check engine 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

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ing, use the proper gear and maintain a steady
speed when climbing a hill. If you stall or roll
backwards, follow the special procedure for
braking described in this manual. Dismount on
the uphill side or to a side if pointed straight up-
hill. Turn the ATV around and remount, following
the procedure described in this manual.

Always check for obstacles before operating in a
new area.

Never attempt to operate over large obstacles,
such as large rocks or fallen trees. Always follow
proper procedures when operating over obsta-
cles as described in this manual.

Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such as
ice, go slowly and be very cautious in order to re-
duce the chance of skidding or sliding out of con-
trol.

Never operate an ATV in fast flowing water or in
water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.

Always use the size and type of tires specified in
this manual.

Always maintain proper tire pressure as de-
scribed in this manual.

Never modify an ATV through improper installa-
tion or use of accessories.

Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow in-
structions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for brak-
ing.
WARNING

EWB00061

Always turn off the engine when refueling.

Do not refuel right after the engine has been
running and is still very hot.

Do not spill gasoline on the engine or ex-
haust pipe/muffler when refueling. Never re-
fuel while smoking, or in the vicinity of
sparks, open flames, or other sources of ig-
nition such as the pilot lights of water heat-
ers and clothes dryers. Gasoline can catch
fire and you could be burned.

When transporting the ATV in another vehi-
cle, be sure it is kept upright and that the fuel

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EBU17781
Indicator light
EBU17881
2-stroke engine oil level warning light “”
This warning light comes on when the oil level in
the 2-stroke engine oil tank is low during operation.
If the warning light comes on during operation,
stop the engine when it is safe to do so, and fill the
oil tank with Yamalube 2 or equivalent 2-stroke en-
gine oil. The warning light should go off after the oil
tank has been refilled.
The electrical circuit of the warning light can be
checked by starting the engine. (See page 6-1.) Ifthe warning light does not come on for a few sec-
onds, then go off, have a Yamaha dealer check the
electrical circuit.CAUTION:

ECB00020
Always make sure there is enough engine oil
before starting the engine.
EBU18061
Handlebar switches
1. Oil level warning light “ ”
1

1. Light switch “LIGHTS”
2. Engine stop switch “ENG. STOP”
1
2

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EBU18070
Engine stop switch “ENG. STOP”
Set this switch to “RUN” before starting the engine.
The engine stop switch controls the ignition and
stops the engine when it is running. Use this switch
to stop the engine in an emergency situation. The
engine will not start or run when this switch is set
to “OFF”.
EBU18110
Light switch “LIGHTS”
Set this switch to “LO” to turn on the low beam and
the taillight. Set the switch to “HI” to turn on the
high beam and the taillight. Set the switch to “OFF”
to turn off all the lights.
NOTE:

The headlight and the taillight can be turned on
only when the engine is running.
EBU18280
Throttle lever
Once the engine is running, movement of the throt-
tle lever will increase the engine speed.
Regulate the speed of the ATV by varying the
throttle position. Because the throttle is spring-
loaded, the ATV will decelerate, and the engine will
return to an idle any time the hand is removed fromthe throttle lever.
Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.WARNING

EWB00250
Malfunction of the throttle could make it diffi-
cult to speed up or slow down when you need
to. This could cause an accident. Check the op-
eration of the throttle lever before you start the
engine. If the throttle does not work smoothly,
check for the cause. Correct the problem be-
1. Throttle lever
1

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EBU19200
PRE-OPERATION CHECKS
EBU19220
Pre-operation check list
Before operating this ATV, be sure to check the items listed in the following table.
NOTE:

The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic
maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a
Yamaha dealer.
ITEM ROUTINE PAGE
Fuel


Check fuel level in fuel tank, and add recommended fuel if neces-
sary.

Check fuel line for leakage. Correct if necessary.4-8, 5-4
2-stroke engine oil

Check oil level in oil tank, and add recommended oil to specified
level if necessary.

Check ATV for oil leakage. Correct if necessary.5-4
Transmission oil

Check oil level in transmission case, and add recommended oil to
specified level if necessary.

