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

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

EBU17430
SAFETY INFORMATION

SAFETY INFORMATION

EBU17591
AN ATV IS NOT A TOY AND CAN BE HAZARD-
OUS TO OPERATE.

An ATV handles differently
from other vehicles, including motorcycles and
cars. A collision or rollover can occur quickly, even
during routine maneuvers such as turning and
riding on hills or over obstacles, if you fail to take
proper precautions.
SEVERE INJURY OR DEATH can result if you do
not follow these instructions:

Read this manual and all labels carefully and fol-
low the operating procedures described.

Never operate an ATV without proper training or
instruction.

Always follow the age recommendation:
– A child under 16 years old should never oper-
ate an ATV with engine size greater than 90 cc.

Never allow a child under age 16 to operate an
ATV without adult supervision, and never allow
continued use of an ATV by a child if he or shedoes not have the abilities to operate it safely.

Never carry a passenger on an ATV.

Always avoid operating an ATV on any paved
surfaces, including sidewalks, driveways, park-
ing lots and paved streets.

Never operate an ATV on any paved street,
paved road or motorway.

Watch carefully for other vehicles when operat-
ing on unpaved public streets or roads. Make
sure you know your country’s laws and regula-
tions before you ride on unpaved public streets
or roads.

Never operate an ATV without wearing an ap-
proved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face
shield), gloves, boots, a long-sleeved shirt or a
jacket, and long pants.

Never consume alcohol or drugs before or while
operating this ATV.

Never operate at speeds too fast for your skills
or the riding conditions. Always go at a speed

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

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

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

cock is in the “OFF” position. Otherwise, fuel
may leak out of the carburetor or fuel tank.

Gasoline is poisonous. If you should swal-
low some gasoline or inhale a lot of gasoline
vapor, or get some gasoline in your eyes,
seek medical help immediately. If gasoline
spills on your skin, wash with soap and wa-
ter. If gasoline spills on your clothing,
change your clothes.
WARNING

EWB00070
Always operate your ATV in an area with ade-
quate ventilation. Never start or run the engine
in a closed area. Exhaust fumes are poisonous
and may cause loss of consciousness and
death within a short time.

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

EBU17731
INSTRUMENT AND CONTROL FUNCTIONS
EBU17750
Main switch
The positions of the main switch are as follows:
ON
All electrical systems are supplied with power. The
headlight and taillight come on when the light
switch is on, and the engine can be started. The
key cannot be removed.
OFF
All electrical systems are off. The key can be re-
moved.

1. Main switch
ON OFF1

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

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

4-3
1
2
34
5
6
7
8
9
10
11

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

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

fore riding the ATV or consult a Yamaha dealer.
EBU18300
Throttle OverRide System
If during operation, the carburetor or the throttle ca-
ble should malfunction and will not close fully, take
your thumb off the throttle lever.
The throttle override system immediately cuts off
the ignition.
WARNING

EWB00260
Riding with a malfunction increases the
chance for an accident and injury. Make sure
that the cause of the malfunction is corrected
before restarting the engine or have the ATV in-
spected by a Yamaha dealer.
EBU18321
Speed limiter
Your ATV was delivered with an adjustable speed
limiter. The speed limiter keeps the throttle from
fully opening, even when the throttle lever is
pushed to the maximum.
1. Loosen the locknut.
2. To increase the maximum engine power avail-
able and the maximum speed of the ATV, turnthe adjusting screw in direction (a). To de-
crease the maximum engine power available
and the maximum speed of the ATV, turn the
adjusting screw in direction (b).
3. Tighten the locknut.
WARNING

EWB00240
Improper adjustment of the speed limiter and
throttle could cause throttle cable damage or
improper throttle operation. You could lose
control, have an accident or be injured. Do not
1. Adjusting screw
2. Locknut
3. No more than 12 mm (0.47 in)
(a)
(b)
3
12

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

EBU18500
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