yamaha_blaster_yfs200r_owners_manual.pdf

This ATV should not be ridden by anyone under 16 years of age.

OWNERS MANUAL

5VM-28199-10

YFS200R

READ THIS MANUAL CAREFULLY!It contains important safety information.

LIT-11626-16-37w

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EBU01200

INTRODUCTIONCongratulations on your purchase of the Yamaha YFS200. It represents the result of many years ofYamaha experience in the production of fine sporting, touring, and pacesetting racing machines. Withthe purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliabilitythat have made Yamaha a leader in these fields.

This manual will provide you with a good basic understanding of the features and operation of thisATV. This manual includes important safety information. It provides information about specialtechniques and skills necessary to ride your ATV. It also includes basic maintenance and inspec-tion procedures. If you have any questions regarding the operation or maintenance of your ATV,please consult a Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE:8 READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COM-

PLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUC-TIONS.8 PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.8 NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING

IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFOR-MATION.8 THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER

16 YEARS OF AGE.8 THIS ATV IS A HIGH PERFORMANCE ATV FOR OFF-ROAD USE ONLY, FOR SPORT TYPE

RECREATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS.www.blasterforum.com Page 3

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EBU00801

IMPORTANT MANUAL INFORMATIONFAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERI-OUS INJURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations:

Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

w Failure to follow WARNING instructions could result in severe injury ordeath to the machine operator, a bystander or a person inspecting orrepairing the machine.

cC A CAUTION indicates special precautions that must be taken to avoiddamage to the machine.

NOTE: A NOTE provides key information to make procedures easier or clearer.


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EBU00011

IMPORTANT NOTICE

This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to oper-ate this machine on any public street, road or highway.This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and regula-tions in effect at the time of manufacture.Please check your local riding laws and regulations before operating this machine.

AFFIX DEALER LABEL HERE

EBU00981

YFS200ROWNERS MANUAL

2002 by Yamaha Motor Corporation, U.S.A.

1st edition, June 2002All rights reserved.

Any reprinting or unauthorized use without the written permission

of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in Japan.P/N LIT-11626-16-37


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LOCATION OF THE WARNING ANDSPECIFICATION LABELS.......................1-1

SAFETY INFORMATION.........................2-1

DESCRIPTION AND MACHINEIDENTIFICATION.....................................3-1

Identification number records ...............3-2Key identification number .....................3-2Vehicle identification number ...............3-3Model label ...........................................3-3

CONTROL FUNCTIONS..........................4-1Main switch...........................................4-1Indicator lights ......................................4-1

Oil level warning light checkingmethod ...............................................4-2

Handlebar switches ..............................4-3Throttle lever ........................................4-4Throttle OverRide System ....................4-5Speed limiter ........................................4-6Clutch lever ..........................................4-7Brake lever ...........................................4-7Brake pedal ..........................................4-8Parking brake .......................................4-8Shift pedal ..........................................4-10Kick starter .........................................4-10Fuel tank cap......................................4-11Fuel cock ............................................4-11Starter (choke)....................................4-12

EBU00014

wIndicates a potential hazard that could resultin serious injury or death.

CONTENTS

1

2

3

4


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Seat ....................................................4-12Front shock absorber

adjustment ........................................4-14Rear shock absorber

adjustment ........................................4-15

PRE-OPERATION CHECKS ...................5-1Front and rear brakes ...........................5-2Fuel ......................................................5-4Engine oil.............................................5-6Transmission oil ...................................5-6Chain ....................................................5-7Throttle lever ........................................5-7Fittings and fasteners ...........................5-7Lights....................................................5-7Switches ...............................................5-7Tires .....................................................5-8How to measure tire pressure ..............5-9Tire wear limit .....................................5-10

OPERATION ............................................6-1Starting a cold engine...........................6-1Starting a warm engine ........................6-3Warming up ..........................................6-3Shifting .................................................6-4To start out and accelerate...................6-5To decelerate .......................................6-6Engine break-in ....................................6-7Parking .................................................6-8Parking on a slope................................6-9Accessories and loading ....................6-10

RIDING YOUR ATV .................................7-1Getting to know your ATV.....................7-3Ride with care and good

judgement...........................................7-4Be careful where you ride...................7-16Turning your ATV ...............................7-23Climbing uphill ....................................7-25Riding downhill ...................................7-30Crossing a slope.................................7-32

5

6

7


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Crossing through shallow water .........7-34Riding over rough terrain....................7-36Sliding and skidding ...........................7-38What to do if... ...................................7-40What to do... ......................................7-40

PERIODIC MAINTENANCE ANDADJUSTMENT.........................................8-1

Owners manual and tool kit .................8-1Periodic maintenance/Lubrication ........8-3Transmission oil ...................................8-6Spark plug inspection ...........................8-8Air filter cleaning.................................8-10Spark arrester cleaning ......................8-13Carburetor settings.............................8-15Idle speed adjustment ........................8-21Throttle lever adjustment ....................8-22Brake fluid level check........................8-22Brake fluid replacement......................8-24Front brake pad inspection.................8-24Rear brake pad inspection .................8-25Front brake lever free play .................8-26

Brake pedal height adjustment...........8-27Parking brake adjustment...................8-28Adjusting the rear brake light switch...8-30Clutch adjustment...............................8-31Autolube pump adjustment.................8-31Drive chain slack check......................8-32Drive chain slack adjustment..............8-32Lubricating the drive chain .................8-33Cable inspection and lubrication ........8-35Brake and shift pedal/brake andclutch lever lubrication......................8-35

Front upper arm and lower arm pivotlubrication .........................................8-35

Steering shaft lubrication....................8-36Wheel removal ...................................8-37Wheel installation ...............................8-37Replacing a headlight bulb .................8-38Headlight beam adjustment................8-42Tail/brake light bulb replacement .......8-42Troubleshooting..................................8-43Troubleshooting chart.........................8-45No spark .............................................8-46

8


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CLEANING AND STORAGE....................9-1A. Cleaning ...........................................9-1B. Storage ............................................9-3

SPECIFICATIONS .................................10-1

NOISE REGULATION............................11-1

MAINTENANCE RECORD ....................12-1

ATV LIMITED WARRANTY ...................13-1

YAMAHA EXTENDED SERVICE(Y.E.S.)...................................................14-1

9

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1-1

EBU00464

LOCATION OF THE WARNING AND SPECIFICATION LABELS

1

23

4

5


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1-2

Read and understand all of the labels on yourmachine. They contain important information forsafe and proper operation of your ATV.

