Yamaha Blaster ysf200k User manual

YAMAHA

152 Pgs

www.blasterforum.com

Page 1

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Dear

New

Yamaha

ATV

Owner:

CONGRATULATIONS

ON

THE

PURCHASE

OF

YOUR

NEW

YAMAHA

ATV.

You

have

purchased

a

quality

Yamaha

product

that,

with

proper

use

and

care,

will

provide

hours

of

riding

pleasure.

BEFORE

YOU

OPERATE

YOUR

NEW

ATV,

Yamaha

recommends

these

important

points:

•

READ

YOUR

OWNER'S

MANUAL

e A CHILD

UNDER

12

YEARS

OLD

SHOULD

NOT

OPERATE

AN

ATV

WITH

ENGINE

SIZE

70CC

OR

GREATER

e A CHILD

UNDER

16

YEARS

OLD

SHOULD

NOT

OPERATE

AN

ATV

WITH

ENGINE

SIZE

GREATER

THAN

90CC

e

TAKE

THE

FREE

HANDS-ON TRAINING

COURSE

OFFERED

BY

YAMAHA -

ASK

YOUR

DEALER

FOR

DETAILS

OR CALL 1-800-447-4700

~

....

:)

LL.

w

a:

If

you

have

any

questions

about

these

points,

or

if you purchased your

ATV

from

an

authorized Yamaha

,11f11

dealership

and

were notinformed

of

the

age

recommendation for your

ATV

by

the

dealership,

please

......_

fill

out

the

information

below

and

mail

this

card

to

Yamaha

today.

CJ

Name:

ATV

Model:

Purchase

Date:

Address:

Primary

Ul

(Engine

Number):

Dealer

Name

& Address:

Telephone:

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Page 2

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BUSINESS

REPLY

MAIL

FIRST

CLASS PERMIT

N0.4

CYPRESS, CA

POSTAGE

WILL

BE

PAID

BY ADDRESSEE

YAMAHA

MOTOR CORPORATION U.S.A.

P.O.

BOX 6555

CYPRESS,

CALIFORNIA

90630·9989

ATTN:

SALES

ADMINISTRATION

II.J

••

JJ

••••

JJ

••••

II

.Jt

•••

t.J

••

J.J

••

J

••

J.J.J

••

J

•••

JJ

NO

POSTAGE

NECESSARY

IF

MAILED

IN THE

UNITED

STATES

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Page 3

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EDA20901 INTRODUCTION

Congratulations on

your

purchase

of

the Yamaha YFS200. It represents the result

of

many years

of

Yamaha experience in

the

production

of

fine

sporting,

touring,

and pacesetting racing

machines. With the purchase

of

this Yamaha, you can

now

appreciate the high degree

of

crafts-

manship and reliability

that

have made Yamaha a leader in these fields.

This manual

will

provide you

with

a good basic understanding

of

the features and operation

of

this machine. This manual includes important safety information. It provides information about

special techniques and skills necessary to ride your machine. It also includes basic mainte-

nance and inspection procedures. If you have any questions regarding the operation

or

mainte-

nance

of

your

machine, please consult a Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE:

•

READ

THIS

MANUAL

TOGETHER WITH TIPS

FOR

THE

ATV

RIDER

CAREFULLY AND COM-

PLETELY

BEFORE

OPERATING YOUR MACHINE. MAKE SURE YOU UNDERSTAND ALL

INSTRUCTIONS.

• PAY

CLOSE

ATTENTION TO

THE

WARNING AND CAUTION LABELS

ON

THE

MACHINE.

•

NEVER

OPERATE

AN ATV WITHOUT

PROPER

TRAINING

OR

INSTRUCTION.

FREE

TRAINING

IS

AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-447-4700

FOR

MORE

INFORMATION.

• THIS ATV, AND ANY

OTHER

ATV

OVER

90cc, SHOULD NOT

BE

RIDDEN

BY

ANYONE UNDER

16

YEARS

OF

AGE.

