New blasters today, blown motor- help please!

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Precisionmike

New Member
Apr 20, 2013
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Hello All,
My 15 yr old son and I decided to get quads. We picked up a pair of 2005 blasters last night. Today, I gave him a lesson, but apparently, not enough training. We were riding along the side of the road for about 1 mile on our way to the desert (we live in AZ). On the way there, I was keeping the rpms low, in 2-3rd gear. He left it in 1st....yep, blew the motor. I pulled the top end apart, and the piston is shot, cylinder has a slight scratch, and the shims on the crank/connecting rod are scuffed. We pulled the motor out of the bike. Here is what Iam looking for advice on:
-How hard is it to crack the lower case? Can I do it without getting into the gear side?
-Is it likely the crank/bottom end are damaged? (guess I will find out)
-Can you recommend some good places to buy parts?
-I see ads on ebay where you can send the jug in for boring/honing, and they supply new top end parts. Any of these a good way to go?

Thanks in advance. This is not a great way to start out, but we will work through it. Good father/son experience to rebuild a motor. More lessons to follow! Mike.
 
Best place for engine I would say is KOr, kenoconnerracing.com

Another great place is rockymountainatvmc.com but they don't have the engine parts like KOR
 
Ken OConner racing would be the I would get the cylinder work done. I wouldn't trust ebay for that. Ken does great work and you can be sure it's done right. He can do all your work for you if your not sure on it yourself.
 
Here is the guy I use : Yamaha YFS200 Blaster Crank Piston Bearings Gaskets New | eBay

100 % feedback, pretty hard to beat that.8-|
I've known Mike for 10+ years as he's local to me. Accurate enough that if there was .0001" difference in pistons the cyl and pistons came back marked "A" & "B" on the Banshee .

He may have other auctions with boreing included, check his store, or call him. His rate for bore is 50-60$, forget exactly. Good turn around too.

Or look here: http://www.blasterforum.com/engine-13/official-builders-shops-51887/
 
Last edited by a moderator:
WOW! Thanks for the quick response and advice. So today we are going to bring the jug to a couple of shops to look at the scratch. I would estimate it is about .5mm. From what I have researched, it looks like pistons are available in .5mm increments, so we are hoping the jug can be bored and go will a larger piston. We also need to crack the lower end and get the crank out. The connecting rod has some scuffs, and the washers on either side of the crank look a bit bent. So is it possible to crack the crank without getting into the gear side? Thanks again!
 
Precisionmike said:
So is it possible to crack the crank without getting into the gear side? Thanks again!
Click to expand...

If you are going to work on the crank too DO NOT try to cut corners.... you will end up paying 3 times as much! Those crank seals will need to be replaced or you will get an air leak that will fry your new motor, & you'll have to start all over again. :eek:
 
^^^ Yep, To get to the crank it requires total engine disassembly, you can make a puller out of fairly thick flat bar if your are handy with a drill press I:I. Its just 3 holes with the one in the middle being larger, I forget the dimensions of the one i made but it took no more than 10-15 mins.
 
If you want the work done by someone Ken O'Connor is the man for the job ! If you want to find parts and the necessary tools to do it yourself check out Rockymountainatvmc.com, they have the best prices and free 3 day shipping on orders over $99. If this will be a DIY you will need a case splitter, a crank puller/installer and a flywheel puller. I found the the case splitter and crank puller/installer tools for $60 a piece made by Tusk. They worked great and were the cheapest by far. The flywheel puller will run you about $15. A flywheel holder and clutch boss holder are reccommended but not neccessarily need if you have an impact gun. You will want to do some reading on leak testing, jetting and plug chops before running the new motor to ensure a long happy life, and of course to prevent the need to spend anymore money on the motor in the near future. Good luck with everything and welcome to the forum !
 
if you need a crank dont get a wiseco the metal comes from china and is not as good as the metal from a hotrods standard crank for 10 dollars less. But go with a Namura cast piston and or a Wiseco piston those are 100% made in america.you just cant beat em keep in ming cylinder sizes go in incriments of .010-.020 through .090 and pistons go in increments of 66.25-66.50-66.75 and so on so dont waste bores on a cylinder ok something to think about
 
This site kicks a$$, tons of support! So I found a guy who can do a full rebuild- crank, connecting rod, piston, all gaskets and seals, and reinstall in the bike for $450, another $50 if we need a bore. Sounds like a good deal to me.
 
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