How to Build a Yamaha Blaster 200 Engine | 1988 - 2006 Full Build Step by Step

How to Build a Yamaha Blaster 200 Engine | 1988 - 2006 Full Build Step by Step
#yamaha #build #howto
Watch this Blaster being built - • Building a Yamaha Blas...
CHAPTERS
0:00 - Intro and Prebuilding Procedures
CENTER CASES
3:24 - Crankshaft Installation
8:12 - Counter Balancer Installation
8:27 - Transmission Installation
9:51 - Shift Forks and Drum
13:10 - Crankcase Assembly
22:54 - Sprocket Assembly
24:27 - Clutch Actuation Arm Installation
TOP END
25:16 - Prebuilding Procedures
26:54 - Checking Ring Gap
29:01 - Piston Ring Installation
30:03 - Piston Installation
33:23 - Cylinder Installation
39:11 - Chinese Cylinder Head Fix 1
43:21 - Chinese Cylinder Head Fix 2
45:44 - Cylinder Head Installation
47:16 - Reed Cage Assembly
49:09 - Exhaust Flange Install
Leakdown Test - • Building a Yamaha Blas...
CLUTCH SIDE (RIGHT SIDE)
50:19 - Primary Drive and Balancer Gears Assembly
55:41 - External Shift Mechanism
59:13 - Idler Gear Installation
1:00:28 - Kick Start Mechanism Installation
1:02:46 - Clutch Assembly Installation
Billet Basket Install - • Fresh Powder Coat, Vap...
1:12:41 - Clutch Free play Adjustment
1:14:19 - Oil Injection System
1:16:02 - Oil Injection Block off
1:16:47 - Clutch Cover Install
STATOR SIDE (LEFT SIDE)
1:19:33 - OEM vs Aftermarket Stator
1:22:12 - Stator Install and Adjustment
1:23:44 - Flywheel Installation
1:25:05 - DRW Case Saver and Stator Cover Install
1:29:01 - Showcasing
1:30:19 - Closing
PARTS AND TOOLS IN THIS VIDEO - (These links may be affiliate links that I get a kick back for; there is no added cost to you)
Service Manual - bit.ly/3Yg9zNK
Crankshaft Install Tool - amzn.to/3nGZ7kk
Yamabond 6B - bit.ly/430xdQI
Lacquer Thinner - amzn.to/40EHdxl
Dead Blow Hammer - amzn.to/3G8P79Y
Hand Driver - amzn.to/3lTiYfX
Engine Bolt Kit - amzn.to/40QBV1q
Torque Wrench - amzn.to/41a46K4
Clutch Holding Tool - bit.ly/3KokIak
Feeler Gauge - cuts2.com/bqMLu
Top End Kit (TESTED) - amzn.to/3lxoAeU
Stainless Head Studs - amzn.to/3IdJE3g
Grease - bit.ly/3TZwtXZ
Assembly Lube - bit.ly/3nCeU4a
Blue Thread lock - bit.ly/3wpg444
Red Thread Lock - bit.ly/3kDQTIn
Torque Wrench Adaptor - bit.ly/3nDeLNQ
M8 Helicoil - amzn.to/3RRVDGH
Dowel (Head Fix) - Part #99530-10114
Drill Bits - amzn.to/3J5Ybi7
M12 Dremel - amzn.to/3U0uDpE
Mini Cutoff Wheel - amzn.to/40wUh87
JIS Screwdrivers Set - amzn.to/3WgdN6F
Snap Ring Pliers - bit.ly/40AlAOD
Billet Clutch Basket - amzn.to/3nCisDm
Oil Injection Block off kit - ebay.us/oBj4lJ
Tusk Engine Seal Kit - bit.ly/3iTmQLX
Billet Oil Plug - ebay.us/CUWt99
Adjustable Stator (TESTED) - ebay.us/EHUGOR
DRW Case Saver - bit.ly/40AJCcg
M18 Sawsall - amzn.to/3FNlAlm
SPONSORS/COMPANIES I TRUST
⬇️ OEM PARTS, PLASTICS, BEARINGS, SEALS ETC ⬇️
Rocky Mountain ATV MC - bit.ly/32OHs02
⬇️ POWDER COATING ⬇️
Bonehead Performance Coatings - boneheadperformance.com/ (Mention my name and get 10% off)
⬇️ SUSPENSION ⬇️
Rocket Ron - www.rocketronracing.com/
⬇️ CASE SAVERS & SKID PLATES ⬇️
DRW Performance - bit.ly/34dxWEp (Code SABO10 for 10% off)
⬇️ PREMIUM BAR CLAMPS & THROTTLES ⬇️
Urmosi - urmosi.com/
⬇️ USED PARTS & REBUILD SERVICES ⬇️
Power Sports Nation - www.powersportsnation.com/
⬇️ PERFORMANCE & OEM REPLICAS ⬇️
Vito's Performance - www.vitosperformance.com/
⬇️ VAPOR BLASTING & ZINC COATING ⬇️
MotoBlast - www.njvaporblast.com/
⬇️ AFFORDABLE REPLACEMENT PARTS & PERFORMANCE ⬇️
Zoom Zoom - zoomzoomparts.com/
MERCH - michael-sabo.creator-spring.com/
Add me on Instagram @michaelsabo350
Companies and Sponsors please contact: [e-mail]
I own the license to use any and all music in this video.

