YSR Blaster conversion
YFS200 motor
You can find the old YZ80 conversion page
Updated 06/14/04
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July 2003
I sent my frame to Joe Huminsky of Team Screams customs.
You can contact him at cinsi1@msn.com
Here's how it came back out of the box. I'm sending it out for powdercoating this week.
I can honestly say, deciding to pay to have Joe blasterize my frame was the best project decision I made. It's nearly a perfect drop-in fit. I couldn't ask for better without actually sending my motor to him! Amazing work.
Custom rear shock mount- more clearance for the carb/filter
Joe even relocated the coil mounts- the fit is absolutely perfect!!!
Cutout for the kick starter. Note frame is fully boxed in on both sides.
The second best decision I made- to buy the Chad Wright swingarm. This allows the blaster motor to drop into the cutout in the front. You can see his products at CWR Performance.
If you cannot afford this awesome swingarm, Joe Huminsky can convert your stock swingarm into a Blaster-capable unit and brace it for a VERY reasonable price.
Swingarm also includes wheel spacers made from billet- good deal!!!
Swingarm is ride-height adjustable by adding or removing plates under the shock mount. Since I have a Fox shock, I found it unnecessary to add any plates. Note neat rear shock pin repalcement.
Here's how it interfaces with the motor
2000 blaster motor
I await the arrival of my new 30mm carb.
Stage 1 porting
This motor was from a 2000 Blaster. The head was in piss-poor condition (pitted), so I bought a whole new ported unit to run instead. A lot of little things had to be changed as well- I have yet to get a satisfactory motor buying experience off ebay.. oh well.
Before the teardown for powdercoating:
July 22, 2003
Frame back from the powdercoaters!!
Note tight filter clearance. I had to run the reed spacer to get the carb to clear the clutch lever too.
The shock reservoir will be mounted on the left side, near the front of the frame.
I just ordered some sprocket specialist sprockets today- should arrive Friday.. Talk about quick service!
After that arrives, I'm just waiting on Tommy Crawford to send me my pipe and I can fire it up! If all goes well, I'll have the bike titled and registered sometime this August.
August 1, 2003
To h@ll with the pipe! I fired it up already ;)
It's LOUD. I mean re-defines LOUD. Jet blast loud.. but at least it let me get my electricals running.
I installed a 42T rear sprocket, and also have a 38T spare for more top speed. I'm going with the big one first for more swingarm clearance. The 15T front / 42T rear combo should give a very hard acceleration to maybe 85-90mph+. We'll see!!
I welded a custom battery mount to the rear turn signal hanger. I put an arctic cat (Tympanium) 12V voltage regulator on the engine basket in front of the motor. I had to re-wire the lighting coil to get it to work.
Note 'custom' battery mount! My tray was cut-off by the previous owner, unfortunately..
The small 12V signals were given to me by a friend. Some yahoo sold them to him on ebay as bolt-ups for the YSR 6V system! HA! They have 12V bulbs!!!
I put an EZ-pull clutch lever on. I had to modify the stock light controls/clutch pod by cutting off the lever mount. It works well if you have large hands like me. If you don't have the reach, the EZ_pull lever cannot be used.
Here's my motion pro twist throttle kit. You can see my CWR performance fork air caps too- boy do these things work! Pump up the forks too much and they lock out- I mean, 230lbs of down force on them (me) doesn't even budge them! Maybe 3-5psi is just right :)
More to come later. I'm still waiting on the Crawford Pipe (I'll give him a call Monday to see how it's coming), and a Tsubaki chain I ordered off ebay. Once these come in, I'll need a new rear seat unit and a windshield, but at least I can get it titled with what I've got. ALL the lights work. The gauges work too (only high beam, turn signal and backlight- no neutral/oil light). I found replacement bulbs for ALL the YSR lights besides the headlight at Pep Boys! The headlight required me to get creative. I disassembled the stock light, opened the hole a bit more (after de-soldering and removing the stock bulb), and put in a bulb off some Yamaha scooter.
I am considering a new intake manifold as well- the stock manifold makes the 30mm carb touch one of the manifold bolts, so I have to run the 1/2" reed spacer to get it to clear properly.
August 4th, 2003
I made a cheap-o body set! Whee!!
I used the un-sellable lower (all cracked and bubbled) to make a test piece to fit to the motor.
I used the old cracked tail to put on there just to have a seat too. This should be enough to get me through the VIN check and light check (if required) when I try to get the bike titled. I don't want to have a nice set on there since it could easily get dinged and scraped up in transit. This will someday become my 'track' faring set too.
Still waitin' on the chain and pipe..... Then it's test ride time!
8/12/03
The pipe is here! As is the chain. The rear bracket which goes to the footpeg is a little too far forwards, but no matter- I'm running the 1" set-backs anyhow. This is something to keep in mind if you have crawford build a pipe for you though- tell him to put the rear mount 1/2-1" further back than it is. Or if you know how to weld, send the rear mount off the pipe and mount it later. Everything else was absolutely perfect!!! A bargain at the price he charges for them!!
My Tsubaki chain arrived too. I busted my Calamari chain breaker- no 520 chains for that thing :(
I bought a motion pro chain breaker- it works great for 420-530 chains.
8/13/03
Calamari stuff arrives! I got a new windscreen too, and a kill switch. I'll put on the windscreen when I put the 'good' fairing set on.
Check out that exhaust can- is that awesome or what?
See- the mount should be about 1/2" back to be a perfect fit, but the bracket makes that a moot point- I like it better where it is now to be out of the way! Keep this in mind if you order one and don't want to run set backs though.
11/3/03
Painting complete! New fairing set installed.
Pro-design intake manifold installed- carb. fits much better now, and the intake manifold spacer is no longer necessary..
Bike completed.. for now.
The stickers look nicer than they really are- the fit was pretty poor on the tail stickers- I had to slice them each into 4 strips to get them to go on right. Sometime I will re-do the tail, but it will stay as it is for awhile. I might jet-hot the pipe someday as well so it doesn't rust. I'll wait and do my pocketbike exhaust at the same time.
06/14/04
I got bored..
So I rigged up a linkage shifter! It's off an R6, I think. Keep it in the (Yamaha) family, right? It now shifts standard pattern, and shifts considerably easier.
Done again.. for now. Perhaps it'll be due for a professional repaint someday. I also need to extend the kick stand..
Special thanks to these folks for making the project a reality:
Tony Tice (the Ticeman himself) for inspiration and help! (www.ticeman.com)
Chris and Daren from the Ticeman YSR info board for reg. info and Blaster info!
Joe Huminsky of Team Screams customs for his beautiful welding job of the frame (cinsi1@msn.com)
Chad Wright of CWR Performance for the awesome swingarm, fork caps, and brake brace (www.cwrperformance.com)
'The Squids' at Team Calamari Racing for all the other upgraded parts on the bike! (www.teamcalamari.com)
Sprocket Specialists for their quick and good work on the sprockets (www.sprocketspecialists.com)
Tommy Crawford at T.C. Exhausts for the Blaster conversion pipe (909) 658-4205
Eric Trenga (Trenga Racing) at www.trengaracing.com (Blaster engine parts)
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