2007 YAMAHA BLASTER 200 check oil

EBU17420
TABLE OF CONTENTS
SAFETY INFORMATION .............................. 1-1
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 2-1
DESCRIPTION .............................................. 3-1
Left view ..................................................... 3-1
Right view................................................... 3-1
Controls and instruments ........................... 3-2
INSTRUMENT AND CONTROL
FUNCTIONS .................................................. 4-1
Main switch ............................................... 4-1
Indicator light ............................................. 4-2
Handlebar switches ................................... 4-2
Throttle lever ............................................. 4-3
Throttle OverRide System ......................... 4-4
Speed limiter ............................................. 4-4
Clutch lever ............................................... 4-5
Brake lever ................................................ 4-5
Brake pedal ............................................... 4-5
Parking brake ............................................ 4-6
Shift pedal ................................................. 4-7
Kickstarter ................................................. 4-7
Fuel tank cap ............................................. 4-8Fuel ............................................................ 4-8
Fuel cock ................................................... 4-9
Starter (choke) ......................................... 4-11
Seat ......................................................... 4-11
Adjusting the front shock absorber
assemblies .............................................4-12
Adjusting the rear shock absorber
assembly ................................................4-13
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ............................. 5-1
Fuel ............................................................ 5-4
2-stroke engine oil ..................................... 5-4
Transmission oil ......................................... 5-4
Front and rear brakes ................................ 5-4
Throttle lever .............................................. 5-5
Drive chain ................................................. 5-5
Tires ........................................................... 5-6
Measuring the tire pressure ....................... 5-7
Tire wear limit ............................................ 5-8
Chassis fasteners ...................................... 5-8
Instruments, lights and switches ................ 5-8
OPERATION...................................................6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-2

Shifting ...................................................... 6-2
Engine break-in ......................................... 6-4
Parking ...................................................... 6-5
Parking on a slope .................................... 6-6
Accessories and loading ........................... 6-6
RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV.............. 7-2
RIDE WITH CARE AND GOOD
JUDGEMENT ...........................................7-2
BE CAREFUL WHERE YOU RIDE ............ 7-8
TURNING YOUR ATV ............................. 7-12
CLIMBING UPHILL .................................. 7-14
RIDING DOWNHILL................................. 7-16
CROSSING A SLOPE.............................. 7-17
CROSSING THROUGH SHALLOW
WATER ..................................................7-18
RIDING OVER ROUGH TERRAIN .......... 7-20
SLIDING AND SKIDDING ........................ 7-20
WHAT TO DO IF... ................................... 7-21
WHAT TO DO... ....................................... 7-21
PERIODIC MAINTENANCE AND MINOR
REPAIR .......................................................... 8-1
Owner’s manual and tool kit ...................... 8-1
Periodic maintenance and lubrication
chart ........................................................ 8-3
Checking the spark plug ............................ 8-7
Transmission oil ........................................ 8-8Autolube pump ......................................... 8-11
Cleaning the air filter element .................. 8-11
Cleaning the spark arrester ..................... 8-14
Changing the carburetor settings ............. 8-16
Adjusting the engine idling speed ............ 8-21
Adjusting the throttle cable free play ........ 8-22
Checking the front and rear brake
pads ....................................................... 8-23
Checking the brake fluid level .................. 8-24
Changing the brake fluid .......................... 8-25
Checking the front brake lever free
play ........................................................ 8-25
Checking the brake pedal position ........... 8-26
Adjusting the parking brake free play ...... 8-27
Brake light switches ................................. 8-29
Adjusting the clutch lever free play .......... 8-29
Drive chain slack ...................................... 8-30
Lubricating the drive chain ....................... 8-32
Checking and lubricating the cables ........ 8-33
Checking and lubricating the brake and
clutch levers ........................................... 8-34
Checking and lubricating the brake and
shift pedals ............................................. 8-34
Checking the wheel bearings ................... 8-34
Lubricating the swingarm pivots .............. 8-34
Lubricating the upper and lower arm
pivots ..................................................... 8-35
Lubricating the steering shaft ................... 8-35
Replacing the headlight bulb ................... 8-36