Never remove any labels from your ATV. If a labelbecomes difficult to read or comes off, a replace-ment label is available from your Yamaha dealer.

1

q

w

e

5FE-21697-01

qWARNINGNEVER ride as a

passenger.Passengers can cause a loss of control,resulting in SEVEREINJURY or DEATH.

5FE-2151H-01

3JM-21696-41


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1-3

r t

4AA-22259-80

qWARNINGThis unit contains high pressure nitrogen gas.Mishandling can cause explosion.8 Read owners manual for instructions.8 Do not incinerate, puncture or open.

5FE-21568-01


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2-1

EBU00927

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently fromother vehicles including motorcycles and cars. A collision or rollover can occur quickly, even duringroutine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper pre-cautions.

SEVERE INJURY OR DEATH can result if you do not follow these instructions:

8 Read this manual and all labels carefully and follow the operating procedures described.8 Never operate an ATV without proper training or instruction. Take a Training Course. Beginners

should receive training from a certified instructor. Contact an authorized ATV dealer or call 1-800-887-2887 to find out about the training courses nearest you.8 Always follow these age recommendation:

A child under 16 years old should never operate an ATV with engine size greater than 90cc.8 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow con-

tinued use of an ATV by a child if he or she does not have the abilities to operate it safely.8 Never carry a passenger on an ATV.

q SAFETY INFORMATION 2


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2-2

8 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lotsand streets.8 Never operate an ATV on any public street, road or highway, even a dirt or gravel one.8 Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You

should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket,and long pants.8 Never consume alcohol or drugs before or while operating this ATV.8 Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is prop-

er for the terrain, visibility and operating conditions, and your experience.8 Never attempt wheelies, jumps, or other stunts.8 Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always

follow the inspection and maintenance procedures and schedules described in this manual.8 Always keep both hands on the handlebars and both feet on the footpegs of the ATV during opera-

tion.8 Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to

changing terrain conditions when operating the ATV.


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2-3

8 Never operate on excessively rough, slippery or loose terrain until you have learned and practicedthe skills necessary to control the ATV on such terrain. Always be especially cautious on thesekinds of terrain.8 Always follow proper procedures for turning as described in this manual. Practice turning at low

speeds before attempting to turn at faster speeds. Do not turn at excessive speed.8 Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills

before attempting larger hills.8 Always follow proper procedures for climbing hills as described in this manual. Check the terrain

carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Nevergo over the top of a hill at high speed.8 Always follow proper procedures for going down hills and for braking on hills as described in this

manual. Check the terrain carefully before you start down any hill. Shift your weight backward.Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicleto lean sharply to one side. Go straight down the hill where possible.8 Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid

hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.Never attempt to turn the ATV around on any hill until you have mastered the turning techniquedescribed in this manual on level ground. Avoid crossing the side of a steep hill if possible.


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2-4

8 Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling,use proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, fol-low the special procedure for braking described in this manual. Dismount on the uphill side or to aside if pointed straight uphill. Turn the ATV around and remount, following the procedure describedin this manual.8 Always check for obstacles before operating in a new area.

Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always followproper procedures when operating over obstacles as described in this manual.8 Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing

at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowlyand be very cautious in order to reduce the chance of skidding or sliding out of control.8 Never operate an ATV in fast flowing water or in water deeper than that recommended in this manu-

al. Remember that wet brakes may have reduced stopping ability. Test your brakes after leavingwater. If necessary, apply them several times to let friction dry out the linings.8 Always use the size and type tires specified in this manual.

Always maintain proper tire pressure as described in this manual.8 Never modify an ATV through improper installation or use of accessories.


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2-5

8 Never exceed the stated load capacity for an ATV. Cargo should be properly distributed andsecurely attached. Reduce speed and follow instructions in this manual for carrying cargo or pullinga trailer. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commissionat 1-800-638-2772, or the ATV Distributor's Safety Hotline at 1-800-852-5344.

2-5


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2-6

POTENTIAL HAZARDImproper handling of gasoline.WHAT CAN HAPPENGasoline can catch fire and you could beburned.HOW TO AVOID THE HAZARDAlways turn off the engine when refueling.Do not refuel right after the engine hasbeen running and is still very hot.Do not spill gasoline on the engine orexhaust pipe/muffler when refueling.Never refuel while smoking, or while in thevicinity of sparks, open flames, or othersources of ignition such as the pilot lightsof water heaters and clothes dryers.

qWARNING When transporting the machine in anothervehicle, be sure it is kept upright and thatthe fuel cock is in the OFF position.Otherwise, fuel may leak out of the carbu-retor or fuel tank.WHAT CAN HAPPENGasoline is poisonous and can causeinjuries.HOW TO AVOID THE HAZARDIf you should swallow some gasoline orinhale a lot of gasoline vapor, or get somegasoline in your eyes, see your doctorimmediately.If gasoline spills on your skin, wash withsoap and water. If gasoline spills on yourclothing, change your clothes.


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2-7

POTENTIAL HAZARDStarting or running the engine in a closedarea.

