2002 YAMAHA BLASTER 200 carburetor

Spark plug inspection .........................8-21
Air filter cleaning .................................8-25
Carburetor settings .............................8-33
Idle speed adjustment ........................8-45
Throttle lever adjustment ....................8-47
Front brake shoe inspection ...............8-49
Rear brake pad inspection .................8-49
Front brake lever free play
adjustment ........................................8-51
Parking brake adjustment ...................8-55
Adjusting the rear brake light switch ...8-57
Clutch adjustment ...............................8-59
Autolube pump adjustment .................8-59
Drive chain slack check ......................8-61
Drive chain slack adjustment ..............8-63
Lubricating the drive chain .................8-65
Cable inspection and lubrication ........8-69
Brake and shift pedal/brake and
clutch lever lubrication ......................8-71
Upper arm and lower arm pivot
lubrication .........................................8-71Steering shaft lubrication ....................8-73
Wheel removal ...................................8-73
Wheel installation ...............................8-73
Replacing the headlight bulb ..............8-75
Headlight beam adjustment ................8-79
Tail/brake light bulb replacement .......8-81
Troubleshooting ..................................8-83
Troubleshooting chart .........................8-87
CLEANING AND STORAGE....................9-1
A. Cleaning ...........................................9-1
B. Storage ............................................9-7
SPECIFICATIONS .................................10-1
HOW TO USE THE CONVERSION
TABLE ....................................................11-1
9
10
11
5KJ-62 (0~3 shou) 4/23/01 3:03 PM Page 14

4-13
EBU00065
Throttle OverRide System
If during operation, the carburetor or the throttle
cable should malfunction and will not close fully,
take your thumb off the throttle lever.
The throttle override system immediately cuts off
the ignition.
w
Riding with a malfunction increases the
chance for an accident and injury. Make sure
that the cause of the malfunction is correct-
ed before restarting the engine or have the
ATV inspected by a Yamaha dealer.
5KJ-62 (4~5 shou) 4/23/01 3:04 PM Page 14

4-25
EBU00092
Fuel tank cap
Remove the fuel tank cap by turning it counter-
clockwise.
EBU00093
Fuel cock
The fuel cock supplies fuel from the fuel tank to
the carburetor.
The fuel cock has three positions.
OFF: With the lever in this position fuel will not
flow. Always turn the lever to this position
when the engine is not running.
ON: With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
RES: This indicates reserve. If you run out of
fuel while riding, turn the lever to this
position. THEN FILL THE FUEL TANK
AT THE FIRST OPPORTUNITY. After
refuelling, return the fuel cock lever to the
“ON” position.
q
RES
OFF
ON
1. Fuel tank cap1. Bouchon de réservoir de carburant1. Tapón del depósito de combustible
5KJ-62 (4~5 shou) 4/23/01 3:04 PM Page 26

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
INITIAL EVERY
ITEM ROUTINE 1 3 6 6 1
month months months months year
Transmission9Replace oil.2 222
9Check condition.
Spark plug9Adjust gap and clean.22222
9Replace if necessary.
Air filter9Clean. Every 20 ~ 40 hours.
9Replace if necessary. (More often in wet or dusty areas)
* Carburetor9Check idle speed / starter operation.
2222
9Adjust if necessary.
* Crankcase breather9Check breather hose for cracks or damage.
222
system9Replace if necessary.
9Check for leakage.
* Exhaust system9Retighten if necessary.222
9Replace gasket if necessary.
* Fuel line9Check fuel hose for cracks or damage.
222
9Replace if necessary.
Throttle operation9Inspect and adjust free play if necessary.22222
Front brake operaion9Inspect and adjust free play if necessary.22222
* Front brake shoes9Check wear limit.
22
9Replace if necessary.
* Rear brake pads9Check pad wear.
222
9Replace if necessary.
* Clutch9Inspect free play and operation.
2 222
9Replace if necessary.
5KJ-62 (8 shou) 4/23/01 3:08 PM Page 8

8-31
NOTE:
The air filter element should be cleaned every
20 ~ 40 hours. It should be cleaned and lubricat-
ed more often if the machine is operated in
extremely dusty areas. Each time filter element
maintenance is performed, check the air inlet to
the filter case for obstructions. Check the air
cleaner rubber joint to the carburetor and mani-
fold fittings for an air-tight seal. Tighten all fit-
tings securely to avoid the possibility of unfil-
tered air entering the engine.
cC
Never operate the engine with the air filter
element removed. This will allow unfiltered
air to enter, causing rapid engine wear and
possible engine damage. Additionally, opera-
tion without the filter element will affect car-
buretor jetting with subsequent poor perfor-
mance and possible engine overheating.
5KJ-62 (8 shou) 4/23/01 3:08 PM Page 32

8-33
EBU00298
Carburetor settings
In extremely cold weather, it is necessary to
change the carburetor settings to maintain opti-
mum engine performance and to prevent engine
damage.
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8Improperly servicing or adjusting the car-
buretor could cause malfunction with the
possibility of an accident or the carburetor
could leak fuel, which would be a fire haz-
ard.
8Carburetor adjustments should only be
performed by a Yamaha dealer. Do not
attempt to perform these procedures
unless you have mechanical knowledge
and the necessary tools.
8Do not perform this procedure while the
engine is hot. Place a rag under the carbu-
retor to catch any fuel. Wipe up any spilled
fuel completely.
8After servicing the carburetor, always
check throttle operation before operating
the ATV to make sure it is working correct-
ly.
5KJ-62 (8 shou) 4/23/01 3:08 PM Page 34

8-35
Standard settings
Carburetor settings chart
1st groove
2nd (
STD)

3rd
4th
5th Jet needle clip position
Position du clip d’aiguille de gicleur
Posición del clip de las agujas
Main jet #230
Jet needle clip position 2nd groove
Pilot air screw 1-1/2 turns out
Temperature Main jet Jet needlePilot air
screw
0°C above
#230 2nd groove1 1/2 turns
(Standard) out
+5°C ~ –15°C #230 2nd groove1 1/2 turns
out
–10°C ~ –30°C #240 3rd groove1 1/2 turns
out
Main jet number
Numéro de gicleur principalNúmero de surtidor principal
Standard position: Groove 2
Position standard: Gorge 2Posición estandar: Ranura 2
5KJ-62 (8 shou) 4/23/01 3:08 PM Page 36

8-37
Changing the carburetor settings
Disassembly
1. Turn the fuel cock to the “OFF” position.
2. Turn out the carburetor drain screw and
drain the fuel.
3. Disconnect the fuel hose and oil delivery
hose.
q
q
w
1. Carburetor drain screw1. Vis de vidange de carburateur1. Tornillo de drenaje del carburador
1. Fuel hose 2. Oil delivery hose
1. Flexible de carburant 2. Flexible d’arrivée d’huile1. Tubo de combustible 2.Tubo de alimentación de aceite
5KJ-62 (8 shou) 4/23/01 3:08 PM Page 38