2005 YAMAHA BLASTER 200 brake light

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
5VM-9-62-01 3/12/04 2:33 PM Page 12

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 ......................8-83Lubricating the front upper and lower
arm pivots .........................................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-9-62-01 3/12/04 2:33 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. 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-9-62-01 3/12/04 2:33 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-9-62-02 3/12/04 4:13 PM Page 38

5-19
EBU00803
Lights
Check the headlight and tail/brake light to make
sure they are in working condition. Repair as
necessary for proper operation.
EBU01170
Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper
operation.
5VM-9-62-02 3/12/04 4:13 PM Page 56

8-8INITIAL EVERY
month 1 3 6 6 12
ITEM ROUTINEWhichever
km 320 1200 2400 2400 4800 comes first
(mi) (200) (750) (1500) (1500) (3000)
hours 20 75 150 150 300
* Front and rear9Check pad wear.
222
brake pads9Replace if necessary.
* Clutch9Inspect free play and operation.
2222
9Replace if necessary.
Drive chain9Lubricate, check free play and alignment.
2222
9Replace if necessary.
* Drive chain guard
9Check wear and replace if necessary.222
and rollers
* Steering system9Inspect play, clean and lubricate with lithium-soap-
22222
based grease.
* Front and rear9Inspect and lubricate with lithium-soap-based
22222
suspensiongrease.
Tires9Inspect air pressure, wheel runout, and tire wear.22222
* Wheels9Inspect bearings.
22222
9Replace bearings if necessary.
* Throttle, control 9Check routing and connection.
22222
cables9Lubricate.
Outside nuts and bolts9Tighten if necessary.22222
Frame9Clean and inspect.2222
Lighting9Inspect.22222
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
5VM-9-62-05 3/12/04 4:15 PM Page 9

8-69
EBU00833
Adjusting the rear brake light switch
The rear brake light switch, which is activated by
the brake pedal and brake lever, is properly
adjusted when the brake light comes on just
before braking takes effect. If necessary, adjust
the brake light switch as follows.
Turn the adjusting nut while holding the rear
brake light switch in place. To make the brake
light come on earlier, turn the adjusting nut in
direction a. To make the brake light come on
later, turn the adjusting nut in direction b.
ba
1
2
1. Rear brake light switch
2. Adjusting nut
1. Contacteur de feu stop sur frein arrière
2. Écrou de réglage
1. Interruptor de la luz de freno trasero
2. Tuerca de ajuste
5VM-9-62-05 3/12/04 4:15 PM Page 70

8-99
EBU00861
Tail/brake light bulb replacement
1. Remove the bulb holder (together with the
bulb) by turning it counterclockwise.
2. Remove the defective bulb from the bulb
holder by pushing it inward and turning it
counterclockwise.
3. Install a new bulb in the bulb holder by
pushing it inward and turning it clockwise.
4. Install the bulb holder (together with the
bulb).
q
q
w
1. Bulb holder1. Fixation d’ampoule1. Portabombillas
1. Bulb holder 2. Bulb
1. Fixation d’ampoule 2. Ampoule1. Portabombillas 2. Bombilla
5VM-9-62-05 3/12/04 4:15 PM Page 100