clutch YAMAHA BLASTER 200 2007 Owners Manual

EBU17420
TABLE OF CONTENTS
SAFETY INFORMATION .............................. 1-1
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 2-1
DESCRIPTION .............................................. 3-1
Left view ..................................................... 3-1
Right view................................................... 3-1
Controls and instruments ........................... 3-2
INSTRUMENT AND CONTROL
FUNCTIONS .................................................. 4-1
Main switch ............................................... 4-1
Indicator light ............................................. 4-2
Handlebar switches ................................... 4-2
Throttle lever ............................................. 4-3
Throttle OverRide System ......................... 4-4
Speed limiter ............................................. 4-4
Clutch lever ............................................... 4-5
Brake lever ................................................ 4-5
Brake pedal ............................................... 4-5
Parking brake ............................................ 4-6
Shift pedal ................................................. 4-7
Kickstarter ................................................. 4-7
Fuel tank cap ............................................. 4-8Fuel ............................................................ 4-8
Fuel cock ................................................... 4-9
Starter (choke) ......................................... 4-11
Seat ......................................................... 4-11
Adjusting the front shock absorber
assemblies .............................................4-12
Adjusting the rear shock absorber
assembly ................................................4-13
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ............................. 5-1
Fuel ............................................................ 5-4
2-stroke engine oil ..................................... 5-4
Transmission oil ......................................... 5-4
Front and rear brakes ................................ 5-4
Throttle lever .............................................. 5-5
Drive chain ................................................. 5-5
Tires ........................................................... 5-6
Measuring the tire pressure ....................... 5-7
Tire wear limit ............................................ 5-8
Chassis fasteners ...................................... 5-8
Instruments, lights and switches ................ 5-8
OPERATION...................................................6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-2

Shifting ...................................................... 6-2
Engine break-in ......................................... 6-4
Parking ...................................................... 6-5
Parking on a slope .................................... 6-6
Accessories and loading ........................... 6-6
RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV.............. 7-2
RIDE WITH CARE AND GOOD
JUDGEMENT ...........................................7-2
BE CAREFUL WHERE YOU RIDE ............ 7-8
TURNING YOUR ATV ............................. 7-12
CLIMBING UPHILL .................................. 7-14
RIDING DOWNHILL................................. 7-16
CROSSING A SLOPE.............................. 7-17
CROSSING THROUGH SHALLOW
WATER ..................................................7-18
RIDING OVER ROUGH TERRAIN .......... 7-20
SLIDING AND SKIDDING ........................ 7-20
WHAT TO DO IF... ................................... 7-21
WHAT TO DO... ....................................... 7-21
PERIODIC MAINTENANCE AND MINOR
REPAIR .......................................................... 8-1
Owner’s manual and tool kit ...................... 8-1
Periodic maintenance and lubrication
chart ........................................................ 8-3
Checking the spark plug ............................ 8-7
Transmission oil ........................................ 8-8Autolube pump ......................................... 8-11
Cleaning the air filter element .................. 8-11
Cleaning the spark arrester ..................... 8-14
Changing the carburetor settings ............. 8-16
Adjusting the engine idling speed ............ 8-21
Adjusting the throttle cable free play ........ 8-22
Checking the front and rear brake
pads ....................................................... 8-23
Checking the brake fluid level .................. 8-24
Changing the brake fluid .......................... 8-25
Checking the front brake lever free
play ........................................................ 8-25
Checking the brake pedal position ........... 8-26
Adjusting the parking brake free play ...... 8-27
Brake light switches ................................. 8-29
Adjusting the clutch lever free play .......... 8-29
Drive chain slack ...................................... 8-30
Lubricating the drive chain ....................... 8-32
Checking and lubricating the cables ........ 8-33
Checking and lubricating the brake and
clutch levers ........................................... 8-34
Checking and lubricating the brake and
shift pedals ............................................. 8-34
Checking the wheel bearings ................... 8-34
Lubricating the swingarm pivots .............. 8-34
Lubricating the upper and lower arm
pivots ..................................................... 8-35
Lubricating the steering shaft ................... 8-35
Replacing the headlight bulb ................... 8-36

