2003 YAMAHA BLASTER 200 air filter

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
5VM-9-60 (0~3 shou) 6/20/02 4:12 PM Page 14

7-69
Test your brakes after leaving the water. Do not
continue to ride your ATV without verifying that
you have regained proper braking ability.
cC
After riding your ATV in water, be sure to
drain the trapped water by removing the
check hose at the bottom of the air filter
case. Wash the ATV in fresh water if it has
been operated in salt water or muddy condi-
tions.
q
1. Check hose1. Tuyau de contrôle1. Manguito de retención
5VM-9-60 (7 shou) 6/20/02 4:18 PM Page 70

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 system9Tighten 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 and rear9Check operation/fluid leakage/see NOTE Page 8-9.
22222
brake operation9Correct if necessary.
* Front and rear9Check pad wear.
222
brake pads9Replace if necessary.
* Clutch9Inspect free play and operation.
2 222
9Replace if necessary.
5VM-9-60 (8 shou) 6/20/02 4:22 PM Page 8

8-31
EBU01291
Air filter element cleaning
NOTE:
There is a check hose at the bottom of the air fil-
ter case. If dust or water collects in this hose,
empty the hose and clean the sponge material
and air filter case.
1. Remove the seat. (See page 4-29 for seat
removal and installation procedures.)
2. Remove the air filter case cover by remov-
ing the screws.
q
21
2
1. Check hose1. Flexible de contrôle1. Manguito de comprobación
1. Air filter case cover 2. Screw (
×4)1. Cache du boîtier de filtre à air 2. Vis (×4)1. Tapa de la caja del filtro de aire 2. Tornillo (×4)
5VM-9-60 (8 shou) 6/20/02 4:22 PM Page 32

8-33
3. Remove the air filter element, and separate
the sponge material from its frame by
removing the screw.
4. Wash the sponge material gently but thor-
oughly in solvent.
w
Always use parts cleaning solvent to clean
the sponge material. Never use low flash
point solvents or gasoline to clean the
sponge material because the engine could
catch fire or explode.
5. Squeeze the excess solvent out of the
sponge material and let it dry.
cC
Do not twist the sponge material when
squeezing it.
q
w
1. Sponge material 2. Frame1. Mousse 2. Armature1. Material esponjoso 2. Marco
5VM-9-60 (8 shou) 6/20/02 4:22 PM Page 34

8-35
6. Inspect the sponge material. If damaged,
replace it.
7. Apply SAE 10W30 engine oil to the sponge
material.
NOTE:
The sponge material should be wet but not drip-
ping.
8. Install the sponge material onto its frame
and install the screw.
9. Install the air filter element.
10. Install the seat.
5VM-9-60 (8 shou) 6/20/02 4:22 PM Page 36

8-37
NOTE:
The sponge material 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 air filter ele-
ment maintenance is performed, check the air
inlet to the filter case for obstructions. Check the
air filter case rubber joint to the carburetor and
manifold fittings for an air-tight seal. Tighten all
fittings 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 air filter element will affect
carburetor jetting with subsequent poor per-
formance and possible engine overheating.
5VM-9-60 (8 shou) 6/20/02 4:22 PM Page 38

10-2
Model YFS200
Engine oil (2-cycle):
Type Air-cooled 2-stroke engine oil
Quantity 1.3 L
Transmission oil:
Type SAE 10W30 type SE motor oil
Recommended transmission oil
classificationAPI Service SE, SF, SG type or higher
cC
In 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 specified. In
addition, do not use oils labeled “ENERGY
CONSERVING
II” or higher.
Quantity:
Periodic oil change 0.65 L
Total amount 0.7 L
Air filter Wet type element
10
5VM-9-60 (9 shou ~) 6/21/02 11:14 AM Page 13