case splitting and tranny work (need help)

[yfzrider310]

Ok I have a 2003 yamaha blaster and the engine is out of the frame with the top end out and the piston out. So im wondering if someone could tell me the best way to get to the shift forks and how hard its going be. Im pretty sure that the 2nd to 3rd gear forks are bent so if anyone has advice (besides "try not to lose s***") it would be geatly appreaciated.

[86 Quad R]

the process is farely easy.

first get a manual if your not comfortable with this. it'll help you in more ways than one

secondly get a tube of three bond or equivelant. these engines arent put together with center gaskets.

thirdly you'll need a rubber hammer to help get the cases split. once you have the cases cracked open a plastic wedge/puddy knife will aid in getting the cases totally apart.

what i usually do afteri get the cases split is inspect and lay everything out as you dissassemble. paying close attention to the tranny and case bearing. you SHOULD pay even closer attention to the counter balancer and its bearings.

you will notice any abnormality in any of the parts as it will stand out at you. it is also a good idea to inspect the crank and rod bearings. as cheap as bearings are i usually replace them regardless, since im already there. and be sure to check the max allowance for the thrust on the rods slack.

hope this helps.

[yfzrider310]

yea that was alot of good ideas thanks and any help is great. Its me and my friends first time splitting the cases or any bottom-end engine work. Any more help is appreaciated

[Jason Hall]

What makes you think the shift forks are bent? I know Blasters have problems with the shift star comeing loose from the shift drum. I think I would check that first. You don't need to split the case to get to the shift star, just take off the clutch cover.

[pods_BMOC]

I am the friend helping him, maybe that is the problem i noticed that the shift pin is slipping off the star so maybe thats the problem, i hope and that would make my life a whole lot easier. the one thing with the shifting is that i can shift from 1st to neutral like a breeze, but any higher it locks like a mo-fo, i sure hope its just the star.

[86 Quad R]

Originally posted by pods_BMOC
i sure hope its just the star.

i hurd dat. :cool:

[pods_BMOC]

how do i replace the shifting star? how much is one these days?

[86 Quad R]

at the risk of sounding like a jerk i'll ask..... got a manual? if not, click

HERE (http://manuals.dqt.be/index.php?option=com_remository&Itemid=36&func=fileinfo&id=28)

[yfzrider310]

no big.....yea we got a kylmer manual (like 400 pages) Just hard cause this will be our first time doing it.

[86 Quad R]

yuppers i understand. at any rate. make use of the link i gave. its the shop manual. much better than a klymer. :cool:

[yfzrider310]

really? Ill check it out right now.

[pods_BMOC]

What is that link?

[yfzrider310]

its an owners manuel thing....its pretty nice!

[pods_BMOC]

Whats the link?