[@Munoz387]

Doesn’t matter how many 2 strokes I’ve personally build throughout the years, if Michael sabo uploads an hour and a half engine build video, I watch. I don’t even own a blaster. Thanks a ton mike

[@shrugger1]

I know right.

[@Munoz387]

@@shrugger1 to this day I still learn little useful tricks of the trade for when the time comes

[@MichaelSabo]

Big compliment man! Thank you for the love on my videos and for supporting 🤘🤘

[@sketchyoperations9181]

couldnt have said it better

[@mikebarriball]

SAME HERE I JUST WATCH THE HOLE VIDEO.''

[@kennynadeau17]

you are one of a kind youtuber for us quad guys Mike! keep it up🔥

[@DUNEATV]

AGREED!!!

[@NickVojtasek]

Michael deserves every quad abandoned and or deserted ❤

[@noahmiller8722]

Agreed for sure

[@MichaelSabo]

You guys are awesome; thank you 🤘

[@BaldVulture87]

I can't imagine the amount of work that goes into editing all the footage from such a project. Many thanks for sharing!

[@MichaelSabo]

Thank you for watching and supporting my work; makes it worth it!

[@BaldVulture87]

@@MichaelSabo Think one day you'll do a superbike swap? Those get me drooling. I'd love to see one get done in detail like this, it would be awesome... Maybe someday?

[@franciscogarcia479]

​@@MichaelSaboetjjfwwfkorw

[@wyattcayea8499]

THE best and most in to detail blaster motor tear down/ rebuild, I’ve been needing this video for months now.. all my worries if not knowing this engine like the back of my hand has went away, other videos don’t go into detail like you do, and show you every possible way to do things.. you actually explain what your doing and tell us what and not to do… which is really awesome great job mike, you really killed it with this one!!

[@MichaelSabo]

Thank you for the love on my video Wyatt, I hope this video can help you and others build ones just like this 🤘🤘

[@salk8566]

Man you made this looks so god damn simple wish I had this video 2 years ago when my old blaster was in a bucket lol 😂

[@MichaelSabo]

Hopefully you can use it down the road man!

[@ericmillersprospectingchan3424]

Dude you make it look easy. Very smart and very knowledgeable stuff I've learned from you.. Thxs!

[@MichaelSabo]

I appreciate the love dude!

[@christopheravery5808]

I just watched it and then sent it to my daughter so she can go through the video when she gets out of school. We are tearing her blaster down this coming weekend and making a parts list so we can start getting her rolling. I’ll probably use the parts you have in the description, I would rather her learn with cheap parts so she doesn’t destroy something expensive. After that I’ll probably pick up some +2 alba arms and some wheel spacers in the back to give her a little more stability. Throw on some nerf bars, kill switch, and hand guards and she will be ready to go for now. I’ll upgrade shocks and stuff for her as she gets faster at riding.

[@MichaelSabo]

Nice dude! Make sure it's jetted right and it should run fine; 7 hard hours on this one and it's still running perfectly.

[@Mikeofindy]

Thanks Mike. I'm downloading this and will watch it on my flight to my honeymoon in like two weeks!!!

[@MichaelSabo]

Congrats on your marriage man!

[@Mikeofindy]

@@MichaelSabo Thank you !!!

[@kenshin3447]

Mike whats your Favorite BIKE! 🚲🚲🚲

[@MichaelSabo]

I feel like this changes daily lol

[@stephencrisson3595]

I love the detail mike I love how you said not to take a hammer to the crank cuz you're right one little blow can knock the crank webs out of whack so much so to where you wouldn't even notice it until it's too late awesome work man as always🤘‼️

[@MichaelSabo]

Thank you for the love man!

