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  4. BLASTER YFS200R
  5. Owner's Manual

Yamaha BLASTER YFS200R Owner's Manual - Introduction

Other manuals for BLASTER YFS200R: Owner's Manual

Summary of BLASTER YFS200R

  • Page 1

    Yamaha motor co., ltd. Printed on recycled paper printed in japan 2002.11—4.8 ×2 ! This atv should not be ridden by anyone under 16 years of age. Owner’s manual 5vm-28199-10 yfs200r read this manual carefully! It contains important safety information. Lit-11626-16-37 (e) w improper atv use can resul...

  • Page 3: Introduction

    Ebu01200 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 craftsman...

  • Page 4: Important Manual Information

    Ebu00801 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: q the safety alert symbol means attention! Become alert! Your safety i...

  • Page 5: Important Notice

    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 t...

  • Page 6: Contents

    Location of the warning and specification labels .......................1-1 safety information .........................2-1 description and machine identification.....................................3-1 identification number records ...............3-2 key identification number .....................3...

  • Page 7

    Seat ....................................................4-12 front shock absorber adjustment ........................................4-14 rear shock absorber adjustment ........................................4-15 pre-operation checks ...................5-1 front and rear brakes ......................

  • Page 8

    Crossing through shallow water .........7-34 riding over rough terrain ....................7-36 sliding and skidding ...........................7-38 what to do if... ...................................7-40 what to do... ......................................7-40 periodic maintenance and adjustment ....

  • Page 9

    Cleaning and storage....................9-1 a. Cleaning ...........................................9-1 b. Storage ............................................9-3 specifications .................................10-1 noise regulation............................11-1 maintenance record ....................

  • Page 10: Location of The Warning and

    1-1 ebu00464 location of the warning and specification labels 1 2 3 4 5 5vm-9-10 ~4 6/20/02 3:11 pm page 8.

  • Page 11: Warning

    1-2 read and understand all of the labels on your machine. They contain important information for safe and proper operation of your atv. Never remove any labels from your atv. If a label becomes difficult to read or comes off, a replace- ment label is available from your yamaha dealer. 1 q w e 5fe-2...

  • Page 12

    1-3 r t 4aa-22259-80 qwarning this unit contains high pressure nitrogen gas. Mishandling can cause explosion. 8 read owner’s manual for instructions. 8 do not incinerate, puncture or open. 5fe-21568-01 5vm-9-10 ~4 6/20/02 3:11 pm page 10

  • Page 13: Safety Information

    2-1 ebu00927 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 ...

  • Page 14

    2-2 8 always avoid operating an atv on any paved surfaces, including sidewalks, driveways, parking lots and 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 s...

  • Page 15

    2-3 8 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 cautious on these kinds of terrain. 8 always follow proper procedures for turning as described in this manual. Practi...

  • Page 16

    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 sid...

  • Page 17

    2-5 8 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 consume...

  • Page 18: Qwarning

    2-6 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 refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or ...

  • Page 19: Qwarning

    2-7 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 atv in an area with adequate ventilation. Qwarning 5vm-9-10 ~4 6/20/02 3:11...

  • Page 20

    3-1 1. Spark arrester 12. Rear shock absorber 2. Seat 13. Tail/brake light 3. Fuel tank cap 14. Rear wheel 4. Headlight 15. Shift pedal 5. Brake pedal 16. Clutch lever 6. Rear brake light switch 17. Parking brake 7. Kick starter 18. Main switch 8. Front shock absorber 19. Brake lever 9. Front wheel ...

  • Page 21

    Ebu00600 identification number records record the key identification number, vehicle identification number and model label informa- tion in the spaces provided for assistance when ordering spare parts from a yamaha dealer or for reference in case the vehicle is stolen. 1. Key identification number: ...

  • Page 22

    3-3 ebu00036 vehicle identification number the vehicle identification number is stamped into the frame. 1. Vehicle identification number note: the vehicle identification number is used to identify your machine. Ebu00787 model label the model label is affixed to the location in the illustration. Reco...

  • Page 23: Control Functions

    Ebu00039 control functions w indicates a potential hazard that could result in serious injury or death. Ebu00041 main switch functions of the respective switch positions are as follows: on: engine can be started only at this position and the headlight and taillight come on when the light switch is o...

  • Page 24

    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 light does not come on (see note). Ask a yamaha dealer to inspect the electrical circuit. Note: if the main switch is turned...

  • Page 25

    Ebu00053 handlebar switches ebu01158 engine stop switch “eng. Stop” make sure that the engine stop switch is in the “run” position before starting the engine. The engine stop switch controls ignition and can be used at all times to stop the engine, especially in an emergency. The engine will not sta...