WHAT CAN HAPPENExhaust fumes are poisonous and maycause loss of consciousness and deathwithin a short time.HOW TO AVOID THE HAZARDAlways operate your ATV in an area withadequate ventilation.

qWARNING


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3-1

1. Spark arrester 12. Rear shock absorber2. Seat 13. Tail/brake light3. Fuel tank cap 14. Rear wheel4. Headlight 15. Shift pedal5. Brake pedal 16. Clutch lever6. Rear brake light switch 17. Parking brake7. Kick starter 18. Main switch8. Front shock absorber 19. Brake lever9. Front wheel 20. Throttle lever

10. Fuel cock 21. Handlebar switches11. Starter (choke)NOTE:The machine you have purchased may differslightly from those shown in the figures of thismanual.

EBU00032

DESCRIPTION AND MACHINE IDENTIFICATION1 2 3 4

567

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EBU00600

Identification number recordsRecord the key identification number, vehicleidentification number and model label informa-tion in the spaces provided for assistance whenordering spare parts from a Yamaha dealer orfor reference in case the vehicle is stolen.

1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATION NUMBER:

3. MODEL LABEL INFORMATION:

EBU00035

Key identification numberThe key identification number is stamped on thekey as shown in the following illustration. Thisnumber can be used for ordering a new key.

1. Key identification number

3-2

1

6

3

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3-3

EBU00036

Vehicle identification numberThe vehicle identification number is stampedinto the frame.

1. Vehicle identification number

NOTE:The vehicle identification number is used toidentify your machine.

EBU00787

Model labelThe model label is affixed to the location in theillustration. Record the information on this labelin the space provided. This information will beneeded to order spare parts from your Yamahadealer.

1. Model label

q1


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EBU00039

CONTROL FUNCTIONS


EBU00041

Main switchFunctions of the respective switch positions areas follows:

ON:Engine can be started only at this position andthe headlight and taillight come on when thelight switch is on.

OFF:All electrical circuits are switched off. The keycan be removed in this position.

EBU00043

Indicator lights

EBU01274

Oil level warning light 7This light comes on when the oil level is low.The light circuit can be checked by the followingprocedure.

cCAlways make sure there is enough engine oilbefore starting the engine.

1. Main switch 2. Oil level warning light 74-1

ONOFF

1

2

4


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EBU00757

Oil level warning light checking method

4-2

Start the engine.

Wait a few seconds.

Engine oil level and electrical circuit are OK.

Supply engine oil.

Oil level warning lightdoes not come on(see NOTE).

Ask a Yamaha dealer to inspect the electrical circuit.

NOTE:If the main switch is turned off after the oil levelwarning light goes off and the engine is immedi-ately started again, the oil level warning lightmay not come on. This does not indicate a cir-cuit failure.

Turn the main switch toON and the enginestop switch to RUN.

Oil level warninglight comes on.

The oil level warninglight stays on.

The oil level warning lightgoes off.


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EBU00053

Handlebar switchesEBU01158

Engine stop switch ENG. STOPMake sure that the engine stop switch is in theRUN position before starting the engine. Theengine stop switch controls ignition and can beused at all times to stop the engine, especially inan emergency. The engine will not start or runwhen the engine stop switch is turned to OFF.

EBU01286

Light switch LIGHTSSet the switch to the LO position to switch onthe low beam and the taillight.Set the switch to the HI position to switch onthe high beam and the taillight.Set the switch to the OFF position to switch offall the lights.

NOTE:The headlight and the taillight can be turned ononly when the engine is started.

4-3

q

w

1. Light switch LIGHTS2. Engine stop switch ENG. STOP


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EBU00062

Throttle leverOnce the engine is running, movement of thethrottle lever will increase the engine speed.Regulate the speed of the machine by varyingthe throttle position. Because the throttle isspring-loaded, the machine will decelerate, andthe engine will return to an idle any time thehand is removed from the throttle lever.

Before starting the engine, check the throttle tobe sure it is operating smoothly. Make sure itreturns to the idle position as soon as the leveris released.

4-4

q

POTENTIAL HAZARDMalfunction of throttle.WHAT CAN HAPPENThe throttle could be hard to operate, mak-ing it difficult to speed up or slow downwhen you need to. This could cause anaccident.HOW TO AVOID THE HAZARDCheck the operation of the throttle leverbefore you start the engine. If it does notwork smoothly, check for the cause.Correct the problem before riding the ATV.Consult a Yamaha dealer if you cant findor solve the problem yourself.

qWARNING

1. Throttle lever


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EBU00064

Throttle OverRide SystemIf during operation, the carburetor or the throttlecable should malfunction and will not close fully,take your thumb off the throttle lever. The throt-tle override system immediately cuts off the igni-tion.

4-5

POTENTIAL HAZARDContinuing to ride the ATV after theThrottle OverRide System (T.O.R.S.) hasstopped the engine.WHAT CAN HAPPENRiding with a malfunction increases thechance for an accident and injury.HOW TO AVOID THE HAZARDMake sure that the cause of the malfunc-tion is corrected before restarting theengine. You should have the ATV inspect-ed by a Yamaha dealer.

qWARNING


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EBU01159

Speed limiterThe speed limiter keeps the throttle from fullyopening, even when the throttle lever is pushedto the maximum. Turning in the adjusting screwlimits the maximum engine power available anddecreases the maximum speed of the ATV.

4-6

POTENTIAL HAZARDImproper adjustment of the speed limiterand throttle.WHAT CAN HAPPENThe throttle cable could be damaged.Improper throttle operation could result.You could lose control, have an accidentor be injured.HOW TO AVOID THE HAZARDDo not turn the adjusting screw out morethan 12 mm (0.47 in). Always make surethe throttle lever free play is adjusted to46 mm (0.160.24 in). See page 8-22.

qWARNING

qa w

1. Locknut 2. Adjusting screwa. No more than 12 mm (0.47 in)


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EBU00068

Clutch leverThe clutch lever is located on the left handlebar. Pull the clutch lever to the handlebar to disen-gage the clutch, and release the lever to engagethe clutch. The lever should be pulled rapidlyand released slowly for smooth clutch operation.