[@kayejaye261]

Mike I just want to say I appreciate all your vids. Well done. U a good teacher. Experience shows. Your humble. Has got me looking for a project. Bought my daughter a four wheeler about 15 years ago. Was fun getting it running good and looking good. Sure u inspire everyone of all ages that love 2 cycle 4 wheelers and dirt bikes. 👍

[@MichaelSabo]

That's awesome to hear! Good luck in your search for a new project and thank you for the kind words!

[@Yfz450garage]

Finally, been waiting for days. Love your videos bro

[@MichaelSabo]

Thank you for the love man!

[@theglitch99]

Been looking forward to your next download/upload!!

[@MichaelSabo]

Thank you for watching this one man!

[@MR-puffnstuff]

I love the blasters they are light fast and fun and the sound they make is un forgettable you are also a pretty decent rider to I love how easy it is to whip these things around.

[@MichaelSabo]

Thank you man! These are definitely fun machines!

[@johnbruzzi4381]

I would love to see a trx450 engine build from you!

[@MichaelSabo]

I need to do one

[@leedchristensen]

My son just traded for a blaster that supposedly had about 20 hrs on a full rebuild and it locked up after about two hours of riding. This will be perfect to help rebuild!

[@markaddy53]

great job lad keep up the good work

[@MichaelSabo]

Thank you sir!

[@user-br5cu1pw8u]

I don’t own and don’t plan on owning a blaster but still watched the whole video without any skips

[@ajtaylor3594]

I wish i could find a mechanic as good as u to restore my blaster best quality ever

[@keithkeller698]

My upp case saver saved my trx250r engine last month.. after watching this video I just ordered my son the drw case saver...

[@richardflatt4824]

Yeah!! New video to kick back and relax to.

[@MichaelSabo]

Thanks for watching RIch!

[@dyvrs3rips305]

wish i could find a video like this on a 2009 rmz 250 lol good video man!

[@MichaelSabo]

If I get my hands on an RMZ I will make one 🤘

[@trevordurham8043]

Great video to watch as I build my bombardier ds650 engine!

[@fadedlight8596]

Ive watched every video for years

[@MichaelSabo]

Thank you for supporting for so long man!

[@patty2Strk]

And a good day gets better !

[@MichaelSabo]

🤘🤘

[@dirtbikelife8070]

You just saved my ass man! I misplaced one of the colars on to the wrong shaft. Watched your video and instantly found my mistake! 😅

[@speed.turtle5705]

I just got a blaster and this helps a lot thx!!!!

[@MichaelSabo]

Glad to help!

[@eager400]

Hey Mike, don't forget to turn off your compressor 😉. Gotta love 3am compressor alarms lol. Love the video!

[@MichaelSabo]

😂 Thank you man!

[@jberry1982]

I know these 200cc Yamaha Blasters were very underrated for there power I've seen some of these make crazy power for there size plus a 6speed transmission made em insane fast and I always thought the chassis was a little small they were awesome Quads

[@MichaelSabo]

Very true man, the lightweight compact platform makes it a really fun power plant

[@jberry1982]

@@MichaelSabo yeah I ain't rode one since the late 90s and it was a weekend racer and my trail quad to through highschool and it never died on me I didn't even rebuild it like a lot of the track guys did every weekend I ran mine until compression dropped about 10-20psi and I didn't even run the single ring weisco like a lot of the competition did I used the weisco but the 2 thin ring dome top setup I did add a milled Curtis Sparks Head and a reed cage they offered for em and it was a beast plus I went to a 30mm Mikuni carb cuz mine did have the big bore jug like my warrior had one thing about every Yamaha I ever had they all came with Mikuni carbs Honda always came with those Khein or however you spell it but you have got me itching for a KFX 450R now I heard Suzuki made a 450 to and In North Alabama everyone always ran Honda or Yamaha quads and Polaris mostly but I always liked the Quad Racers I had a 250 QuadRacer 250 later on and it was awesome I wanted a QuadZiLLA so bad but nobody wanted to sell em if they had em lol kinda like 250R Honda's id really love to see A Yamaha Warrior or YFZ chassis with a YZ 250 two stroke on it I think Yamaha really missed a opportunity with a factory 2 stroke 250cc Quad

[@DUNEATV]

Be sure to position your rod in the right location!

