om

om

om
ENGINE DISASSEMBLY ENG ,
- .

.c

.c

.c
um

um

um
1. Remove:
•Spark plug CD
or

or

or
•Cylinder head®
rf

rf

rf
• Gasket ® (Cylinder head)
te

te

te
•Cylinder @
as

as

as
• Gasket ® (Cylinder)
• Dowel pins ®
Bl

Bl

Bl
NOTE: --------------------------
Loosen the nuts (Cylinder head) 1/2 turn each
time, and remove.

om
om

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

2. Remove:
• Piston pin clip CD
• Piston pin ®
•Piston ®
•Bearing @

om
m

NOTE:--------------------------
o

• Before removing the piston pin clip, cover the

.c
.c

crankcase with a clean rag so you will not

m
um

accidentally drop the clip into the crankcase.

ru
• Before removing the piston pin, deburr the
or

fo
clip groove and pin hole area. If the piston
rf

er
pin groove is deburred and piston pin is still
te

difficult to remove, use Piston Pin Puller.

st
as

a
Bl
Bl

Piston Pin Puller:

P/N YU-01304
P/N 90890-01304
om

om

om

Do not use a hammer to drive the piston pin

.c

.c

.c

out.
m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-6 Page 76

 I l'-1

om

om

om
ENGINE DISASSEMBLY . ENG

.c

.c

.c
-
--------------------------------~CLUTCH

um

um

um
or

or

or
W --------::::;--;;h~ clutch can be
rf

rf

rf
NOTE:
"th the engm . e mounted,
. g thet efol ow ing parts.
b y removm
te

te

te
I .
maintamed 1
• Footrest (Right)
as

as

as
Bl

Bl

Bl
1 Remove:

om
om

.• Kick crank CD (Right)

• Crankcase cover ®

.c
.c

• Gasket

m
um

• Dowel pins

u
or
or

rf
rf

te
te

as
as

Bl
Bl

2 Remove:
· • Bolts CD . ®
• Clutch spnngs
• Pressure plate @
. t"lon plates@
• F nc ®
• Clutch plates )

om
m

• Nut ®( Clutch boss

o

.c
.c

Lock washer (J)

• ®

m
um

• Clutch boss

ru
•Spacer ® . ®
or

• Clutch housmg

fo
rf

er
• Spacer (jJ) . washer @
te

• Conical spnng
st
as

•Ball @
a

• Push rod ®
Bl
Bl

NOTE: . the nut (Clutch boss ) ' straight·

emovmg
•Before r k washer tab. Universal Clutch
en the loc I
• Hold the c u tch boss
en the nut 4; (Clutch boss).
by the,.,
om

om

om

Holder CD to loos
.c

.c

.c

.
Umversa I Clutch
91042Holder:
m

um

P/N YM·
ru

ru

P/N 90890·0408 6
or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4·7 Page 77

 om

om

om
ENGINE DISASSEMBLY _ I ENGI~I _ .., _

.c

.c

.c
um

um

um
3. Remove:
• Push lever CD
or

or

or
rf

rf

rf
te

te

te
as

as

as
Bl

Bl

Bl
PRIMARY DRIVE GEAR AND BALANCER

om
om

GEAR
NOTE: ___________________________

.c
.c

With the engine mounted, the primary drive

m
um

gear and balancer gear can be maintained by

u
or
or

removing the following parts.

• Footrest (Right)

rf
rf

te
te

• Kick crank

as
as

• Crankcase cover (Right)

•Clutch

Bl
Bl

om
om

.c
.c

m
um

ru
or

fo
1. Remove:
rf

• Nut CD (Balancer gear)

er
3
te

• Lock washer ®
st
as

• Balancer gear @
a
Bl
Bl

•Key ®
• Nut ® (Primary drive gear)
• Primary drive gear ®
• Balancer drive gear (j)
•Key@
•Collar®
om

om

om
.c

.c

.c

NOTE: -------------------------
•Before removing the nut (Balancer gear),
m

um

straighten the lock washer tab.

ru

ru

• Loosen both nuts simultaneously (Primary

or
fo

fo

drive gear and balancer gear).

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-8 Page 78

 l'-1

om

om

om
ENGINE DISASSEMBL V ENG

.c

.c

.c
um

um

um
•Hold the rotor (CDI magneto) by the Rotor
Holder CD to loosen the nuts (Primary drive
or

or

or
gear ®and balancer gear® ).
rf

rf

rf
te

te

te
Rotor Holder:
as

as

as
P/N YU-01235
P/N 90890-01235
Bl

Bl

Bl
KICK AXLE

om
om

NOTE: __________________________
With the engine mounted, the kick axle can be

.c
.c

maintained by removing the following parts.

m
um

• Footrest (Right)

u
or
or

• Kick crank
• Crankcase cover (Right)

rf
rf

te
te

•Clutch

as
as

Bl
Bl

1. Unhook the kick spring from its position.

2. Remove:
• Kick axle assembly CD
Rotate the shaft counterclockwise.

om
o m

.c
.c

m
um

ru
or

fo
3. Remove:
rf

• Circlip CD
er
te

• Plain washer ®
st
as

• Kick idle gear ®

a
Bl
Bl

• Plain washer@
•Circlip ®

JT
(J 0
om

om

om

SHIFT SHAFT AND STOPPER LEVER

.c

.c

.c

NOTE: _________________________
m

um

With the engine mounted, the shift shaft and

ru

ru

or

stopper lever can be maintained by removing

fo

fo

the following parts.

rf
er

er

te

• Footrest (Right)
st

st

• Kick crank
as
a

•Crankcase cover (Right)

Bl

Bl

Bl

•Clutch

www.blasterforum.com 4-9 Page 79

 om

om

om
ENGINE DISASSEMBLY . I ENGI~I
. .. . , .

.c

.c

.c
um

um

um
1. Remove:
• Change pedal CD
or

or

or
rf

rf

rf
te

te

te
as

as

as
Bl

Bl

Bl
2. Remove:
• Shift shaft CD

om
om

• Spring

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

3. Remove:
• Stopper lever CD
• Spring

om
om

.c
.c

m
um

ru
or

CDI MAGNETO
fo
rf

er
te

NOTE:--------------------------
st

With the engine mounted, the CDI magneto can

as

be maintained by removing the following parts.

