2007 YAMAHA BLASTER 200 engine

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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

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3. Remove the screw and washer.
4. Remove the air filter element out of the air fil-
ter case.
5. Remove the sponge material from the air filter
element frame.6. Wash the sponge material gently but thor-
oughly in solvent.
WARNING
EWB01940
Always use parts cleaning solvent to clean the
sponge material. Never use low-flash-point
solvents or gasoline to clean the sponge mate-
rial because the engine could catch fire or ex-
plode.
7. Squeeze the excess solvent out of the sponge
material and let it dry.
1. Air filter case cover
2. Screw
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1. Sponge material
2. Air filter element frame
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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
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2. Remove the tailpipe by pulling it out of the
muffler.
3. Tap the tailpipe lightly, and then use a wire
brush to remove any carbon deposits from the
spark arrester portion of the tailpipe and inside
of the tailpipe housing.4. Make sure the gasket is properly positioned,
then insert the tailpipe into the muffler and
align the screw holes.
5. Install the screws and tighten them.
WARNING
EWB02340
Do not start the engine when cleaning the
spark arrester, otherwise it could cause injury
to the eyes, burns, carbon monoxide poison-
ing, possibly leading to death, and start a fire.
Always let the exhaust system cool prior to
1. Screw
1

1. Tailpipe
2. Spark arrester
3. Gasket
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touching exhaust components.
EBU23971
Changing the carburetor settings
In extremely cold weather, it is necessary to
change the carburetor settings to maintain opti-
mum engine performance and to prevent engine
damage.
WARNING

EWB02000

Improperly servicing or adjusting the carbu-
retor could cause it to malfunction with the
possibility of an accident, or the carburetor
could leak fuel, which would be a fire hazard.

Carburetor adjustments should only be per-
formed by a Yamaha dealer. Do not attempt
to perform these procedures unless you
have mechanical knowledge and the neces-
sary tools.

Do not perform this procedure while the en-
gine is hot. Place a rag under the carburetor
to catch any fuel. Wipe up any spilled fuel
completely.

After servicing the carburetor, always check
the throttle lever operation before operating
the ATV to make sure it is working correctly.
Standard settings

Main jet #230
Jet needle clip position 2nd groove
Pilot air screw 1 1/2 turns out
1. Main jet number
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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
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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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CAUTION:

ECB00560
The drive chain must be lubricated after wash-
ing the ATV or riding in the rain.
1. Clean the drive chain with kerosene and a
small soft brush.
CAUTION:

ECB00570
To prevent damaging the O-rings, do not clean
the drive chain with steam cleaners, high-pres-
sure washers or inappropriate solvents.
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain with a
special O-ring chain lubricant.
CAUTION:

ECB00580
Do not use engine oil or any other lubricants
for the drive chain, as they may contain sub-
stances that could damage the O-rings.
EBU24900
Checking and lubricating the cables
The operation and the condition of all control ca-
bles should be checked before each ride, and the
cables and cable ends should be lubricated if nec-
essary. If a cable is damaged or does not move
smoothly, have a Yamaha dealer check or replace
it.
WARNING

EWB02130
Inspect cables frequently and replace if dam-
aged. Corrosion can result when the cable
sheaths become damaged, and cables can
also become frayed or kinked, which could re-
strict the operation of controls and lead to an
accident or injury.
1. O-rings
Recommended lubricant:
Engine oil