[@MichaelSabo]

😁

[@nicholaspraderio7387]

You should trying doing a build series on an kids atv such as an lt80, 4 zinger, atc 70 or trx90

[@MichaelSabo]

I have that on my build board but I don't know when I will do that

[@bradynfrontz1602]

The amount of time you put into these machines and videos is crazy, huge props to you man. Your doing great thing

[@leebarker7563]

These video's are quality. People all over the world will be referencing these because you are explaining brilliantly. A variation of different engines/manufacturers and you are onto a winner. Nice work 👏

[@joenewberry5912]

The internet NEEDS a Cannondale 440 How To Build series! You built a great fun machine. I had a Blast riding it. Got me looking for one to build now !

[@keeganhache6667]

You are the highest most real KZbinr I have came across. I’ve learned to much from your videos and I just wanted to thank you for all the engine knowledge you are not afraid to show if something goes wrong

[@darrenfullagar]

Love these super long engine builds 🤙🏻 thanks for going to so much effort Mike and thanks for keeping us all entertained 😎

[@austinramsey4540]

Let’s go man, excited to watch

[@MichaelSabo]

Thank you for watching!

[@craigc1130]

I only ride 4 strokes besides my boat but I love watching miles build videos on these older 2 strokes

[@MichaelSabo]

Glad you like them man; thanks for watching!

[@juliandoiron4718]

Awesome tutorial dude. Super well shot, explanations about component function that will help me troubleshoot without ever having touched these before.

[@stevewallace326]

Definitely the best diy video that I have ever seen. Great explanations, great video work. Keep it up!

[@me-pv4fn]

Absolutely love your channel it has helped me out alot with my rebuilds keep up the great work and us all happy watching your vids.

[@joemusicman64]

Just when I was going through withdrawals you dropped this one in. Nice. So awesome watching these well done vid's. Plus I'm an engine nerd so this one is extra good.

[@novaeverything4020]

Dude I watch everything you put out it's all super high quality stuff

[@WhiteNorthStar1]

Phenomenal teacher and human 😃

[@mikebarriball]

A GOOD CLEAN BUILD, YOU EXPLAIN YOURSELF WELL, AND GO THE EXTRA DISTANCE.

[@DestinationDesert]

Top notch as usual. You've found your calling brother! Love watching. God bless! 🙏🇺🇸

[@MichaelSabo]

Thank you dude!

[@jeschreindl]

I recently discovered your channel and have been really enjoying it! Im currently restoring my 72 Honda XL250 so its fun to watch your full builds :)

[@motoblast3574]

This video is simply amazing! Those cases look great by the way 😉

[@jcnpresser]

I always enjoy the full engine builds

[@MichaelSabo]

Glad you enjoy them!

[@wilvany]

This is a great video , I’m trying to find a blaster , never have one , great knowledge you have God bless you

[@Grummett35]

love when you do full rebuilds like this very helpful information i wish you had a full rebuild video on an ltr 450 im going through hell with mine right now

[@aaronbenns9051]

Im learning alot thanks dude

[@rafaelarciga6912]

Fantastic video Mike. Thanks!

[@dan2397102]

Thanks for posting this

[@frankkrezel7922]

Awesome content! Appreciate the amount of time you put into these videos. Gonna get some merch!!🤙

[@MichaelSabo]

I appreciate that man!

[@djasmr7075]

Just got one of these said top end needs to be redone but ty I'm new here and will be saving this video.

[@quintoneversull4219]

Im going to need to take apart one of my spare blaster engines in a bit for a motorcycle project. This video is something ill watch a few times before i reassemble it. I have a 1972 ct175 that the engine was shot to pieces in. I decided to take a spare blaster engine and put a vitos 244 stroker kit on it with a 38 mm high velocity lectron carb on it just to see what its like. Im going to make a custom scrambler out of it. The 12volt system will be a nice upgrade from the old 6volt.

[@MR-puffnstuff]

I I were to rebuild a video and at least know how to fix things decently and achieve great satisfaction from doing things yourself this video would be more then perfect to walk through each step just like sabo said the manufacturers ATV book is a must usually cost around hundred bucks for a brand new one I would invest in one.

[@masterblaster1167]

Perfection 👌🏻

[@MichaelSabo]

Thank you dude 🤘

[@kenoconnorracing]

Nice work Mike. Keep the vids coming.

[@olzhasjaxylyk6205]

Плюс один новый подписчик на этот канал!!! респект и уважуха из России!

[@drdanger95]

When mike uploads my day turns around 👊🏼🤘🏼

[@elrapecapullos]

increíble paciencia increíble resultado tus manos son oro :) un abrazo desde Asturias, España :)

[@davidstoner27]

Lots of good info for sure good job

[@MichaelSabo]

Thank you as always brother!

[@davidstoner27]

@@MichaelSabo would not miss a video

[@martinmartinez8161]

Awesome video. Thanks for sharing.

