2003 YAMAHA BLASTER 200 check oil

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 lights ......................................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
Brake lever .........................................4-17
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
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CONTENTS
1
2
3
4
5
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4-3
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Indicator lights
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Oil level warning light “7”
This light comes on when the oil level is low.
The light circuit can be checked by the following
procedure.
cC
Always make sure there is enough engine oil
before starting the engine.
1
1. Oil level warning light “7”1. Témoin d’avertissement du niveau d’huile “7”1. Luz de aviso del nivel del aceite “7”
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4-5
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Oil level warning light checking method
Start the engine.
Wait a few seconds.
Engine oil level and
electrical circuit are OK.Supply engine oil.
Oil level warning light
does not come on
(see NOTE).
Ask a Yamaha dealer to
inspect the electrical circuit.
NOTE:
If the main switch is turned off after the oil level
warning light goes off and the engine is immedi-
ately started again, the oil level warning light
may not come on. This does not indicate a cir-
cuit failure.
Turn the main switch to
“ON” and the engine
stop switch to“RUN”.
Oil level warning
light comes on.
The oil level warning
light stays on.The oil level warning light
goes off.
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5-1
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PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Brakes9Check operation, free play, fluid level and fluid leakage. 5-5–5-7
9Fill with DOT 4 brake fluid if necessary. 8-55–8-63
Clutch9Check operation, condition and lever free play. 8-71
Parking brake9Check operation, condition and cable free play. 8-65
Fuel 9Check fuel level.
9Fill with fuel if necessary.5-9–5-11
Transmission oil9Check oil level.
9Fill with oil if necessary.5-15, 8-17–8-23
2-cycle engine oil9Check oil level.
9Fill with oil if necessary.5-13
Drive chain9Check chain slack and condition.
9Adjust if necessary.5-17, 8-73–8-79
Throttle9Check for proper throttle cable operation. 5-17, 8-53
Wheels and tires9Check tire pressure, wear and damage. 5-21–5-27, 8-87
Fittings and fasteners9Check all fittings and fasteners. 5-17
Lights9Check for proper operation. 5-19, 8-89–8-99
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8-7
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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.
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8-9
NOTE:
8Recommended brake fluid: DOT 4
8Brake fluid replacement:
9When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally
check the brake fluid level and add fluid as required.
9On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two
years.
9Replace the brake hoses every four years, or if cracked or damaged.
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EBU01277
Transmission oil
Transmission oil measurement
1. Place the machine on a level place.
2. Warm up the engine for several minutes,
and stop it.
3. Check the oil level through the level window
located at the right side crankcase cover.
NOTE:
Wait a few minutes until the oil level settles
before checking.
4. The oil level should be between the maxi-
mum and minimum marks. If the level is low,
add oil to raise it to the proper level.
1
2
3
1
1. Level window
2. Maximum level mark 3. Minimum level mark
1. Regard
2. Repère de niveau maximum 3. Repère de niveauminimum
1. Mirilla
2. Marca de máximo 3. Marca de mínimo
8-17
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8-23
7. Start the engine and warm up for a few min-
utes. While warming up, check for oil leak-
age. If oil leakage is found, stop the engine
immediately, and check for the cause.
8. Check the oil level.
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