  • Page 26: Qwarning

    Ebu00062 throttle lever once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time th...

  • Page 27: Qwarning

    Ebu00064 throttle override system if during operation, the carburetor or the throttle cable 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 hazard continuing to ride the atv after t...

  • Page 28: Qwarning

    Ebu01159 speed limiter the speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the atv. 4-6 potential hazard improper adjustment of the ...

  • Page 29

    Ebu00068 clutch lever the 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 engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. 1. Clutch lever ebu00988 brake le...

  • Page 30

    Ebu00989 brake pedal the brake pedal is located on the right side of the machine. Push down on the pedal to apply the rear brake. Ebu00080 parking brake use the parking brake when you have to start the engine or park the machine, especially on a slope. Squeeze the clutch lever while pushing the butt...

  • Page 31: Qwarning

    4-9 q w potential hazard improper use of the parking brake. What can happen the atv could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake disc could overheat if you ride the atv without releasing the...

  • Page 32

    Ebu00082 shift pedal this machine is equipped with a constant-mesh 6-speed transmission. The shift pedal is located on the left side of the engine and is used in com- bination with the clutch when shifting. 1. Shift pedal n. Neutral ebu00089 kick starter rotate the kick starter away from the engine....

  • Page 33

    Ebu00092 fuel tank cap remove the fuel tank cap by turning it counter- clockwise. 1. Fuel tank cap ebu00093 fuel cock the fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. Off: with the lever in this position fuel will not flow. Always turn the lever to...

  • Page 34

    Ebu00094 starter (choke) starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. 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. (se...

  • Page 35

    To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. Note: make sure that the seat is securely fitted. 4-13 5vm-9-10 ~4 6/20/02 3:11 pm page 4-13.

  • Page 36: Qwarning

    4-14 ebu01104 front shock absorber adjustment the spring preload can be adjusted to suit the rider’s 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...

  • Page 37

    Ebu01287 rear shock absorber adjustment the spring preload can be adjusted to suit the rider’s 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 decrease the spring preload, turn the...

  • Page 38: Qwarning

    4-16 potential hazard this shock absorber contains highly pres- surized nitrogen gas. What can happen the shock absorber could explode, caus- ing injury or property damage. Cylinder damage could also result in poor handling which could cause an accident. How to avoid the hazard 8 do not tamper with ...

  • Page 39

    4-17 ebu00112 w indicates a potential hazard that could result in serious injury or death. 5vm-9-10 ~4 6/20/02 3:11 pm page 4-17.

  • Page 40: Pre-Operation Checks

    5-1 pre-operation checks before using this machine, check the following points: item routine page brakes 9 check operation, free play, fluid level and fluid leakage. 5-2–5-3, 8-22–8-27 9 fill with dot4 brake fluid if necessary. Clutch 9 check operation, condition and lever free play. 8-31 parking br...

  • Page 41: Qwarning

    Ebu01092 front and rear brakes brake lever and brake pedal 8 check that there is no free play in the brake lever. If there is free play, have a yamaha dealer adjust it. 8 check for correct brake pedal height. If the pedal height is incorrect, have a yamaha dealer adjust it. 8 check the operation of ...

  • Page 42: Qwarning

    Brake fluid leakage check to see if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs. Apply the brakes firmly for one minute. If there is any leakage, the brake system should be inspected by a yamaha dealer. Brake operation test the brakes at slow speed after starting out ...

  • Page 43

    Ebu00129 fuel make sure there is sufficient gasoline in the tank. Your yamaha engine has been designed to use premium unleaded gasoline with a pump octane number ([r+m]/2) of 90 or higher, or research octane number of 95 or higher. If knocking or pinging occurs, use a different brand of gaso- line. ...

  • Page 44: Qwarning

    Potential hazard improper care when refueling. What can happen fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. How to avoid the hazard do not overfill the fuel tank. ...

  • Page 45

    5-6 ebu00448 engine oil make 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 it is properly seated. Ebu01289 transmission oil make sure the transmission oil is at the specified level. ...

  • Page 46

    C c 8 in order to prevent clutch slippage (since the transmission oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “cd” or oils of a higher quality than speci- fied. In addition, do not use oils labeled “energy conserving ii” or highe...

  • Page 47: Qwarning

    5-8 ebu00157 tires potential hazard operating this atv with improper tires, or with improper or uneven tire pressure. What can happen use of improper tires on this atv, or oper- ation of this atv with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. How ...

