1990-2007 Yamaha Blaster YFS200 (U-A) ATV Service Manual (P/N 3JM-28197-10)

• Official Yamaha publication P/N 3JM-28197-10 (First edition: October 1987) spanning 252 pages of factory-authorized reference material
• Documents the air-cooled 195cc two-stroke engine, chassis, and electrical systems for YFS200U variants
• Contains 97 exploded-view assembly diagrams and 35 technical specification reference tables
• Details the 2XJ-series model code and serial number ranges specifically for the U.S. and Canadian markets

Mechanical Systems and Maintenance

The technical documentation for the 1990–2007 Yamaha Blaster YFS200 equips technicians and DIY rebuilders with the exact schematics needed to tackle complex jobs. It provides detailed exploded views outlining the entire machine to eliminate guesswork during teardown and assembly. Chapters encompass general information alongside comprehensive engine overhaul parameters for the 2-stroke cylinder, piston, and crank assembly. You also get deep dives into the constant-mesh 6-speed transmission and clutch components. Moving beyond the engine, the chassis section outlines suspension tuning, steering geometry, and braking system configurations for both the front drum and rear disc setups. Always ensure you are working in a well-ventilated area with proper protective gear when handling heavy engine components or chemical solvents to prevent injury.

Specification Highlights

Factory tolerances are critical for a reliable engine rebuild. The engine data section lists the standard cylinder bore at 66.00–66.02 mm, with cylinder head bolt torque specified at precisely 27 Nm. Crankshaft bearing runout limits are strictly documented at 0.03 mm. For electrical diagnostics, the manual provides a magneto pickup coil resistance of 16–24 ohms at 20°C. Since this is an air-cooled model, you will not find coolant routing diagrams, but the transmission oil capacity is noted at 0.65 liters for routine fluid changes. While intake valve clearance does not apply to this two-stroke powerplant, reed valve thickness is clearly specified at 0.35–0.49 mm.