Yamaha 8DJ Manuals

Manuals and User Guides for Yamaha 8DJ. We have 1 Yamaha 8DJ manual available for free PDF download: Service Manual

Yamaha 8DJ Service Manual

Yamaha 8DJ Service Manual (210 pages)

Brand: Yamaha | Category: Snowmobiles | Size: 4.76 MB

Table of Contents

Notice
2
Illustrated Symbols
3
Index
4
Chapter 1. General Information

8
- Engine Serial Number
  8
- Frame Serial Number
  8
- Machine Identification
  8
- All Replacement Parts
  9
- Important Information
  9
- Preparation for Removal and Disassembly
  9
- Bearings and Oil Seals
  10
- Circlips
  10
- Gaskets, Oil Seals, and O-Rings
  10
- Lock Washers/Plates and Cotter Pins
  10
- For Engine Service
  11
- For Tune up
  11
- Special Tools
  11
- For Power Train Service
  12
Chapter 2. Periodic Inspections and Adjustments

14
- Introduction
  14
- Periodic Maintenance Table
  14
- Engine
  16
- Spark Plugs
  16
- Standard Spark Plug
  16
- Air Bleeding
  17
- Oil Pump
  17
- Cable Adjustment
  18
- Fuel Line Inspection
  18
- Cooling Fan Belt Inspection
  19
- Carburetor Synchronization
  22
- Engine Idle Speed Adjustment
  23
- Throttle Cable Freeplay Adjustment
  24
- Throttle Override System (To.r.s.) Check
  25
- Exhaust System Inspection
  26
- Starter Cable Freeplay Adjustment
  26
- Power Train
  27
- Sheave Distance and Offset Adjustment
  27
- Shim Size
  28
- Drive V-Belt
  29
- Engagement Speed Check
  31
- Parking Brake Adjustment
  31
- Parking Brake Pad Inspection
  31
- Brake Fluid Level Inspection
  32
- Brake Pad Inspection
  32
- Bleed Screw
  33
- Brake Hose Inspection
  33
- Drive Chain
  34
- Oil Replacement
  35
- Recommended Oil
  35
- Chain Slack Adjustment
  36
- Track Tension Adjustment
  36
- Slide Runner Inspection
  38
- Chassis
  39
- Freeplay Check
  39
- Ski/Ski Runner
  39
- Steering System
  39
- Brake Lever, Throttle Lever and Throttle Cable End
  40
- Lubrication
  40
- Front and Rear Suspension
  41
- Recommended Lubricant
  41
- Electrical
  42
- Headlight Beam Adjustment
  42
- Battery Inspection
  43
- Battery Charging
  45
- Carburetor Tuning
  46
- Carburetor Tuning Data
  46
- Tuning
  46
- High Altitude Tuning
  47
- MID-Range and High Speed Tuning
  47
- Guide for Carburetion
  48
- Low Speed Tuning
  49
- Pilot Mixture Screw
  49
- Gear Selection
  54
- Chain and Sprocket Part Number
  55
- Gear Ratio
  55
- Gear Selection
  55
- Secondary Spring
  55
- Primary Spring
  56
- Torque Cam
  56
- High Altitude Tuning
  57
- Front Suspension
  58
- Rear Suspension
  58
- Spring Preload
  58
- Stopper Band
  58
- Rear Suspension - Full Rate
  59
Chapter 3. Chassis

60
- Handlebar Removal
  60
- Steering
  60
- Steering Column and Tie Rod Removal
  61
- Installation
  63
- Ski
  65
- Front Suspension
  67
- Ski Spindle Camber
  70
- Ski Alignment
  71
Chapter 4. Power Train

72
- Primary Sheave and Drive V-Belt
  72
- Primary Sheave Disassembly
  73
- Secondary Sheave
  80
- Drive Chain Housing
  86
- With Reverse Model
  89
- Jackshaft
  93
- Jackshaft and Drive Chain Housing Installation
  95
- Brake
  96
- Brake Pad Replacement
  97
- Brake Caliper Disassembly
  101
- Brake Caliper Inspection and Repair
  101
- Brake Caliper Assembly
  102
- Brake Master Cylinder Disassembly
  103
- Brake Master Cylinder Removal
  103
- Brake Master Cylinder Assembly
  104
- Slide Rail Suspension
  105
- Front Axle and Track
  112
Chapter 5. Engine

114
- Exhaust Assembly
  114
- Engine Assembly
  116
- Installation
  117
- Cylinder Head and Cylinder
  118
- Oil Pump, CDI Magneto, Crankcase and Crankshaft
  128
- Big End Side Clearance
  129
- Dial Range
  129
- Small End Freeplay
  129
- Engine Cooling Fan
  133
- Engine Cooling Fan Removal
  133
- Recoil Starter
  137
- Recoil Starter Removal
  137
- Carburetors
  140
Chapter 6. Carburetion

140
- Carburetor Separation
  141
- Carburetor Disassembly
  142
- Fuel Pump
  148
- Fuel Pump Removal
  148
Chapter 7. Electrical

150
- Switch Inspection
  150
- Electrical Starting System
  151
- Starter Motor Does Not Operate
  152
- Main Switch
  153
- Starter Motor
  154
- Armature Coil Resistance
  155
- Brush Spring Pressure
  156
- Charging System
  157
- Battery Is Not Charged
  158
- Battery
  159
- Battery Storage and Maintenance Tips
  159
- Charging Coil
  159
- No Spark or Weak Spark
  161
- Troubleshooting
  161
- CDI Magneto
  162
- Ignition Coil
  162
- Spark Plug Cap
  162
- Throttle Override System
  163
- Carburetor Switch
  164
- Handlebar Switch
  164
- Main Switch
  165
- Lighting System
  167
- Bulb
  168
- Headlight Beam Switch
  168
- CDI Magneto
  169
- Brake Light Does Not Come on
  171
- Oil Level Indicator Lights Do Not Come on
  171
- Back Buzzer Does Not Sound
  172
- Brake Light Switch
  173
- Gear Position Switch
  173
- Signal System
  173
- Tail/Brake Light Bulb
  173
- DC Back Buzzer
  174
- Oil Level Switch
  174
- Grip Warmer System
  175
- Grip Warmer Does Not Operate
  176
- Grip and Thumb Warmer Coil
  177
- Passenger Grip Warmer
  177
- Variable Resistor
  177
- Passenger Grip Warmer Switch
  178
Chapter 8. Specifications

179
- General Specifications
  179
- Maintenance Specifications
  181
- High Altitude Settings
  190
- Tightening Torque
  191
- Cable Routing
  194
- Color Code
  209

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