clutch YAMAHA BLASTER 200 2003 Owners Manual

LOCATION OF THE WARNING AND
SPECIFICATION LABELS .......................1-1
SAFETY INFORMATION .........................2-1
DESCRIPTION AND MACHINE
IDENTIFICATION.....................................3-1
Identification number records ...............3-3
Key identification number .....................3-5
Vehicle identification number ...............3-7
Model label ...........................................3-9
CONTROL FUNCTIONS..........................4-1
Main switch ...........................................4-1
Indicator lights ......................................4-3
Oil level warning light checking
method ...............................................4-5
Handlebar switches ..............................4-9Throttle lever ......................................4-11
Throttle OverRide System ..................4-13
Speed limiter ......................................4-15
Clutch lever ........................................4-17
Brake lever .........................................4-17
Brake pedal ........................................4-19
Parking brake .....................................4-19
Shift pedal ..........................................4-23
Kick starter .........................................4-23
Fuel tank cap ......................................4-25
Fuel cock ............................................4-25
Starter (choke) ....................................4-27
Seat ....................................................4-29
Front shock absorber adjustment .......4-31
Rear shock absorber adjustment .......4-33
PRE-OPERATION CHECKS ...................5-1
Front and rear brakes ...........................5-5
Fuel ......................................................5-9
EBU00015
CONTENTS
1
2
3
4
5
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Spark plug inspection .........................8-25
Air filter element cleaning ...................8-31
Carburetor settings .............................8-39
Idle speed adjustment ........................8-51
Throttle lever adjustment ....................8-53
Brake fluid level check ........................8-55
Brake fluid replacement ......................8-57
Front brake pad inspection .................8-59
Rear brake pad inspection .................8-59
Front brake lever free play .................8-61
Brake pedal height adjustment ...........8-63
Parking brake adjustment ...................8-65
Adjusting the rear brake light switch ...8-69
Clutch adjustment ...............................8-71
Autolube pump adjustment .................8-71
Drive chain slack check ......................8-73
Drive chain slack adjustment ..............8-75
Lubricating the drive chain .................8-77
Cable inspection and lubrication ........8-81
Brake and shift pedal/brake and
clutch lever lubrication ......................8-83Front upper and lower arm pivot
lubrication .........................................8-83
Steering shaft lubrication ....................8-85
Wheel removal ...................................8-87
Wheel installation ...............................8-87
Replacing the headlight bulb ..............8-89
Headlight beam adjustment ................8-97
Tail/brake light bulb replacement .......8-99
Troubleshooting ................................8-101
Troubleshooting chart .......................8-105
CLEANING AND STORAGE....................9-1
A. Cleaning ...........................................9-1
B. Storage ............................................9-7
SPECIFICATIONS .................................10-1
Conversion table ....................................11-1
9
10
11
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3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION
1. Seat 11. Rear shock absorber
2. Fuel tank cap 12. Tail/brake light
3. Headlight 13. Rear wheel
4. Brake pedal 14. Shift pedal
5. Rear brake light switch 15. Clutch lever
6. Kick starter 16. Parking brake
7. Front shock absorber 17. Main switch
8. Front wheel 18. Brake lever
9. Fuel cock 19. Throttle lever
10. Starter (choke) 20. Handlebar switches
NOTE:
The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
123
4
5 6
t
yu
oi
p
78
90
qwe
r
5VM-9-60 (0~3 shou) 6/20/02 4:12 PM Page 54

4-17
EBU00068
Clutch lever
The clutch lever is located on the left handlebar.
Pull the clutch lever to the handlebar to disen-
gage the clutch, and release the lever to engage
the clutch. The lever should be pulled rapidly
and released slowly for smooth clutch operation.
EBU00988
Brake lever
The brake lever is located on the right handle-
bar. Pull it toward the handlebar to apply the
front brake.
q
q
1. Clutch lever1. Levier d’embrayage1. Palanca de embrague
1. Brake lever
1. Levier de frein1. Palanca del freno
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4-19
EBU00989
Brake pedal
The brake pedal is located on the right side of
the machine. Push down on the pedal to apply
the rear brake.
EBU00081
Parking brake
Use the parking brake when you have to start
the engine or park the machine, 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 2,300 r/min. Be sure the parking
brake is released before moving the throttle
lever. Otherwise, the engine will misfire, pre-
venting normal operation.
q
q
w
1. Brake pedal1. Pédale de frein1. Pedal del freno
1. Button 2. Lock plate
1. Bouton 2. Plaque de verrouillage1. Botón 2. Placa de bloqueo
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4-23
EBU00082
Shift pedal
This machine 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 com-
bination with the clutch when shifting.
EBU00089
Kick starter
Rotate the kick starter away from the engine.
Push the starter down lightly with your foot until
the gears engage, then kick smoothly and force-
fully to start the engine. This model has a prima-
ry-coupled kick starter so the engine can be
started in any gear if the clutch is disengaged.
However, shifting to neutral before starting is
recommended.
q
6
5
4
3
2
N
1
q
1. Shift pedal N. Neutral1. Pédale de sélection N. Point mort1. Pedal del cambio N. Punto muerto
1. Kick starter
1. Pédale de kick1. Pedal de arranque
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5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Brakes9Check operation, free play, fluid level and fluid leakage. 5-5–5-7
9Fill with DOT 4 brake fluid if necessary. 8-55–8-63
Clutch9Check operation, condition and lever free play. 8-71
Parking brake9Check operation, condition and cable free play. 8-65
Fuel 9Check fuel level.
9Fill with fuel if necessary.5-9–5-11
Transmission oil9Check oil level.
9Fill with oil if necessary.5-15, 8-17–8-23
2-cycle engine oil9Check oil level.
9Fill with oil if necessary.5-13
Drive chain9Check chain slack and condition.
9Adjust if necessary.5-17, 8-73–8-79
Throttle9Check for proper throttle cable operation. 5-17, 8-53
Wheels and tires9Check tire pressure, wear and damage. 5-21–5-27, 8-87
Fittings and fasteners9Check all fittings and fasteners. 5-17
Lights9Check for proper operation. 5-19, 8-89–8-99
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5-15
EBU01308
Transmission oil
Make sure the transmission oil is at the specified
level. Add oil as necessary. (See pages 8-17–
8-23.)
cC
8In order to prevent clutch slippage (since
the transmission oil also lubricates the
clutch), do not mix any chemical additives.
Do not use oils with a diesel specification of
“CD” or oils of a higher quality than speci-
fied. In addition, do not use oils labeled
“ENERGY CONSERVING
II” or higher.
8Make sure that no foreign material enters
the crankcase.
Recommended oil:
SAE 10W30
Recommended oil classification:
API Service SE, SF, SG type or higher
Oil quantity:
Total amount:
0.7 L
Periodic oil change:
0.65 L
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6-11
EBU00198*
Shifting
This model has a 6-speed forward transmission.
The transmission allows you to control the
amount of power you have available at a given
speed or for starting, accelerating, climbing hills,
etc. To shift into neutral, return the throttle lever
to its original position, apply the clutch and
repeatedly depress the shift pedal until it stops.
When it stops, it will be in first gear. Raise the
pedal slightly to neutral.
6
5
4
3
2
N
1
N. NeutralN. Point mortN. Punto muerto
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6-13
cC
8Do not coast for long periods with the
engine off, and do not tow the machine a
long distance. Even in neutral position,
the transmission is only properly lubri-
cated when the engine is running.
Inadequate lubrication may cause dam-
age.
8Always use the clutch when changing
gears. The engine, transmission and
drive train are not designed to withstand
the shock of forced shifting and can be
damaged by shifting without the clutch.
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