Yamaha Blaster TORS Delete Guide: OEM and Aftermarket Carburetors

The Yamaha Blaster TORS can be removed while retaining the factory Mikuni VM26 carburetor or when upgrading to an aftermarket carburetor. This guide explains the differences, the parts required and the basic installation process for both setups.

What Is the Yamaha Blaster TORS?

TORS stands for Throttle Override System. The system monitors the throttle assembly and carburetor slide. If it detects that the carburetor remains open when the thumb throttle is released, it interrupts the ignition to stop the engine.

A malfunctioning TORS can cause:

• No spark
• Intermittent spark
• An engine that starts but will not rev
• Cutting out or misfiring
• An excessively large and complicated carburetor top
• Problems when installing an aftermarket carburetor

Deleting TORS removes the carburetor-mounted switch, throttle switch and associated wiring from the ignition circuit.

Choose Your Carburetor Setup

Carburetor	Required cable and parts
Factory Mikuni VM26	TORS eliminator cable, replacement carburetor top and external idle-adjustment screw
Aftermarket 26mm carburetor	Standard TORS-delete throttle cable
Keihin PWK 28mm	Standard TORS-delete throttle cable and any necessary intake or airbox adapter

Option 1: TORS Delete With the OEM Mikuni VM26 Carburetor

The factory VM26 uses the oversized TORS assembly as its carburetor top. Removing it requires a conventional carburetor cap, a different throttle cable and a new method of adjusting idle speed.

Parts Required

• Motion Pro TORS Eliminator Cable and Top for OEM VM26 Carburetor
• External idle-adjustment screw
• Correct drill and tap for installing the idle screw
• Cable lubricant
• Basic hand tools

The Motion Pro cable-and-top kit sold by Ken OConnor Racing does not include the tap, drill, or idle screw required for the idle-adjustment screw. Please purchase them separately.

Removing the Factory TORS Carburetor Top

1. Turn the fuel petcock off.
2. Remove the seat, fuel tank and any bodywork necessary to access the carburetor and throttle cable.
3. Disconnect the electrical connector leading to the TORS unit on top of the carburetor.
4. Unscrew and remove the large factory TORS carburetor-top assembly.
5. Carefully remove the slide, needle and spring.
6. Note the direction of the slide and the position of the needle retaining parts.
7. Disconnect and remove the original TORS throttle cable.

Installing the New Cable and Carburetor Top

1. Route the new throttle cable along the original cable path.
2. Avoid tight bends, hot exhaust components and steering components.
3. Connect the cable to the thumb throttle.
4. Install the cable through the replacement carburetor cap and spring.
5. Attach the cable end to the carburetor slide.
6. Reinstall the needle and retaining components in their original positions.
7. Insert the slide into the carburetor with its locating groove properly aligned.
8. Thread the new cap onto the carburetor and tighten it securely by hand.
9. Turn the handlebars completely left and right while verifying that the throttle operates freely.

Installing the VM26 External Idle Screw

The original TORS assembly controls idle by holding the throttle slide slightly open. Once that assembly is removed, an external idle screw must be installed in the VM26 carburetor.

The carburetor body has a cast boss where the idle screw is installed. This boss must be drilled and tapped correctly so the new screw contacts the throttle slide.

1. Remove the carburetor from the engine.
2. Completely disassemble it before drilling.
3. Locate the factory idle-screw boss on the LEFT side of the carburetor.
4. Drill the boss straight and all the way through the carburetor body .
5. Remove the tapered section of the boss with a file or mill. Remove enough material until the inner chamfer of the hole is gone. Be sure to cut the boss square and flat.
6. Tap the hole using the thread specified by the idle-screw kit. Be sure to use cutting oil on the tap.
7. Thoroughly clean the carburetor to remove every metal chip.
8. Install the idle screw, spring and related hardware.
9. Reassemble and reinstall the carburetor.
10. Adjust the screw until the engine maintains a reliable idle. A rough setting is for the slide to be open 1/32 of an inch when resting against the idle screw.

Option 2: TORS Delete With an Aftermarket Keihin 28PWK Carburetor

Most conventional aftermarket carburetors already have a normal carburetor cap and built-in idle-adjustment screw. They do not require the VM26 replacement top or the drill-and-tap procedure.

Parts Required

• Motion Pro TORS-Delete Throttle Cable
• Properly sized aftermarket carburetor
• Correct intake and airbox connections
• Correct jets for the engine combination

Available carburetor options include:

• Genuine Keihin PWK 28mm Carburetor
• Keihin PWK 28mm Carburetor Adapter
• 28mm Carburetor Clamp Kit

Aftermarket Carburetor Installation

1. Turn off the fuel and remove the factory carburetor.
2. Disconnect the wiring from the factory TORS carburetor top.
3. Remove the original TORS throttle cable.
4. Route the new TORS-delete throttle cable along the factory route.
5. Connect it to the thumb throttle and aftermarket carburetor slide.
6. Install the carburetor into the intake boot.
7. Connect the airbox boot or required adapter.
8. Verify that both connections are properly seated and clamped.
9. Connect the fuel line and check for leakage.
10. Adjust throttle-cable free play.
11. Turn the handlebars fully in both directions and confirm that engine speed cannot change.
12. Rejet the carburetor for the engine, exhaust, intake, temperature and elevation.