Bl
Bl

• Crankcase cover (Left)

om

om

om

1. Remove:
.c

.c

.c

• Nut CD
m

um

•Washer ®
ru

ru

• Rotor ®
or
fo

fo

•Key@
rf
er

er

• Stator assembly @
te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-10 Page 80

 I

om

om

om
ENGINE DISASSEMBLY ENG ,,_,

.c

.c

.c
um

um

um
NOTE=-------------------------
• Hold the rotor by the Rotor Holder CD to
or

or

or
loosen the nut ® .
rf

rf

rf
• Remove the rotor by the Rotor Puller® .
te

te

te
as

as

as
Rotor Holder:
P/N YU-01235
Bl

Bl

Bl
P/N 90890-01235
Rotor Puller:
P/N YM-01189
P/N 90890-01189

om
om

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

CRANKCASE (RIGHT)
1. Remove:
• Bearing stoppers CD (Main axle and crank-
shaft)

om
om

.c
.c

m
um

ru
or

fo
2. Remove:
rf

• Bolts (Crankcase)
er
te

st
as

NOTE=------------------------
a

Loosen each screw 1/4 turn, and remove them

Bl
Bl

after all are loosened.

om

om

om

3. Remove:
.c

.c

.c

• Crankcase (Right)
m

um

• Dowel pins
ru

ru

or
fo

fo

Removal step:
rf
er

er

• Turn the shift cam to the position shown in

te

the figure so that it does not contact the

st

st

as

crankcase.
a

a
Bl

Bl

Bl

www.blasterforum.com 4-11 Page 81

 IENG 1~1

om

om

om
ENGINE DISASSEMBLY

.c

.c

.c
I•
um

um

um
Attach the Crankcase Separating Tool CD .
or

or

or
Crankcase Separating Tool:
rf

rf

rf
P/N YU-01135
te

te

te
P/N 90890-01135
as

as

as
Bl

Bl

Bl
NOTE=------------------------
Fully tighten the tool holding bolts, but
make sure the tool body is parallel with the
case. If necessary, one screw may be backed
out slightly to level tool body.

om
om

• As pressure is applied, alternately tap on the

front engine mounting boss, transmission

.c
.c

shafts, and shift cam.

m
um

u
or
or

rf
rf

Use soft hammer to tap on the case half. Tap

te
te

only on reinforced portions of case. Do not

as
as

tap on gasket mating surface. Work slowly

Bl
Bl

and carefully. Make sure the case halves

separate evenly. If one end "hangs up", take
pressure off the push screw, realign, and
start over. If the cases do not separate, check
for a remaining case screw or fitting. Do not
force.

om
om

.c
.c

m
um

ru
or

fo
SHIFTER, TRANSMISSION AND BALANCER
rf

er
1. Remove:
te

• Guide bars CD
st
as

• Shift forks ®
a
Bl
Bl

•Shift cam ®

NOTE: -------------------------
Note the position of each part. Pay particular
attention to the location and direction of shift
forks.
om

om

om
.c

.c

.c
m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4·12 Page 82

 I ENGJ~I

om

om

om
ENGINE DISASSEMBLY -._,

.c

.c

.c
---------------------------------------------------------

um

um

um
2. Remove:
• Balancer weight CD
or

or

or
rf

rf

rf
te

te

te
as

as

as
Bl

Bl

Bl
3. Remove:
• Transmission assembly

om
om

Tap lightly on the transmission drive shaft

.c
.c

with a soft hammer.

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

NOTE:
While removing the drive axle from the crank-
case, pay careful attention to the oil seal lip.
A recommended practice is to fit the 0-ring CD
and to apply grease over the fitted area.

om
om

.c
.c

m
um

ru
or

CRANKSHAFT
fo
rf

1. Remove:
er
te

• Crankshaft
st
as

a
Bl
Bl

NOTE: --------------------------
•Attach the Crankcase Separating Tool CD to
remove the crankshaft.

Crankcase Separating Tool:

P/N YU-01135
om

om

om

P/N 90890-01135
.c

.c

.c

• Fully tighten the tool holding bolts, but make

m

um

sure the tool body is parallel with the case.

ru

ru

If necessary, one screw may be backed out

or
fo

fo

slightly to level tool body.

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4·13 Page 83

 om

om

om
INSPECTION AND REPAIR . I ENGI~I _ ._.,.

.c

.c

.c
um

um

um
AUTOLUBEPUMP
1. Remove:
or

or

or
• Circlip CD
rf

rf

rf
•Autolube pump gear®
te

te

te
•Pin ®
as

as

as
•Circlip@
Bl

Bl

Bl
• Autolube pump ®
• Drive shaft ® (Autolube pump)
•Washer (j)

om
om

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

INSPECTION AND REPAIR

CYLINDER HEAD
1. Eliminate:
• Carbon deposits
Use a rounded scraper CD .

om
om

NOTE: --------------------------

.c
.c

Take care to avoid damaging the spark plug

m
um

threads. Do not use a sharp instrument. Avoid

ru
scratching the aluminum.
or

fo
rf

er
2. Measure:
te

• Cylinder head warpage

st
as

Out of specification-+ Resurface.

a
Bl
Bl

Warpage Limit:
0.03 mm (0.0012 in)
om

om

om

Warpage measurement and resurfacement

.c

.c

.c

steps:
m

um

• Attach a straight edge and a thickness gauge

ru

ru

or

on the cylinder head.

fo

fo

rf

• Measure the warpage.

er

er

te

•If the warpage is out of specification, resur-

st

st

as

face the cylinder head.

a

a
Bl

Bl

Bl

www.blasterforum.com 4-14 Page 84

 I I'-I

om

om

om
INSPECTION AND REPAIR ENG

.c

.c

.c
um

um

um
• Place a 400 ~ 600 grit wet sandpaper on the
surface plate, and resurface the head using
or

or

or
a figure-eight sanding pattern.
rf

rf

rf
NOTE: ________________________
te

te

te
as

as

as
Rotate the head several times to avoid remov-
ing too much material from one side.
Bl

Bl

Bl
CYLINDER AND PISTON
1. Eliminate:

om
om

• Carbon deposits

.c
.c

From the piston crown and ring grooves.

m
um

2. Eliminate:

u
• Score marks and lacquer depostis

or
or

From the sides of piston.

rf
rf

Use a 600 ~ 800 grit we sandpaper.

te
te

NOTE:--------------------------

as
as

Sand in a crisscross pattern. Do not sand exces-

Bl
Bl

sively.

