2004 YAMAHA BLASTER 200 wheel

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 check ........................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
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2-5
8Never operate at speeds too fast for your
skills or the conditions. Always go at a speed
that is proper for the terrain, visibility and
operating conditions, and your experience.
8Never attempt wheelies, jumps, or other
stunts.
8Always inspect your ATV each time you use it
to make sure it is in safe operating condition.
Always follow the inspection and maintenance
procedures and schedules described in this
manual.
8Always keep both hands on the handlebars
and both feet on the footrests of the ATV dur-
ing operation.
8Always go slowly and be extra careful when
operating on unfamiliar terrain. Always be
alert to changing terrain conditions when
operating the ATV.
5VM-9-61-01 3/14/03 9:34 PM Page 40

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. Parking brake
7. Front shock absorber 17. Main switch
8. Front wheel 18. Brake lever
9. Fuel cock 19. Throttle lever
10. Starter (choke) 20. Handlebar switches
NOTE:
The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
123
4
5 6
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p
78
90
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5VM-9-61-01 3/14/03 9:34 PM Page 54

5-1
EBU00113
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. 8-65–8-67
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
Lights and switches9Check for proper operation. 5-19, 8-89–8-99
5VM-9-61-02 3/14/03 9:35 PM Page 38

6-17
7. Open the throttle part way and gradually
release the clutch lever.
8. Follow the same procedure when shifting to
the next higher gear.
w
Opening the throttle abruptly or releasing the
clutch lever too quickly would increase the
chance of an accident or could make the
machine wheelie including overturn. Always
open the throttle gradually and release the
clutch lever gradually.
5VM-9-61-03 3/14/03 10:47 PM Page 18

6-19
EBU00208
To decelerate:
When slowing down or stopping, release the
throttle and apply the brakes smoothly and
evenly. As you slow down, shift to a lower gear.
Be sure that the engine has sufficiently slowed
before engaging a lower gear. Improper use of
the brakes or shifting can cause the tires to lose
traction, reducing control and increasing the
possibility of an accident.
w
Make sure the engine has sufficiently slowed
before shifting to a lower gear. Engaging a
lower gear when the engine speed is too
high could make the wheels stop rotating.
This could cause loss of control, an accident
and injury. It could also cause engine or
drive train damage.
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6-27
EBU01175
Parking on a slope
w
Avoid parking on hills or other inclines.
Parking on a hill or other incline could cause
the ATV to roll out of control, increasing the
chance of an accident. If you must park on
an incline, put the machine in low gear, apply
the parking brake, and block the front and
rear wheels with rocks or other objects.
Do not park the ATV at all on hills that are so
steep you could not walk up them easily.
1. Bring the machine to a stop by applying the
brakes in low gear.
2. Stop the engine and release the clutch
lever.
3. With the rear brake applied, apply the park-
ing brake and slowly release the brake
pedal.
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7-21
During operation
Always keep your feet on the footboards during
operation. Otherwise your feet may contact the
rear wheels.
w
Always keep both hands on the handlebars
and both feet on the footboards of your ATV
during operation. Removing even one hand
or foot can reduce your ability to control the
ATV or could cause you to lose your balance
and fall off of the ATV. If you remove a foot
from a footboard, your foot or leg may come
into contact with the rear wheels, which
could injure you or cause an accident.
5VM-9-61-04 3/14/03 9:37 PM Page 22