1. Clutch lever

EBU00988

Brake leverThe brake lever is located on the right handle-bar. Pull it toward the handlebar to apply thefront brake.

1. Brake lever

4-7

q

q


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EBU00989

Brake pedalThe brake pedal is located on the right side ofthe machine. Push down on the pedal to applythe rear brake.

EBU00080

Parking brakeUse the parking brake when you have to startthe engine or park the machine, especially on aslope. Squeeze the clutch lever while pushingthe button, then push in the lock plate to applythe parking brake. Squeeze the clutch lever torelease the parking brake.NOTE:When the parking brake is used, engine speedis limited to 2,300 r/min. Be sure the parkingbrake is released before moving the throttlelever. Otherwise, the engine will misfire, pre-venting normal operation.

4-8

q

1. Brake pedal


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4-9

q

w

POTENTIAL HAZARDImproper use of the parking brake.WHAT CAN HAPPENThe ATV could start moving unexpectedlyif the parking brake is not applied beforestarting the engine. This could cause lossof control or a collision.The brake disc could overheat if you ridethe ATV without releasing the parkingbrake. You could lose braking perfor-mance which could cause an accident.You could also wear out the brakes pre-maturely.HOW TO AVOID THE HAZARDAlways set the parking brake before start-ing the engine.Always be sure you have released theparking brake before you begin to ride.

qWARNING

1. Button 2. Lock plate


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EBU00082

Shift pedalThis machine is equipped with a constant-mesh6-speed transmission. The shift pedal is locatedon the left side of the engine and is used in com-bination with the clutch when shifting.

1. Shift pedal N. Neutral

EBU00089

Kick starterRotate the kick starter away from the engine.Push the starter down lightly with your foot untilthe gears engage, then kick smoothly and force-fully to start the engine. This model has a prima-ry-coupled kick starter so the engine can bestarted in any gear if the clutch is disengaged.However, shifting to neutral before starting isrecommended.

1. Kick starter

4-10

q

65432N1

q


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EBU00092

Fuel tank capRemove the fuel tank cap by turning it counter-clockwise.

1. Fuel tank cap

EBU00093

Fuel cockThe fuel cock supplies fuel from the fuel tank tothe carburetor.The fuel cock has three positions.

OFF: With the lever in this position fuel will notflow. Always turn the lever to this positionwhen the engine is not running.

ON: With the lever in this position, fuel flowsto the carburetor. Normal riding is donewith the lever in this position.

RES: This indicates reserve. If you run out offuel while riding, turn the lever to thisposition. THEN FILL THE FUEL TANKAT THE FIRST OPPORTUNITY. Afterrefuelling, return the fuel cock lever to theON position.

4-11

RES

OFF

ON

1


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EBU00094

Starter (choke)Starting a cold engine requires a richer air-fuelmixture. A separate starter circuit supplies thismixture. Move in direction a to turn on the starter(choke). Move in direction b to turn off the starter(choke). Refer to Starting a cold engine for proper oper-ation. (See page 6-1.)

1. Starter (choke)

EBU00567

SeatTo remove the seat, pull the seat lock leverupward and pull up the seat at the rear.

1. Seat lock lever

4-12

q

a

b

1


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To install the seat, insert the projections on thefront of the seat into the seat holders and pushdown on the seat at the rear.NOTE:Make sure that the seat is securely fitted.

4-13


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4-14

EBU01104

Front shock absorber adjustmentThe spring preload can be adjusted to suit theriders weight and riding conditions.Adjust the spring preload as follows.To increase the spring preload, turn the adjust-ing ring in direction a.To decrease the spring preload, turn the adjust-ing ring in direction b.

NOTE:A special wrench can be obtained at a Yamahadealer to make this adjustment.

qa

b

w POTENTIAL HAZARDImproper shock absorber adjustment.WHAT CAN HAPPENUneven adjustment can cause poor han-dling and loss of stability, which couldlead to an accident.HOW TO AVOID THE HAZARDAlways adjust the shock absorbers on theleft and right side to the same setting.

qWARNING

Standard position: BA Minimum (Soft)E Maximum (Hard)

1. Adjusting ring 2. Position indicator


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EBU01287

Rear shock absorber adjustmentThe spring preload can be adjusted to suit theriders weight and riding conditions.Adjust the spring preload as follows.

1. Loosen the locknut.2. To increase the spring preload, turn the

adjusting nut in direction a. To decreasethe spring preload, turn the adjusting nut indirection b.

cCNever attempt to turn the adjusting nutbeyond the maximum or minimum setting.

3. The length of the spring changes 1 mm(0.04 in) per turn of the adjusting nut.

4-15

a

Standard length: 230 mm (9.1 in)Minimum length (hard): 222 mm (8.7 in)Maximum length (soft): 234 mm (9.2 in)

q

w

b a

1. Adjusting nut 2. Locknuta. Spring length


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4-16

POTENTIAL HAZARDThis shock absorber contains highly pres-surized nitrogen gas.WHAT CAN HAPPENThe shock absorber could explode, caus-ing injury or property damage.Cylinder damage could also result in poorhandling which could cause an accident.HOW TO AVOID THE HAZARD8 Do not tamper with or attempt to open

the cylinder assembly.8 Do not subject the shock absorber to

an open flame or other high heat.8 Do not deform or damage the cylinder

in any way.8 Do not dispose of a damaged or worn

out shock absorber yourself. Take theunit to a Yamaha dealer.

qWARNING4. Tighten the locknut to the specified torque.

cCAlways tighten the locknut to the specifiedtorque.

Tightening torque:55 Nm (5.5 m0kgf, 40 ft0lbf)


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4-17

EBU00112



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5-1

PRE-OPERATION CHECKSBefore using this machine, check the following points:

ITEM ROUTINE PAGE

Brakes 9 Check operation, free play, fluid level and fluid leakage. 5-25-3, 8-228-279 Fill with DOT4 brake fluid if necessary.