  • Page 48

    5-9 ebu00159 how to measure tire pressure use the low-pressure tire gauge. Note: the low-pressure tire gauge is included as stan- dard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set pressu...

  • Page 49

    5-10 ebu00160 tire wear limit when the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. A a. 3 mm (0.12 in) 5vm-9-10 5, 6 6/20/02 3:12 pm page 11.

  • Page 50: Operation

    6-1 ebu00161 operation w indicates a potential hazard that could result in serious injury or death. 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....

  • Page 51

    6-2 6 position 1: cold engine start- ambient temperature below 5°c (40°f). Position 2: cold engine start- ambient temperature at 0°c (30°f)–30°c (90°f) and warming up position. Position 3: cold engine start- ambient temperature above 25°c (80°f) and warm engine start posi- tion. 1. Fully open 2. Hal...

  • Page 52

    Ebu00180 starting a warm engine to start a warm engine, refer to the “starting a cold engine” section. The starter (choke) should not be used. The throttle should be opened slightly. Ebu00182 warming up to get maximum engine life, always warm up the engine before starting off. Never accelerate hard ...

  • Page 53

    6-4 ebu00198* shifting this model has a 6-speed forward transmission. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, return the throttle lever to its original position, apply th...

  • Page 54: Qwarning

    Ebu00203 to start out and accelerate: 1. Release the throttle lever. C c always close the throttle while shifting gears. Otherwise, damage to the engine and drive 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 s...

  • Page 55: Qwarning

    6-6 ebu00207 to decelerate: when slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires ...

  • Page 56

    6-7 ebu00209 engine break-in there is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first s...

  • Page 57

    6-8 ebu00212 parking when parking, stop the engine and shift into low gear. Turn the fuel cock to “off” and apply the parking brake. 1. Button 2. Lock plate q w 5vm-9-10 5, 6 6/20/02 3:12 pm page 6-7.

  • Page 58: Qwarning

    Ebu01174 parking on a slope 1. Bring the machine to a stop by applying the brakes in low gear. 2. Stop the engine and release the clutch lever. 3. With the rear brake applied, apply the park- ing brake and slowly release the brake pedal. 6-9 potential hazard parking on a hill or other incline. What ...

  • Page 59

    6-10 ebu00221 accessories and loading ebu00222 accessories accessories can affect the handling and control of your atv. Keep the following in mind when considering an accessory or operating an atv which has accessories. 8 choose only accessories designed for your atv. Your yamaha dealer has a variet...

  • Page 60

    Ebu00584 loading as originally equipped, this atv is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. Keep the following points in mind: 8 never exceed the weight limits shown. An...

  • Page 61: Qwarning

    6-12 potential hazard overloading this atv or carrying or tow- ing cargo improperly. What can happen could cause changes in vehicle handling which could lead to an accident. How to avoid the hazard never exceed the stated load capacity for this atv. Cargo should be properly distributed and securely ...

  • Page 62

    6-13 ebu01176 w indicates a potential hazard that could result in serious injury or death. 5vm-9-10 5, 6 6/20/02 3:12 pm page 6-12.

  • Page 63: Riding

    7-1 riding your atv 7 5vm-9-10 7 6/20/02 3:16 pm page 7-1.

  • Page 64

    7-2 5vm-9-10 7 6/20/02 3:16 pm page 7-2.

  • Page 65

    Getting to know your atv this atv is intended for recreational use by experienced operators only. Even though you are an experienced operator of all other all terrain vehicles or motorcycles, rid- ing the atv requires special skills acquired through practice. Take your time to fully learn techniques...

  • Page 66: Qwarning

    7-4 ride with care and good judgement get training if you are inexperienced. Beginners should get training from a certified instructor. Become familiar with this atv at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum perfor- mance until you are totall...

  • Page 67: Qwarning

    7-5 not recommended for children under 16 years of age. Potential hazard failure to follow the age recommendations for this atv. What can happen use by children of atvs that are not rec- ommended for their age can lead to severe injury or death of the child. How to avoid the hazard a child under 16 ...

  • Page 68: Qwarning

    7-6 this atv is designed to carry operator only - passengers prohibited. Potential hazard carrying a passenger on this atv. What can happen greatly reduces your ability to balance and control this atv. Could cause an acci- dent, resulting in harm to you and/or your passenger. How to avoid the hazard...

  • Page 69: Qwarning

    Apparel operating without protective clothing increases your chances of severe injury in the event of an accident. How to avoid the hazard always wear an approved motorcycle hel- met that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or ...

