2002-2006 Yamaha Blaster YSF200 Repair Manual

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This manual covers the YSF200, a popular sport ATV produced from 1988 to 2006. Known for its affordability and ease of modification, the Blaster has been a foundational model in...

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Typ: Atv

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Art.-Nr: 93781

Stichworte: 2002 2003 2004 2005 2006 ATV Blaster Models Blaster YSF200 Powersports Yamaha

Produktvarianten

Beschreibung

This manual covers the YSF200, a popular sport ATV produced from 1988 to 2006. Known for its affordability and ease of modification, the Blaster has been a foundational model in the recreational ATV market. This vehicle features a 196cc two-stroke, air-cooled engine, a 6-speed sequential transmission with a manual clutch, and hydraulic disc brakes on both the front and rear. Its durable steel frame and integrated footwells with heel guards are designed for rider protection. The YSF200 series, including variants like YFS200P through YFS200V and YSF200 (U-A), offers a straightforward yet capable riding experience. This comprehensive Factory Service Manual provides detailed guidance for the maintenance and repair of all Blaster models. It covers essential areas such as engine disassembly and assembly, fuel system diagnosis and repair, transmission and final drive servicing, and suspension and brake system maintenance. The manual also includes procedures for electrical system troubleshooting, body and frame work, and offers a complete maintenance schedule with recommended service intervals for oil changes, filter cleaning, and component checks. With step-by-step instructions, torque specifications, and detailed wiring diagrams, this manual is an indispensable resource for owners and technicians aiming to keep their YSF200 in optimal condition.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

Blaster YSF200

Model Variant:

YSF200, YFS200P, YFS200R, YFS200S, YFS200T, YFS200SEV, YFS200V, YSF200 (U-A)

Product Name:

2002-2006 Yamaha Blaster YSF200 Repair Manual

Codes

Chassis Code:

YSF200, YFS200 series

👋 Introduction

Market Position

Positioning:

Essential maintenance and repair guide for owners and technicians of the Yamaha Blaster YSF200, a popular entry-level sport ATV known for its affordability and ease of modification.

Competitive Analysis

Competition:

Competes with similar models from Honda (e.g., TRX250X/EX), Suzuki (e.g., LT-Z250), and Kawasaki (e.g., KSF250 Mojave) in the recreational ATV market. This manual provides Yamaha-specific insights.

Key Features

Features:

Instantly downloadable, no special software required, printable, permanent access upon download, covers all aspects of repair and maintenance.

📋 Manual Details

Coverage Areas

Years Covered:

1988-2006

Model Coverage:

All Blaster models including YSF200, YFS200P, YFS200R, YFS200S, YFS200T, YFS200SEV, YFS200V, YSF200 (U-A)

Page Count

Estimated Page Count:

Varies by specific edition, typically 200-400 pages for comprehensive factory service manuals.

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital Downloadable (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, inspection, repair, and assembly.

Fuel System:

Carburetor (Mikuni VM26SS or similar) diagnosis, cleaning, adjustment, and rebuilding; fuel pump, fuel lines, and tank maintenance.

Cooling System:

Air cooling system principles and maintenance (no liquid cooling on Blaster).

Transmission:

Gearbox maintenance, clutch operation and adjustment, transmission fluid changes.

Final Drive:

Chain drive maintenance, lubrication, adjustment, and sprocket replacement.

Body And Frame:

Frame inspection, body panel removal/installation, seat, fenders, and handlebars.

Steering And Suspension:

Front and rear suspension systems, shock absorbers, A-arms, steering linkage, bearing maintenance.

Brakes:

Front and rear hydraulic brake systems, caliper service, master cylinder, brake fluid bleeding, pad replacement.

Electrical:

Ignition system, lighting, starter system, battery maintenance, fuses, switches, and electrical component testing.

Wiring Diagrams:

Detailed electrical wiring schematics for all systems.

Procedures Included

Maintenance:

Regular scheduled maintenance, inspections, lubrication, and fluid checks.

Troubleshooting:

Diagnostic procedures for common problems, symptom-based troubleshooting guides.

Repair:

Step-by-step instructions for component removal, installation, and repair.

Rebuilds:

Complete engine and carburetor rebuild procedures.

