The Banzai Build....

Discussion in 'Full Rebuilds' started by BanzaiBlaster, Jul 16, 2017.

  1. BanzaiBlaster

    BanzaiBlaster Member

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    Hi All! My name is Jeff, born a bred Michigander. My last quad was #214 2001 Raptor that I spent years building(Full Yoshi, pro design intake, lonestar axle, one of the first to do Yfz450 front shocks, Hyper carbon rims, nerfs etc,etc) I sold it due to divorce and now 10 years later my boss gave me this Blaster basically because for him to have someone go through it and fix everything wrong would've cost him more than it's value. It's a 2005 White with red frame.
    This was a blessing because I've REALLY missed building and riding.

    ITS TIME TO GET BACK OUT AND PLAY!!

    THE BIKE WAS COMPLETELY STOCK BESIDES OIL INJECTION DISABLED, 2 HOLES IN AIRBOX LID AND BOYSEN REEDS. NO REJET WAS DONE, STILL 230 MAIN IN WHEN INSPECTED.

    After inspection-
    1. Counter shaft seal was popped right out
    2. Bike completely covered in oil and dirt from being ridden with blown seal
    3. Chain and sprockets toast
    4. Front tires bald, rims bent and rusting
    5. Front brakes shot, lever pull almost to grip. 20170423_183301.jpg
    20170423_183138.jpg
     
    Last edited: Jul 16, 2017
  2. Markblaster

    Markblaster Custom blaster

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    Photos of the bike. :)
     
  3. BanzaiBlaster

    BanzaiBlaster Member

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    After pulling front sprocket and seal and seeing black grit caked in bearing I knew I'd have to split the cases. Here's some pics after stripping and 5 hours of cleaning. 20170601_181107.jpg 20170601_181115.jpg
    She's not too bad under all the grime... but this baby needs some work for this guy to ride...
     
  4. BanzaiBlaster

    BanzaiBlaster Member

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    20170618_155743.jpg 20170618_155805.jpg 20170618_155824.jpg
    20170719_171937.jpg

    I got the bike in late April and started stalking this forum, researching parts etc. I watched Ken's videos and decided thats the guy i want to massage my top end. BIG THANK YOU TO KEN OCONNER RACING! I had Ken do his head rechamber/mod, trail port and bore/ hone, chamfer to 66.5mm.
     
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  5. Markblaster

    Markblaster Custom blaster

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    Good start. :)
     
  6. BanzaiBlaster

    BanzaiBlaster Member

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    I started this back in April and I have a bunch of pics and a story to tell but I have to do some pic resizing and I'm uploading these from my phone so be patient all, there's a lot more to come. I've just started working on the chassis this last week . Im hoping to have the bike ready to ride by mid to late August. Ive got a pile of goodies and more on the way.

    About 90% of the products used were bought on Ebay. I spent countless hours researching and price comparing using oddball search terms etc. To find the beat deals. Any OEM items I needed were ordered from Partszilla direct.

    20170708_155625.jpg
     
    Last edited: Jul 17, 2017
  7. BanzaiBlaster

    BanzaiBlaster Member

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    It was me, a can of Berryman's Chem-dip, many assorted brushes, Simple Green Max, hot water and MANY MANY hours of cleaning. In the weeks the top end was off to Ken. I started the bottom end. Following his videos verbatim.

    I used a 30mm axle socket and put it in the oven @450 for over an hour to set on the crank bearing inner races. IT WORKED PERFECTLY! The cases went together exactly as Ken demonstrates.
    20170620_182528.jpg 20170620_193251.jpg 20170620_203723.jpg 20170620_203746.jpg 20170620_211852.jpg

    I did have to slightly bend the crankshaft seal retainer to put pressure on the seal.


    The clutch hub and basket mod should definately help keep things bathed in fresh oil and cool....Thanks Ken Oconner!!


    20170717_135604.jpg
     
    Last edited: Jul 17, 2017
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  8. BanzaiBlaster

    BanzaiBlaster Member

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    OOPS! You kids be careful with those power tools...
     