3. Inspect:
• Piston wall
Wear/Scratches/Damage~ Replace.

om
om

.c
.c

m
um

307-002

ru
or

fo
4. Eliminate:
rf

• Carbon deposits
er
te

Use a rounded scraper CD .

st
as

a
Bl
Bl

om

om

om

5. Inspect:
.c

.c

.c

•Cylinder wall
m

um

Wear/Scratches~ Rebore or replace.

ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-15 Page 85

 I l'\.1

om

om

om
INSPECTION AND REPAIR ENG

.c

.c

.c
um

um

um
6. Measure:
• Piston-to-cylinder clearance
or

or

or
rf

rf

rf
Piston-to-cylinder clearance measurement
te

te

te
steps:
as

as

as
First step:
Bl

Bl

Bl
• Measure the cylinder bore "C'' with a
Cylinder Bore Gauge.

NOTE:
Measure the cylinder bore "C" in parallel to

om
om

and at right angles to the crankshaft. Then,

.c
.c

find the average of the measurements.

m
um

u
~

or
or

Standard Wear Limit

rf
rf

te
te

Cylinder 66.00 ~ 66.02 mm 66.1 mm

Bore "Cu {2.598 ~ 2.599 in)

as
as

{2.602 in)
0.08 mm

Bl
Bl

Taper "T" - {0.003 in)

Out of 0.05 mm
Round"R"
- {0.002 in)

c= Maximum 0

om
m

T= {Maximum 01 or 02) -
{Minimum Os or 06 )
o

R= {Maximum 01, 03 or Os) -

.c
.c

{Minimum 0 2 , 04 or 06)

m
um

ru
or

•If out of specification, rebore or replace

fo
cylinder, and replace piston and piston rings
rf

er
te

as a set.
st

2nd step:
as

• Measure the piston skirt diameter "P" with

Bl
Bl

a micrometer.

@ 10.0 mm (0.39 in) from the piston bottom edge.

~ Piston Size P
om

om

om

65.965 ~ 66.000 mm
Standard
{2.597 ~ 2.598 in)
.c

.c

.c
m

um

Oversize 1 66.25 mm {2.608 in)

ru

ru

Oversize 2 66.50 mm {2.618 in)

or
fo

fo

rf
er

er

•If out of specification, replace piston and

te

piston rings as a set.

st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-16 Page 86

 om

om

om
INSPECTION AND REPAIR ENG\.

.c

.c

.c
um

um

um
3rd step:
• Calculate the pi·ston-to-cylinder clearance
or

or

or
with following formula:
rf

rf

rf
te

te

te
Piston-to-cylinder Clearance=
as

as

as
Cylinder Bore "C" -
Bl

Bl

Bl
Piston Skirt Diameter "P"

•If out of specification, reb ore or replace

cylinder, and replace piston and piston rings
as a set.

om
om

~ Piston-to-cylinder Clearance:
0.035 ~ 0.040 mm

.c
.c

(0.0014 ~ 0.0016 in)

m
um

Limit: 0.1 mm (0.004 in)

u
or
or

rf
rf

te
te

as
as

Bl
Bl

PISTON RINGS
1. Measure:
• Side clearance
Out of specification -+ Replace piston and/
or rings.
Use a Feeler Gauge CD .

om
om

.c
.c

0.03 ~ 0.05 mm
Top (0.0012 ~ 0.0020 in)

m
um

307-005 Side
1---;w Clearance 0.03 ~ 0.05 mm

ru
(0.0012 ~ 0.0020 in)
2
or

nd

fo
rf

er
te

2. Install:
st
as

• Piston ring
a

(Into the cylinder)

Bl
Bl

Push the ring with the piston crown.

3. Measure:
• End gap
Out of specification -+ Replace rings as a
set.
om

om

om

Use a Feeler Gauge CD .

.c

.c

.c

0.20 ~ 0.35 mm
m

um

Top
(0.008 ~ 0.014 in)
ru

ru

or

0.20 ~ 0.35 mm
fo

fo

2nd
(0.008 ~ 0.014 in)
rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-17 Page 87

 om

om

om
INSPECTION AND REPAIR ENGI\al

.c

.c

.c
um

um

um
PISTON PIN AND BEARING
1. Lubricate:
or

or

or
• 2 cycle oi I (Lightly)
rf

rf

rf
(To the piston pin and bearing)
te

te

te
2. Install:
as

as

as
• Small end bearing
Bl

Bl

Bl
• Piston pin
(Into the small end of connecting rod)

3. Check:

om
om

• Free play
There should be no noticeable for the play.

.c
.c

Free play exists --+ Inspect the connecting

m
um

rod for wear/Replace the pin and/or con-

u
necting rod as required.

or
or

4. Install:

rf
rf

• Piston pin

te
te

(Into the piston pin hole).

as
as

5. Check:

Bl
Bl

• Free play (When the piston pin is in place

- - in the piston)
There should be no noticeable for the play.
Free play exists --+ Replace piston pin and/
~ or piston.

[rr 6. Inspect:

om
m

I
• Piston pin and bearing
o

.c
.c

['./ Signs of heat discoloration--+ Replace.

m
um

ru
or

fo
CLUTCH
rf

er
1. Inspect:
te

st
• Friction plate
as

Damage/Wear --+ Replace friction plate as

a
Bl
Bl

a set.
2. Measure:
• Friction plate thickness
Out of specification --+ Replace friction
311-IXXJ
plate as a set.
Measure at all four point.
om

om

om

~Wear Limit:
.c

.c

.c

2.8 mm (0.11 in)

m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-18 Page 88

 om

om

om
INSPECTION AND REPAIR _ IENGI_~I
.. . , _

.c

.c

.c
um

um

um
3. Inspect:
• Clutch plate
or

or

or
Damage-+ Replace clutch plate as a set.
rf

rf

rf
4. Measure:
te

te

te
• Clutch plate warpage
as

as

as
Out of specification-+ Replace clutch plate
Bl

Bl

Bl
as a set.
Use a surface plate and Feeler Gauge CD

~ Warp Limit:
311·002

0.05 mm (0.002 in)

om
om

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

5. Measure:
• Clutch spring free length
Out of specification -+ Replace spring as a
set.

Clutch Spring Minimum Length:

om
m

30.0 mm (1.18 in)

o

.c
.c

m
um

302·005

ru
or

fo
6. Inspect:
rf

er
• Dogs on the clutch housing
te

Cracks/Wear/Damage -+ Deburr or replace.

