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Thank Thanks for all the replies and help. Just after I posted that I ended up splitting the case. It looks like the transmission was binding. I had joined the case halves without using a crank puller. It was not easy and I think it led to binding. The dumb thing is that I have a crank...

I just finished putting my case back together after opening it up to pull part of a wrist bearing out after it fell in while replacing my piston. I noticed that I somehow bent the shift cam stopper while pulling the case apart. I removed the stopper and straightened it without trouble then put...

Has there been an oil pump delete? If so, is the entire mechanism removed?

I recently finished a complete overhaul on a 2002 Blaster (thanks to you guys that answered a bunch of questions). It runs great but I notice some backfiring when I let off the throttle. I believe it has the original reeds but I didn't notice a ton of damage to them when I did the rebuild. I...

I had a similar issue on a recent blaster purchase. Air leaks everywhere. Probably the biggest was where previous owner had reed gasket on the wrong side of the reeds. Also had bad seals and no cap on deleted oil line to carb. I good clue is if revs high inappropriately. Leakdown test up front.

Blaster, that's a great description of idle/pilot adjust. Here's a related question: my TORS was previously deleted but whoever did it basically just cut the electrical connections to the TORS, meaning they left that TORS block in place on top of the carb. There is no idle adjust screw in the...

Good call, the case is open and I have replaced the seals and cleaned out what was likely a rod from a blown wrist bearing on the piston. After the case opened, I found the main shift shaft and it’s shift fork (#2) laying loose on my bench. It must have fallen out. This has turned into quite...

I do think that there is likely debris in the case so I am in the midst of splitting the case. I have seen some resources that say the case can be split from the stator side without opening the clutch cover side at all. I have been able to separate the halves a bit using a case splitter tool...

Thanks, I'm going to split the case and take a look. I did have some parts of the wrist bearing get loose while removing the old piston so it's possible one might be in the case.

I’m replacing the piston and cylinder on my ‘02. At some point in time while I had the cylinder off, the piston arm became locked. I can pivot the arm but can’t move it up or down, including with the Kickstarter. This is without the cylinder on, so it has nothing to do with bore size, rings...

I ended up doing a traditional oil pump delete, and the piston and cylinder were cruddy enough that I decided to replace them both. As I tore it all apart I found misplaced gaskets and missing gaskets galore. It’s become a rebuild. One hurdle I have hit is that the crank seems to be locked—I...

My son just bought a 2002 blaster as a project. He was told that the pistons and rings were recently replaced. The headlight, kill switch, rear brake, and kick starter didn’t work. We fixed the kick starter and I should be good with the others parts. One thing that bothers me is that it...