  • Page 70: Qwarning

    7-8 do not operate after consuming alcohol or drugs. Operator’s performance capability is reduced by the influence of alcohol or drugs. Potential hazard operating this atv after consuming alco- hol or drugs. What can happen could seriously affect your judgment. Could cause you to react more slowly. ...

  • Page 71: Qwarning

    7-9 pre-operation checks always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the atv. Potential hazard failure to inspect the atv before operat- ing. Failure to properly maintain the atv. What can happen increases the possibility of an accident or e...

  • Page 72: Qwarning

    W indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. Speed limiter for riders inexperienced with this model, this model is equipped with a speed limiterin the throttle lever housing. The speed limiter limits...

  • Page 73: Qwarning

    7-11 loading and accessories use extra caution when riding the atv with additional loads, such as accessories or cargo. The atv’s handling may be adversely affected. Reduce your speed when adding additional loads. Maximum loading limit vehicle loading limit (total weight of rider, cargo and accessor...

  • Page 74: Qwarning

    7-12 during operation always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. Potential hazard removing hands from handlebars or feet from footboards during operation. What can happen removing even one hand or foot can reduce your ability to control...

  • Page 75: Qwarning

    7-13 avoid wheelies and jumping. You may lose con- trol of the atv or overturn. Potential hazard attempting wheelies, jumps, and other stunts. What can happen increases the chance of an accident, including an overturn. How to avoid the hazard never attempt stunts, such as wheelies or jumps. Don’t tr...

  • Page 76: Qwarning

    7-14 modifications potential hazard operating this atv with improper modifi- cations. What can happen improper installation of accessories or modification of this vehicle may cause changes in handling which in some situa- tions could lead to an accident. How to avoid the hazard never modify this atv...

  • Page 77: Qwarning

    Exhaust system the exhaust system on the atv is very hot dur- ing and following operation. To prevent burns, avoid touching the exhaust system. Park the atv in a place where pedestrians or children are not likely to touch it. 7-15 potential hazard hot exhaust system. What can happen dry grass or bru...

  • Page 78: Qwarning

    7-16 be careful where you ride this atv is designed for off-road use only. Riding on paved surfaces can cause loss of con- trol. Potential hazard operating this atv on paved surfaces. What can happen atvs are designed for off-road use only. Paved surfaces may seriously affect han- dling and control ...

  • Page 79: Qwarning

    7-17 do not ride on any public road, street, or high- way. Riding on public roads can result in collisions with other vehicles. Potential hazard operating this atv on public streets, roads or highways. What can happen you can collide with another vehicle. How to avoid the hazard never operate this a...

  • Page 80: Qwarning

    7-18 know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden haz- ards which may cause the atv to upset. Potential hazard failure to use extra care when operating this atv on unfamiliar terrain. What can happen you ...

  • Page 81: Qwarning

    7-19 potential hazard failure to use extra care when operating on excessively rough, slippery or loose terrain. What can happen could cause loss of traction or vehicle control, which could result in an accident, including an overturn. How to avoid the hazard do not operate on excessively rough, slip...

  • Page 82: Qwarning

    7-20 when riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the atv. Do not use the flag pole bracket as a trailer hitch. Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. Potential hazard o...

  • Page 83

    7-21 select a large, flat area off-road to become familiar with your atv. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Always avoid r...

  • Page 84: Qwarning

    7-22 c c do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before eng...

  • Page 85: Qwarning

    7-23 turning your atv to achieve maximum traction while riding off- road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the atv will resist turning. A special tu...

  • Page 86

    7-24 this procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your atv may continue to go straight. If the atv doesn’t turn, come to a stop and then practice the procedure again. If the riding surface is slip- pery or ...

  • Page 87: Qwarning

    7-25 climbing uphill use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneu- ver your atv well on flat ground before attempt- ing any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In ...

  • Page 88: Qwarning

    7-26 potential hazard climbing hills improperly. What can happen could cause loss of control or cause the atv to overturn. How to avoid the hazard always follow proper procedures for climbing hills as described in this owner’s manual. Always check the terrain carefully before you start up any hill. ...

  • Page 89: Qwarning

    7-27 if you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the atv around while you still have forward motion (provided you have the room to do so) and go down the hill. Potential hazard improperly crossing hills or turning on h...

  • Page 90: Qwarning

    7-28 if your atv has stalled or stopped and you believe you can continue up the hill, restart care- fully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the atv on the uphill side. Physically turn the atv aroun...

  • Page 91

    7-29 when fully stopped, apply rear brake as well, and then lock the parking brake. Dismount on uphill side or to a side if pointed straight uphill. Turn the atv around and remount, following the proce- dure described in the owner’s manual. 5vm-9-10 7 6/20/02 3:16 pm page 7-29.