st
as

• Clutch housing bearing

a
Bl
Bl

Scoring/Wear/Damage -+ Replace clutch

housing.
NOTE:-------------------------
Scoring on the clutch housing dogs will cause
eratic operation.
om

om

om

7. Inspect:
.c

.c

.c

•Clutch boss splines

m

um

Scoring/Wear/Damage -+ Replace clutch

ru

ru

boss.
or
fo

fo

NOTE: __________________________
rf
er

er

te

Scoring on the clutch boss splines will cause

st

st

as

erratic operation.
a

a
Bl

Bl

Bl

www.blasterforum.com 4-19 Page 89

 IENG l'--1

om

om

om
INSPECTION AND REPAIR

.c

.c

.c
um

um

um
8. Check:
• Circumferential play
or

or

or
Free play exists-+ Replace.
rf

rf

rf
te

te

te
as

as

as
Bl

Bl

Bl
9. Measure:
• Push rod runout (Long rod)

om
om

Out of specification -+ Replace.

.c
.c

Use the V-B locks and Digal Gauge.

m
um

u
Runout Limit:

or
or

0.30 mm (0.012 in)

rf
rf

te
te

311·003

as
as

Bl
Bl

10. Inspect:
• Push lever
Wear/Damage -+ Repair using 300 "' 400
grit sand paper or replace.

om
om

.c
.c

m
um

ru
or

fo
PRIMARY DRIVE
rf

1. Inspect:
er
te

• Primary drive gear teeth CD

st
as

• Primary driven gear teeth®

a
Bl
Bl

.l Wear/Damage-+ Replace both gears.

Excessive noises during operation -+ Re-
place both gears.
om

om

om

TRANSMISSION AND SHIFTER

.c

.c

.c

1. Inspect:
m

um

• Shift fork cam follower CD

ru

ru

• Shift fork pawl ®

or
fo

fo

Scoring/Bends/Wear-+ Replace.
rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-20 Page 90

 I 1\al

om

om

om
INSPECTION AND REPAIR _ ENG _ _

.c

.c

.c
um

um

um
2. Inspect:
• Shift cam groove
or

or

or
• Shift cam segment
rf

rf

rf
Wear/Damage--+ Replace.
te

te

te
as

as

as
Bl

Bl

Bl
3. Check:
• Shift fork movement

om
om

Unsmooth operation --+ Replace shift fork

.c
.c

and/or guide bar.

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

4. Inspect:
•Guide bar
Roll the guide bar on a flat surface.
Bends--+ Replace.

j\ WARNING:

om
om

Do not attempt to straighten a bent guide bar.

.c
.c

m
um

ru
or

fo
5. Measure:
rf

• Axle ru nout
er
te

Use centering device and dial gauge.

st
as

Out of specification--+ Replace bent axle.

a
Bl
Bl

~ Runout Limit:
0.08 mm (0.003 in}
om

om

om

6. Inspect:
.c

.c

.c

•Gear teeth
m

um

Blue discoloration/Pitting/Wear--+ Replace.

ru

ru

• Mated dogs
or
fo

fo

Rounded edges/Cracks/Missing portions --+

rf

Replace.
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-21 Page 91

 I I~ I

om

om

om
INSPECTION AND REPAIR ENG

.c

.c

.c
um

um

um
7. Check:
• Proper gear engagement (Each gear)
or

or

or
(To its counter part)
rf

rf

rf
Incorrect --7 Reassemble.
te

te

te
• Gear movement
as

as

as
Roughness --7 Replace.
Bl

Bl

Bl
8. Inspect:
•Circlips

om
om

Damage/Looseness/Bends --7 Replace.

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

KICK STARTER
1. Inspect:

l • Kick gear teeth CD

• Kick idle gear teeth ®
Damage/Wear --7 Replace both gears.

om
om

.c
.c

m
um

ru
or

fo
2. Measure:
rf

• Kick clip tension

er
te

Out of specification --7 Replace.

st
as

Use a spring balance CD.

a
Bl
Bl

Kick Clip Tension:

0.8 ~ 1.2 kg {1.8 ~ 2.61b)

317-003
om

om

om

Do not try to bend the clip.

.c

.c

.c
m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-22 Page 92

 l\.1

om

om

om
INSPECTION AND REPAIR ENG

.c

.c

.c
um

um

um
SHIFT SHAFT
1. Inspect:
or

or

or
• Spring CD
rf

rf

rf
Damage--+ Replace.
te

te

te
• Shift shaft ®
as

as

as
Damage/Bends/Wear--+ Replace.
Bl

Bl

Bl
AUTOLUBEPUMP
Wear or an internal malfunction may cause

om
om

pump output to vary from the factory setting.

.c
.c

This situation is, however, extremely rare. If

m
um

improper output is suspected, inspect the

u
following:

or
or

1. Inspect:

rf
rf

• Delivery line

te
te

Obstructions--+ Blow out.

as
as

• Pump body seal/Crankcase cover seal

Bl
Bl

Wear/Damage--+ Replace.
• Check ball/Spring
Miss/Improper--+ Repair.
2. Inspect:
• Allowing air
Air exists--+ Air bleed.

om
m

3. Check:
o

• Pump output

.c
.c

Out of specification --+ Adjust.

m
um

ru
or

Output at 200 Stroke:

fo
3.47 ~ 4.23 cm 3 (0.122 ~ 0.149 Imp oz,
rf

er
0.117 ~ 0.143 US oz)
te

st
as

a
Bl
Bl

om

om

om

CRANKSHAFT
.c

.c

.c

1. Measure:
m

um

• Runout
ru

ru

Use a centering device and Dial Gauge.

or

Out of specification--+ Replace or repair.

fo

fo

rf
er

er

te

~ Runout Limit:
st

st

as

0.03 mm (0.0012 in)

a

a
Bl

Bl

Bl

www.blasterforum.com 4-23 Page 93

 om

om

om
INSPECTION AND REPAIR ENG "\·

.c

.c

.c
um

um

um
-F 2. Measure:
•Small end free play "F"
or

or

or
Use a Dial Gauge.
rf

rf

rf
Out of specification-+ Replace the defective
te

te

te
parts.
as

as

as
Bl

Bl

Bl
Small End Free Play:
0.8 ~ 1.0 mm (0.031 ~ 0.039 in)

3. Measure:

om
om

•Big end side clearance "D"

Use a Feeler Gauge.

