2002 YAMAHA BLASTER 200 clutch

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 and warning lights ..................4-3
Oil level warning light “OIL” ..................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
Front brake lever ................................4-17
Rear 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
5KJ-62 (0~3 shou) 4/23/01 3:03 PM Page 12

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

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. Main switch
7. Front shock absorber 17. Parking brake
8. Front wheel 18. Front brake lever
9. Fuel cock 19. Throttle lever
10. Starter (choke) 20. Handlebar switch
NOTE:
The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
q
we
r
t
y
!5 !6!7
!8
!9
@0
io!0u!1!2 !3
!4
5KJ-62 (0~3 shou) 4/23/01 3:03 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.
EBU00070
Front brake lever
The front brake lever is located on the right han-
dlebar. Pull it toward the handlebar to apply the
front brake.
q
q
1. Clutch lever1. Levier d’embrayage1. Palanca de embrague
1. Front brake lever
1. Levier de frein avant1. Palanca del freno delantero
5KJ-62 (4~5 shou) 4/23/01 3:04 PM Page 18

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
5KJ-62 (4~5 shou) 4/23/01 3:04 PM Page 24

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brake9Check operation, condition and free play.
5-5~ 5-7, 8-49 ~ 8-53
9Adjust if necessary.
Rear brake9Check operation and brake pad. 5-5 ~ 5-7, 8-49
Clutch9Check operation, condition and lever free play. 8-59
Parking brake9Check operation, condition and cable free play. 8-55
Fuel 9Check fuel level.
9Fill with fuel if necessary.5-9 ~ 5-11
Transmission oil9Check oil level.
9Fill with oil if necessary.5-15, 8-13 ~ 8-19
Engine oil9Check oil level.
9Fill with oil if necessary.5-13
Drive chain9Check chain slack and condition.
9Adjust if necessary.5-17, 8-61 ~ 8-67
Throttle9Check for proper throttle cable operation. 5-17, 8-47
Wheels and tires9Check tire pressure, wear and damage. 5-21 ~ 5-27, 8-73
Fittings and Fasteners9Check all fittings and fasteners. 5-17
Lights9Check for proper operation. 5-19, 8-75 ~ 8-81
5KJ-62 (4~5 shou) 4/23/01 3:04 PM Page 38

5-15
EBU00490
Transmission oil
Make sure the transmission oil is at the specified
level. Add oil as necessary. (See pages 8-13 ~
8-19.)
cC
Be sure to use motor oils that do not contain
anti-friction modifiers. Passenger car motor
oils (often labeled “Energy Conserving”)
contain anti-friction additives which will
cause clutch and/or starter clutch slippage,
resulting in reduced component life and poor
engine performance.
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
5KJ-62 (4~5 shou) 4/23/01 3:04 PM Page 52

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
5KJ-62 (6 shou) 4/23/01 3:05 PM Page 12