  • Page 92: Qwarning

    7-30 riding downhill when riding your atv downhill, shift your weight as far to the rear and uphill side of the atv as possible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the engine compression to do most of the braking for you. Improper braking may ca...

  • Page 93

    7-31 5vm-9-10 7 6/20/02 3:16 pm page 7-31.

  • Page 94: Qwarning

    7-32 crossing a slope traversing a sloping surface on your atv requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough ter...

  • Page 95

    7-33 avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the atv. 5vm-9-10 7 6/20/02 3:16 pm page 7-33.

  • Page 96: Qwarning

    7-34 crossing through shallow water the atv can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or ups...

  • Page 97

    7-35 test your brakes after leaving the water. Do not continue to ride your atv without verifying that you have regained proper braking ability. C c after riding your atv in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the atv in fre...

  • Page 98: Qwarning

    7-36 riding over rough terrain riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the atv or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the atv as loss of control an...

  • Page 99

    7-37 5vm-9-10 7 6/20/02 3:16 pm page 7-37.

  • Page 100

    7-38 sliding and skidding care should be used when riding on loose or slippery surfaces since the atv may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the fr...

  • Page 101: Qwarning

    7-39 with practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneu- vers should always be avoided on extremely slippery surfa...

  • Page 102

    7-40 what to do if ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. What to do ... 8 if your atv doesn’t turn when you want it to: bring the atv to a stop and practice the turn- ing maneuvers again. Be sure you are putting your ...

  • Page 103

    7-41 8 if your atv is traversing a sloping surface: be sure to ride with your weight positioned towards the uphill side of the atv to maintain proper balance. If the atv starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the atv is goin...

  • Page 104: Periodic

    Ebu00515 periodic maintenance and adjustment periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obliga- tion of the machine owner. The most important points of machine inspection, adjustment and lubrication are exp...

  • Page 105: Qwarning

    8-2 the service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the owner’s tool kit are suffi- cient for this purpose, except that a torque wrench is als...

  • Page 106

    8-3 ebu00261 periodic maintenance/lubrication initial every item routine 1 3 6 6 1 month months months months year transmission 9 replace oil. 2 2 2 2 9 check condition. Spark plug 9 adjust gap and clean. 2 2 2 2 2 9 replace if necessary. Air filter 9 clean. Every 20–40 hours. 9 replace if necessary...

  • Page 107

    8-4 * it is recommended that these items be serviced by a yamaha dealer. ** lithium-soap-based grease initial every item routine 1 3 6 6 1 month months months months year drive chain 9 lubricate, check free play and alignment. 2 2 2 2 9 replace if necessary. * drive chain guard 9 check wear and repl...

  • Page 108

    Note: 8 recommended brake fluid: dot 4 8 brake fluid replacement: 9 when disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add fluid as required. 9 on the inner parts of the master cylinder and caliper cylinder, replace the oil s...

  • Page 109

    8-6 ebu01277 transmission oil transmission oil measurement 1. Place the machine on a level place. 2. Warm up the engine for several minutes, and stop it. 3. Check the oil level through the level win- dow located at the right side crankcase cover. Note: wait a few minutes until the oil level settles ...

  • Page 110

    4. Remove filler cap and drain bolt to drain the oil. 1. Transmisson oil filler cap 1. Drain bolt 5. Install the drain bolt and tighten to specifi- cation. 6. Fill the engine with oil and install the filler cap. Q recommended oil: see page 10-2 oil quantity: total amount: 0.7 l (0.62 imp qt, 0.74 us...

  • Page 111

    8-8 c c 8 be sure to use motor oils that do not contain anti-friction modifiers. Passenger car motor oils (often labeled “energy conserving ii”) contain anti-friction additives which will cause clutch and/or starter clutch slippage, resulting in reduced component life and poor engine performance. 8 ...

  • Page 112

    1. Spark plug wrench inspection the spark plug is an important engine compo- nent and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. The ideal color on the white insulator around the center electrode is a medium-to-light tan color for a atv that is bein...

  • Page 113

    Installation 1. Measure the electrode gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 2. Clean the gasket surface. Wipe off any grime from the threads. 3. Install the spark plug and tighten it to the specified torque. Note if a torque wrench is not available when ...

  • Page 114: Qwarning

    1. Air filter case cover 2. Screw ( ×4) 3. Remove the air filter element, and sepa- rate the sponge material from its frame by removing the screw. 4. Wash the sponge material gently but thor- oughly in solvent. 5. Squeeze the excess solvent out of the sponge material and let it dry. C c do not twist...