.c
.c

Out of specification-+ Replace the defective

m
um

parts.

u
or
or

Big End Side Clearance:

rf
rf

0.4 ~ 0.7 mm (0.016 ~ 0.028 in)

te
te

as
as

Bl
Bl

4. Measure:
• Big end radial clearance "E"
Use a Dial Gauge.
Out of specification-+ Replace the defective
parts.

om
m

Big End Radial Clearance:

o

.c
.c

0.021 ~ 0.035 mm
(0.0008 ~ 0.0014 in)

m
um

ru
or

fo
5. Inspect:
rf

er
• Crankshaft bearing
te

Pitting/Damage-+ Replace.
st
as

NOTE:--------------------------
Bl
Bl

Lubricate the bearing immediately after examin-

ing them to prevent rust.

6. Inspect:
•Oil seals
om

om

om

Wear/Damage-+ Replace.
.c

.c

.c
m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-24 Page 94

 om

om

om
INSPECTION AND REPAIR ENG\.

.c

.c

.c
um

um

um
CRANKCASE
1. Thoroughly wash the case halves in mild
or

or

or
solvent.
rf

rf

rf
2. Clean all the gasket mating surfaces and
te

te

te
crankcase mating surfaces thoroughly.
as

as

as
Bl

Bl

Bl
3. Inspect:

om
om

• Crankcase
Cracks/Damage-+ Replace.

.c
.c

• 0 iI delivery passages

m
um

Clog-+ Blow out with compressed air.

u
or
or

rf
rf

te
te

as
as

Bl
Bl

om
om

.c
.c

m
um

ru
or

fo
rf

er
te

st
as

a
Bl
Bl

om

om

om
.c

.c

.c
m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4·25 Page 95

 IENG 1~1

om

om

om
ENGINEASSEMBLYANDADJUSTMENT

.c

.c

.c
um

um

um
------------...... ENGINE ASSEMBLY AND ADJUST-
MENT
or

or

or
rf

rf

rf
AUTOLUBEPUMP
te

te

te
1. Install:
as

as

as
•Washer CD
Bl

Bl

Bl
• Drive shaft ® (Autolube pump)
•Autolube pump@
•Circlip @
•Pin ®
• Auto lube pump gear ®
• Circlip (J)

om
om

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

CARANKSHAFT

To protect the crankshaft against scratches or

to facilitate the operation of the installation.
Apply the grease to the oil seal lips, and apply

om
m

the engine oil to each hearing.

o

.c
.c

m
um

ru
or

fo
1 . Install:
rf

er
• Crankshaft
te

st
as

NOTE=-------------------------
a

• Attach the Crankshaft Installing Tool to install

Bl
Bl

the crankshaft.

Crankshaft Installing Tool:

P/N YU-90050
P/N YM-1383
om

om

om

P/N 90890-01274
P/N 90890-01275
.c

.c

.c

P/N 90890-01278
m

um
ru

ru

• Hold the connecting rod at top dead center

or
fo

fo

with one hand while turning the nut of the

rf
er

er

Installing Tool with the other. Operate the

te
st

st

Installing Tool until the crankshaft bottoms

as
a

against the bearing.

Bl

Bl

Bl

www.blasterforum.com 4-26 Page 96

 IENG I~ I

om

om

om
ENGINE ASSEMBLy AND ADJUSTMENT

.c

.c

.c
um

um

um
AUTOLUBEPUMP
CD Autolube pump
or

or

or
® Gasket
rf

rf

rf
@Washer
te

te

te
@ Drive shaft
@Pin
as

as

as
@Oil seal
Bl

Bl

Bl
(j) Circlip
@ Autolube pump gear

om
om

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

om
m

A USE NEW ONE

o

.c
.c

m
um

ru
ft-----® ..---Ar -USE
or

-------.
U
fo
NEW ONE
rf

er
te

st
as

a
Bl
Bl

6
om

om

om
.c

.c

.c

5 Nm (0.5 m•kg, 3.6 ft·lb)

m

um

7
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-27 Page 97

 IENG I'\al

om

om

om
ENGINE ASSEMBL v AND ADJusTMENT

.c

.c

.c
um

um

um
CRANKSHAFT, PISTON AND BALANCER
CD Balancer gear @Bearing @Bush
or

or

or
®Bearing @Piston ring @) Conecting rod
rf

rf

rf
@Key (jJ) Piston pin clip (j]) Crank pin
te

te

te
@Balancer @Piston ®Bearing
@Bearing @Piston pin @Crank (Left)
as

as

as
® Balancer drive gear @Bearing @Key
Bl

Bl

Bl
CD Oil seal @Key @Bearing
@Collar @Crank (Right) @Oil seal

PISTON-TO-CYLINDER CLEARANCE: D CRANKSHAFT:

- F

om
om

A
0.035 ~ 0.040 mm (0.0014 ~ 0.0016 in)
A: 57.90 ~ 57.95 mm

~~
END GAP (INSTALLED):

.c
.c

B (2.280 ~ 2.281 in)

0.20 ~ 0.35 mm (0.008 ~ 0.014 in)

m
um

C: 0.03 mm (0.0012 in)

SIDE CLEARANCE: D: 0.4 ~ 0.7 mm

u
c 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in) (0.016 ~ 0.028 in)

or
or

E: 0.021 ~ 0.035 mm

ili

rf
rf

(0.0008 ~ 0.0014 in)

te
te

F: 0.8 ~ 1.0 mm

as
as

(0.03 ~ 0.04 in) A

Bl
Bl

55 Nm (5.5 m·kg, 40 ft•lb)

om
m

5
o

.c
.c

m
um

ru
or

fo
rf

er
te

st
as

a
Bl
Bl

USE NEW ONE

om

om

om
.c

.c

.c
m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-28 Page 98

 l\•l

om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT ENG

.c

.c

.c
um

um

um
BALANCER, TRANSMISSION AND SHIFTER
1 . Install:
or

or

or
• Balancer weight CD
rf

rf

rf
te

te

te
as

as

as
Bl

Bl

Bl
.~ 2. Install:
'jl • Transmission assembly

om
om

NOTE=-------------------------

.c
.c

While installing the drive axle into the crankcase,

m
um

pay careful attention to the oil seal lip.

