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I recently rebuilt my blaster and I am noticing it doesn't want to shift, if I shift without the clutch it shifts fine but for example if I pull in the clutch and start gearing down it will only go down 1 gear if I don't ease of the clutch a little it won't go down anymore at all even though I...

Just a rubber mallet work twice before did it the same exact way, it's all together crankshaft moves fine ordered my piston today should be here next week.

Well I tapped it in little by little like I did on my yz and kx, the inner part is less than a 16th of an inch from each side of the case. It doesn't lock down when I tighting the bolts but it gets tension on it. It's not as easy to turn I don't wanna throw the rod.

Okay I will check it when it's here. I am having trouble getting the split case back together. Everything was where it was supposed to be but when I get all the bolts in and snug if I tighten them the crank locks down and won't turn, my kx 250 and my yz 125 was just tap together easy, this one...

How critical is chamfering the port, I did the best I could with a air grinding tool then took fine grit sand paper to it. My finger dorsnt catch and it doesn't feel sharp, I honed it after that.

Okay thanks for the help. It's kinda rough just didn't know wanted to be sure, he helped me bore it and he said cast shouldn't be smooth. I have to get new honing stones for my honing tool then ill be done, looking at the manual we brought the cylinder bore to 66.504mm (2.6183 Inches) the piston...

Had it bored today with what I got out of the manual, how smooth should the finish be. My yz was sent off to be plated, and it was slick as a babies a**. This one not so much. Mÿ dad who used to rebuild engines says its fine.

I would think its cast, the one I put in my kx 250 looked cast.

It's a namura piston not sure what that one is.

I have done posted on here, an diagnosed it, either got to hot and the ring caught the port or there was not any oil, the bearings and everything were gone. I have already ripped it apart rebuilt the bottom end, removed the oil pump with a block plate all I have left is to bore it, I need the...

Okay, so the other day my blaster seized, not sure what happened. I am rebuilding it, I work at a machine shop an we have everything we need to bore the cylinder our selves. I need someone to tell me the clearances, if I am right the piston is undersized, we are trying to clean it up and I need...

Okay, I got the seal off, so now I just need to know a good ways to plug the hole where it was injected into the carb.

My blaster locked up for no reason 3 days after I got it that why I removed it I dot like oil pumps I would rather premix that's why I removed it. I got the pin out but now the seal is stuck on there how can I get it off. I still need to plug the carb somehow

I am trying to remove it but I can't get the bushing out of the case so I can put my block plate on, what's the best way to get it out? Also what's the best way to plug the carb where the oil was injected?

Okay, They look good thats probably what I will do, plus its cheaper than buying the OEM flaps. Ill post back if I come up with anything else I need help finding. I am gonna make a post in the Full Rebuild section tomorrow after I can get some pictures, I would love opinions.

Thanks, I decided to do a full restoration on the whole blaster. I have split the case, and waiting on some money to come in to order the kits for the bottom end.

Okay, I am gonna take the cover I got now that I think about it, and just fab a plastic piece to fit in the slot where the hose go in. about the fender this piece is missing. http://thumbs4.ebaystatic.com/d/l225/m/mk6rQ3jFiRIx19SFBXHA0yA.jpg if you look at the left side of the picture...

Not sure, I looked at a OEM picture and it showed something listed as a flap, bolted to the fender right behind your heels, there is an opening in my fender on the right side like something is missing. I have the blaster in pieces as of now, got a list with about 20 items on it, only things I...

I am currently doing a complete restore on my 03 Blaster, I am in need of some parts, I am missing the cover that holds the oil light, but I removed the oil light, so I am looking for a replacement for that, and I am looking the cover that goes ever where I put my block plate, but without the...

Yea thanks, I am gonna get a wiesco bottom end kit and a wiesco top end kit and send my cylinder to powersealusa for a over bore, gonna cost me around 320-350 but at least I will know that it's good then, I hate buying people's hand me downs. How would I go about taking loose the nut that's...