  • Page 115

    6. Inspect the sponge material. If damaged, replace it. 7. Apply yamaha foam air filter oil or other quality foam air filter oil to the sponge material. If foam air filter oil is not avail- able, engine oil may be used. Note: the sponge material should be wet but not drip- ping. 8. Install the spong...

  • Page 116

    Ebu01298 spark arrester cleaning be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the screws. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, then use a wire brush to remove any carbon deposits from the spark arrester p...

  • Page 117: Qwarning

    8-14 potential hazard improper cleaning of the spark arrester. Hot exhaust system what can happen could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. How to avoid the hazard when cleaning the spark arrester: always let the e...

  • Page 118: Qwarning

    Ebu01282 carburetor settings in extremely cold weather, it is necessary to change the carburetor settings to maintain opti- mum engine performance and to prevent engine damage. Potential hazard improperly servicing or adjusting the car- buretor. What can happen the carburetor could malfunction. This...

  • Page 119

    8-16 carburetor setting chart changing the carburetor settings disassembling the carburetor 1. Turn the fuel cock to the “off” position. 2. Loosen the carburetor float bowl drain screw and drain the fuel. Q 1st groove 2nd (standard) 3rd 4th 5th jet needle clip position q 1. Main jet number temperatu...

  • Page 120

    8-17 3. Disconnect the fuel hose and the oil hose. 4. Loosen the clamp screws on each side of the carburetor, and then remove the carbu- retor. 5. Remove the securing plate by removing the screw. 6. Remove the mixing chamber cap by unscrewing it. Q w 1 2 3 2 4 1. Securing plate 2. Clamp screw ( ×2) ...

  • Page 121

    8-18 7. Disconnect the throttle cable from the throttle valve by removing the holder screws and holder. 1. Carburetor cap 2. Throttle valve 3. Holder 4. Screw ( ×2) 5. Throttle cable 8. Remove the float chamber by removing the screws. 1. Float chamber 2. Screw ( ×4) 1 5 3 2 4 1 2 2 2 5vm-9-10 8 6/20...

  • Page 122

    9. Remove the float by removing the pin. 10. Remove the needle valve by unhooking it from the float arm. 11. Change the main jet and the jet needle clip position. (see page 8-16.) 1. Float 2. Pin 3. Needle valve 4. Float arm 5. Main jet note: an optional main jet can be obtained at a yamaha dealer. ...

  • Page 123

    8-20 5. Install the mixing chamber cap and tighten it. 6. Install the securing plate by installing the screw. Note: when installing the securing plate, align the slot in the securing plate with a projection on the car- buretor mixing cap. 1. Screw 2. Projection 3. Slot 7. Install the carburetor and ...

  • Page 124

    8-21 ebu01143 idle speed adjustment note: a diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throt...

  • Page 125

    Ebu00307 throttle lever adjustment note: adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 4–6 mm (0.16–0.24 in). 3. Tighten the locknut. 1. Adjusting bolt 2. Locknut a. Free play ebu0...

  • Page 126

    8-23 1. Minimum level mark 1. Minimum level mark 8 refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reac- tion and lead to poor brake performance. 8 be careful that water does not enter the brake fluid reservoir when refilling. Water will signifi- cantly lower...

  • Page 127

    8-24 ebu01186 brake fluid replacement complete fluid replacement should be done only by trained yamaha service personnel. Have a yamaha dealer replace the following compo- nents during periodic maintenance or when they are damaged or leaking. 8 replace the oil seals every two years. 8 replace the br...

  • Page 128

    8-25 ebu00314 rear brake pad inspection a wear indicator is provided on each brake pad. This indicator allows checking of brake pad wear without disassembling the brake. Apply the brake and inspect the wear indicator. If the brake pads are worn to the wear limit, have a yamaha dealer replace the pad...

  • Page 129: Qwarning

    Ebu01189 front brake lever free play the front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a yamaha dealer adjust it. A. Free play a potential hazard operating with improperly serviced or adjusted brakes. What can happen you could lose braking ability, whi...

  • Page 130: Qwarning

    8-27 ebu01191 brake pedal height adjustment the top of the brake pedal should be positioned 0–10 mm (0–0.4 in) below the top of the footrest. If not, have a yamaha dealer adjust it. A. Brake pedal position a potential hazard operating with improperly serviced or adjusted brakes. What can happen you ...

  • Page 131

    Ebu01193 parking brake adjustment parking brake adjustment may be required if the parking brake does not hold properly. The cable length “a” should be adjusted to 64–68 mm (2.52–2.68 in). A. Cable length 1. Fully loosen the locknut and the adjusting bolt at the clutch lever. 1. Locknut 2. Adjusting ...