4-2
1
2
34
5
6
7
8
9
10
11

EBU17781
Indicator light
EBU17881
2-stroke engine oil level warning light “”
This warning light comes on when the oil level in
the 2-stroke engine oil tank is low during operation.
If the warning light comes on during operation,
stop the engine when it is safe to do so, and fill the
oil tank with Yamalube 2 or equivalent 2-stroke en-
gine oil. The warning light should go off after the oil
tank has been refilled.
The electrical circuit of the warning light can be
checked by starting the engine. (See page 6-1.) Ifthe warning light does not come on for a few sec-
onds, then go off, have a Yamaha dealer check the
electrical circuit.CAUTION:

ECB00020
Always make sure there is enough engine oil
before starting the engine.
EBU18061
Handlebar switches
1. Oil level warning light “ ”
1

1. Light switch “LIGHTS”
2. Engine stop switch “ENG. STOP”
1
2

5-1
1
2
3
45
6
7
8
9
10
11

EBU19200
PRE-OPERATION CHECKS
EBU19220
Pre-operation check list
Before operating this ATV, be sure to check the items listed in the following table.
NOTE:

The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic
maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a
Yamaha dealer.
ITEM ROUTINE PAGE
Fuel


Check fuel level in fuel tank, and add recommended fuel if neces-
sary.

Check fuel line for leakage. Correct if necessary.4-8, 5-4
2-stroke engine oil

Check oil level in oil tank, and add recommended oil to specified
level if necessary.

Check ATV for oil leakage. Correct if necessary.5-4
Transmission oil

Check oil level in transmission case, and add recommended oil to
specified level if necessary.

Check ATV for oil leakage. Correct if necessary.5-4, 8-8
Front brake

Check operation. If soft or spongy, have Yamaha dealer bleed
hydraulic system.

Check brake pads for wear, and replace if necessary.

Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.

Check hydraulic system for leakage. Correct if necessary.5-4, 8-23, 8-24, 8-25

5-4
1
2
3
45
6
7
8
9
10
11

EBU19540
Fuel
Make sure that there is sufficient fuel in the tank.
(See page 4-8.)
WARNING

EWB00520

Do not overfill the fuel tank. Fuel expands
when it heats up. If the fuel tank is overfilled,
fuel could spill out due to heat from the en-
gine or the sun.

Be careful not to spill fuel, especially on the
engine or exhaust pipe which can cause a
fire and severe injury. Wipe up any spilled
fuel immediately.

Do not refuel right after the engine has been
running and is still very hot.

Be sure the fuel tank cap is closed securely.
EBU19572
2-stroke engine oil
Make sure that there is sufficient 2-stroke engine
oil in the oil tank. Add oil as necessary. (See
page 10-1.)
EBU19580
Transmission oil
Make sure that the transmission oil is at the speci-
fied level. Add oil as necessary. (See page 8-8.)
EBU19710
Front and rear brakes
Brake lever and brake pedal

Check that there is no free play in the brake le-
ver. If there is free play, have a Yamaha dealer
check the brake system.

Check for correct brake pedal height. (See
page 8-26.) If the pedal height is incorrect, have
1. Engine oil tank filler cap1

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

8-8
1
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4
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78
9
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11

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)

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

To check the transmission oil level
1. Place the ATV on a level surface.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Wait a few minutes until the oil settles, and
then check the oil level through the check win-
dow located at the right side of the crankcase.NOTE:

The transmission oil should be between the mini-
mum and maximum level marks.
4. If the oil is at or below the minimum level mark,
remove the oil filler cap, add sufficient oil of
the recommended type to raise it to the cor-
rect level, and then install and tighten the oil
filler cap.
To change the transmission oil
1. Place the ATV on a level surface.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
1. Transmission oil level check window
2. Maximum level mark
3. Minimum level mark
11
32

1. Transmission oil filler cap
1