Clutch 9 Check operation, condition and lever free play. 8-31Parking brake 9 Check operation, condition and free play. 8-28

Fuel 9 Check fuel level.9 Fill with fuel if necessary.

5-45-5

Transmission oil 9 Check oil level.9 Fill with oil if necessary.

5-65-7, 8-68-8

2-cycle engine oil 9 Check oil level.9 Fill with oil if necessary.

5-6

Drive chain 9 Check chain slack and condition.9 Adjust if necessary. 5-7, 8-328-34

Throttle 9 Check for proper throttle cable operation. 5-7, 8-22Wheels and tires 9 Check tire pressure, wear and damage. 5-85-10, 8-37Fittings and fasteners 9 Check all fittings and fasteners. 5-7Lights 9 Check for proper operation. 5-7, 8-388-43


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EBU01092

Front and rear brakesBrake lever and brake pedal8 Check that there is no free play in the brake

lever. If there is free play, have a Yamahadealer adjust it.8 Check for correct brake pedal height. If the

pedal height is incorrect, have a Yamahadealer adjust it.8 Check the operation of the lever and pedal.

They should move smoothly and there shouldbe a firm feeling when the brakes are applied.If not, have a Yamaha dealer inspect thebrake system.

Brake fluid levelCheck the brake fluid level. Add fluid if neces-sary. (See pages 8-228-24.)

5-2

POTENTIAL HAZARDFailure to inspect the ATV before operat-ing.Failure to properly maintain the ATV.WHAT CAN HAPPENIncreases the possibility of an accident orequipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV each time youuse it to make sure the ATV is in safeoperating condition.Always follow the inspection and mainte-nance procedures and schedulesdescribed in the Owners Manual.

qWARNING

5

Recommended brake fluid: DOT 4


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Brake fluid leakageCheck to see if any brake fluid is leaking out ofthe pipe joints or brake fluid reservoirs. Applythe brakes firmly for one minute. If there is anyleakage, the brake system should be inspectedby a Yamaha dealer.

Brake operationTest the brakes at slow speed after starting outto make sure they are working properly. If thebrakes do not provide proper braking perfor-mance, inspect the brake pads for wear. (Seepage 8-248-25.)

5-3

POTENTIAL HAZARDRiding with improperly operating brakes.WHAT CAN HAPPENYou could lose braking ability, whichcould lead to an accident.HOW TO AVOID THE HAZARDAlways check the brakes at the start ofevery ride. Do not ride the ATV if you findany problem with the brakes. If a problemcannot be corrected by the adjustmentprocedures provided in this manual, havea Yamaha dealer check for the cause.

qWARNING


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EBU00129

FuelMake sure there is sufficient gasoline in thetank.

Your Yamaha engine has been designed to usepremium unleaded gasoline with a pump octanenumber ([R+M]/2) of 90 or higher, or researchoctane number of 95 or higher. If knocking orpinging occurs, use a different brand of gaso-line. Unleaded fuel will give you longer sparkplug life and reduced maintenance cost. Ifunleaded gasoline is not available, then leadedpremium gasoline can be used.

GasoholThere are two types of gasohol; gasohol con-taining ethanol and that containing methanol.Gasohol containing ethanol can be used ifethanol content does not exceed 10%. Gasoholcontaining methanol is not recommended byYamaha because it may cause fuel systemdamage or vehicle performance problems.

1. Filler tube 2. Fuel level

5-4

Recommended fuel:PREMIUM UNLEADED FUEL

Fuel tank capacity:Total: 9 L (1.98 Imp gal, 2.38 US gal)Reserve: 2.0 L (0.44 Imp gal, 0.53 US gal)


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POTENTIAL HAZARDImproper care when refueling.WHAT CAN HAPPENFuel can spill, which can cause a fire andsevere injury.Fuel expands when it heats up. If the fueltank is overfilled, fuel could spill out dueto heat from the engine or the sun.HOW TO AVOID THE HAZARDDo not overfill the fuel tank. Be careful notto spill fuel, especially on the engine orexhaust pipe. Wipe up any spilled fuelimmediately. Be sure the fuel tank cap isclosed securely.Do not refuel right after the engine hasbeen running and is still very hot.

qWARNING

5-5


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5-6

EBU00448

Engine oilMake sure the engine oil is at the specified level.Add oil as necessary. See page 10-2.

1. Oil tank filler cap

NOTE:Be sure to push the cap into the filler neck until itis properly seated.

EBU01289

Transmission oilMake sure the transmission oil is at the specifiedlevel. Add oil as necessary. (See pages 8-68-8.)

q

Recommended oil:Yamalube 2-cycle oil or 2-stroke engine oil

Oil quantity:Total amount:

1.3 L (1.14 Imp qt, 1.37 US qt)Recommended oil:

Yamalube 4 (10W30) or SAE 10W30Recommended oil classification:

API Service SE, SF, SG type or higher Oil quantity:

Total amount:0.7 L (0.62 Imp qt, 0.74 US qt)

Periodic oil change:0.65 L (0.57 Imp qt, 0.69 US qt)


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cC8 In order to prevent clutch slippage (since

the transmission oil also lubricates theclutch), do not mix any chemical additives.Do not use oils with a diesel specification ofCD or oils of a higher quality than speci-fied. In addition, do not use oils labeledENERGY CONSERVING II or higher.8 Make sure that no foreign material enters

the crankcase.

EBU00498

ChainCheck the general condition of the chain andcheck the chain slack before every ride.Lubricate and adjust the chain as necessary.(See pages 8-328-34 for details.)EBU01083

Throttle leverCheck to see that the throttle lever operates cor-rectly. It must open smoothly and spring back tothe idle position when released. Have a Yamahadealer repair as necessary for proper operation.

EBU01162

Fittings and fastenersAlways check the tightness of chassis fittingsand fasteners before a ride. Take the machineto a Yamaha dealer or refer to the ServiceManual for correct tightening torque.

