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Yamaha BLASTER 200 ATV Full Service & Repair Manual 2002-2006

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The Yamaha Blaster YFS200 is a capable All-Terrain Vehicle (ATV) produced from 2002 to 2006, known for its sporty performance and recreational appeal. Built upon a legacy of quality in...
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Type: Atv
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Yamaha BLASTER 200 ATV Full Service & Repair Manual 2002-2006Yamaha BLASTER 200 ATV Full Service & Repair Manual 2002-2006Yamaha BLASTER 200 ATV Full Service & Repair Manual 2002-2006Yamaha BLASTER 200 ATV Full Service & Repair Manual 2002-2006
The Yamaha Blaster YFS200 is a capable All-Terrain Vehicle (ATV) produced from 2002 to 2006, known for its sporty performance and recreational appeal. Built upon a legacy of quality in powersports, this model features a 195cc 2-stroke, air-cooled engine, a 6-speed transmission, and a robust chassis designed for off-road agility. Its engineering prioritizes reliability and ease of operation, making it a popular choice for riders seeking an engaging off-road experience. Notable features include wide handlebars for enhanced control and protective floorboards with heel guards. This comprehensive factory service repair workshop manual provides full coverage for all aspects of maintenance, servicing, troubleshooting, and repair for the Yamaha Blaster YFS200. It details procedures for the engine, drivetrain, chassis, electrical systems, and braking components, offering hundreds of pages of expert guidance. The manual includes routine maintenance schedules, detailed repair instructions, systematic troubleshooting steps, and diagnostic information, supplemented by numerous photos and diagrams. It is an essential resource for owners and technicians aiming to maintain the optimal performance and longevity of their vehicle.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Blaster
Model Code:
YFS200
Type:
ATV (All-Terrain Vehicle)
Generation
Covered Years:
2002, 2003, 2004, 2005, 2006
👋 Introduction
Market Position
Target Audience:
Yamaha Blaster 200 owners seeking to perform their own maintenance, repairs, or seeking in-depth technical understanding.
Competitive Analysis
Value Proposition:
Provides comprehensive factory-level repair information, reducing reliance on expensive dealership service and offering lifetime access.
Key Features
Content Quality:
Professionally written, step-by-step instructions with detailed visual aids mirroring dealership technician resources.
Accessibility:
Instant download format for immediate use on common computing devices.
📋 Manual Details
Coverage Areas
Primary Focus:
Full Service, Repair, and Workshop Procedures
Scope:
All aspects of maintenance, servicing, troubleshooting, and repair.
Page Count
Estimated Pages:
Hundreds (specific count not provided, but described as 'very detailed' with 'hundreds of pages')
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English (Implied by product description and common practice for service manuals)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine disassembly, assembly, tuning, lubrication, cooling system, fuel system (carburetor), exhaust system.
Drivetrain:
Transmission, clutch, drive chain, final drive maintenance and repair.
Chassis:
Frame, suspension (front and rear), steering system, wheels, tires.
Electrical:
Ignition system, lighting, battery, charging system, starter, wiring diagrams, troubleshooting electrical faults.
Braking:
Front and rear brake system maintenance, hydraulic components, bleeding, pad/shoe replacement.
Bodywork:
Body panels, plastics, fenders, seat maintenance and removal.
Procedures Included
Maintenance:
Routine checks, lubrication schedules, filter replacements, fluid changes, spark plug service.
Repair:
Component overhaul, part replacement, engine rebuilds, transmission repairs, suspension component replacement.
Troubleshooting:
Systematic diagnosis of common and uncommon problems, fault finding based on symptoms.
Diagnostics:
Engine performance diagnostics, electrical system fault finding, carburetor tuning and adjustment.
Technical Depth
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts.
Visuals:
Hundreds of detailed photos and diagrams, including exploded views.
📊 Manual Specifications
File Format
File Type:
PDF
Compatibility:
Windows and macOS
Print Quality
Printability:
Printable (single pages or entire manual)
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper Type:
N/A (Digital PDF Download)
Licensing
Usage Rights:
Lifetime use on multiple devices, no expiry dates.
