Yamaha YFS200 Blaster Repair Manual 1988-2005

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Item # M488-5  ISBN: 0892878835




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This repair manual covers Yamaha Blaster YFS200 including: 1988 YFS200U, 1989 YFS200W, 1990 YFS200A, 1991 YFS200B, 1992 YFS200D, 1993 YFS200E, 1994 YFS200F, 1995 YFS200G, 1996 YFS200H, 1997 YFS200J, 1998 YFS200K, 1999 YFS200L, 2000 YFS200M, 2001 YFS200N, 2002 YFS200P, 2003 YFS200R, 2004 YFS200S, and 2005 YFS200.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE — GENERAL INFORMATION
Manual organization | Notes, Cautions and warnings | Safety first | Service hints | Serial numbers | Torque specifications | Fasteners | Lubricants | Sealant, adhesive and cleaners | Expendable supplies | Basic hand tools | Precision measuring tools | Test equipment | Special tools | Mechanic's tips | Ball bearing replacement | Seals

CHAPTER TWO — TROUBLESHOOTING
Operating requirements | Starting the engine | Starting difficulties | Engine performance | Engine | Engine noises | 2-Stroke leak down test | Fuel system | Electrical troubleshooting | Ignition system | Clutch | Transmission | Kickstarter | Drive train noise | Headlight troubleshooting | Taillight troubleshooting | Oil lever indicator system troubleshooting | Autolube oil injection pump | Handling | Frame noise | Brakes (2002-2004)

CHAPTER THREE — LUBRICATION, MAINTENANCE AND TUNE-UP
Service intervals | Tune-up | Engine oil | Transmission oil | Air filter | Spark plug | Carburetor | Exhaust system | Autolube pump and engine oil lines | Crankcase ventilation hose inspection | Engine compression check | Ignition timing | Control cable lubrication | Throttle cable and peed limiter adjustment | Clutch cable adjustment | Brake inspection and adjustment (1998-2002) | Drive chain | Tires, wheels and bearings | Steering and front suspension | Rear suspension | Frame | Nuts, bolts and other fasteners | Lighting equipment | Storage

CHAPTER FOUR — ENGINE TOP END
Engine principles | Engine lubrication | Cleanliness | Exhaust system | Cylinder head | Cylinder | Piston, piston pin and piston rings | Reed valve assembly

CHAPTER FIVE — ENGINE BOTTOM END
Servicing engine in frame | Engine | Drive sprocket | Countershaft seal replacement | Left side main bearing seal | Crankcase and crankshaft | Transmission shifting check | Engine break-in

CHAPTER SIX — CLUTCH, KICKSTARTER AND EXTERNAL SHIFT MECHANISM
Right crankcase cover | Clutch service | Clutch pushlever | Clutch cable replacement | Kickstarter | Idler gear external shift mechanism | Primary drive gear and balancer gears

CHAPTER SEVEN — TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation | Transmission troubleshooting | Transmission | Transmission overhaul | Transmission inspection | Internal shift mechanism

CHAPTER EIGHT — FUEL SYSTEM
Carburetor | Float adjustment | Carburetor rejetting | Fuel tank | Fuel shutoff valve | Air box Throttle cable replacement | Throttle lever assembly

CHAPTER NINE — ELECTRICAL SYSTEM
Component testing | Capacitor discharge ignition | Flywheel | CDI unit | Ignition coil | Throttle override system (T.O.R.S.) | Lighting system | Oil level indicator system | Lighting voltage tests | Voltage regulator | Switches | Wiring diagrams

CHAPTER TEN — OIL INJECTION SYSTEM
System components | Oil pump bleeding | Autolube pump output test | Autolube pump | Oil hoses | Oil level indicator | Oil tank

CHAPTER ELEVEN — FRONT SUSPENSION AND STEERING
Front wheel | Front brake drum/bearing assembly (1998-2002) | Front suspension | Shock absorber | Steering knuckle | Control arms | Handlebar | Tie rods | Steering shaft | Tires and wheels

CHAPTER TWELVE — REAR SUSPENSION
Rear wheels | Rear wheel hubs | Rear axle | Rear axle housing | Drive chain | Driven sprocket | Tire change and tire repairs | Shock absorber | Rear swing arm

CHAPTER THIRTEEN — BRAKES
Front drum brake (1998-2002) | Front brake shoe replacement | Front brake shoes and brake panel | Rear brake caliper | Rear brake disc | Front brake cable replacement | Rear/parking brake cable replacement | Rear brake pedal

CHAPTER FOURTEEN — BODY
Seat | Front cover (1998-2002) | Fuel tank cover | Front guard | Front bumper | Front fender | Rear fender | Footpegs

SUPPLEMENT — 2003-2005 BRAKE INFORMATION

Yamaha YFS200 Blaster Repair Manual 1988-2005