Update: April 2, 2011.
Operating the Blast had been a treat up until a couple days ago, when I had geared down to first abruptly.
Essentially, I kicked the shift lever down, and instead of popping back to its location, I had caused the lever to slip, and point towards the ground. After hobbling home in first gear, I looked at the mechanism and was surprised at how it was put together. On the left is where the lever attaches to the clutch. Note the machined finish around the drum.
Now, here is a closeup of the lever. The inside diameter finish is perfectly machined.
The problem with this design is that it relies solely on friction fit. The bolt has to be tightened very well in order to prevent slippage. A more conventional design is to incorporate splines on the outside and inside diameters so they lock into each other, and also employ a friction fit. Apparently, this ability to 'slip' is to prevent shifter shaft damage in the case of a spill. For a beginner bike, this is appropriate enough, and it works as intended.
However, this design was compromised by the bolt that held both parts together as it was too long, and bottomed out before making appropriate contact. In order to correct this, I had to add washers. Also, I found the gap that closes up as the bolt is tightened being too narrow, and had to file it down.
The bolt is a hex-socket design, and can be tightened with a 3/16" Allen Key. But in most cases, the bolt will be facing the ground and that will make for some awkward adjustments. I found a better approach was to use a ratchet, extension, and a hex-head as it helped me to keep the lever steady while adjusting, and apply maximum torque. Applying force with the Allen will likely cause stripping.
I am not rendering judgement at this point as to whether the bolt was intended for this application or not. Harley utilizes this "H-D GRD8" bolt in all its bikes, and in many applications. My Blast uses the bolt on its crankcase, the suspension, and on the frame. There is a chance the previous owner may have lost the proper bolt, and substituted it with a 'GRD8.' Either way, this caught me off guard, as it betrays the Blast's relatively care-free nature.
Bikes like the Blast and Suzuki's S40 are built with newbies in mind, so even if you're a bit jittery, they'll help build confidence real fast. You may actually find yourself quite relaxed once things get rolling, and you've gotten a bit better with the throttle/clutch. I know I have.