• THIS ATV

IS

A HIGH PERFORMANCE ATV

FOR

OFF-ROAD

USE

ONLY,

FOR

SPORT

TYPE

RECREATIONAL AND COMPETITIVE

USE

BY

EXPERIENCED OPERATORS.

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Page 4

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EDA10001 IMPORTANT

MANUAL

INFORMATION

FAILURE 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:

ffi

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE-

TY

IS

INVOLVED!

F!\!N:-1;1~1!~(d

Failure

to

follow

WARNING instructions could result in severe

injury

or

death

to the machine operator, a bystander

or

a person inspecting

or

repairing the

machine.

CAUTION:

NOTE:

A CAUTION indicates special precautions

that

must

be

taken

to

avoid damage

to

the machine.

A NOTE provides key

information

to

make procedures easier

or

clearer.

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Page 5

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EDA20100 IMPORTANT NOTICE

This

machine

is designed and manufactured

for

OFF-ROAD use only. It is illegal and unsafe

to

operate

this

machine on

any

public

street, road

or

highway.

This

machine

complies

with

all applicable OFF-ROAD noise level and spark arrester laws and

regulations in effect at

the

time

of

manufacture.

Please check

your

local

riding

laws and regulations before operating

this

machine.

EDAOOOOO

L AFFIX DEALER

LABEL

HERE

_j

EDA00100

YFS200K

OWNER'S MANUAL

Motor

Corporation,

U.S.A.

1st Edition, April1997

unauthorized use without the written

permission of Yamaha Motor Corporation,

U.S.A.

is

expressly prohibited.

Printed

in

Japan

P/N

LIT-11626-10-97

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Page 6

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EDA25001

A

WARNING

Indicates a potential hazard

that

could result

in

serious injury or death.

CONTENTS

aLOCATION

OF

THE

"WA~NING

AND

SPECIFICATION LABELS ......................

1-1

~SAFETY

INFORMATION.........................

2-1

II

DESCRIPTION

AND

MACHINE

IDENTIFICATION.....................................

3-1

Identification

numbers

record ...........3-2

Key

identification

number

..................3-2

Vehicle

identification

number

............3-3

Model

label .........................................3-3

I

CON~ROL

_FUNCTIONS..........................

4-1

Ma1n

sw1tch .........................................

4-1

Indicator

lights

....................................

4-1

Oil level

inidcator

light

checking

method

................................................4-2

Handlebar

switches

............................4-3

Thrattle

lever

.......................................4-4

Throttle

OverRide System .................4-5

Speed

limiter

.......................................4-6

Clutch

lever

.........................................4-7

Front

brake

lever

.................................

4-7

Rear brake pedal.................................4-8

Parking brake ......................................4-8

Shift

pedal .........................................4-10

Kick

starter

........................................4-10

Fuel

tank

cap .....................................4-11

Fuel cock............................................4-11

Starter

"CHOKE"

..............................4-12

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Page 7

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Seat....................................................

4-12

Front shock absorber 1OPERA:noN ··············:·····························6-1

Starting a cold

eng~ne

.........................

G-1

adjustment

........................................4-14 Starting a

warm

engine .....................

6-3

Rear shock absorber

Warming

up ........................................6-3

adjustment

.......................................

.4-15

Shifting

................................................6-4

To start

out

and accelerate: ...............6-5

I PRE-OPERATION CHECKS.....................

5-1

Front

and rear brakes .........................

5-2

To decelerate: .....................................

6-6

Engine break-in...................................

6-7

Fuel ......................................................

5-3 Parking.................................................

G-8

Engine oil ...........................................

5-5 Parking on a slope ..............................

6-9

Transmission oil .................................

5-5 Accessories and loading ..................6-10

Chain....................................................

5-6

Throttle

lever.......................................

5-6

Fittings and fasteners.........................5-6 II

RIDIN~

YOUR

MOT0-4

..........................

7-1

Getting

to

know

your

MOT0-4

...........7-3

Lights ...................................................

5-G

Ride

with

care and

good

Switches..............................................

5-G

judgement

...........................................

7-4

Tires .....................................................

