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Marqck
Posted on Monday, January 23, 2012 - 04:41 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Hi, everyone. I am trying to begin the process of addressing all the issues I have with my 2003 Blast I got in October. It has ~15k miles.

-The reserve function wasn't working when I got the bike

I have reason to believe that there is water in the tank. I get about 70-90 miles per tank of premium. I replaced the gas cap O-ring and I think that has helped, but I am still trying to drain it, sea foam, and see what I can do about the reserve line.

-Front left fork seal leaking

I bought one of those seal cleaners but I haven't used it yet. It seems that I need to remove the fork tube but I'm not sure exactly what I need to do this. If that doesn't work then I'm going to try buy one of those kits for resealing the forks.

-Transmission won't go past 2nd

This problem happened recently and it is my biggest priority. It happened while I was riding, though it wasn't the result of some traumatic incident. It happened while I was leisurely riding around. Before this happened, it would grind into 1st, but I was of the opinion this was common on Blasts. It appears the first step would be to attempt the shifter pawl adjustment and see where that gets me (though it might be a tuning fork issue). I'm willing to crack the case, once I have all that I need. If I'm taking the engine off, then I'm definitely going to go ahead and do the 515cc kit.

I don't have a garage, but I have a lot of space to work. Besides the tools and replacement parts, what would I need to remove the engine? I think I AT LEAST need a stand and a jack, but I'm not sure.

Also, any resources or experience you can add about undergoing these procedures would be greatly appreciated!

-M
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Crackhead
Posted on Tuesday, January 24, 2012 - 11:39 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

before you do the shifter paw adjustment, redo the primary chain and clutch adjustment. If the primary is to tight it will flex the clutch basket and the transmission gears will not be aligned properly. Also try shifting the bike by hand (when it is off) and see if it will go into the upper gears (you might need to rock the bike).
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Ezblast
Posted on Wednesday, January 25, 2012 - 01:00 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Fork seal - use 35mm film, stick about a foot in and slowly pull out while rotating the film around the inside of the seal, repeat till no dirt comes out. Do it carefully and smoothly and chances are your seal will reseal.
EZ
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