Target Audience:
Owners of Yamaha Blaster 200 ATVs from 2002-2006 seeking to perform their own maintenance, repairs, and diagnostics to save on professional service costs.
Value Proposition:
Provides professional-level repair and maintenance information, enabling significant cost savings compared to dealer service. Offers a comprehensive A-Z repair coverage.
Format Advantage:
Easy-to-use PDF format, accessible on PC & MAC, with the ability to print specific pages as needed, avoiding wear and tear of traditional manuals.
Instant Delivery:
Digital download provided via email immediately after payment, allowing for quick access to repair information.
Customer Support:
Offered technical assistance via email for users who encounter difficulties with the manual or require clarification on procedures.
Years Covered:
2002, 2003, 2004, 2005, 2006
Regions Covered:
Global (standard specifications)
Estimated Pages:
Highly detailed (exact page count not specified, but implied to be comprehensive)
Type:
Service Repair Workshop Manual
Format:
PDF (Portable Document Format)
Engine:
Full engine overhaul, top-end rebuild, bottom-end rebuild, lubrication system, cooling system (air-cooled), fuel system (carburetor), ignition system.
Transmission:
Clutch operation and adjustment, gearbox inspection and repair, drive chain maintenance.
Chassis And Suspension:
Frame inspection, front suspension (steering, A-arms, shocks), rear suspension (swingarm, shock absorber), wheel bearings, steering components.
Brakes:
Front and rear brake system diagnostics, hydraulic system bleeding, pad replacement, caliper service, lever and pedal adjustments.
Electrical:
Wiring diagrams, lighting system, ignition system troubleshooting, starter motor, battery maintenance, CDI unit, kill switch.
Fuel System:
Carburetor (Mikuni VM26SS) disassembly, cleaning, adjustment, jetting, fuel tank, fuel lines, petcock.
Exhaust System:
Exhaust pipe and muffler inspection, spark arrestor cleaning.
Body And Trim:
Fender removal and installation, seat service, handlebar and control adjustments, graphics and plastics.
Maintenance:
Routine maintenance checks, oil change, air filter cleaning/replacement, spark plug inspection/replacement, chain lubrication/adjustment, brake adjustments, pre-ride inspections.
Troubleshooting:
Detailed symptom-based troubleshooting guides for engine performance issues, starting problems, electrical faults, braking concerns, and handling issues.
Repair:
Step-by-step repair instructions for all major components and systems, including engine rebuilds, carburetor overhauls, suspension repairs, and electrical diagnostics.
Rebuild:
Comprehensive instructions for complete engine rebuilds, including piston replacement, ring installation, cylinder honing, crankshaft inspection, and seal replacement.
Depth:
Professional-level detail, covering everything from basic fluid changes to full engine and transmission overhauls. Suitable for both DIY enthusiasts and professional mechanics.
Searchability:
Likely text-searchable if generated from a native digital source, enhancing ease of use.
Printability:
Printable pages, allowing users to create hard copies of specific sections or the entire manual as needed.
Binding Type Digital:
Not applicable (digital format)
Paper Type Digital:
Not applicable (digital format)
Engine Type:
Two-stroke, single-cylinder, reed valve, liquid-cooled (Note: Blaster 200 is typically air-cooled, the manual may cover variations or the description might be slightly inaccurate, standard is air-cooled).
Displacement:
195cc (approx.)
Bore X Stroke:
66.0 mm x 57.0 mm (Typical for this model)
Compression Ratio:
7.4:1 (Typical for this model)
Carburetor:
Mikuni VM26SS (Single)
Ignition:
CDI (Capacitor Discharge Ignition)
Horsepower:
Approx. 17-19 HP (Varies by year and tuning)
Torque:
Not explicitly stated, but consistent with a small displacement two-stroke
Fuel Type:
Unleaded gasoline (minimum 87 octane recommended)
Fuel Mixture:
Pre-mix oil and gasoline at 50:1 ratio (for two-stroke oil injection system)
Fuel Tank Capacity:
2.0 US gal (approx. 7.5 Liters)
Safety Standards:
Complies with EPA emission standards and relevant ATV safety guidelines for its class and era.
Brakes:
Hydraulic disc brakes front and rear for effective stopping power.
Throttle Limiter:
Some models may have adjustable throttle stops for beginner riders (details in manual).
Handlebar Design:
Ergonomic handlebar design with padded crossbar for control and rider comfort.
Footwells:
Wide, non-slip footwells to protect the rider's feet.
Oil Change:
Every 3000 km or 1 year (for transmission/clutch oil). Engine oil: Refer to manual for specific usage-based intervals.
Air Filter Cleaning:
Every 1000 km or as needed based on operating conditions (dusty environments require more frequent cleaning/replacement).
Spark Plug Maintenance:
Check and clean every 1000 km, replace as needed.
Chain Lubrication Adjustment:
Lubricate every 500 km, adjust chain slack as needed.
Transmission Oil:
Yamalube 2-stroke oil or equivalent API GL-4, SAE 10W-30 or 20W-40 transmission oil (check manual for exact specification).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Type:
Air-cooled (no coolant required).
Carburetor Fouling:
Common issue with older two-strokes; regular cleaning and proper fuel mixture are crucial.
Clutch Slippage:
Can occur with heavy use or improper oil levels/quality; clutch adjustment and inspection are important.
Suspension Wear:
Shocks and bushings can wear over time, affecting handling. Manual provides procedures for inspection and replacement.
Electrical Connection Corrosion:
As with many off-road vehicles, electrical connections can corrode; manual provides wiring diagrams for troubleshooting.
Yamaha Atv Legacy:
Yamaha has a long-standing reputation for producing reliable and performance-oriented ATVs, with the Blaster being a popular entry-level to intermediate sport ATV.
Blaster Development:
The Blaster 200 was introduced as a lightweight, nimble, and fun sport ATV, appealing to a wide range of riders. The 2002-2006 models represent a specific generation with minor updates.
Production Period:
The Yamaha Blaster 200 was produced from 1988 to 2006, with this manual covering the later years of its production run.
