02 Blaster blew up, need service manual

[RM250BS]

My little brother's 2002 Blaster blew up (piston broke) and there is a puncture in the bottom of the case. Does anyone know where I can download a service manual?
Thank you,
Brian Henry

[hardlydangerous]

[Only registered and activated users can see links. ]

good luck and feel free to ask any questions you may have.

[TRXman86]

what is it you want to attempt to do to it?

[RM250BS]

Thanks guys. I needed all the torque settings so I can put a new top end in it, and I also need to split the case because a few pieces of the piston fell down into the engine.

[MotoMan]

I MIGHT have a service manual for a blaster left out in the barn...if I do it's yours, I will check this evening and let you know.

[2fun]

Originally posted by MotoMan
I MIGHT have a service manual for a blaster left out in the barn...if I do it's yours, I will check this evening and let you know.

Dude!
You are awesome!

I'm sure you already knew that though.

[MotoMan]

Thanks 2fun, but unfortunatly I must have given the service manual to the guy who bought my blaster, I could have sworn that I had it but I guess I don't.

Sorry man, now I feel like an ***.

[2fun]

Originally posted by MotoMan
Thanks 2fun, but unfortunatly I must have given the service manual to the guy who bought my blaster, I could have sworn that I had it but I guess I don't.

Sorry man, now I feel like an ***.

No problem Motoman. Its the thought that counts anyways. Besides, he was directed to a free online manual anyways. Just download to your computer, and walah!!

[MotoMan]

Good point, but I still should have kept my mouth shut until I knew for sure....I guess that kinda goes against my nature though, keeping my mouth shut.

[TRXman86]

LOL i was going to try to help out, but the tourqe stuff.... it's the thought that counts motoman, like 2fun said

[hardlydangerous]

most common abbreviations

TDC = top dead center
ATDC = after top dead center
BTDC = before top dead center
BDC = bottom dead center
ABDC = after bottom dead center
BBDC = before bottom dead center
C = Celsius (centigrade)
cc = cubic centimeters
CDI = capacitor discharge ignition
cu.in. = cubic inch
F = Fahrenheit
ft.lbs = foot -pounds
hp = horse power
in. = inches
kg = kilograms
km = kilometers
L = liter
M = Meter
MAG = Magneto
ml = milliliter
mm = millimeter
N.m = Newton-meters
oz.= Ounce
PSI = pounds per square inch
pt. = Pint
qt. = Quart
rpm = Revolutions per minute
-----------------------------------------------------------------------------------------------

Regular oil change
650ml 0.69U.S qt. 0.57Imp.qt
After overhaul or flush
700ml 0.74U.S qt 0.62Imp.qt

Idle speed 1450 rpm -1550 rpm

Spark plug BR8ES or B8ES
Plug gap 0.7-0.8mm .028-.032in

Stock jetting
88-02
Mixture screw 1 ½ turns out
Jet needle clip 2nd groove
Main jet 230
2003-
mixture screw 1 1/2 turns out
jet needle clip 3rd groove
main jet 230

Stock lighting specs?

Headlight 45W/45W X 1, 12V
Tail light 3.5W X 1, 12V
Oil light 3.5W X 1, 12V
-----------------------------------------------------------------------------------------------


Piston sizes avaiable for the stock sleeve?
Wiseco (forged)
STD, .010", .020", .030", .040", .050", .060", .070", .080", .090".
Yamaha (cast)
STD .020", .040", .060", .080"
----------------------------------------------------------------------------------------------

Acceptable clearances
Piston-Cylinder limit: .035 -0.040mm (0.0014 in -0.0016 in)
Taper limit: 0.08mm (0.003 in.)
Out of round limit: 0.05mm (0.002 in.)
ring end gap .20 - .30 mm(.008 in - .014 in)
Crank shaft runout limit .03 mm (0.0012 in)
BE (big end) side clearance 0.4 - 0.7 mm ( o.o16 - 0.028 in)
SE (small end) free play 0.8 - 1mm (0.031 - 0.039 in)

Reeds
Reed stop height 8.3 -8.9 mm (.33 -.34 in)
valve bend limit .5mm (0.02 in)
-----------------------------------------------------------------------------------------------


Torque specs

cylinder head nuts 20 ft.lb
cylinder base nuts 18 ft.lb
spark plug 18 ft.lb
exhaust nuts 15 ft.lb
reeds cage bolts 6 ft.lb
primary drive gear 58 ft.lb
clutch nut 58 ft.lb
clutch spring bolts 4.5 ft.lb
clutch adjuster nut 5 ft.lb
kick pedal nut 47 ft.lb
shift pedal 10 ft.lb
flywheel nut 54 ft.lb
trans drain plug 15.ft.lb
oil pump cover bolts 5 ft.lb
clutch cover bolts 7.5 ft.lb
stator cover bolts 7.5 ft.lb
stator bolts 6 ft.lb
main bearing stop 12 ft.lb
case bolts 6 ft.lb
shift cam stop 10 ft.lb
engine mount bolts front 33 ft.lb
rear 24 ft.lb



----------------------------------------------------------------------------------------------
Tune up and inspection

Once a month or sooner

Clean air filter
Change transmission oil
Adjust and Lube all cables
Grease all zerks
Lube all pivot points
Clean and adjust chain tension
Check all nut and bolts
Tire pressure

Every 3 months or sooner

Bleed injection system
Clean injector tank filter
Replace spark plug
Re-pack wheel bearings, axle bearing and swing arm bearings.
Grease brake cams, shock bushings, rear brake caliper, upper steering bearings,kick pedal pivot
Check compression
Flush fuel tank and trans

[2fun]

Excellent post Hardly!
As usual!

[RM250BS]

I am having some trouble getting the flywheel off. I have the nut off, but the rotor will not come off. Any ideas? Thanks guys, the download is a big help.

[drman]

You are gonna need a flywheel puller...there is sadly no way around it.

[MotoMan]

Yep, you can pick one up at any yamaha dealer for around $5.

[hardlydangerous]

These guys are right
You will need the proper flywheel

To use it remove the center bolt from the puller base and screw the base into the flywheel. Remember this is a left hand threaded tool/flywheel so you install the puller counter clockwise. Once it's in and snug install the center bolt and tighten it down.

Now using a wrench hold the base of the puller steady while you tighten the center bolt in the puller and the flywheel will pop right off.

good luck.

[RM250BS]

I think I have a problem, I have a rag under the engine sitting on the table and on the rag I found a tiny tiny spring and a ball bearing that is smaller than a BB. Does it go in the kick start gear shaft? I pulled it off and it looks like it would, but I am not sure. Thanks again!

[MotoMan]

Post a pic of that bearing and spring if you would.

[hardlydangerous]

yes that's where it's from. It's the the locking mec. that holds the kick starter in place when it's turned in towards the engine. be very thankful you found them. usually they blast off never to be found again.
grease them up well before you re-install them as well as the pivot shaft.

[RM250BS]

Another ball bearing fell out the other day, but I have no clue where it is from. It is slightly larger. Would you happen to know where it goes? Will it hurt the engine if I lose them and can not get them back in? Thanks for the info!