Yamaha Blaster YFS200T 2004 ATV Manual Set (P/N LIT-11626-18-05)

Use the P supplement with the U base material and A supplement in the combined service manual. The R supplement also calls for the P supplement. The forewords identify the original U service manual as LIT-11616-06-41 / 2XJ-28197-10.

YFS200T coverage is for operation and owner maintenance. Workshop procedures are grouped under U, A, P, and R, with no dedicated YFS200T service supplement in this set. Match the model and brake or ignition layout before choosing a shop procedure.

PDF Bookmarks and Wiring Detail

Search and navigation: Both PDFs have bookmarks. Text search covers the P and R supplements and the main chapters of the owner's manual. The U-A service pages and some owner back matter are outside text search. Small wire and connector labels in the service diagrams are readable when zoomed in.

The ZIP contains 511 pages in two printable PDFs: a 345-page service file and a 166-page owner's file. The total includes five service cover pages, the owner's front and back covers and inside-cover warning, six pages of owner back matter, and a two-page safety card.

Two-Stroke Overhaul, Brake Service, and Riding

These selected topics show what the manuals cover. The owner's book also explains speed-limiter adjustment and spark arrester cleaning.

• Engine and drivetrain: Engine removal and installation, top-end and crankcase teardown, crankshaft and balancer work, clutch and transmission repair, and Autolube pump inspection.
• Carburetor and intake: Mikuni VM26SS removal, disassembly and inspection, float and fuel-level checks, reed valve service, throttle adjustment, and cold-weather settings.
• Chassis and brakes: Wheel and axle service, steering and suspension, swingarm, chain and sprockets, plus hydraulic caliper and master-cylinder work in the R supplement.
• Electrical diagnosis: Ignition and TORS fault isolation, switch continuity, coil and lighting tests, oil-level warning diagnosis, cable routing, and wiring diagrams.
• Riding and controls: Pre-ride checks, cold and warm starting, shifting, break-in, hill and slope techniques, parking, and loading.
• Owner maintenance: Scheduled checks and lubrication, brake pad inspection, basic troubleshooting, cleaning, storage, and factory specifications.

The owner's manual gives riders operating instructions and basic maintenance procedures, while Yamaha wrote the workshop material for dealers and qualified mechanics with a working knowledge of mechanical repair.

Engine Assembly and Lubrication

Exploded views guide disassembly of the cylinder head, cylinder, piston, and rings. The overhaul chapter also covers the primary drive, kickstarter, shift mechanism, and CDI magneto. Torque tables, lubrication points, wear limits, and clearances support inspection and reassembly.

Yamaha identifies the crankcase separator YU-01135 / 90890-01135, rotor puller YM-01189 / 90890-01189, and crankshaft installation tools YU-90050 / 90890-01274 / 90890-01275. The Autolube section calls for bleeding the pump and delivery line after the oil circuit has been opened, the ATV has been laid on its side, or the oil tank has run dry. Air in the line can interrupt two-stroke lubrication.

Carburetor, Chassis, and Brake Changes

The A supplement adds a cold-weather jet and needle chart, cable routing, transmission-oil service, and parking-brake adjustment. The P supplement updates cable routing, rear brake-light switch adjustment, and signal-system testing.

The base service section covers front drum and mechanical rear disc brakes. The R supplement covers hydraulic front and rear discs, including pad replacement, bleeding, and parking-brake setup. Its assembly notes specify hose position, new copper sealing washers, and parking-brake spring orientation. Support the ATV securely during steering, suspension, or brake service and follow the precautions for the applicable brake layout.

Ignition Tests and Wiring Diagrams

For no spark or intermittent spark, the diagnostic flow separates CDI magneto and ignition-coil checks from continuity tests at the throttle and carburetor switches in the Throttle Override System (TORS). The special-tool list identifies the dynamic coil tester YU-34487 / 90890-03144.

The service file includes the U circuit and wiring diagrams, P and R wiring diagrams, and separate ignition, lighting, and oil-level signal circuit diagrams. The R supplement provides its own ignition and lighting tests.

YFS200T Operation and Safety

The owner's book explains how TORS cuts ignition if the throttle fails to close and how to operate the constant-mesh six-speed transmission. It identifies the Blaster as a high-performance, single-rider ATV for off-road use and warns against carrying passengers, riding on public roads, or operation by anyone under 16.

Examples of Plug, Load, and Brake Specifications

For YFS200T spark plug service, the owner's manual lists the NGK BR8ES, a gap of 0.7–0.8 mm (0.028–0.031 in), and a tightening torque of 25 Nm (18 ft-lbf). Its loading section gives a combined limit of 100 kg (220 lb) for rider, cargo, and accessories.

For YFS200R hydraulic brake inspection, the service supplement specifies a front and rear pad wear limit of 1.0 mm (0.04 in).