3-2
1
23
4
5
6
7
8
9
10
11

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Controls and instruments
NOTE:

The ATV you have purchased may differ slightly
from the figures shown in this manual.
1. Clutch lever
2. Parking brake lock plate
3. Main switch
4. Front brake lever
5. Throttle lever
6. Handlebar switches
1
26
3
4
5

4-5
1
2
34
5
6
7
8
9
10
11

turn the adjusting screw out more than 12 mm
(0.47 in) or the throttle cable could be dam-
aged. Always make sure the throttle lever free
play is adjusted to 4.0–6.0 mm (0.16–0.24 in).
(See page 8-22.)
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Clutch lever
The clutch lever is located on the left handlebar. To
disengage the clutch, pull the clutch lever toward
the handlebar grip. To engage the clutch, release
the clutch lever. The clutch lever should be pulled
rapidly and released slowly for smooth clutch oper-
ation.
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Brake lever
The brake lever is located at the right handlebar
grip. To apply the front brake, pull the brake lever
toward the handlebar grip.
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Brake pedal
The brake pedal is located on the right side of the
ATV. To apply the rear brake, push down on the
brake pedal.
1. Clutch lever
1

1. Brake lever
1

4-6
1
2
34
5
6
7
8
9
10
11

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Parking brake
Use the parking brake before starting the engine or
parking the ATV, especially on a slope. Squeeze
the clutch lever while pushing the button, then
push in the lock plate to apply the parking brake.
Squeeze the clutch lever to release the parking
brake.
NOTE:

When the parking brake is used, engine speed is
limited to 2300 r/min. Be sure the parking brake is
released before moving the throttle lever. Other-wise, the engine will misfire, preventing normal op-
eration.
1. Brake pedal
1

1. Button
2. Parking brake lock plate
1
2

4-7
1
2
34
5
6
7
8
9
10
11
WARNING

EWB00220

Always set the parking brake before starting
the engine. The ATV could start moving un-
expectedly if the parking brake is not ap-
plied. This could cause loss of control or a
collision.

Always be sure you have released the park-
ing brake before you begin to ride. The brake
could overheat if you ride the ATV without re-
leasing the parking brake. You could lose
braking performance which could cause an
accident. You could also wear out the brakes
prematurely.
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Shift pedal
This ATV is equipped with a constant-mesh 6-
speed transmission. The shift pedal is located on
the left side of the engine and is used in combina-
tion with the clutch when shifting.
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Kickstarter
Fold out the kickstarter lever, move it down lightly
with your foot until the gears engage, and then
1. Locked position
1

1. Shift pedal
2. Neutral position
6
5
4
3
2
N
1
1 2

4-8
1
2
34
5
6
7
8
9
10
11

push it down smoothly but forcefully. This model is
equipped with a primary kickstarter, allowing the
engine to be started in any gear if the clutch is dis-
engaged. However, shifting the transmission into
the neutral position before starting is recommend-
ed.
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Fuel tank cap
Remove the fuel tank cap by turning it counter-
clockwise.
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Fuel
Make sure that there is sufficient fuel in the tank.
Fill the fuel tank to the bottom of the filler tube as
shown.
1. Kickstarter
1

1. Fuel tank cap
1

5-2
1
2
3
45
6
7
8
9
10
11

Rear brake

Check operation. If soft or spongy, have Yamaha dealer bleed
hydraulic system.

Check brake pads for wear, and replace if necessary.

Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.

Check hydraulic system for leakage. Correct if necessary.5-4, 8-23, 8-24, 8-26
Clutch

Check operation, and correct if necessary.

Lubricate cable if necessary.

Check lever free play, and adjust if necessary.8-29
Throttle lever

Make sure that operation is smooth. Lubricate cable and lever hous-
ing if necessary.

