2004 YAMAHA BLASTER 200 brake

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
EBU00015
CONTENTS
1
2
3
4
5
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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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2-13
8Never attempt to operate over large obsta-
cles, such as large rocks or fallen trees.
Always follow proper procedures when oper-
ating over obstacles as described in this man-
ual.
8Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such
as ice, go slowly and be very cautious in
order to reduce the chance of skidding or slid-
ing out of control.
8Never operate an ATV in fast flowing water or
in water deeper than that recommended in
this manual. Remember that wet brakes may
have reduced stopping ability. Test your
brakes after leaving water. If necessary, apply
them several times to let friction dry out the
linings.
8Always use the size and type tires specified in
this manual.
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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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78
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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.
EBU00988
Brake lever
The brake lever is located on the right handle-
bar. Pull it toward the handlebar to apply the
front brake.
q
q
1. Clutch lever1. Levier d’embrayage1. Palanca de embrague
1. Brake lever
1. Levier de frein1. Palanca del freno
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4-19
EBU00989
Brake pedal
The brake pedal is located on the right side of
the machine. Push down on the pedal to apply
the rear brake.
EBU00081
Parking brake
Use the parking brake when you have to start
the engine or park the machine, especially on a
slope. Squeeze the clutch lever while pushing
the button, then push in the lock plate to apply
the parking brake. Squeeze the clutch lever to
release the parking brake.
NOTE:
When the parking brake is used, engine speed
is limited to 2,300 r/min. Be sure the parking
brake is released before moving the throttle
lever. Otherwise, the engine will misfire, pre-
venting normal operation.
q
q
w
1. Brake pedal1. Pédale de frein1. Pedal del freno
1. Button 2. Lock plate
1. Bouton 2. Plaque de verrouillage1. Botón 2. Placa de bloqueo
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4-21
w
8Always set the parking brake before start-
ing the engine. The ATV could start mov-
ing unexpectedly if the parking brake is
not applied. This could cause loss of con-
trol or a collision.
8Always be sure you have released the
parking brake before you begin to ride.
The brake could overheat if you ride the
ATV without releasing the parking brake.
You could lose braking performance
which could cause an accident. You could
also wear out the brakes prematurely.
q
1. Locked position2. Verrouillé3. Posición bloqueada
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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
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