  • Page 132

    Note if the cable cannot be adjusted to specification, consult a yamaha dealer. 4. Tighten the locknut at the clutch lever. 5. Screw in the adjusting bolt at the rear brake caliper by hand until it feels tight, then screw it out 1/8 turn. Tighten the lock- nut to the specified torque. 1. Adjusting b...

  • Page 133: Qwarning

    Ebu00833 adjusting the rear brake light switch 1. Rear brake light switch 2. Adjusting nut the rear brake light switch, which is activated by the brake pedal and brake lever, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light swi...

  • Page 134

    Ebu00539 clutch adjustment the clutch lever free play should be 5–10 mm (0.20–0.39 in). If the free play is incorrect, adjust as follows. 1. Loosen the locknut. 2. Turn the adjusting bolt so that clutch lever free play is 5–10 mm (0.20–0.39 in). 3. Tighten the locknut. 1. Locknut 2. Adjusting bolt a...

  • Page 135

    Ebu01144 drive chain slack check note move the atv back and forth and find the tight- est position of the drive chain. Check and/or adjust the chain slack while it is in this tightest position. To check the drive chain slack, all tires must be touching the ground and there should be no weight on it....

  • Page 136

    1. Locknut 2. Chain adjuster 3. Alignment marks 3. After adjusting, be sure to tighten the lock- nuts and the wheel hub bolts. Ebu00805 lubricating the drive chain the drive chain must be cleaned and lubricated at the intervals specified in the periodic mainte- nance and lubrication chart, otherwise...

  • Page 137

    1. O-rings c c to prevent damaging the o-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate sol- vents. 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special o-ring chain lubricant. C c do not use engine oil or any other lubr...

  • Page 138: Qwarning

    Ebu00356 cable inspection and lubrication lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a yamaha dealer to replace them. Ebu00737 brake and shift pedal/brake and clutch lever lubrication lubricate the pivoting parts of each lever and pedal. Ebu01018 front ...

  • Page 139

    1. Grease nipple ( ×3) 1. Grease nipple ( ×3) ebu01281* steering shaft lubrication lubricate the pivot points with a grease gun. 1. Grease nipple 1 recommended lubricant: lithium-soap-based grease 8-36 1 left side 1 right side 5vm-9-10 8 6/20/02 3:20 pm page 37.

  • Page 140

    Ebu01112 wheel removal 1. Loosen the wheel nuts. 2. Elevate the atv and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Ebu01300 wheel installation 1. Install the wheel and the nuts. 2. Lower the atv to the ground. 3. Tighten the wheel nuts to the spec...

  • Page 141

    Ebu01292 replacing a headlight bulb if a headlight bulb burns out, replace the bulb as follows. 1. Remove the front panel by removing the screws. 2. Remove the headlight beam adjusting screw, the washer, the spring and the nut. Note when removing the headlight adjusting screw, be careful not to lose...

  • Page 142

    1. Headlight unit assembly 2. Screw ( ×2) 4. Remove the headlight unit assembly from the headlight body by removing the screws. 5. Remove the headlight bulb holder cover. 6. Turn the headlight bulb holder counter- clockwise, and then remove the defective bulb. 1. Headlight bulb holder cover 2. Headl...

  • Page 143: Qwarning

    7. Put a new headlight bulb into position and secure it in place with the bulb holder. A. Do not touch the glass part of the bulb. C c do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life wi...

  • Page 144

    8. Install the headlight bulb holder cover. C c make sure the headlight bulb holder cover is securely fitted over the bulb holder and seat- ed properly. 9. Install the headlight unit assembly by installing the screws. 1. Headlight unit assembly 2. Screw ( ×2) 10. Install the headlight beam adjusting...

  • Page 145

    Ebu01089 headlight beam adjustment c c it is advisable to have a yamaha dealer make this adjustment. To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b. 1. Adjusting screw ebu00861 tail/brake light bulb replacement 1. Remove the bul...

  • Page 146

    2. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 1. Bulb holder 2. Bulb 3. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise. 4. Install the bulb holder (together with the bulb) by turning it clockwise. Ebu00412...

  • Page 147: Qwarning

    8-44 potential hazard checking the fuel system while smoking or near an open flame. What can happen fuel can ignite or explode, causing severe injury or property damage. How to avoid the hazard do not smoke when checking the fuel sys- tem. Make sure there are no open flames or sparks in the area, in...

