2001 Blaster Top End Rebuild - Completed Dec 2025

2001 Blaster Top End Rebuild - Completed Dec 2025

Virgil put this Blaster together as a solid, reliable ride for a kid or someone just getting started. No fancy performance mods here—just a clean, stock bike that runs like a champ. Think of it as a blank canvas. You want to add some performance down the road? This is your starting point. Stock Blasters typically push out around 15 to 17 horsepower from that 195cc engine, with a top speed hovering around 55 MPH. 

This one still has the oil injection and TORS intact. After getting a new top end rebuild, the engine now has about 200cc. For a little more punch, we could throw a pipe and jets on it—though that means ditching the oil injection system. It would be running premix like a Banshee does.

Here's the backstory: 

We've been picking up Blasters here and there that need some love. This particular one came from another local shop that had too many projects on their plate. When we got it, it was complete except the engine was out of it. Virgil grabbed an engine from another Blaster we had, opened it up, and found it needed a fresh piston and a cylinder bore. Off to the machine shop it went.

While the cylinder and piston were getting sorted, Virgil cleaned up and inspected the rest of the bike. Once the machined parts came back, he reassembled the engine without a hitch. He pulled the bowl off the carb, cleaned out the main and pilot jets, buttoned it back up, and—boom—it fired right up.

Pretty straightforward build, honestly. In our shop, we handle everything from simple repairs like this all the way up to full-blown performance Banshee engine builds and resto mods. I almost didn't write this one up since it was so simple and we're usually neck-deep in Banshee projects. But then I thought—if you've got a Blaster sitting around that needs work, this shows just how budget-friendly and manageable these repairs can be.

This one was for sale, but it has sold. Teryl has been having so much fun on his 421 Serval Banshee we built for him, that he decided to pick this Blaster up for his son, with a few upgrades added. Now they can go riding together.

Keep scrolling down ⬇️ to see the project specs. 

 

Q- QUESTIONS About Your Project?
A- You can call 📞📱 or message us at 541-419-6054. 

Whether you're restoring a vintage ATV, upgrading your suspension, or planning an engine build, we're happy to help. We specialize in Yamaha Banshees. If you have a different project in mind, contact us and we will let you know if we can take it on and what you can expect. 

We are flexible and will work with you. We offer a range of services. We can:

  1. Help you select the parts for your DIY build and ship them to you.
  2. Help you Pack and Ship your Engine to us, then build your engine and ship it back to you to install.
  3. Complete the whole engine build for you and install in your Banshee.
  4. We can inspect, repair and service the whole Banshee for you if you'd like.
  5. We can build or restore your Banshee, if that's what you need.
  6. We may also be able to locate a local Banshee for you and install your newly built engine in it.

Project Specs

NOTE: I'm still pulling together some of these specs. I've posted what I have so far. ~Janel 😉

  • BUILD NAME: 2001 Blaster Top End Rebuild
  • DISPLACEMENT:  200 cc (Stock is 195 cc)
  • CYLINDER:  Stock Cylinder Bored to 66.5 mm (0.50 mm over stock)
  • PORTING:  None 
  • PISTON:  Wiseco 66.5 mm 573 Piston (573M06650) (0.50 mm over stock)
  • CYLINDER HEAD:  Stock
  • DOME:  Stock 
  • CRANKSHAFT:  Stock 
  • COMPRESSION:  _____ psi
  • REEDS / CAGE:  
  • CARB:  Stock 
  • CARB JETTING:  25 pilot  ____ main
  • NEEDLE:  ___
  • AIR SCREW ADJUSTMENT:  ___ turn out
  • FUEL RECOMMENDATION:  Premium Non-Ethanol (91-94 Octane)
  • CLUTCH:  OEM 
  • EXHAUST:  Stock pipe & silencer
  • TIMING:  Set to ___ degrees advanced

 

Back to blog

References:

  • We calculate engine displacement based on the bore in the engine's cylinders and the stroke length of the crankshaft. Click here for more explanation in our Banshee Engine Displacement blog article. 
  • Click here for information about Banshee engine break-in procedures. This includes our recommendations for Fuel to Oil Ratios and Selecting the Correct Fuel.

About the Authors:

This project article was written by Janel with plenty of help from Virgil. Virgil is the Banshee mechanic, and I am the website mechanic. I do own and ride a Banshee, which helps. 

The Re-Do crew hopes sharing our project info and specs may help some with their own projects, or that you find it interesting. I want our technical info to be accurate and helpful.

Please do let us know if you like our project articles, or if you think I need to correct something. You can send an email to info@redo-parts.com - and your comments will be passed along to me. 

Thanks ~Janel 😉👌