5-7

Be

careful

where

you

ride................

7-16

How

to

measure

tire

pressure ...........5-8

Turning

your

MOT0-4

......................

7-23

Tire

wear

limit

.....................................

5-9

Climbing

uphill

.................................7-25

Riding

downhill

.................................7-30

Crossing a slope ...............................

7-32

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Crossing

through

shallow

water

.....7-34 Parking brake

adjustment

................

8-21

Riding

over

rough terrain ................7-36 Clutch

adjustment

............................8-22

Sliding

and skidding.........................7-38

Autolube

pump

adjustment.............8-22

What

to

do if... .................................7-40 Drive chain slack check ....................8-23

What

to

do........................................7-40 Drive chain slack adjustment...........8-23

Drive chain cleaning and

lubrication .........................................8-24

Cable inspection and lubrication.....8-25

I PERIODIC MAINTENANCE

AND

ADJUSTMENT........................................

8-1

Owner's

manual and

tool

kit..............

8-1

Brake and

shift

pedal/brake and

Periodic maintenance/Lubrication.....8-3 clutch lever

lubrication

.....................8-25

Transmission oil .................................8-5

Upper

and

lower

arm

pivot

Spark plug inspection ........................8-7 lubrication .........................................8-25

Air

filter

cleaning ................................8-8 Steering

shaft

lubrication.................8-26

Carburetor settings...........................

8-11

Wheel removal..................................8-27

Idle speed

adjustment..

....................8-16 Wheel installation.............................8-27

Throttle

lever adjustment.................8-17 Replacing

the

headlight

bulb

...........8-28

Front brake shoe inspection ............8-18 Headlight beam

adjustment

............8-29

Rear brake pad inspection ...............8-18

Troubleshooting

...............................8-30

Front brake lever free play

Troubleshooting

chart......................

8-31

adjustment

........................................8-19 No spark ............................................8-32

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I

CLEANING_

AND

STORAGE ...................

9-1

A. Clean1ng ..........................................

9-1

B.

Storage

............................................9-3

I

SPECIFICATIONS..................................

10-1

Ill

NOISE REGULATION ...........................

11-1

II

MAINTENANCE

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

II

MOT0-4

LIMITED

WARRANTY

...........

