2000 Blaster Frame Up Build

Tmorr325

Member
Feb 10, 2016
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Pennsylvania
I just picked up a 2000 Blaster. My wife and I are going to be doing a full frame up rebuild. As it sits it is in sad shape. I started tearing it down today, just to find one problem after another. Good news is, it only cost me $250 and came with a new FMF Fatty Pipe. I'll post pictures as soon as I upload them. Our plans for it are a blue frame with white Maier racing fenders, +4 swing arm, +3 +1 a-arms, and a +4 rear axle. We also plan on replacing every cable and bushing as well as simplifying the wiring.
 
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Pics as promised
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Ok, so I didn't have a lot of time when I posted last evening. So I wanted to let you guys know what I've found so far. Multiple missing bolts, hacked up wiring harness, cracked clutch cover, stripped carb body threads, broken tie rod that was welded, it's missing an oil seal and a clip on the kick start shaft, and the clutch won't engage so I think the ball maybe welded to the rod. On the plus side, the engine turns over clean by hand.
 
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Got some time this morning to work on the wiring while I wait on parts to arrive. I stripped everything off of the frame and have the engine ready to come out today or tomorrow. I never knew there were so many useless wires. I think I have it down to just 6 or 7 wires now. Only things connected are the Stator to CDI, CDI to Coil, Kill Switch and Grounds.
 
There are threads on here on simplifying the wiring harness that will make your job real easy.

I with all the things that you have posted that you found, that motor could be in sad shape. I would inspect it real good and make sure by the time you are done with it, it is air tight. I'd bet money that thing has a bad air leak in it somewhere and its a miracle that you can still crank it by hand.

Sounds like a fun project though. Mine was in similar shape when I got mine. Luckily they are really simple to work on.
 
I just pulled the reed box and the PO only had 3 bolts holding it on and 2 "gaskets". One looked original, the other was made from a cereal box. Also, at some point new reeds were put in. However, the clear plastic protective wrap wasn't removed prior to installation and I found little pieces of "seran wrap" in the intake port. Does anyone know if I purchase the Blaster bolt kits, do they include every bolt? I can't find the exact bolt on the parts fiche and I am missing so many bolts it may be worth it to get the kit.
 
Just ordered my nuts and bolts. Also put an order in from Ron Ayers for OEM gaskets and seals. It may not matter, but certain things I like to have OEM. I'm going to test the stator in the morning and replace with OEM as well if necessary.
 
Awsome project, sounds like a killer end game in it. Most the stuff wronge doesnt matter since your swapping it all out anyway. In the future, Ken Occonor Racing also stocks oem stuff for that bad boy.
 
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Just pulled the clutch assembly apart. More bad news. The basket is badly grooved and whoever replaced the clutch before lost the ball. Good news is the ball is not welded to either rod and everything moves as it should. I'll be replacing the bent actuator arm and looking for a basket in better shape. I think this one may be beyond filing.
 
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View attachment 26502 View attachment 26503 Just pulled the clutch assembly apart. More bad news. The basket is badly grooved and whoever replaced the clutch before lost the ball. Good news is the ball is not welded to either rod and everything moves as it should. I'll be replacing the bent actuator arm and looking for a basket in better shape. I think this one may be beyond filing.
I have a brand new PE/Magnum aluminum clutch basket for sale, never installed. Won't ever groove, and gives better lubrication to plates. 100 bucks shipped. It's a deal, look them up.
 
I have a brand new PE/Magnum aluminum clutch basket for sale, never installed. Won't ever groove, and gives better lubrication to plates. 100 bucks shipped. It's a deal, look them up.

A buddy of mine actually just hooked me up with an almost new OEM basket for free. Thanks for the offer.