u
A recommended practice is to fit the 0-ring CD

or
or

and apply grease over the fitted area.

rf
rf

te
te

as
as

Bl
Bl

3. Check:
• Transmission operation
Unsmooth operation--? Repair.

om
om

.c
.c

m
um

ru
or

fo
4. Install:
rf

•Shift cam CD
er
te

• Shift forks ®
st
as

• Guide bars ®
a
Bl
Bl

NOTE: -------------------------
Each shift forks is identified by a number cast
on its side. All the numbers should face the left
side.
om

om

om

5. Check:
.c

.c

.c

• Shifter operation
m

um

Unsmooth operation--? Repair.

ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-29 Page 99

 om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT ENG~-

.c

.c

.c
um

um

um
TRANSMISSION
CD Drive axle @Wheel gear (5th) @Pinion gear (5th)
or

or

or
®Bearing (j]) Special washer ®Pinion gear (3rd/4th)
rf

rf

rf
®Oil seal @Wheel gear (3rd) @Pinion gear (6th)
te

te

te
@ Drive sprocket @Wheel gear (4th) @ Pinion gear (2nd)
@Bearing
as

as

as
®Sprocket @Wheel gear (6th)
®Bearing @Wheel gear (2nd)
Bl

Bl

Bl
(J) Circlip @Bearing stopper
®Washer @Bearing
® Wheel gear (1st) @Main axle

om
om

RUNOUT LIMIT:
0.08 mm (0.003 in)

.c
.c

m
um

10 Nm (1.0 m·kg, 7.2 ft·lb)

u
or
or

rf
rf

te
te

as
as

Bl
Bl

om
o m

.c
.c

m
um

ru
or

fo
rf

er
te

st
as

a
Bl
Bl

om

om

om
.c

.c

.c

RUNOUT LIMIT:
m

um

0.08 mm (0.003 in)

ru

ru

or
fo

fo

rf
er

er

a
te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-30 Page 100

 om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT ENG~. .

.c

.c

.c
um

um

um
SHIFTER
CD Circlip
or

or

or
® Guide bar 1
rf

rf

rf
@ Shift fork (#3)
te

te

te
@) Shift fork (# 1)
as

as

as
®Shift cam
®Shift fork (#2)
Bl

Bl

Bl
(J) Guide bar 2
® Stopper lever
®Spring

om
om

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

om
o m

.c
.c

m
um

ru
or

fo
rf

er
te

st
as

a
Bl
Bl

14 Nm (1.4 m•kg, 10 ft·lb)

om

om

om
.c

.c

.c
m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-31 Page 101

 IENGI\·1

om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT . _ _

.c

.c

.c
um

um

um
CRANKCASE (RIGHT)
1. Apply:
or

or

or
• Sealant (Quick Gasket®)
rf

rf

rf
To the mating surfaces of both crankcase
te

te

te
halves.
as

as

as
Bl

Bl

Bl
Sealant (Quick Gasket®):
P/N ACC-11001-05-01
Yamaha Bond No.4:
P/N 90890-05143

2. Install:

om
om

•Dowel pins

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

3. Install:
• Crankcase (Right)

Installation step:
• Apply the lithium soap base grease to the
oil seal lips.

om
m

• Fit the left crankcase onto the right case.

o

.c
.c

Tap lightly on the case with a soft hammer.

m
um

NOTE: ------------------------

ru
Turn the shift cam to the position shown in
or

fo
the figure so that it does not contact the
rf

er
crankcase when installing the crankcase.
te

st
as

•Tighten the bolts (Crankcase).

Bl
Bl

Before installing and torquing the bolts

(Crankcase) be sure to check whether the
transmission is functioning properly by
om

om

om

manually rotating the shift cam either way.

.c

.c

.c

NOTE=------------------------
m

um

Tighten the bolts (Crankcase) in stage, using

ru

ru

a crisscross pattern.
or
fo

fo

rf
er

er

te

Bolts (Crankcase):
st

st

as

10 Nm (1.0 m· kg, 7.2 ft·lb)

a

a
Bl

Bl

Bl

www.blasterforum.com 4-32 Page 102

 om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT ENG\.

.c

.c

.c
um

um

um
•Install the Bearing stoppers.

or

or

or
Screws (Bearing Stopper CD-
rf

rf

rf
Main Axle):
te

te

te
10 Nm (1.0 m·kg, 7.2 ft·lb)
as

as

as
Screw (Bearing Stopper ® -
Crankshaft):
Bl

Bl

Bl
16 Nm (1.6 m·kg, 12 ft·lb)
Apply LOCTITE®

4. Apply:
• 2-stroke oil

om
om

To the crank pin, bearing and oil delivery

hole.

.c
.c

5. Check:

m
um

• Crankshaft and transmission operation

u
Unsmooth operation~ Repair.

or
or

rf
rf

te
te

as
as

Bl
Bl

COl MAGNETO
1. Install:
• Stator assembly CD
•Key ®
•Rotor ®
•Washer ®

om
m

•Nut@
o

.c
.c

m
um

Screws (Stator Assembly):

