Rebuild help

Powerbandaddict · Sep 16, 2014

Okay I'm new to two strokes and this is my first blaster. I have a 2003 blaster stock 200cc to my knowledge. The motor locked down on me, I pulled the head found chunks of metal on top of the piston (it was seized). So I pulled the jug found my piston broken at the skirt. I would like to know what is the best way for me to go on a tight budget, but want decent parts. Thinking about going with a wiseco piston .30 over any info would be greatly appreciated thanks

Blaaster · Sep 16, 2014

No matter what piston you choose, it will work well.

Unfortunately you are going to have to split the crankcase to remove bits of the old piston!

You would be advised to replace bearings and seal while you are in the split mode!

We will just hope that it has not cracked the cases.

You really should leak tested before you pulled it apart as a case crack would have shown up.

Powerbandaddict · Sep 16, 2014

What are the chances of having a cracked case do you think. Thanks for the info

Blaaster said:
No matter what piston you choose, it will work well.

Unfortunately you are going to have to split the crankcase to remove bits of the old piston!

You would be advised to replace bearings and seal while you are in the split mode!

We will just hope that it has not cracked the cases.

You really should leak tested before you pulled it apart as a case crack would have shown up.

speedyslyder · Sep 16, 2014

have cylinder checked out measured bored/honed ect
you will half to split cases....good luck
someone before you might have just threw a piston in there and it broke cuz of improper clearances

Blaaster · Sep 16, 2014

Chances of a cracked case is fairly high if the engine locked up?

There is very little room in the case for the crankshaft to revolve, let alone having piston skirts in the way!

Powerbandaddict · Sep 16, 2014

speedyslyder said:
have cylinder checked out measured bored/honed ect
you will half to split cases....good luck
someone before you might have just threw a piston in there and it broke cuz of improper clearances

How much do you think it going to cost to have my machine work done? Thanks for your help.

Powerbandaddict · Sep 16, 2014

Blaaster said:
Chances of a cracked case is fairly high if the engine locked up?

There is very little room in the case for the crankshaft to revolve, let alone having piston skirts in the way!

It didn't really lock up I don't think, kinda just seized up. Idk if their is a differance

speedyslyder · Sep 16, 2014

Powerbandaddict said:
How much do you think it going to cost to have my machine work done? Thanks for your help.

depends on where you take it
cheapest place i know of is ken oconnor racing i think it is only $55 for bore/honed ports chaffered
the shop that is closest to me wants 100 dollars

Powerbandaddict · Sep 16, 2014

speedyslyder said:
depends on where you take it
cheapest place i know of is ken oconnor racing i think it is only $55 for bore/honed ports chaffered
the shop that is closest to me wants 100 dollars

Wheew that's not bad I was thinking like around 300 to 400 to get all the machine work done. That's great news thanks man

tbrooks · Sep 17, 2014

A shop should tell you, but you just need to go up one size in piston if you get it bored. There is no benefit in going any larger. Unless the cylinder is just damaged badly enough to need more. If you decide to go to a shop to get the cases split and replace bearings then you will easily be looking at $400 with parts and labor, and a bore and piston. Inspect the cases very well for cracks. Welcome and you will find all the help you need here

Powerbandaddict · Sep 17, 2014

Thanks tbrooks I've learned a little within the past 24 hours haha I'm gonna try and rebuild it my self seem pretty easy but I'm gonna have my machine work done

jbuckster07 · Sep 17, 2014

As long as you dont rush a rebuild its a fairly easy process. I have had a skirt break on me and the cases will 100% need split, but not has hard as you think. a few tools make this job 100000x easier...

flywheel puller
clutch basket tool
yamabond
Ken O'Connor Racing YouTube Channel
Ken's Website

Couple tips from having to tear my motor apart 9 times before i got it right lmao!

- Buy the hex head case bolts, cover bolts from Ken, makes the entire process MUCH easier when putting back together

- Zipblock bags. Take off something right into a bag with a label. I had around 20 different bags by tthe time I was done.

- DONT LOSE CLUTCH BALL. Be very carefull when taking off the clutch plate

- Build a cheap stand out of wood, think I made the inside hole 8"x5"

- Take as many pics as you can! helps with the rebuild process.

- If you have any questions ASK, there are a lot of VERY knowledgeable people on here that could out one of these motors together with their eyes closed and chop sticks lol.

- And finally, build and or buy a leak down tester. they are very important tool to have in any 2 strokers tool box. A leak in this motor will destroy a fresh engine.

jbuckster07 · Sep 17, 2014

some other things!

c-clip pliers
Impact screw driver

DeJay1206 · Sep 17, 2014

Good luck on the rebuild... they suck... but at the same time it's great to learn and get your hands dirty. If you lived out my way you could have the top end done for $25 from a machine shop that a few of the dealers around here send their stuff to. He does great work, an old school machinist! I can give you his information if you want to see if he will accept the top end shipped and ship it back.

Powerbandaddict · Sep 17, 2014

Thanks guys I've it the motor pulled off my bike but I'm gonna have to go buy almost all of the tools but that's okay because I plan on building it again the next time it goes. I called my local machine shop around 55 dollars to bore it out

Powerbandaddict · Sep 17, 2014

If i do a .30 over bore do I need to jet my carb and will I need reeds?

speedyslyder · Sep 17, 2014

leak test, plug chop...you got a long way to go sooo read up on here and peoples mistakes that they have done,and dont make the same mistakes as they did...oem base gasket...no rtv,on cylinder,,ect ect

jetting is whenever you change the fuel air ratio...air filters pipes pre mix ect..30 thousands of an inch aint chit

dirtysquared · Sep 17, 2014

Powerbandaddict said:
If i do a .30 over bore do I need to jet my carb and will I need reeds?

Just for the Bore, you should need to rejet. The only time Jetting come into play is air flow in and out of the engine, Temps, Elevation.

You should still go into the carb and see what Jets you have in there, where the clip is on the needle, set floats, and clean it out while your in there.

You only will need reeds if yours are damaged, or you want to changed them or Upgrade them.

Have the shop measure that cylinder, and have them bore it to the next acceptable oversize piston. You want them to match the cyliner to the piston so its within specs.

And Jbuckster07's advise about the ziplock bags is what I do too. I get 2 packs of the 2 gallon ones at the dollar store, and write on them with a sharpie. It keeps things organized and alot easier to find when your putting it back together. Its a good $3.00 spent!!

Herpderplol · Sep 17, 2014

the above post was meant to say "you shouldnt need to rejet"

reeds will be needed if they are cracked and/or you accidentally break one

jus_me · Sep 17, 2014

For the $$ you are going to save on rebuilding yourself. Send the head out to get done. Around 65$ i think to Kor. Best bang fir the buck. You should have it back before bore is done. Better yet send cylinder and head there and still be well under what you expected to pay and know its done right. While u r waiting watch his vids on doing a clutch mod and look up how to perform a 2 stroke leakdown test.

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