Check ATV for oil leakage. Correct if necessary.5-4, 8-8
Front 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, 8-25

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EBU19540
Fuel
Make sure that there is sufficient fuel in the tank.
(See page 4-8.)
WARNING

EWB00520

Do not overfill the fuel tank. Fuel expands
when it heats up. If the fuel tank is overfilled,
fuel could spill out due to heat from the en-
gine or the sun.

Be careful not to spill fuel, especially on the
engine or exhaust pipe which can cause a
fire and severe injury. Wipe up any spilled
fuel immediately.

Do not refuel right after the engine has been
running and is still very hot.

Be sure the fuel tank cap is closed securely.
EBU19572
2-stroke engine oil
Make sure that there is sufficient 2-stroke engine
oil in the oil tank. Add oil as necessary. (See
page 10-1.)
EBU19580
Transmission oil
Make sure that the transmission oil is at the speci-
fied level. Add oil as necessary. (See page 8-8.)
EBU19710
Front and rear brakes
Brake lever and brake pedal

Check that there is no free play in the brake le-
ver. If there is free play, have a Yamaha dealer
check the brake system.

Check for correct brake pedal height. (See
page 8-26.) If the pedal height is incorrect, have
1. Engine oil tank filler cap1

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the speed of the ATV regularly. Do not operate it at
one set throttle position.
160–320 km (100–200 mi) or 10–20 hours
Avoid prolonged operation above 3/4 throttle. Rev
the engine through the gears freely, but do not use
full throttle at any time.
320 km (200 mi) or 20 hours and beyond
The ATV can now be operated normally.
CAUTION:

ECB00220
If any engine trouble should occur during the
engine break-in period, immediately have a
Yamaha dealer check the ATV.
EBU20721
Parking
When parking the ATV, stop the engine, shift into
first gear, apply the parking brake, and then turn
the fuel cock to “OFF”.
1. Button
2. Parking brake lock plate
1
2

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16
*
Shock absorber
assemblies

Check operation and correct if necessary.

Check for oil leakage and replace if necessary.
√√√
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*
Steering shaft


Lubricate with lithium-soap-based grease.
√√√
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*
Steering system


Check operation and repair or replace if damaged.

Check toe-in and adjust if necessary.
√√√√√
19
*
Carburetor


Check starter (choke) operation and correct if nec-
essary.

Check engine idling speed and adjust if neces-
sary.
√√√√
20
*
Crankcase breather
system

Check breather hose for cracks or other damage,
and replace if necessary.
√√√
21 Transmission oil

Change.

Check ATV for oil leakage, and correct if neces-
sary.
√ √√√
22
*
Autolube pump


Check operation and bleed if necessary.
√√√
23
*
Moving parts and
cables


Lubricate.
√√√√
24
*
Throttle lever hous-
ing and cable


Check operation and correct if necessary.

Check throttle cable free play and adjust if neces-
sary.

Lubricate throttle lever housing and cable.
√√√√√
25
*
Exhaust system


Check for leakage and replace gasket(s) if neces-
sary.

Check for looseness and tighten all screw clamps
and joints if necessary.
√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth 1 3 6 6 12
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300

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EBU23211
Checking the spark plug
The spark plug is an important engine component,
which is easy to check. Since heat and deposits
will cause any spark plug to slowly erode, the spark
plug should be removed and checked in accor-
dance with the periodic maintenance and lubrica-
tion chart. In addition, the condition of the spark
plug can reveal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown, with thespark plug wrench included in the owner’s tool
kit.
To check the spark plug
1. Check that the porcelain insulator around the
center electrode of the spark plug is a medi-
um-to-light tan (the ideal color when the ATV
is ridden normally).
NOTE:

If the spark plug shows a distinctly different color,
the engine could be operating improperly. Do not
attempt to diagnose such problems yourself. In-
stead, have a Yamaha dealer check the ATV.
1. Spark plug cap
1

1. Spark plug wrench
1