13-1

I

~~~;~~-~~~~-~-~~-~-~-~-~~-~.~~

...........

14-1

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Page 10

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EDA40000 LOCATION OF THE

"WARNING

AND

SPECIFICATION LABELS"

1-1

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Page 11

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Read and understand all

of

the labels on

your

machine. They contain

important

information

for

safe and

proper

operation

of

your

MOT0-4.

Never

remove

any

labels

from

your

MOT0-4.

If

a label becomes

difficult

to

read

or

comes

off,

a

replacement

label

is

available

from

your

Yamaha dealer.

CD

A WARNING

~

Operating this ATV if you are under

the age of 16 increases your chance

of severe injury

or

death.

NEVER operate this

ATV

if

you are

under age 16.

YAMAHA

3FA-2415A-OO 1-2

I

A WARNING

NEVER ride

as

a

~

passenge<

Passengers

can

cause

a

loss

of

control,

resulting

in

SEVERE

INJURY

or

DEATH.

4WU-2151H.OO

A WARNING

IMPROPER

TIRE

PRESSURE

OR

OVERLOADING

CAN

CAUSE

LOSS OF CONTROL.

LOSS

OF CONTROL

CAN

RESULT

IN

SEVERE

INJURY

OR DEATH.

OPERATING TIRE PRESSURE : Set

with

tires cold

• Recommended : FRONT : 30

kPa,

{0.30 kgf/cm'l. 4.4 psi

REAR

:

25

kPa,

{0.25 kgf/cm'}, 3.6 psi

•

Minimum

: FRONT :

27

kPa,

{0.27 kgf/cm'}, 3.9 psi

REAR

:

22

kPa,

{0.22 kgf/cm'}, 3.2 psi

• Never set tire pressure

below

minimum.

It could cause

the

tire

to

dislodge

from

the rim.

LOADING

•

Maximum

Vehicle Load : 100 kg, (220 lbs)

Includes

weight

of

operator, cargo and accessories.

YAMAHA

3JM-21696-00

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Page 12

Blasterforum.com

®

£WARNING

This

unit

contains high pressure nitrogen gas.

Mishandling

can cause explosion.

• Read

owner's

manual

for

instructions.

• Do

not

incinerate, puncture

or

open.

YAMAHA

4AA-22259-00

1-3

A WARNING

Improper

ATV

use

can

result

in

SEVERE

INJURY

or

DEATH.

-~~-

ALWAYS

USE

NEVER

USE

NEVER

CARRY

NEVER

USE

AN

APPROVED

ON

PUBLIC

PASSENGERS

WITH

DRUGS

HELMET

AND

ROADS

OR

ALCOHOL

PROTECTIVE

GEAR

NEVER

operate :

•

without

proper

training

or

instruction.

• at speeds

too

fast

for

your

skills

or

the conditions.

• on public

roads-a

collision can

occur

with

another vehicle.

• with a passenger-passengers affect balance

and steering and increase risk

of losing control.

ALWAYS:

• use proper riding techniques

to

avoid

vehicle overturns on hills and rough terrain

and in turns.

• avoid paved

surfaces-pavement

may

seriously affect handling and control.

LOCATE

AND

READ

OWNER'S

MANUAL

FOLLOW

ALL

INSTRUCTIONS

AND

WARNINGS.

(For replacement manual, call 1-800-532-1558)

4WU-21568-00

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Page 13

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EDA30202

A SAFETY INFORMATION

AN ATV IS NOT A TOY AND CAN

BE

HAZARDOUS TO OPERATE.

An

ATV

handles

differently

from

other

vehicles

including

motorcycles

and cars. A

collision

or

rollover

can

occur

quickly,

even

during

routine

maneuvers

such as

turning

and

riding

on

hills

or

over

obstacles,

if

you

fail

to

take

proper

precautions.

SEVERE INJURY

OR

DEATH can result

if

you

do

not

follow

these

instructions:

• Read

this

manual

and all labels

carefully

and

follow

the

operating

procedures

described.

•

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 deal-

er

or

call 1-800-447-4700

to

find

out

about

the

training

courses nearest

you.

•

Always

follow

these age

recommendation:

-A

child

under

16 years

old

should

never

operate

an

ATV

with

engine

size

greater

than

90cc.

•

Never

allow

a

child

under

age 16

to

operate

an

ATV

without

adult

supervision,

and

never

allow

continued

use

of

an

ATV

by

a

child

if

he

or

she does

not

have

the

abilities

to

operate

it

safely.

•

Never

carry

a passenger on an ATV.

2-1

I

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Page 14

Blasterforum.com

•

Always

avoid operating an ATV on

any

paved surfaces,

including

sidewalks, driveways, park-

ing lots and streets.

• Never operate

an

ATV on

any

public street, road

or

highway,

even a

dirt

or

gravel one.

• 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.

• Never

consume

alcohol

or

drugs

before

or

while

operating

this

ATV.

• Never operate at speeds

too

fast

for

your

skills

or

the

conditions.

Always

go

at a speed

that

is

proper

for

the terrain,

visibility

and operating conditions, and

your

experience.

• Never

attempt

wheelies,

jumps,

or

other stunts.

•

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.

•

Always

keep both hands on the handlebars and both feet on

the

footpegs

of

