Hi Moto Maniacs

To all the wrenchers out there: I just rebuilt a 99 blaster from top to bottom without a book, now it sounds like I need one. The problem is the the clutch (which worked before I rebult it) is acting like the push rod isnt even in the shaft . I pull the clutch and its all air except for the last inch which has a very small push on the clutch basket. I think I have 7 fiber plates starting and ending in the basket with metal plates between. I ve taken this basket off several times (which gets old quick) and cannt figure out why I have no clutch tension. I did adjust the screw on the inner circle of the basket but to no avail. Hints, tips, ideas would be appreciated.

Thanks,
Scuff

 

Still got the ball bearing between the two push rods? Make sure you got the mark on the pressure plate lined up with the mark on the clutch boss. Also, undo the lock nut and turn that adjustment screw until the clutch push lever is poitning at the mark on the crank case. The clutch push lever is what pushes on the clutch pushrod(s) directly across from the clutch basket on the otherside of the motor. Your clutch cable will be attached to it. It has a shape that makes it come to a point and there should be a mark on the crankcase where it will line up when adjusted right. Also make sure you got the clutch springs tight enough, they should be tightened down to 4.3 ft-lb in 2 or 3 stages. I'm putting my money on the missing ball bearing though. Also check your Private Messages. I sent you a link.

 

I ordered the ball bearing, because I didnt see it in there. It should be in soon, I ll try that and see if that is the problem. Oh yeah, is it just me or do Blaster brakes "suck"?

 

pre-03 blaster brakes are the worst....the front are drum.....what a bad design the back has one of the worst calipers i have ever seen thats why i custom designed the warrior front brakes to fit mine not that hard and soon ill put rear hydros in in

 

hay check out enginetics,the offer go cart brakes that bolt right up to the blaster. you wont have the hand brake anymore but havin hydros in the back makes it worth the switch off.end to end ? maybe 230-250 bucks.check em out you wont be sorry

 

Can anyone offer some assistance? My son was riding my 1990 Blaster suddenly it seems like the clutch cable is stretched out. When I pull on the handle the cable moves some and pulls engine end of cable slightly. think it is the cable or something else?
thanks
Mark

 

It's usually either a stretched out cable or the clutch needs replacement or adjustment. I'd pull the clutch cover and adjust the clutch.... Cable adjustment is finger adjust..... You should have already tried that.