Installing an aftermarket carburetor does not automatically provide correct jetting. The engine must be jetted for the complete combination before it is operated under load.

Removing or Bypassing the TORS Wiring

Yamaha used different ignition and TORS wiring on 1988–2002 and 2003–2006 Blasters. Do not assume that instructions for one generation apply to the other.

1988–2002 Yamaha Blaster

These models use a separate TORS control unit.

1. Locate the TORS control unit beneath the front bodywork.
2. Disconnect the control unit from the wiring harness.
3. Disconnect the electrical connector from the carburetor-mounted TORS switch.
4. Disconnect the wiring from the thumb-throttle switch.
5. Secure the unused connectors so they cannot contact the frame, exhaust or steering components.
6. Leave the key switch and handlebar run/stop switch functional.

2003–2006 Yamaha Blaster

The later ignition system is wired differently and must not be treated like the earlier separate-control-box system.

1. Disconnect the switch on the original TORS carburetor top.
2. Trace the two-wire lead from the thumb-throttle switch to its connector.
3. The throttle-switch circuit must be properly bypassed for the ignition to operate.
4. You will have two wires (black and yellow). Cut the connectors off. One set under hood, One set under seat. Once again, make sure you have cut the connectors on ECU side not carb and throttle side.
5. Lastly, strip the ends of the wires and splice the yellow and black wires together where they have been cut. (you must splice both sets).
6. Make the bypass at the correct connector, then solder and heat-shrink the connection.
7. Do not randomly connect wires at the CDI.
8. Keep the key switch and handlebar run/stop switch operational.
9. Secure all abandoned connectors against moisture and accidental grounding.

The parking-brake switch on 2003–2006 models can also limit engine speed. If the engine starts but repeatedly cuts out when the throttle is opened, inspect the parking-brake switch and its adjustment before assuming the carburetor is incorrectly jetted.

Throttle Adjustment and Safety Inspection

Before starting the engine:

1. Adjust the cable to provide a small amount of free play at the thumb throttle.
2. Press and release the throttle repeatedly.
3. Listen for the slide to close firmly each time.
4. Turn the handlebars completely left and right.
5. Confirm that steering movement does not pull the cable or raise the slide.
6. Check that the carburetor cap is tight.
7. Verify that the intake boot and airbox connection are sealed.
8. Confirm that the handlebar kill switch works.
9. Start the engine with the transmission in neutral.
10. Test the throttle-return action again before riding.

Never operate the Blaster if the throttle binds, closes slowly or changes position as the handlebars are turned.

Common Problems After a TORS Delete

The engine has no spark

Check the year-specific TORS bypass, handlebar run/stop switch, key switch, grounds and wiring connectors. Do not replace the CDI until the wiring has been tested.

The engine starts but will not rev

On 2003–2006 models, inspect the throttle-switch bypass and parking-brake switch. A rich carburetor condition can also make the engine break up under throttle.

The OEM carburetor will not idle

Verify that the external idle screw was installed in the correct location and contacts the slide. Also inspect the pilot jet, air screw, intake boot and crankcase for air leaks.

The engine idles higher when the handlebars are turned

The throttle cable is routed incorrectly, adjusted too tightly or too short for the application. Correct the problem before operating the machine.

The engine bogs after installing an aftermarket carburetor

A TORS delete does not correct jetting. The pilot jet, needle position, main jet, float height and air screw must match the engine combination.

Frequently Asked Questions

Does a TORS delete increase horsepower?

No. Removing TORS does not directly increase horsepower. It simplifies the throttle system, eliminates potential electrical problems and makes aftermarket-carburetor installation possible.

Can I keep the OEM VM26 carburetor?

Yes. Use the replacement cable and carburetor-top kit, then install an external idle-adjustment screw.

Does an aftermarket carburetor need the VM26 top kit?

No. A conventional aftermarket carburetor already has its own cap and idle screw. It normally requires only the correct TORS-delete throttle cable and installation adapters.

Can I simply unplug everything?

Not on every model. The 1988–2002 and 2003–2006 ignition systems are different. Later models require the throttle-switch circuit to be bypassed correctly.

Should I twist wires together and cover them with tape?

No. Any required bypass should be soldered and protected with adhesive-lined heat-shrink tubing. Loose or exposed wiring can create intermittent ignition problems.

Final Check

A proper Yamaha Blaster TORS delete should leave you with:

• Smooth throttle operation
• Correct cable free play
• A slide that snaps fully closed
• A working idle adjustment
• A functional kill switch
• Sealed intake and airbox connections
• Correct carburetor jetting
• No loose or exposed wiring