  9. BanzaiBlaster

    BanzaiBlaster Member

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    Some info on the motor- someone had attempted to remove the flywheel by prying on cases and chipped the L.H. case around where the rubber plug goes near clutch arm. They also removed the eight magnet retaining screws around the flywheel and tried to kick motor over...not knowing any better assumed it was seized up.

    Because of the blown counter shaft seal the transmission had ingested a bunch of grime/sand(Michigan trails) which led to clutch failure. The only other parts that suffered subsequent damage were the shift forks and of course the bearings. All were replaced as well as the crank bearings. I did do the shift star mod but only took about 1mm off and rounded over. I knew I'd be running nerf bars and wearing boots so I didn't want it too shift TOO easily.
    I also did the clutch hub and basket modifications that Ken demonstrates in his video.

    ENGINE WAS ASSEMBLED USING -
    - Koyo crankshaft bearings(Wiseco)
    - Hot Rods transmission bearing kit(some Koyo , some Taiwanese)
    -Moose seals (Locktite outer lip, grease inner)
    - K&S gasket set
    - Genuine Yamaha cylinder base gasket
    - Wiseco piston, pin, clips
    - Vito's upper rod bearing
    - Stainless hex bolt kit
    - Tusk clutch and spring set
    - Vito's Bullseye reed cage w/ 2 stage reeds
    - Vito's adjustable timing plate SET AT 0 DEGREES ADVANCE. ( I got the plate for $30 NIP couldn't resist)
    - Moose carb rebuild kit
    - Moose TORS elimination kit
    - Vito's jet kit (280-340 main jets)
    - I installed a 320 MAIN with stock 32.5 Pilot. Float height to 21mm. I will plug chop down from there.
    - Moose foldable shifter
    - NGK B8ES @ .030
    - 14 Tooth front( counter shaft) sprocket
     
    Last edited: Jul 23, 2017
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  10. BanzaiBlaster

    BanzaiBlaster Member

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    Heres the basic finished assembly. 20170704_203150.jpg
    Here's the epoxy repair I did to the case. 20170705_153358.jpg
    I don't believe the hype but $70 for a billet cage with 2 stage reeds... hell yes 20170705_155945.jpg !
     
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  11. BanzaiBlaster

    BanzaiBlaster Member

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  12. BanzaiBlaster

    BanzaiBlaster Member

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    Ready to go back in!
    Note- HOLES in oil line plug were filled with black RTV . I still need to source a cap for oil feed nipple on carb.
    20170716_083713.jpg
     
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  13. BanzaiBlaster

    BanzaiBlaster Member

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  14. BanzaiBlaster

    BanzaiBlaster Member

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    20170716_100020.jpg 20170629_145905.jpg
    Baby's got some new shoes....

    Alba beadlocks- 10x5 3+2 4/156, 9x8 3+5 4/115
    MASSFX tires 21/7/10, 20/10/9
    YFZ450R Rear hub
     
    Last edited: Jul 16, 2017
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  15. BanzaiBlaster

    BanzaiBlaster Member

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    Yesterday I finished the front brakes, mounted
    the front bumper and wheels. 20170716_123107.jpg 20170716_122951.jpg
     
  16. Awk08

    Awk08 Administrator Staff Member Technician

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    Good stuff Jeff !
     
  17. BanzaiBlaster

    BanzaiBlaster Member

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    20170715_183009.jpg I also clearanced the skid plate for the chain guide. The finish and build quality of the +3" Swingarm Shop swinger is excellent! It comes with bearings and seals already installed. You will need your original outer caps and sleeves.
    Thank you sir! More to come...
     
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  18. BanzaiBlaster

    BanzaiBlaster Member

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    Side view... the TMD dual roller is a bit bulky but....
    20170715_183314.jpg
     
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  19. BanzaiBlaster

    BanzaiBlaster Member

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    That's pretty much up to date.
    Today I'm gonna fill that big empty hole in the frame....
    More info and pics to come....
     
  20. Markblaster

    Markblaster Custom blaster

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    Nice work. :) Keep it up and the photos coming. :)
     

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