New project 99 blaster

Discussion in 'Full Rebuilds' started by Taco, May 20, 2020.

  1. Taco

    Taco Member

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    I apologize in advance for grammar errors, misspelled words or just stupid sentences.


    Well here go. Purchased a 99 blaster lastnight. Was advertised as 99 blaster engine starts but unable to get into gear due to the clutch going limp. (There words not mine). I figured the bb welded to the adjusting rod or something along those lines. So I go look it over and sure enough it fires on the 1st kick. The clutch actuator rod wasnt being held by the spring and able to move up and down. The clutch cable had tons of slack. I felt pretty good about my purchase. Especially since it came with another set of plastics, new uninstalled titan clutch, another carb and a new carb rebuild kit. I get it home kinda late and decide to wait till morning to tear into it.

    Morning comes and it get her all set up to open up. Start pulling the cover and start noticing the bolts arent the oem ones, some are missing, and its been dripping oil all night. In my mind worse case was retap get new bolts and a new gasket and problem solved. I take it off and there is no gasket and missing a dowel pin. Still not a big deal. Moved on to inspecting the clutch. It wasnt engaged and the adjusting nut was in the flywheel stupidly. I say stupidly because on my 98 that i just replaced the clutch on the nut sat on top of the pressure plate and this one was flush. I pull the bolts holding the springs and remove the pressure plate and the nut had a attached washer that was sitting inside the pressure plate. How it even ran before is beyond me, because when i started removing the clutch there was no "spring ring" in the stack. Anyway, now with everything finally out of my way i start tugging on the adjusting rod and sure enough it dont wanna come out. I end up taking the cage off and grabbing it with vise grips and hammed it for a while and got it to move some but not enough to get out.

    At this point I figured might as well pull the engine and start splitting the case. Engine comes out fine found out the fuel valve doesnt shut off in the off position. Nothing a pair of visegrips can't fix. Moving on engine is out on my make shift table get down to the flywheel and i think, "sh*t i dont have a puller". Well im currently in the process reaching out to alot of my friends to see if i can locate one. While waiting i start pulling the head and here is were my heart sank. Head came off fine, no play in the piston. Cylinder slides off and i see score marks in the cylinder and piston. So much that 1 of the piston rings is pinned flush to 1 side of the piston. Now i feel even after i get the clutch rods replaced i got to mill the head and get a new piston. While looking over the engine i notice it has a wiseco rod. Now without a micrometer or snap gauge i dont know if the cylinder had already been milled. Piston on top says 65.94. Currently at a stand still. Ill repost with more info as days go by and try to get some pictures up. I tried putting them on a imagine hosting site but when i put the html link in the brackets here it thinks im a robot ad and doesnt allow me to post.
     
    Last edited: May 20, 2020
  2. Taco

    Taco Member

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    After searching and reading i thought id ask you guys what reasonably priced top end rebuild kit do you guys recommend?
     
  3. Slydog

    Slydog Member Technician

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    Need to get cylinder measured to see how much is needed to clean it up .then get a quality forged piston kit like a weisco or so .
    Or a quality cast piston like pro-x piston kit.
    I personally run forged in mine.but either will work. Oem gaskets are hard to beat for head and base. And most kits dont come with the wristpin bearing
     
  4. Slydog

    Slydog Member Technician

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    Did you get it for a good price. Do you have pictures of the cylinder
     
  5. Taco

    Taco Member

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    Loaded it up for a grand. Though with the extras it was worth it, with the engine firing up.
     
    Last edited: May 20, 2020
  6. Taco

    Taco Member

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    Top piston ring is stuck flush to the piston.
     

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  7. 300iFordguy

    300iFordguy New Member

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    Wow that piston looks brutal
     
  8. Slydog

    Slydog Member Technician

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    Seen better days for sure.
     
  9. Taco

    Taco Member

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    So i figured out why the engine looks the way it does. The exhaust on it is a fmf front pipe, that i dont think goes to it, and a dg rear. It also has, what looks like, a aftermarket reeds and cage. Also no air filter cover. All that is fine and good but the purchased came with a extra carb. I start wondering what main jet it had in the carb on it. Popped it open and laughed at the 230 in her. Opened the extra carb sent and it has a 300. How much riding do you think it did to end up looking like that? Previous owner claimed he only rode with a couple hours before he lost the clutch tension.
     
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  10. Slydog

    Slydog Member Technician

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    The 230 That will do it. Are both carbs real mikuni carbs. Or just the one with the 300 jet?
     
  11. Taco

    Taco Member

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    Yeah both are stock mikuni carbs or at least they look identical to mine which i know is from the factory.
     
  12. Taco

    Taco Member

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    Well stuff started coming in for the project. Should get a new shift drum tomorrow and i can get the case back together and the head on. The clutch rods were welded to the ball bearing.

    Desided to ride my running 98 tonight and the throttle cable started sticking. Recently did a tors delete cap and cable but i had the cable resting on the exhaust slightly. So lesson learned.
     

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  13. Slydog

    Slydog Member Technician

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    That sucks
     
  14. Taco

    Taco Member

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    Well, more stuff started rolling in today. New shift drum installed and got the case back together and head on. Just waiting for a seal kit before i can button her up the rest of the way. 20200528_144825_compress37.jpg 20200528_144842_compress7.jpg 20200528_144830_compress46.jpg 20200528_153737_compress63.jpg 20200528_153726_compress44.jpg
     
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  15. Slydog

    Slydog Member Technician

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    Looking good man. Did you have a broken case half? Looks like two different halves
    Its a nice feeling when you get close to finishing. You fell like you accomplished something.keep it up
     
  16. Taco

    Taco Member

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    Yeah it was cracked. I have a friend who ciuld fix it but for the same price i got that half. 20200520_093033_compress69.jpg 20200520_093415_compress0.jpg
     
  17. Slydog

    Slydog Member Technician

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    Looks almost ready to drop it in the frame. After you button up clutch side.
     
  18. Taco

    Taco Member

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    Yeah i ordered a clutch boss spring like 6 days ago from bikebandit and i still haven't heard anything about it. Ive emailed them but no reply.
     
  19. Slydog

    Slydog Member Technician

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    It's hard to get a timely reply. Shipping seems to be alittle unpredictable right now too. Im waiting on nerfbars. Still. Allot of stuff seems to be on back order.
     
  20. Taco

    Taco Member

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    Yeah been looking for someone parting out a engine just so i can get that spring. Thats gonna be the only thing holding me up for break in.
     

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