2007 YAMAHA BLASTER 200 Owners Manual

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NOTE:

If the specified idling speed cannot be obtained as
described above, have a Yamaha dealer make the
adjustment.
EBU24043
Adjusting the throttle cable free play
The throttle cable free play should be checked
and, if necessary, adjusted at the intervals speci-
fied in the periodic maintenance and lubricationchart.
The throttle cable free play should measure 4.0–
6.0 mm (0.16–0.24 in) at the throttle lever. Period-
ically check the throttle cable free play and, if nec-
essary, adjust it as follows.
NOTE:

The engine idling speed must be checked, and ad-
justed if necessary, before adjusting the throttle ca-
ble free play.
1. Loosen the locknut.
2. To increase the throttle cable free play, turn
the adjusting bolt in direction (a). To decrease
the throttle cable free play, turn the adjusting
bolt in direction (b).
1. Throttle stop screw
Engine idling speed:
1450–1550 r/min
1 (b)(a)

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3. Tighten the locknut.
EBU24130
Checking the front and rear brake pads
The front and rear brake pads must be checked for
wear at the intervals specified in the periodic main-
tenance and lubrication chart.
EBU24161
Front brake pads
Check each front brake pad for damage and mea-
sure the lining thickness. If a brake pad is dam-aged or if the lining thickness is less than 1.0 mm
(0.04 in), have a Yamaha dealer replace the brake
pads as a set.
EBU24190
Rear brake pads
Each brake pad is provided with a wear indicator,
which allows you to check the brake pad wear
without having to disassemble the brake. To check
the brake pad wear, check the position of the wear
indicator while applying the brake. If a brake pad
has worn to the point that the wear indicator almost
touches the brake disc, have a Yamaha dealer re-
place the brake pads as a set.
1. Throttle lever free play adjusting bolt
2. Locknut
3. Throttle lever free play
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1. Lining thickness
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EBU24251
Checking the brake fluid level
Insufficient brake fluid may allow air to enter the
brake system, possibly causing it to become inef-
fective.
Before riding, check that the brake fluid is above
the minimum level mark and replenish if neces-
sary. A low brake fluid level may indicate worn
brake pads and/or brake system leakage. If the
brake fluid level is low, be sure to check the brake
pads for wear and the brake system for leakage.
Front brake
1. Wear indicator
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1. Minimum level mark
LOWER
1

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Rear brake

Observe these precautions:

When checking the fluid level, make sure that
the top of the brake fluid reservoir is level.

Use only the recommended quality brake fluid,
otherwise the rubber seals may deteriorate,
causing leakage and poor braking performance.

Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor braking performance.

Be careful that water does not enter the brake
fluid reservoir when refilling. Water will signifi-
cantly lower the boiling point of the fluid and may
result in vapor lock.

Brake fluid may deteriorate painted surfaces or
plastic parts. Always clean up spilled fluid imme-
diately.

As the brake pads wear, it is normal for the brake
fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a
Yamaha dealer check the cause.
EBU24290
Changing the brake fluid
Have a Yamaha dealer change the brake fluid at
the intervals specified in the NOTE after the peri-
odic maintenance and lubrication chart. In addi-
tion, have the oil seals of the master cylinders and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are dam-
aged or leaking.

Oil seals: Replace every two years.

Brake hoses: Replace every four years.
EBU24390
Checking the front brake lever free play
The brake lever free play must be checked at the
1. Minimum level mark
Recommended brake fluid:
DOT 4
LOWER
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intervals specified in the periodic maintenance and
lubrication chart. The brake lever should have a
free play of zero mm (zero in) as shown. If the free
play is incorrect, have a Yamaha dealer check the
brake system.
WARNING

EWB02070
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly and
that the free play is correct.

Make sure the brakes do not drag.

Make sure the brakes are not spongy. All air
must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
EBU24611
Checking the brake pedal position
The brake pedal position must be checked and, if
necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.
The top of the brake pedal should be positioned
0.0–10.0 mm (0.00–0.39 in) below the top of the
footrest as shown. If the brake pedal is not posi-
tioned as specified, have a Yamaha dealer adjust
it.
1. Brake lever free play
1

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WARNING

EWB02110
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly and
that the brake pedal position is correct.

Make sure the brakes do not drag.

Make sure the brakes are not spongy. All air
must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
EBU24670
Adjusting the parking brake free play
The parking brake free play must be checked and,
if necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.
Cable length “A” should measure 64–68 mm
(2.52–2.68 in). Adjust the parking brake free play
as follows.
1. Release the parking brake.
2. Fully loosen the locknut and the adjusting bolt
at the clutch lever.
1. Brake pedal position
1

1. Cable length “A”
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3. Loosen the locknut and the adjusting bolt at
the rear brake caliper.
4. Turn the adjusting bolt at the clutch lever in di-
rection (a) to increase the cable length, and in
direction (b) to decrease it.
NOTE:

If the cable length cannot be adjusted to specifica-
tion, consult a Yamaha dealer.
5. Tighten the locknut at the clutch lever.
6. Turn in the adjusting bolt at the rear brake cal-
iper by hand until it feels tight, then turn it out1/8 turn and tighten its locknut to the specified
torque.
CAUTION:

ECB00520
When tightening the locknut, hold the adjust-
ing bolt with a wrench so that it does not turn
together with the locknut.
1. Locknut
2. Adjusting bolt
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(a)
(b)

1. Adjusting bolt
2. Locknut
Tightening torque:
Locknut (rear brake caliper):
16 Nm (1.6 m·kgf, 11 ft·lbf)
1
2

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WARNING

EWB02090
Operating with improperly serviced or adjust-
ed brakes could cause the brakes to malfunc-
tion, resulting in reduced braking
performance. This could increase the chance
of a collision or accident. After adjusting the
parking brake free play, block the rear of the
ATV off the ground and spin the rear wheels.
Check to make sure there is no brake drag. If
brake drag is noticed, perform the adjustment
again.
EBU24740
Brake light switches
The operation of the brake light switches must be
checked and, if necessary, adjusted at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
The brake light switch for the brake pedal can be
adjusted as follows, but the other brake light
switches should be adjusted by a Yamaha dealer.
NOTE:

The brake light switch is properly adjusted when
the brake light comes on just before braking takes
effect.
Turn the adjusting nut while holding the 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 adjust-
ing nut in direction (b).
EBU24810
Adjusting the clutch lever free play
The clutch lever free play must be checked and, if
necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.
The clutch lever free play should measure 2.0–3.0
1. Brake light switch
2. Brake light switch adjusting nut1
2 (a)
(b)