All terrain vehicles are exposed to harsh riding environments that can accelerate the effects of wear and tear on the motor and transmission. Demanding conditions are much harder on the transmission used by Yamaha's 200 cc Blaster ATV because it uses a manual, lever-operated clutch to transmit power to the rear wheels. Spirited riding and the effects of time may eventually wear out the metal and fiber plates within the clutch, causing the transmission to slip under power. Removing the clutch for a complete overhaul is simpler than it appears and can be done in less than an hour.
Things You'll Need
- Oil pan
- 10,12,14, 17 millimeter sockets
- Socket wrench
- Torque wrench
- Strap wrench
- Flat screwdriver
Place an oil pan below the transmission oil drain plug, positioned under the right side of the Blaster's motor. Unscrew the drain plug with a 17-mm socket and socket wrench. Drain the transmission oil into the oil pan. Screw the drain plug into place. Tighten the drain plug to 14 foot-pounds with a torque wrench.
Remove the right floor plate and foot rest from the Blaster to access the clutch. Unscrew the bolts securing the plate and the foot rest to the frame, using a 14-mm socket and a socket wrench. Pull the foot rest away from the frame, then unhook the spring from the top of the rear brake pedal.
Unscrew the large nut from the base of the kick start lever, positioned above the right side of the motor, using a 17-mm socket and a socket wrench. Pull the kick start lever off the kick start shaft.
Unscrew the bolts from the edge of the clutch cover, positioned on the right side of the motor, using a 10-mm socket and a socket wrench. Pull the clutch cover and its gasket off the motor.
Hold the clutch steady with a strap wrench. Unscrew the small nut from the center of the clutch and five bolts from the pressure plate on the face of the clutch, using a 12-mm socket and a socket wrench. Withdraw the bolts with their attached clutch springs and pull the pressure plate off the clutch. Pull the six clutch plates off the clutch by hand, followed by all six fiber friction plates.
Bend the sides of the locking washer away from the large clutch boss nut at the center of the clutch with a flat screwdriver. Hold the clutch steady with a strap wrench and unscrew the clutch boss nut with a 17-mm socket and a socket wrench. Pull the clutch boss nut's lock washer, the clutch boss and the spacer out of the clutch housing by hand. Pull the clutch housing and the remaining spacer off the motor by hand.
- "The Professional Motorcycle Repair Program"; Professional Career Development Institute; 1995
- "Yamaha YFS-200N Service Manual"; Yamaha Motor Corp.; 2001
- "Yamaha YFS-200U Service Manual"; Yamaha Motor Corp.; 1987
How to Install a Clutch on a Yamaha Banshee
After thousands of squeezes the clutch on your Yamaha Banshee finally needs replacing. Instead of taking it to the shop and paying...
How to Fix a Clutch on a Yamaha ATV
Fixing a clutch on a Yamaha ATV is easy and can be done by the backyard mechanic. The procedures are the same...
How to Remove a Clutch Cable
Removing the clutch cable from your motorcycle, either for replacement or maintenance reasons, is a straightforward process. Although there are minor differences...
How to Change Yamaha Blaster Brakes
Changing worn-out brake shoes and pads on a Yamaha Blaster is a fairly simple task that is well within the reach of...
How to Remove the W32 Blaster Worm
The W32 Blaster Worm enters your computer from a network connection and causes it to shut down or restart at random times....
My Yamaha Blaster Won't Start: Carburetor
Engine starting issues on the Blaster, when narrowed down to the carburetor, will often be caused by improper jetting, debris lodged in...
How to Adjust the Clutch for a Katana Motorcycle
You Suzuki Katana's transmission relies on a cable to actuate its clutch. Over time, the clutch cable stretches and creates excessive slack...
How to Get the PTO Clutch Off a Cub Cadet 1045
The electric PTO clutch on a Cub Cadet L1045 allows the mower blades to engage. The electric clutch is located directly under...
How to Install the Clutch on a Yamaha Blaster
The clutch in your Yamaha Blaster ATV can often be one of the first components to malfunction due to the punishment it...
Signs That the Friction Clutch Disc and Pressure Plate Are Bad
Serving as the connection between the engine and the transmission, the clutch assembly in a manual transmission withstands extreme pressures and stress...