2007 YAMAHA BLASTER 200 maintenance

8-4
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78
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6
*
Rear brake

Check operation and correct if necessary.

Check fluid level and ATV for fluid leakage, and
correct if necessary.
√√√√√

Replace brake pads. Whenever worn to the limit
7
*
Brake hoses

Check for cracks or other damage, and replace if
necessary.
√√√√

Replace. Every 4 years
8
*
Parking brake

Check operation and adjust if necessary.
√√√√√
9
*
Wheels

Check runout and for damage, and replace if nec-
essary.
√√√√√
10
*
Tires

Check tread depth and for damage, and replace if
necessary.

Check air pressure and balance, and correct if
necessary.
√√√√√
11
*
Wheel bearings


Check for looseness or damage, and replace if
necessary.
√ √√√
12
*
Upper and lower
arm pivots


Lubricate with lithium-soap-based grease.
√√√
13 Drive chain

Check chain slack and adjust if necessary.

Check rear wheel alignment and correct if necess-
sary.

Clean and lubricate.
√ √√√
14
*
Drive chain rollers


Check for wear and replace if necessary.
√√√
15
*
Chassis fasteners


Make sure that all nuts, bolts, and screws are
properly tightened.
√√√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300

8-5
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4
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78
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11

16
*
Shock absorber
assemblies

Check operation and correct if necessary.

Check for oil leakage and replace if necessary.
√√√
17
*
Steering shaft


Lubricate with lithium-soap-based grease.
√√√
18
*
Steering system


Check operation and repair or replace if damaged.

Check toe-in and adjust if necessary.
√√√√√
19
*
Carburetor


Check starter (choke) operation and correct if nec-
essary.

Check engine idling speed and adjust if neces-
sary.
√√√√
20
*
Crankcase breather
system

Check breather hose for cracks or other damage,
and replace if necessary.
√√√
21 Transmission oil

Change.

Check ATV for oil leakage, and correct if neces-
sary.
√ √√√
22
*
Autolube pump


Check operation and bleed if necessary.
√√√
23
*
Moving parts and
cables


Lubricate.
√√√√
24
*
Throttle lever hous-
ing and cable


Check operation and correct if necessary.

Check throttle cable free play and adjust if neces-
sary.

Lubricate throttle lever housing and cable.
√√√√√
25
*
Exhaust system


Check for leakage and replace gasket(s) if neces-
sary.

Check for looseness and tighten all screw clamps
and joints if necessary.
√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth 1 3 6 6 12
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300

8-6
1
2
3
4
5
6
78
9
10
11

EBU23070
NOTE:


The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.

Replace the brake hoses every four years and if cracked or damaged.
26 Spark arrester

Clean.
√√√
27
*
Front and rear brake
switches


Check operation and correct if necessary.
√√√√√
28
*
Lights and switches


Check operation and correct if necessary.

Adjust headlight beam.
√√√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300

8-7
1
2
3
4
5
6
78
9
10
11

EBU23211
Checking the spark plug
The spark plug is an important engine component,
which is easy to check. Since heat and deposits
will cause any spark plug to slowly erode, the spark
plug should be removed and checked in accor-
dance with the periodic maintenance and lubrica-
tion chart. In addition, the condition of the spark
plug can reveal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown, with thespark plug wrench included in the owner’s tool
kit.
To check the spark plug
1. Check that the porcelain insulator around the
center electrode of the spark plug is a medi-
um-to-light tan (the ideal color when the ATV
is ridden normally).
NOTE:

If the spark plug shows a distinctly different color,
the engine could be operating improperly. Do not
attempt to diagnose such problems yourself. In-
stead, have a Yamaha dealer check the ATV.
1. Spark plug cap
1

1. Spark plug wrench
1

8-8
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78
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2. Check the spark plug for electrode erosion
and excessive carbon or other deposits, and
replace it if necessary.
To install the spark plug
1. Measure the spark plug gap with a wire thick-
ness gauge and, if necessary, adjust the gap
to specification.2. Clean the surface of the spark plug gasket
and its mating surface, and then wipe off any
grime from the spark plug threads.
3. Install the spark plug with the spark plug
wrench, and then tighten it to the specified
torque.NOTE:

If a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque as
soon as possible.
4. Install the spark plug cap.
EBU23350
Transmission oil
The transmission oil level should be checked be-
fore each ride. In addition, the transmission oil
must be changed at the intervals specified in the
periodic maintenance and lubrication chart. Specified spark plug:
NGK/BR8ES
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
1. Spark plug gap
Tightening torque:
Spark plug:
25 Nm (2.5 m·kgf, 18 ft·lbf)

8-11
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EBU23360
Autolube pump
The Autolube pump is a vital part of the engine and
requires very sophisticated adjustment. The Autol-
ube pump should be checked and, if necessary,
adjusted at the intervals specified in the periodic
maintenance and lubrication chart. Any adjusting
should be left to a Yamaha dealer who has the pro-
fessional knowledge and experience to do so.
EBU23781
Cleaning the air filter element
The air filter element should be cleaned at the in-
tervals specified in the periodic maintenance and
lubrication chart. Clean the air filter element more
frequently if you are riding in unusually wet or dusty
areas.
NOTE:

There is a check hose at the bottom of the air filter
case. If dust or water collects in this hose, empty
the hose and clean the air filter element and air fil-
ter case.1. Remove the seat. (See page 4-11.)
2. Remove the air filter case cover by removing
the screws.
1. Air filter case check hose
1

8-14
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78
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13. Install the air filter case cover by installing the
screws.
14. Install the seat.
NOTE:

The air filter element should be cleaned every 20–
40 hours. It should be cleaned and lubricated more
often if the ATV is operated in extremely dusty ar-
eas. Each time the air filter element maintenance
is performed, check the air inlet of the air filter case
for obstructions. Check the air filter case rubber
joint to the carburetor fittings and the rubber joint
manifold fittings for an air-tight seal. Tighten all fit-tings securely to avoid the possibility of unfiltered
air entering the engine.
CAUTION:

ECB00460

Make sure that the air filter element is prop-
erly seated in the air filter case.

Never operate the engine with the air filter el-
ement removed. This will allow unfiltered air
to enter the engine, causing rapid engine
wear and possible engine damage. Addition-
ally, operation without the air filter element
will affect carburetor jetting with subsequent
poor performance and possible engine over-
heating.
EBU28310
Cleaning the spark arrester
Be sure the exhaust pipe and muffler are cool be-
fore cleaning the spark arrester.
1. Remove the screws.
1. Washer
1

8-21
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7. Install the carburetor and tighten the clamp
screws.
8. Connect the fuel hose and the oil hose.
9. Tighten the carburetor float bowl drain screw.
EBU24000
Adjusting the engine idling speed
The engine idling speed must be checked and, if
necessary, adjusted as follows at the intervals
specified in the periodic maintenance and lubrica-
tion chart.
NOTE:

A diagnostic tachometer is needed to make this
adjustment.
1. Start the engine and warm it up.
NOTE:

The engine is warm when it quickly responds to the
throttle.
2. Attach the tachometer to the spark plug lead.
3. Check the engine idling speed and, if neces-
sary, adjust it to specification by turning the
throttle stop screw at the carburetor. To in-
crease the engine idling speed, turn the throt-
tle stop screw in direction (a), and to decrease
it, turn the screw in direction (b).
1. Screw
2. Projection
3. Slot
12
3