the ATV

during

operation.

•

Always

go

slowly

and be extra careful

when

operating

on

unfamiliar

terrain.

Always

be alert

to

changing terrain

conditions

when

operating

the

ATV.

2-2

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Page 15

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• Never operate on excessively rough,

slippery

or

loose

terrain

until

you

have learned and

practiced the skills necessary

to

control the ATV on such terrain.

Always

be especially cau-

tious

on these kinds

of

terrain.

•

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.

• Never operate the ATV on hills

too

steep

for

the

ATV

or

for

your

abilities. Practice on

smaller

hills before

attempting

larger

hills.

•

Always

follow

proper

procedures

for

climbing

hills

as described in

this

manual. Check the ter-

rain

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. Never go

over

the

top

of

a hill at

high

speed.

•

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 vehicle

to

lean sharply

to

one side. Go

straight

down

the

hill where possible.

•

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

turn-

ing technique described in

this

manual on level

ground.

Avoid

crossing

the

side

of

a steep

hill

if

possible.

2-3

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Page 16

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•

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,

follow

the special procedure

for

braking described in

this

manual.

Dismount

on

the

uphill

side

or

to

a side

if

pointed

straight uphill.

Turn

the

ATV

around

and remount, fol-

lowing

the

procedure described in

this

manual.

•

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

fol-

low

proper

procedures

when

operating

over

obstacles

as

described in

this

manual.

•

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

slowly

and be

very

cautious in

order

to

reduce the change

of

skidding

or

sliding

out

of

control.

• Never operate

an

ATV in fast

flowing

water

or

in

water

deeper than

that

recommended in

this

manual.

Remember

that

wet

brakes

may

have reduced

stopping

ability.

Test

your

brakes

after leaving water. If necessary,

apply

them

several

times

to

let

friction

dry

out

the linings.

•

Always

use

the

size and

type

tires specified in

this

manual.

Always

maintain

proper

tire pressure

as

described in

this

manual.

• Never

modify

an

ATV

through

improper

installation

or

use

of

accessories.

2-4

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Page 17

Blasterforum.com

• Never exceed the stated load capacity

for

an

ATV. Cargo

should

be

properly

distributed and

securely attached. Reduce speed and

follow

instructions

in

this

manual

for

carrying cargo

or

pulling

a trailer.

Allow

greater distance

for

braking.

FOR MORE

INFORMATION

ABOUT

ATV

SAFETY,

call

the

Consumer

Products

Safety

Commission

at 1-800-638-2772,

or

the ATV

Distributor's

Safety Hotline at 1-800-852-5344.

2-5

www.blasterforum.com

Page 18

Blasterforum.com

A WARNING

POTENTIAL HAZARD

Improper

handling

of

gasoline.

WHAT

CAN HAPPEN

Gasoline

can catch

fire

and

you

could

be

burned.

HOW TO AVOID

THE

HAZARD

Always

turn

off

the

engine

when

refuel-

ing.

Do

not

refuel

right

after

the

engine

has

been

running

and is

still

very

hot.

Do

not

spill

gasoline

on

the

engine

or

exhaust

pipe/muffler

when

refueling.

Never

refuel

while

smoking,

or

while

in

the

vicinity

of

sparks,

open

flames,

or

other

sources

of

ignition

such as

the

pilot

lights

of

water

heaters and

clothes

dryers.

2-6

When

transporting

the

machine

in

another

vehicle, be sure

it

is

kept

upright

and

that

the

fuel

cock

is

in

the

"OFF"

position.

Otherwise,

fuel

may

leak

out

of

the

carbu-

retor

or

fuel

tank.

WHAT

CAN HAPPEN

Gasoline

is

poisonous

and

can

cause

injuries.

HOW

TO AVOID THE HAZARD

If

you

should

swallow

some

gasoline

or

inhale

a

lot

of

gasoline vapor,

or

get

some

gasoline

in

your

eyes,

see

your

doctor

immediately.

If

gasoline spills

on

your

skin,

wash

with

soap and

water.

If

gasoline spills on

your

clothing,

change

your

clothes.

www.blasterforum.com

Page 19

Blasterforum.com

2-7

A

WARNING

POTENTIAL HAZARD

Starting

or

running

the

engine in a closed

area.

WHAT CAN HAPPEN

Exhaust

fumes

are

poisonous

and

may

cause

loss

of

consciousness

and

death

within

a

short

time.

HOW TO AVOID THE HAZARD

Always

operate

your

machine

in an area

with

adequate

ventilation.

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Page 20

Blasterforum.com

Yamaha Blaster YSF200K User manual

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