EBU00803

LightsCheck the headlight and tail/brake light to makesure they are in working condition. Repair asnecessary for proper operation.

EBU01170

SwitchesCheck the operation of all switches. Have aYamaha dealer repair as necessary for properoperation.

5-7


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5-8

EBU00157

Tires

POTENTIAL HAZARDOperating this ATV with improper tires, orwith improper or uneven tire pressure.WHAT CAN HAPPENUse of improper tires on this ATV, or oper-ation of this ATV with improper or uneventire pressure, may cause loss of control,increasing your risk of accident.HOW TO AVOID THE HAZARD

1. The tires listed below have beenapproved by Yamaha Motor Co., Ltd.for this model. Other tire combinationsare not recommended.

qWARNING2. The tires should be set to the recom-

mended pressure:8 Recommended tire pressure

Front 30 kPa (0.30 kgf/cm2, 4.4 psi)Rear 25 kPa (0.25 kgf/cm2, 3.6 psi)8 Check and adjust tire pressures when

the tires are cold.8 Tire pressures must be equal on both

sides.3. Tire pressure below the minimum

specified could cause the tire to dis-lodge from the rim under severe ridingconditions. The following are minimums:Front 27 kPa (0.27 kgf/cm2, 3.9 psi)Rear 22 kPa (0.22 kgf/cm2, 3.2 psi)

Manufacturer Size Type

FrontDUNLOP AT21 7 10 KT851A

CHENG SHIN AT21 7 10 C873N

RearDUNLOP AT21 10 8 KT895A

CHENG SHIN AT21 10 8 C874N


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5-9

EBU00159

How to measure tire pressureUse the low-pressure tire gauge.

NOTE:The low-pressure tire gauge is included as stan-dard equipment. Make two measurements of thetire pressure and use the second reading. Dustor dirt in the gauge could cause the first readingto be incorrect.

Set pressure with tires cold.Set tire pressures to the following specifications:

1. Low-pressure tire gauge

q

30 kPa(0.30 kgf/cm2,

4.4 psi)27 kPa

(0.27 kgf/cm2,3.9 psi)


4.7 psi)25 kPa

(0.25 kgf/cm2,3.6 psi)


3.2 psi)28 kPa

(0.28 kgf/cm2,4.0 psi)

Front

Rear

Recommendedpressure Minimum Maximum

4. Use no more than the following pres-sures when seating the tire beads.Front 330 kPa (3.3 kgf/cm2, 47 psi)Rear 280 kPa (2.8 kgf/cm2, 40 psi)Higher pressures may cause the tire toburst. Inflate the tires very slowly andcarefully. Fast inflation could causethe tire to burst.


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5-10

EBU00160

Tire wear limitWhen the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire.

a

a. 3 mm (0.12 in)


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6-1

EBU00161

OPERATION


EBU00511

Starting a cold engine

1. Set the parking brake.2. Turn the fuel cock to ON.3. Turn the main switch to ON and the engine

stop switch to RUN.4. Shift the transmission into neutral.5. Use the starter (choke) in reference to the

figure:

POTENTIAL HAZARDOperating ATV without being familiar withall controls.WHAT CAN HAPPENLoss of control, which could cause anaccident or injury.HOW TO AVOID THE HAZARDRead the Owners Manual carefully. Ifthere is a control or function you do notunderstand, ask your Yamaha dealer.

qWARNING

POTENTIAL HAZARDFreezing control cables in cold weather.WHAT CAN HAPPENYou could be unable to control the ATV,which could lead to an accident or colli-sion.HOW TO AVOID THE HAZARDWhen riding in cold weather, always makesure all control cables work smoothlybefore you begin riding.

qWARNING


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6-2

6

Position 1: Cold engine start-ambient temperature below 5C(40F).

Position 2: Cold engine start-ambient temperature at 0C(30F)30C (90F) and warmingup position.

Position 3: Cold engine start-ambient temperature above 25C(80F) and warm engine start posi-tion.

1. Fully open 2. Half open 3. Closed a. Starter (choke)

6. Completely close the throttle lever and startthe engine by kicking the kick starter.

7. If the engine is started with the starter(choke) in position 1, the starter (choke)should be returned to position 2 to warm upthe engine. If the engine is started with thestarter (choke) in position 2 , keep thestarter (choke) in this position to warm upthe engine.

8. Continue warming up the engine until it idlessmoothly and return the starter (choke) toposition 3 before riding.

cCSee the Engine break-in section prior tooperating engine for the first time.

eq

0

30

10 20 30

50 70 90 F

CAMBIENT TEMP. / STARTER (CHOKE) POSITION

w

eq w

a


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EBU00180

Starting a warm engineTo start a warm engine, refer to the Starting acold engine section. The starter (choke) shouldnot be used. The throttle should be openedslightly.

EBU00182

Warming upTo get maximum engine life, always warm upthe engine before starting off. Never acceleratehard with a cold engine! To see whether or notthe engine is warm, check if it responds to thethrottle normally with the starter (choke) turnedoff.

6-3


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6-4

EBU00198*

ShiftingThis model has a 6-speed forward transmission.The transmission allows you to control theamount of power you have available at a givenspeed or for starting, accelerating, climbing hills,etc. To shift into neutral, return the throttle leverto its original position, apply the clutch andrepeatedly depress the shift pedal until it stops.When it stops, it will be in first gear. Raise thepedal slightly to neutral.

N. Neutral

cC8 Do not coast for long periods with the

engine off, and do not tow the machine along distance. Even in neutral position,the transmission is only properly lubri-cated when the engine is running.Inadequate lubrication may cause dam-age.8 Always use the clutch when changing

gears. The engine, transmission anddrive train are not designed to withstandthe shock of forced shifting and can bedamaged by shifting without the clutch.

65432N1


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EBU00203

To start out and accelerate:1. Release the throttle lever.

cCAlways close the throttle while shiftinggears. Otherwise, damage to the engine anddrive train may result.