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-Stroke, Air-Cooled
Displacement:
195cc (11.9 cubic inches)
Bore X Stroke:
66.0 x 57.0 mm (2.60 x 2.24 in)
Compression Ratio:
6.7:1
Carburetor:
Mikuni VM26SS (single)
Ignition:
CDI (Capacitor Discharge Ignition)
Performance
Horsepower:
Approximately 18-20 HP (varies slightly by source and tuning)
Torque:
Not explicitly stated, but typically in the 15-17 lb-ft range for this displacement.
Fuel System
Fuel Type:
Unleaded Gasoline (minimum 87 octane recommended)
Fuel Oil Mix Ratio:
50:1 (Yamaha 2-stroke oil recommended)
Cooling System
Type:
Air-Cooled
🔧 Transmission
Standard
Type:
Constant-Mesh, 6-Speed
Clutch:
Wet, Multiple-Disc
Drive:
O-ring sealed chain, 520 pitch
Features
Reverse:
No
📐 Dimensions
Exterior
Length:
Approx. 1700 mm (66.9 in)
Width:
Approx. 1070 mm (42.1 in)
Height:
Approx. 1020 mm (40.2 in)
Wheelbase:
Approx. 1210 mm (47.6 in)
Ground Clearance:
Approx. 260 mm (10.2 in)
Weights
Dry Weight:
Approx. 130 kg (287 lbs)
Fuel Capacity:
9.0 L (2.4 US gal)
🛡️ Safety Features
Ratings
Certification:
Designed for recreational off-road use only, not street legal in most jurisdictions.
Active Features
Throttle Limiter:
Thumb throttle with a governor system (adjustable in some models/configurations).
Parking Brake:
Lever-operated parking brake.
Passive Features
Handlebars:
Wide handlebars for control and leverage.
Footwells:
Aggressive floorboards with heel guards for foot protection.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic utility vehicle, no infotainment system)
Driver Assistance
Driver Assistance Features:
N/A
Connectivity
Connectivity Options:
N/A
🔧 Maintenance
Service Intervals
Oil Change Engine:
Not applicable for 2-stroke (pre-mix fuel)
Spark Plug Service:
Inspect/clean every 3 months or 10 hours; replace every 6 months or 20 hours (refer to manual for exact specification).
Air Filter Cleaning:
Clean every 3 months or 10 hours; replace as needed (refer to manual).
Chain Lubrication Adjustment:
Lubricate every 3 months or 10 hours; adjust tension every 6 months or 20 hours (refer to manual for specific slack).
Carburetor Cleaning Adjustment:
Inspect and clean annually or as needed; adjust idle speed and mixture as per manual.
Fluid Specifications
2 Stroke Oil:
Yamaha 2-stroke oil (or equivalent API-TC rated oil) mixed at 50:1 ratio with fuel.
Gear Oil:
Yamalube Gear Oil or equivalent SAE 80 hypoid gear oil (capacity ~0.7 L)
Brake Fluid:
DOT 3 or DOT 4 brake fluid (check reservoir cap for specific type).
Known Issues
Carburetor Fouling:
Common issue with 2-strokes, requiring periodic cleaning and adjustment, especially if not ridden regularly or with incorrect fuel/oil mix.
Clutch Wear:
Can wear over time with aggressive riding, requiring adjustment or replacement of friction plates.
Suspension Seals:
Front fork seals can degrade and leak over time, requiring replacement.
Engine Overheating:
Due to air cooling, proper airflow is crucial. Blocked fins or operating in extreme heat can lead to issues.
📚 Vehicle History
Brand Heritage
Heritage:
Yamaha has a long-standing reputation for performance and reliability in powersports, including ATVs.
Model Evolution
Blaster Legacy:
The Yamaha Blaster (YFS200) was introduced in the late 1980s and remained a popular choice for its affordable price point and sporty performance, particularly among younger riders and recreational users, through its production run.
Production
Production Period:
Original production began in 1988 and continued until 2006 for this specific generation.
🏆 Awards & Recognition
Recognitions
Market Recognition:
The Blaster consistently received positive reviews for its fun factor and affordability, making it a popular entry-level sport ATV.
Ratings
User Satisfaction:
High user satisfaction for its intended recreational use, appreciated for its robust design and ease of maintenance.
Certifications
Emissions Compliance:
Compliance with relevant emissions standards for its production era; specific certifications would be detailed in the full manual if applicable.
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