Specifications:

Torque values, clearances, fluid capacities, and other critical technical data.

Technical Depth

Depth:

Comprehensive, covering everything from basic checks to full engine overhauls and electrical diagnostics.

📊 Manual Specifications

File Format

Format:

Searchable:

Typically Yes (depending on PDF creation)

Print Quality

Quality:

Identical to printed book, high-resolution diagrams and images.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Type:

2-stroke, reed valve, air-cooled

Displacement:

196cc

Bore X Stroke:

66.0 mm x 57.0 mm

Compression Ratio:

7.3:1

Ignition:

CDI (Capacitor Discharge Ignition)

Performance

Horsepower:

Approximately 17-18 HP (varies slightly by year and tuning)

Torque:

Approximately 15-16 lb-ft

Fuel System

Carburetor Model:

Mikuni VM26SS (or equivalent)

Fuel Type:

Unleaded gasoline (87 octane recommended)

2-Stroke Oil Mix:

Premix (specific oil-to-gas ratio detailed in manual, typically 50:1 for Yamalube 2R or equivalent).

🔧 Transmission

Standard

Type:

Constant mesh, 6-speed sequential

Optional

Optional Types:

N/A (all models use the 6-speed manual)

Features

Clutch:

Wet, multi-plate, manual clutch operation

Final Drive:

O-ring sealed chain drive

Fluid Specifications

Transmission Oil Type:

Yamaha Motorcycle Gear Oil SAE 80 API GL-4 (or equivalent)

Transmission Oil Capacity:

Approx. 0.8 liters (0.85 US qt)

📐 Dimensions

Exterior

Overall Length:

Approx. 1710 mm (67.3 in)

Overall Width:

Approx. 1070 mm (42.1 in)

Overall Height:

Approx. 1015 mm (40.0 in)

Weights

Dry Weight:

Approx. 127 kg (280 lbs)

Curb Weight:

Approx. 136 kg (300 lbs)

Weight Distribution:

Evenly balanced for stability, specifics detailed in manual.

🛡️ Safety Features

Ratings

Safety Certification:

Meets ANSI/SVIA 1-2001 and 1-2010 standards for recreational ATVs.

Active Features

Brakes:

Hydraulic disc brakes front and rear.

Throttle Limiter:

Adjustable thumb throttle with limiter (often used for beginner settings).

Passive Features

Frame Design:

Durable steel frame for rider protection.

Footwells:

Wide, integrated footwells with heel guards for rider protection.

💡 Technology Features

Infotainment

Features:

N/A (Basic recreational ATV with no digital infotainment systems).

Driver Assistance

Features:

N/A (No electronic driver assistance features).

Connectivity

Features:

N/A (No connectivity features).

🔧 Maintenance

Service Intervals

Oil Change:

Every 10-20 hours of operation or annually, depending on usage.

Air Filter:

Clean every 10-20 hours, replace as needed.

Spark Plug:

Inspect every 10-20 hours, replace at recommended intervals (e.g., 100 hours).

Chain Lubrication Adjustment:

Lubricate every 10 hours, adjust chain slack as needed.

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4 brake fluid (refer to manual for specific type).

Coolant:

Not applicable (air-cooled engine).

Known Issues

Carburetor Fouling:

Common with 2-stroke engines, requires regular cleaning and proper fuel/oil mix.

Clutch Wear:

Clutch plates can wear over time with aggressive riding; adjustment and replacement are covered.

Suspension Bushings:

Bushings in A-arms and suspension components can degrade, leading to play.

Maintenance Schedule

Comprehensive Schedule:

The manual provides a detailed initial and periodic maintenance schedule covering all aspects of the ATV.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Corporation, a leading Japanese manufacturer of motorcycles, marine products, and other motorized vehicles.

Model Evolution

Development:

The Blaster (YSF200/YFS200) was introduced in 1988 and remained largely unchanged throughout its production run, a testament to its effective and simple design. It was a foundational model in the sport ATV segment.

Production

Production Years:

1988-2006

Manufacturing Location:

Primarily Japan, with some assembly potentially occurring in other regions.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

While specific awards for the Blaster YSF200 are not widely publicized, it was highly regarded as a best-in-class beginner/intermediate sport ATV for many years due to its performance, durability, and value.