Check cable free play, and adjust if necessary.5-5, 8-22
Control cables

Make sure that operation is smooth. Lubricate if necessary. 8-33
Drive chain

Check chain slack, and adjust if necessary.

Check chain condition. Lubricate if necessary.5-5, 8-30, 8-32
Wheels and tires

Check wheel condition, and replace if damaged.

Check tire condition and tread depth. Replace if necessary.

Check air pressure. Correct if necessary.5-6, 5-7, 5-8
Brake and shift pedals

Make sure that operation is smooth. Lubricate pedal pivoting points
if necessary.8-34
Brake and clutch levers

Make sure that operation is smooth. Lubricate lever pivoting points
if necessary.8-34
Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened. 5-8
Instruments, lights and
switches

Check operation, and correct if necessary. 5-8
ITEM ROUTINE PAGE

6-3
1
2
3
4
56
7
8
9
10
11

To shift into neutral, return the throttle lever to the
closed position, apply the clutch, and then repeat-
edly depress the shift pedal until it stops.
When it stops, it will be in first gear. Raise the pedal
slightly to reach the neutral position.
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To start out and accelerate
1. Release the throttle lever.
CAUTION:

ECB00200
Always close the throttle before shifting gears,
otherwise damage to the engine and drive train
may result.
2. Pull the clutch lever to disengage the clutch.
3. Shift into first gear.
4. Open the throttle gradually and at the same
time, release the clutch lever slowly.
5. Once the ATV has attained adequate speed,
release the throttle, and at the same time,
quickly pull in the clutch lever.
6. Shift the transmission into second gear.
(Make sure not to shift the transmission into
neutral)
7. Open the throttle part way and gradually re-
lease the clutch lever.
8. Follow the same procedure when shifting to
the next higher gear.WARNING

EWB00730
Opening the throttle abruptly or releasing the
clutch lever too quickly could make the ATV
wheelie, which would increase the chance of
an accident, including an overturn.
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To decelerate
When slowing down or stopping, release the throt-
tle and apply the brakes smoothly and evenly. As
1. Neutral position
2. Shift pedal
6
5
4
3
2
N
1
1
2

6-4
1
2
3
4
56
7
8
9
10
11

you slow down, shift to a lower gear. Be sure that
the engine has sufficiently slowed before engaging
a lower gear. Improper use of the brakes or shifting
can cause the tires to lose traction, reducing con-
trol and increasing the possibility of an accident.
WARNING

EWB00710
Make sure the engine has sufficiently slowed
before shifting to a lower gear. Engaging a low-
er gear when the engine speed is too high
could make the wheels stop rotating and lose
traction. This could cause loss of control, an
accident and injury. It could also cause engine
or drive train damage.
CAUTION:

ECB00180

Even with the transmission in the neutral po-
sition, do not coast for long periods of time
with the engine off, and do not tow the ATV
for long distances. The transmission is prop-
erly lubricated only when the engine is run-
ning. Inadequate lubrication may damage
the transmission.

Always use the clutch when changing gears.
The engine, transmission and drive train are
not designed to withstand the shock offorced shifting and can be damaged by shift-
ing without using the clutch.
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Engine break-in
NOTE:


For ATVs equipped with an odometer or an hour
meter, follow the figures given in km (mi) or the
figures given in hours.

For ATVs not equipped with an odometer or
hour meter, follow the figures given in hours.
There is never a more important period in the life of
your engine than the first 320 km (200 mi) or 20
hours of riding. For this reason, you should read
the following material carefully.
Since the engine is brand new, do not put an ex-
cessive load on it for the first 320 km (200 mi) or 20
hours. The various parts in the engine wear and
polish themselves to the correct operating clear-
ances. During this period, prolonged full-throttle
operation or any condition that might result in en-
gine overheating must be avoided.
0–160 km (0–100 mi) or 0–10 hours
Avoid prolonged operation above 1/2 throttle. Vary