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Did it leave any protruding you can get a hold of with a pair of small vice grips or is it flush/recessed? If there is a bit sticking out you can get a hold of, you can carefully heat the area around the broken bolt with a propane torch (not oxy/acetylene!) and it should move. If flush or...

How is your clutch cable adjustment?

Absolutely, otherwise you will need to keep it touched up by re-sanding periodically.

Ah gotcha. Most axles for most all machines I can recall from back in those days had a sort of zinc coated look to them like the hardware

Here is where you can download the service manuals https://blasterforum.com/threads/yamaha-blaster-parts-service-and-owner-manuals-free-download.17325/

The kill switch and key switch kills ignition by grounding it. There is a downloadable service manual on this site which will have the electrical schematic. Sounds like you have a ground issue

I've seen good results progressive sanding axles followed by clear coat to preserve the finish. The hubs, I might get PCed or get a new set of Banshee spec rear hubs which will bolt up and allow the use of 9" rims which opens up lots of better tire options.

I've only been on this forum a short time since getting an older Blaster for my daughter last fall and going through it. But I've been on 3Wheelerworld for about 15 years. Seems this forum is suffering the same effects of FB that many forums have. Sounds like you have a nice build in the...

This is very puzzling to me and not the first time I've heard of it. About the only thing I can think of if the flywheel key is sheared. I've owned 250Rs for years and have never had this happen with them. Engine running backwards can only be a timing issue.

Yeah that seems achievable but you lost some grunt getting there. Guessing you went up two teeth on the countershaft sprocket?

The best advice I can offer is to avoid Amazon (Chinesium) jets. Always buy genuine Mikuni (or Keihin if you are running a Keihin carb) jets. I've always obtained my jets from Jetsrus. Assuming your carb is the original, here is what Jetsrus offers for the OEM Mikuni carb on your Blaster. These...

Sounds like you have some mechanical binding in your throttle setup as well as an electrical gremlin to hunt down and address.

Sounds to me like that engine has some mods done to it like a stroker crank and/or re-chambered head. The stack of spacers needed to allow the engine to turn over leads me to lean toward the stroked crank. As to piston skirt destruction, there aren't many things that will cause that. Excessive...

That's going to be a bit hot of a plug. I'd run BR9ES

It will always be cheaper to rebuild your engine if you can do the work yourself. An engine that has sat a decade can seize for several reasons, piston/cylinder seized, lower rod bearing seized, crank bearings seized, any or all of those. We it me, I would probably take it down to bare...

I would bore that cylinder assuming it's not at max bore already. Good chance the piston is scored and needs to be replaced. Need to ascertain the reason why and address it.

I trust Kens work. He rebuilt the crank for my daughters Blaster. Price was very reasonable and turn-around was fast. He knows his stuff. A stroker crank will always add a good bump in power. Make sure and freshen up your bottom end of you are going that route. Crank bearings and seals...

No problem. As to jet size increments, as I said above I'm not real familiar with Mikunis jet sizing. Check PJ Motorsports or Jets R Us for jet size increments. You'll need to know what your carb model is to find the correct jets for it. So a bored over cylinder and piston, not an actual big...

While I am not intimately familiar with Mikuni jet sizing as I am with Keihin, I can say with confidence you should start with 4-5 steps richer on the main and about 2-3 steps richer on the pilot. You'll need to source a small assortment of genuine jets to dial it in. Jets R Us and PJ...

Disconnect the cable from the clutch lever on the handlebars Then mount the cable keeper to the cylinder stud and tighten it down Insert cable into the cable keeper Connect cable end to clutch arm on the crankcase Reconnect cable to the clutch lever and adjust leaving the correct amount of...