8 Nm (0.8 m· kg, 5.8 ft·lb)

ru
or

Use LOCTITE®

fo
rf

er
te

NOTE=--------------------------
st

•When installing the CDI magneto, make sure

as

the key is properly seated in the key way of

Bl
Bl

the crankshaft. Apply a light coating of lithium

soap base grease to the tapered portion of the
crankshaft end.
• Hold the rotor by the Rotor Holder CD to
tighten the nut ® .
om

om

om

Rotor Holder:
.c

.c

.c

P/N YU-01235
m

um

P/N 90890-01235
ru

ru

or
fo

fo

rf

Nut (Rotor):
er

er

73 Nm (7.3 m·kg, 53 ft·lb)

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-33 Page 103

 om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT ENG ~••

.c

.c

.c
um

um

um
COl MAGNETO
CD Stator assembly
or

or

or
®Rotor
rf

rf

rf
@Washer
te

te

te
as

as

as
Bl

Bl

Bl

om
om

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

om
o m

.c
.c

m
um

ru
2
or

fo
rf

er
te

st
as

a
Bl
Bl

8 Nm (0.8 m·kg, 5.8 ft·lb)

om

om

om
.c

.c

.c
m

um
ru

ru

or
fo

fo

73 Nm (7.3 m·kg, 53 ft·lb)

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-34 Page 104

 om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT ENG~-

.c

.c

.c
um

um

um
STOPPER LEVER AND SHIFT SHAFT
1. Install:
or

or

or
•Spring
rf

rf

rf
• Stopper lever CD
te

te

te
2. Set the stopper lever and torsion spring as
as

as

as
properly position.
Bl

Bl

Bl
Bolt (Stopper Lever):
14Nm (1.4m·kg, 10ft·lb)
Apply LOCTITE®

om
om

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

3. Install:
•Spring
• Shift shaft CD

om
om

.c
.c

m
um

ru
or

fo
4. Install:
rf

• Change pedal CD
er
te

5. Check:
st
as

•Change operation
a
Bl
Bl

Unsmooth operation--+ Repair.

om

om

om

KICK AXLE
.c

.c

.c

1 . Install:
m

um

•Circlip CD
ru

ru

• Plain washer ®
or
fo

fo

• Kick idle gear®

rf

• Plain washer @
er

er

te

il •Circlip ®
st

st

as
a

uO
Bl

Bl

Bl

www.blasterforum.com 4-35 Page 105

 ..
om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT ENG~

.c

.c

.c
um

um

um
SHIFT SHAFT
CD Shift shaft
or

or

or
®Spring
rf

rf

rf
@ Circlip
te

te

te
@ Oil seal
® Change pedal
as

as

as
Bl

Bl

Bl

om
om

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

14 Nm (1.4 m·kg, 10 ft·lb)

om
o m

.c
.c

m
um

ru
or

fo
rf

er
te

st
as

a
Bl
Bl

om

om

om
.c

.c

.c

5
m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-36 Page 106

 om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT ENG ~. .

.c

.c

.c
um

um

um
KICK AXLE
CD Kick crank @Washer
or

or

or
®Oil seal QD Kick idle gear
®
rf

rf

rf
Spring guide
te

te

te
@Kick spring
®Washer
as

as

as
®Kick gear
Bl

Bl

Bl
(J) Clip
®Kick axle
® Circlip

om
om

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

65 Nm (6.5 m·kg, 47 ft·lb)

om
o m

.c
.c

m
um

ru
or

fo
rf

er
te

st
as

a
Bl
Bl

om

om

om
.c

.c

.c
m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-37 Page 107

 ENGI\·1

om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT

.c

.c

.c
um

um

um
2. Install:
• Kick axle assembly CD
or

or

or
Rotate the shaft clockwise.
rf

rf

rf
te

te

te
NOTE: --------------------------
• Make sure that the kick stopper is stopped at
as

as

as
the projection of the crankcase.
Bl

Bl

Bl
• Make sure that the spring is engaged with the
crankcase hole.

3. Set the kick spring CD to the spring hook.

4. Check:

om
om

• Kick axle operation

.c
.c

Unsmooth operation~ Repair.

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

PRIMARY DRIVE GEAR AND BALANCER

GEAR
1 . Install:
• Collar CD
•Key ®
• Balancer drive gear ®

om
m

• Primary drive gear @)

o

.c
.c

• Nut® (Primary drive gear)

m
um

•Key ®

ru
• Balancer gear (j)
or

• Lock washer ®

fo
rf

• Nut ® (Balancer gear)

er
te

st
as

a
Bl
Bl

om

om

om

NOTE: --------------------------
.c

.c

.c

Note that there is the punched mark CD on the

m

um

drive gear and punched mark CD on the balancer

ru

ru

gear which must be aligned to install the balancer

or
fo

fo

gear.
rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-38 Page 108

 -
om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT ENG ~

.c

.c

.c
um

um

um
NOTE: --------------------------
• Hold the rotor (CD I magneto) by the Rotor
or

or

or
Holder CD to tighten the nuts (Primary drive
rf

rf

rf
gear® and balancer gear@).
te

te

te
as

as

as
Rotor Holder:
Bl

Bl

Bl
P/N YU-01235
P/N 90890-01235

• Tighten both the nuts simultaneously (Primary

drive gear and balancer gear).

om
om

Nut (Primary Drive Gear):

.c
.c

80 Nm (8.0 m· kg, 58 ft·lb)

m
um

Nut (Balancer Gear):

u
55 Nm (5.5 m· kg, 40 ft·lb)

or
or

rf
rf

2. Bend the lock washer tab.

te
te

as
as

&WARNING:

Bl
Bl

Always use a new lock washer.

om
om

.c
.c

m
um

ru
or

fo
CLUTCH
rf

1. Install:
er
te

• Push lever CD
st
as

2. Apply:
a
Bl
Bl

• Lithium soap base grease

To push lever surface ®and bearing @ .
om

om

om
.c

.c

.c
m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-39 Page 109

 ENGI\al

om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT

.c

.c

.c
um

um

um
3. Install:
•Push rod CD
or

or

or
•Ball ®
rf

rf

rf
• Conical spring washer ®
te

te

te
•Spacer ®
as

as

as
• Clutch housing ®
•Spacer ®
Bl

Bl

Bl
• Clutch boss (j)
• Lock washer ®
• Nut® (Clutch boss)
4. Apply:
• Lithium soap base grease

om
om

To push rod CD and ball® .

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

NOTE: --------------------------
• Be careful to install the conical spring washer
CD in proper position as shown.
•Install the lock washer tab into the hole of the
clutch boss.

om
om

& WARNING:

.c
.c

Always use a new lock washer.

m
um

ru
or

fo
NOTE: --------------------------
rf

• Hold the clutch boss by the Universal Clutch

er
te

Holder CD to tighten the nut ®(Clutch boss).

st
as

a
Bl
Bl

Universal Clutch Holder:

P/N YM-91042
P/N 90890-04086

Nut (Clutch Boss):

om

om

om

80 Nm (8.0 m·kg, 58 ft·lb)

.c

.c

.c

• Bend the lock washer tab.

m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-40 Page 110

 l\.-1

om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT _ ENG _ I _

.c

.c

.c
um

um

um
5. Install:
• Clutch plates CD
or

or

or
• Friction plates ®
rf

rf

rf
• Pressure plate @
te

te

te
• Clutch springs @
as

as

as
•Bolts ®
Bl

Bl

Bl
NOTE: --------------------------
• Align the pressure plate mark CD with the

om
om

clutch boss mark® .

