the carb so it would run properly.
retested them on the dyno and they are putting out 38 horsepower like this.
these mods didn't take much time to do at all, about 30 minutes to remove the cylinder and take it to haveit bored out, about 2 days time for them to get around to boring it out.
30 minutes to reassemble it with the new piston and bored cylinder on it.
about 20 minutes to replace the reed spacer and the reeds, about 20 minutes to replace the chain and the sprockets.
boost bottle took about 10 minutes to install.
the baffle was simple to remove 3 screws, and then drilling the hole alltogether about 10 minutes.
removing the airbox cover took about 2 minutes.
readjusting the carb took about 30 minutes of trial and error to get it dialed in right.