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
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