  • Page 148

    8-45 ebu00440 troubleshooting chart check fuel flow 1. Fuel check if there is fuel in the fuel tank 2. Compression kick the kick lever to see if there is compression 3. Ignition remove plug and check electrodes wet wipe clean with dry cloth dry attach plug cap and ground to chassis kick the kick sta...

  • Page 149: Qwarning

    8-46 ebu00414 no spark throttle override system (t.O.R.S.) is incorpo- rated in the ignition circuit, and if the system should fail, the spark plug will not spark. Potential hazard testing for an ignition system problem by disconnecting the throttle override system (t.O.R.S.). What can happen with t...

  • Page 150: Cleaning and Storage

    Ebu00417 cleaning and storage a. Cleaning frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to prevent water...

  • Page 151: Qwarning

    9-2 4. Once the majority of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bottle brush is handy for hard-to-get-at places. 5. Rinse the machine off immediately with clean water and dry all surfaces with a chamois, clean towel or so...

  • Page 152

    9-3 ebu00527 b. Storage long term storage (60 days or more) of your machine will require some preventive proce- dures to guard against deterioration. After thor- oughly cleaning the machine, prepare for stor- age as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of yamah...

  • Page 153: Specifications

    10-1 ebu00428 specifications model yfs200 dimension: overall length 1,735 mm (68.3 in) overall width 1,035 mm (40.7 in) overall height 1,040 mm (40.9 in) seat height 740 mm (29.1 in) wheel base 1,100 mm (43.3 in) ground clearance 120 mm ( 4.7 in) minimum turning radius 3,000 mm (118 in) basic weight...

  • Page 154

    10-2 model yfs200 engine oil (2-cycle): type yamalube 2-cycle oil or air cooled 2-stroke engine oil quantity 1.3 l (1.14 imp qt, 1.37 us qt) transmission oil: type yamalube 4 (10w30) or sae 10w30 type se motor oil recommended transmission oil api service se, sf, sg type or higher classification quan...

  • Page 155

    10-3 model yfs200 air filter: wet type element fuel: type premium unleaded gasoline only tank capacity 9.0 l (1.98 imp gal, 2.38 us gal) reserve amount 2.0 l (0.44 imp gal, 0.53 us gal) carburetor: type/manufacturer vm26ss/mikuni spark plug: type/manufacturer br8es (ngk) gap 0.7–0.8 mm (0.028–0.031 ...

  • Page 156

    10-4 model yfs200 gear ratio 1st 34/11 (3.091) 2nd 31/14 (2.214) 3rd 25/15 (1.667) 4th 20/16 (1.250) 5th 19/18 (1.056) 6th 19/21 (0.905) chassis: frame type steel tube frame caster angle 9.0° trail 40 mm (1.57 in) tire: type tubeless size – front at21 × 7 - 10 rear at21 × 10 - 8 brake: front brake t...

  • Page 157

    10-5 model yfs200 suspension: front double wishbone rear swingarm (monocross) shock absorber: front coil spring, oil damper rear coil spring, gas-oil damper wheel travel: front 180 mm (7.09 in) rear 180 mm (7.09 in) electrical: ignition system c.D.I. Generator system c.D.I. Magneto headlight type: b...

  • Page 158: Noise Regulation

    11-1 ebu00430 noise regulation tampering with noise control system prohibited: federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inopera- tive by any person other than for purposes of maintenance, repair, or replacement of any device or element of design i...

  • Page 159: Maintenance Record

    Ebu00431 maintenance record copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof o...

  • Page 160

    13-1 ebu00432 5vm-9-10 9~ 6/20/02 3:22 pm page 13-2.

  • Page 161

    13-2 13 5vm-9-10 9~ 6/20/02 3:22 pm page 13-3.

  • Page 162

    14-1 ebu00435 5vm-9-10 9~ 6/20/02 3:22 pm page 14-2.

  • Page 163

    14-2 14 5vm-9-10 9~ 6/20/02 3:22 pm page 14-3.

  • Page 164

    14-3 ebu00436 w indicates a potential hazard that could result in serious injury or death. 5vm-9-10 9~ 6/20/02 3:22 pm page 14-4.

  • Page 165: Protect Your Investment

    Ebu00437 protect your investment 5vm-9-10 9~ 6/20/02 3:22 pm page 14-8.

  • Page 166

    Yamaha motor co., ltd. Printed on recycled paper printed in japan 2002.11—4.8 ×2 ! This atv should not be ridden by anyone under 16 years of age. Owner’s manual 5vm-28199-10 yfs200r read this manual carefully! It contains important safety information. Lit-11626-16-37 (e) w improper atv use can resul...