[@MichaelSabo]

Thank you for watching!

[@pablomora3699]

Hey dude ur awesome! I will use it in the future on my dt 175 chasis that has a blaster engine 🔥

[@Adamdub612]

Another great video. thanks mike

[@johnbruzzi4381]

Mike going to trade school doesn't make a good mechanic, I know you know this, experience does and clearly you have plenty of that.

[@MichaelSabo]

100% John!

[@ethanschweiss981]

Awesome vid Mike!

[@Vitalogy78]

Awesome video, very glad I found this. I have a 1984 Yamaha DT200 dualsport motorcycle which uses the exact same bottom end. (The DT used a liquid cooled cylinder+YPVS) and eventually I would like to rebuild it...

[@christurner5473]

You sir are definitely a true craftsman, I wish I knew a tenth of what you know

[@MichaelSabo]

I appreciate that Chris; hopefully I can transfer my knowledge through my videos 🤘

[@krudlumpstv7854]

Thank you mike! 💯💯💯

[@MichaelSabo]

Thank you for watching 👊

[@jones_bright9178]

Thank you for all ur knowledge 🤙🤙🇦🇺

[@MichaelSabo]

Thank you for watching!

[@bobbymckinney1264]

The Mad scientist has built another awesome engine..good video mike

[@MichaelSabo]

Thank you Bobby!

[@-jeffreybollenbach-]

Wow mike I hate how late I am to this video but thank you so much. Love the videos man. You make the atv world amazing. Thank you so much

[@MichaelSabo]

Thank you for the love and support man; can't do this without you 👊

[@shepss217]

Miss building those little blasters, so easy to work on compared to these modern bikes

[@theoutdoorduck701]

Keep up the great work, i enjoy whatching these even though I will likely not do it

[@davidleblanc3134]

Thx for the content i was waiting daysss for this lol

[@MichaelSabo]

Thank you for watching man!

[@mrblaze8191]

Man I would love to see you do this on Suzuki ltz400 one day soon cause your work rocks

[@MichaelSabo]

Thank you for the love man; If I do an LTZ/KFX/DVX 400, I will make a build tutorial for it!

[@CameronH-fv4tx]

Hey I really like your videos I have learned a lot keep it going but sometime you should build a trx700xx

[@MichaelSabo]

Glad you like my videos man! I have a 700XX on my build board!

[@mixonmachines]

Great video brother, as always!! 🎉

[@MichaelSabo]

Thank you man!

[@justinambrose4387]

Biggest time saver would have been heating up the crank bearing and freezing the crank. It will literally drop in…..no need for the crank puller. Love your videos! I’m the owner of a 50+ hp drag blaster on methanol lol they can definitely be little rippers!

[@floridatrailrider305]

Great video Sabo!

[@user-vj1fe6rg9s]

Felicidades desde cali Colombia Mike gran maestro 😉

[@hunterbroskee6184]

Damn good video man, ill be using to reference

[@The207Boys]

love your videos!!!

[@MichaelSabo]

Thank you for watching them Ant!

[@ethanschweiss981]

The quality of your videos is honestly immaculate bro! Love the extra lube tip btw ill make a note.🤣💯

[@stuartbellwithvintage2stro375]

Great video

[@davidstoner27]

Have to take the victorys when we can good job bro

[@MichaelSabo]

Thank you as always man!

[@kevinconnors9396]

Hell yea bud nice work

[@MichaelSabo]

Thank you Kevin!

[@chadstanley9868]

That's pretty sweet dude

[@electricianslife1984]

Thank you brother

[@chaddessailliers2714]

WoW thanks you

[@andrewcook3988]

I'm new here but I love your videos

[@dustinrichards8401]

Yfz or ltr 450 build would be sweet!

[@MichaelSabo]

Yes sir they would be!

[@ronnieanderson9821]

We need to find someone to build bilet cases for the blaster saving money up now for cnc to bring parts to the community we need to make sure we can keep all these great machines running for year to come

[@MichaelSabo]

A billet trans would be nice too

[@samuelpanasyuk2955]

Love the vids, must take an eternity editing😂 Gotta make a vid about jetting

[@fabiorodriguez4823]

Que maquina!!!

[@antonyattwood7524]

Off road /yz 2 stoke/ on road/ aprillia sxv 550 supermoto

[@DatBoiGimp]

Hey man love your videos you actually make them pretty comprehensive this might be asking to much I know you do more quad stuff but if you ever get the chance could you do a full motor rebuild guide on a 2008 Kawasaki kx250f