.c
.c

m
um

u
or
or

rf
rf

te
te

as
as

Bl
Bl

6. Tighten:
• Bolts (Pressure plate)

Bolts (Pressure Plate):

6 Nm (0.6 m· kg, 4.3 ft·lb)

om
m

NOTE: ___________________________
o

Tighten the bolts (Pressure plate) in stage, using

.c
.c

a crisscross pattern.

m
um

ru
or

fo
7. Install:
rf

•Dowel pins
er
te

•Gasket
st
as

•Crankcase cover CD (Right)

a
Bl
Bl

• Kick crank ®

NOTE: --------------------------
Tighten the bolts (Crankcase Cover - Right)
in stage, using a crisscross pattern.
om

om

om

Bolts (Crankcase Cover- Right):

10 Nm (1.0 m·kg, 7.2 ft·lb)
.c

.c

.c

r---~ Bolt (Kick Crank):

m

um

65 Nm (6.5 m· kg, 47 ft·lb)

ru

ru

or
fo

fo

rf
er

er

& WARNING:
te
st

st

Always use a new gasket.

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-41 Page 111

 om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT ENG \e

.c

.c

.c
um

um

um
CLUTCH
CD Clutch spring ®Clutch housing
or

or

or
(2) Pressure plate @Spacer
(jJ) Conical spring washer
rf

rf

rf
®Push plate
te

te

te
@)Cushion spring @Push rod (#1)
® Clutch plate @Ball
as

as

as
® Friction plate @Push rod (#2)
Bl

Bl

Bl
(j) Clutch boss @Push lever
@Spacer @ Primary drive gear

CLUTCH SPRING FREE

om
om

6 Nm (0.6 m·kg, 4.3 ft·lb)

A LENGTH LIMIT:
30.0 mm (1.18 in)

.c
.c

FRICTION PLATE WEAR LIMIT:

m
um

B
2.8 mm (0.11 in)

u
or
or

C CLUTCH PLATE WARP LIMIT:

0.05 mm (0.002 in)

rf
rf

te
te

as
as

Bl
Bl

7 Nm (0.7 m·kg,
5.1 ft·lb)

om
o m

.c
.c

m
um

ru
or

fo
rf

er
te

st
as

a
Bl
Bl

om

om

om
.c

.c

.c
m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-42 Page 112

 ENGI\.1

om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT

.c

.c

.c
um

um

um
CYLINDER HEAD, CYLINDER AND PISTON
1. Install:
or

or

or
• Bearing CD
rf

rf

rf
•Piston ®
te

te

te
• Piston pin ®
as

as

as
• Piston pin clip ®
Bl

Bl

Bl
NOTE: - - - - - - - - - - - - - - - - - - - - - - - -
• Apply 2-stroke oil to the piston pin, bearing,
piston ring grooves and piston skirt areas.
• The arrow on the piston must point to the
front of the engine.

om
om

• Before installing the piston pin clip, cover

the crankcase with a clean towel or rag so

.c
.c

you will not accidentally drop the pin cliP,

m
um

and material into the crankcase.

u
or
or

rf
rf

& WARNING:

te
te

Always use a new piston pin clip.

as
as

Bl
Bl

om
om

.c
.c

m
um

ru
or

fo
2. Install:
rf

• Dowel pins CD
er
te

•Gasket ®
st
as

•Cylinder ®
a
Bl
Bl

•Gasket ®
• Cylinder head ®
• Spark plug ®
om

om

om
.c

.c

.c
m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-43 Page 113

 om

om

om
ENGINE ASSEMBLY AND ADJUSTMENT
ENG''·'
.c

.c

.c
um

um

um
NOTE: ___________________________
• Be sure to check the manufactuer's marks or
or

or

or
numbers stamped on the rings are on the top
rf

rf

rf
side of the rings.
te

te

te
• Make sure the ring ends CD are properly fitted
as

as

as
around the ring locating pins in the piston
Bl

Bl

Bl
grooves.
• Before installing the cylinder, apply a liberal
coating of 2-stroke oil to the piston rings.
•Install the cylinder with one hand while com-
pressing the piston rings with the other hand.

om
om

&WARNING:

.c
.c

m
um

Always use a new gasket.

u
or
or

rf
rf

te
te

as
as

Bl
Bl

NOTE:-------------
Install the gasket (Cylinder head) with the "UP"
mark CD faced upward.

om
om

.c
.c

m
um

ru
or

fo
3. Tighten:
rf

• Nuts (Cylinder)
er
te

• Nuts (Cylinder head)

st
as

• Spark plug
a
Bl
Bl

Nuts (Cylinder):
25 Nm (2.5 m· kg, 18 ft·lb)
Nuts (Cylinder Head):
27 Nm (2.7 m· kg, 20 ft·lb)
Spark Plug:
om

om

om

25 Nm (2.5 m· kg, 18 ft·lb)

.c

.c

.c
m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-44 Page 114

 IENG I'\aI

om

om

om
ENGINE ASSEMBLy AND ADJUSTMENT

.c

.c

.c
um

um

um
CYLINDER HEAD AND CYLINDER
CD Spark plug
or

or

or
® Cylinder head
rf

rf

rf
@Gasket
te

te

te
@)Cylinder
@Dowel pin
as

as

as
®Gasket
Bl

Bl

Bl
CYLINDER HEAD WARPAGE LIMIT:

om
om

A
0.03 mm (0.0012 in)
CYLINDER BORE:

.c
.c

8 66.00 ~ 66.02 mm

m
um

(2.598 ~ 2.599 in)

u
or
or

rf
rf

te
te

as
as

Bl
Bl

om
o m

.c
.c

m
um

ru
or

fo
rf

er
te

st

25 Nm (2.5 m·kg,
as

18 ft·lb)
Bl
Bl

om

om

om
.c

.c

.c
m

um
ru

ru

or
fo

fo

rf
er

er

te
st

st

as
a

a
Bl

Bl

Bl

www.blasterforum.com 4-45 Page 115