2. Pull the clutch lever to disengage the clutch.3. Shift into first gear.4. Open the throttle gradually and at the same

time, release the clutch lever slowly.5. Once the machine has attained adequate

speed, release the throttle, and at the sametime, quickly pull in the clutch lever.

6. Shift into second gear. (be careful not toshift into neutral)

7. Open the throttle part way and graduallyrelease the clutch lever.

8. Follow the same procedure when shifting tothe next higher gear.

6-5

POTENTIAL HAZARDOpening the throttle abruptly or releasingthe clutch lever too quickly.WHAT CAN HAPPENThe machine could wheelie. This wouldincrease the chance of an accident,including overturn.HOW TO AVOID THE HAZARDOpen the throttle gradually.Release the clutch lever gradually.

qWARNING


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6-6

EBU00207

To decelerate:When slowing down or stopping, release thethrottle and apply the brakes smoothly andevenly. As you slow down, shift to a lower gear.Be sure that the engine has sufficiently slowedbefore engaging a lower gear. Improper use ofthe brakes or shifting can cause the tires to losetraction, reducing control and increasing thepossibility of an accident.

POTENTIAL HAZARDEngaging a lower gear when the enginespeed is too high.WHAT CAN HAPPENThe wheels could stop rotating. This couldcause loss of control, an accident andinjury. It could also cause engine or drivetrain damage.HOW TO AVOID THE HAZARDMake sure the engine has sufficientlyslowed before shifting to a lower gear.

qWARNING


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6-7

EBU00209

Engine break-inThere is never a more important period in thelife of your machine than the period betweenzero and 20 hours.For this reason, we ask that you carefully readthe following material. Because the engine isbrand new, you must not put an excessive loadon it for the first several hours of running. Duringthe first 20 hours, the various parts in the enginewear and polish themselves to the correct oper-ating clearances.During this period, prolonged full throttle opera-tion or any condition which might result in exces-sive engine heating must be avoided. However,momentary (23 seconds maximum) full throttleoperation under load does not harm the engine.Each full throttle acceleration sequence shouldbe followed with a substantial rest period for theengine by cruising at lower r/min so the enginecan rid itself of the temporary build up of heat.

If any abnormality is noticed during this period,consult a Yamaha dealer.

1. 010 hours:Avoid continuous operation above half throt-tle. Allow a cooling off period of five to tenminutes after every hour of operation. Varythe speed of the machine from time to time.Do not operate it at one set throttle position.

2. 1020 hours:Avoid prolonged operation above 3/4 throt-tle. Rev the machine freely through thegears but do not use full throttle at any time.

3. After break-in:Avoid prolonged full throttle operation. Varyspeeds occasionally.


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6-8

EBU00212

ParkingWhen parking, stop the engine and shift into lowgear. Turn the fuel cock to OFF and apply theparking brake.

1. Button 2. Lock plate

q

w


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EBU01174

Parking on a slope

1. Bring the machine to a stop by applying thebrakes in low gear.

2. Stop the engine and release the clutchlever.

3. With the rear brake applied, apply the park-ing brake and slowly release the brakepedal.

6-9

POTENTIAL HAZARDParking on a hill or other incline.WHAT CAN HAPPENThe ATV could roll out of control, increas-ing the chance of an accident.HOW TO AVOID THE HAZARDAvoid parking on hills or other inclines. Ifyou must park on an incline, put themachine in low gear, apply the parkingbrake, and block the front and rear wheelswith rocks or other objects.Do not park the ATV at all on hills that areso steep you could not walk up them easi-ly.

qWARNING


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6-10

EBU00221

Accessories and loading

EBU00222

AccessoriesAccessories can affect the handling and controlof your ATV. Keep the following in mind whenconsidering an accessory or operating an ATVwhich has accessories.8 Choose only accessories designed for your

ATV. Your Yamaha dealer has a variety ofgenuine Yamaha accessories. Other acces-sories may also be available on the market.However, it is not possible for Yamaha to testall non-Yamaha accessories, nor have anycontrol over the quality or suitability of them.Choose a genuine Yamaha accessory, or onethat is equivalent in design and quality.

8 Accessories should be rigidly and securelymounted. An accessory which can shift posi-tion or come off while you are riding couldaffect your ability to control the ATV.8 Do not mount an accessory where it could

interfere with your ability to control the ATV.Examples include (but are not limited to) aheavy or bulky object attached to the handle-bars which could make steering difficult, anaccessory that limits your ability to movearound on the seat, or one that limits yourview.8 Use extra caution when riding an ATV with

accessories. The ATV may handle differentlythan it does without accessories.


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EBU00584

LoadingAs originally equipped, this ATV is not designedto carry cargo or tow a trailer. If you choose toadd accessories so that you can carry cargo ortow a trailer, you must use common sense andgood judgment. Keep the following points inmind:8 Never exceed the weight limits shown. An

overloaded ATV can be unstable.

8 Load cargo on the carriers as close to thecenter of the vehicle as possible. Put cargo atthe rear of the front carrier and at the front ofthe rear carrier. Center the load from side toside.

8 Tie down cargo securely to the carriers. Makesure cargo in the trailer cannot move around.A shifting load can cause an accident.8 Make sure the load does not interfere with

controls or your ability to see where you aregoing.8 Ride more slowly than you would without a

load. The more weight you carry, the sloweryou should go. Although conditions vary, it isgood practice not to exceed 2nd gear when-ever you are carrying heavier loads or whentowing a trailer.8 Allow more braking distance. A heavier vehi-

cle takes longer to stop.8 Avoid making sharp turns unless at very slow

speeds.8 Avoid hills and rough terrain. Choose terrain

carefully. Added weight affects the stabilityand handling of the ATV.

6-11

MAXIMUM LOADING LIMITVehicle loading limit (total weight of cargo, rider and accessories):

100 kg (220 lb)


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6-12

POTENTIAL HAZARDOverloading this ATV or carrying or tow-ing cargo improperly.WHAT CAN HAPPENCould cause changes in vehicle handlingwhich could lead to an accident.HOW TO AVOID THE HAZARDNever exceed the stated load capacity forthis ATV.Cargo should be properly distributed andsecurely attached.Reduce speed when carrying cargo orpulling a trailer. Allow greater distance forbraking.

qWARNING


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6-13

EBU01176



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7-1

Riding Your ATV

7


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7-2


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GETTING TO KNOW YOUR ATVThis ATV is intended for recreational use byexperienced operators only.Even though you are an experienced operator ofall other all terrain vehicles or motorcycles, rid-ing the ATV requires special skills acquiredthrough practice.Take your time to fully learn techniques beforeattempting more difficult maneuvers.

Riding your new ATV can be a very enjoyableactivity, providing you with hours of pleasure.But it is essential to familiarize yourself with theoperation of the ATV to achieve the skill neces-sary to enjoy riding safely. Before you begin toride, be sure you have read this Owners Manualcompletely and understand the operation of the

controls. Pay particular attention to the safetyinformation on pages 2-12-7. Please also readall caution and warning labels on your ATV.


7-3


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7-4

RIDE WITH CARE AND GOOD JUDGEMENT

Get training if you are inexperienced.Beginners should get training from a certifiedinstructor.Become familiar with this ATV at slow speedsfirst, even if you are an experienced operator.Do not attempt to operate at maximum perfor-mance until you are totally familiar with theATVs handling and performance characteristics.

Riding your ATV requires skills acquiredthrough practice over a period of time.Take the time to learn the basic techniques wellbefore attempting more difficult maneuvers.

POTENTIAL HAZARDOperating this ATV without proper instruc-tion.WHAT CAN HAPPENThe risk of an accident is greatly increasedif the operator does not know how to oper-ate the ATV properly in different situationsand on different types of terrain.

HOW TO AVOID THE HAZARDBeginning and inexperienced operatorsshould complete the certified trainingcourse offered by Yamaha. They shouldthen regularly practice the skills learned inthe course and the operating techniquesdescribed in this Owners Manual.For more information about the trainingcourse, contact an authorized ATV dealeror call 1-800-887-2887.

qWARNING


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7-5

Not recommended for children under 16years of age.

POTENTIAL HAZARDFailure to follow the age recommendationsfor this ATV.WHAT CAN HAPPENUse by children of ATVs that are not rec-ommended for their age can lead to severeinjury or death of the child.HOW TO AVOID THE HAZARDA child under 16 should never operate anATV with engine size greater than 90cc.

qWARNING


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7-6

This ATV is designed to carry operator only -passengers prohibited.

POTENTIAL HAZARDCarrying a passenger on this ATV.WHAT CAN HAPPENGreatly reduces your ability to balanceand control this ATV. Could cause an acci-dent, resulting in harm to you and/or yourpassenger.HOW TO AVOID THE HAZARDNever carry a passenger. The long seat isto allow the operator to shift position asneeded during operation. It is not for car-rying passengers.

qWARNING


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Apparel Operating without protective clothingincreases your chances of severe injury inthe event of an accident.HOW TO AVOID THE HAZARDAlways wear an approved motorcycle hel-met that fits properly.You should also wear:

eye protection(goggles or face shield)glovesbootslong-sleeved shirt or jacketlong pants

7-7

POTENTIAL HAZARDOperating this ATV without wearing anapproved motorcycle helmet, eye protec-tion and protective clothing.WHAT CAN HAPPENOperating without anapproved motorcyclehelmet increasesyour chances of asevere head injury ordeath in the event ofan accident.Operating withouteye protection canresult in an accidentand increases yourchances of a severeinjury in the event ofan accident.

qWARNING

Gloves

Goggles

Boots

Helmet

Protectiveclothing


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7-8

Do not operate after consuming alcohol ordrugs.Operators performance capability is reduced bythe influence of alcohol or drugs.

POTENTIAL HAZARDOperating this ATV after consuming alco-hol or drugs.WHAT CAN HAPPENCould seriously affect your judgment.Could cause you to react more slowly.Could affect your balance and perception.Could result in an accident.HOW TO AVOID THE HAZARDNever consume alcohol or drugs before orwhile driving this ATV.

qWARNING


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7-9

Pre-operation checksAlways perform the pre-operation checks listedon page 5-1 before riding for safety and propercare of the ATV.

POTENTIAL HAZARDFailure to inspect the ATV before operat-ing.Failure to properly maintain the ATV.WHAT CAN HAPPENIncreases the possibility of an accident orequipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV each time youuse it to make sure the ATV is in safeoperating condition. Always follow theinspection and maintenance proceduresand schedules described in the OwnersManual.

qWARNING

POTENTIAL HAZARDOperating this ATV with improper tires, orwith improper or uneven tire pressure.WHAT CAN HAPPENUse of improper tires on this ATV, or oper-ation of this ATV with improper or uneventire pressure, may cause loss of control,increasing your risk of an accident.HOW TO AVOID THE HAZARDAlways use the size and type tires speci-fied in the Owners Manual for this vehicleon pages 5-85-9.Always maintain proper tire pressure asdescribed in the Owners Manual on page5-9.

qWARNING


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Do not operate at speeds too fast for yourskills or the conditions.

Speed limiterFor riders inexperienced with this model, thismodel is equipped with a speed limiterin thethrottle lever housing. The speed limiter limitsthe power and top speed of the ATV. Turningthe adjusting screw in decreases top speed, andturning it out increases top speed. (See page 4-6 for details.)

7-10

POTENTIAL HAZARDOperating this ATV at speeds too fast foryour skills or the conditions.WHAT CAN HAPPENIncreases your chances of losing controlof the ATV, which can result in an acci-dent.HOW TO AVOID THE HAZARDAlways go at a speed that is proper for theterrain, visib

Documents

yamaha_blaster_yfs200r_owners_manual.pdf