1990–1997 Yamaha Waverunner III 650/700 PWC Service Manual Set (P/N E20701-0)

Each manual has its own specifications and service procedures. Matching the model and primary identification number to the appropriate section helps keep carburetor settings, engine clearances and assembly details tied to the correct configuration.

Coverage limits: The WRA650D section is missing printed page 8-17, listed for engine-hatch inspection and installation. Later hull chapters refer to a separate Water Vehicle FRP Repair Manual for additional repair details; that publication is not included.

Engine, Jet Pump and Electrical Service

• Engine repair: Engine removal, cylinder and piston inspection, reed-valve service, crankshaft checks, crankcase assembly and engine installation with coupling alignment.

• Fuel and lubrication: Carburetor disassembly, diaphragm and needle-valve inspection, float-arm measurement, fuel-pump checks and oil-injection system installation.

• Jet pump and driveline: Impeller removal, drive-shaft and bearing service, pump assembly, intermediate-shaft inspection and bilge-system maintenance.

• Electrical diagnosis: CDI and ignition-coil testing, rectifier-regulator checks, starter-motor overhaul, wiring diagrams and troubleshooting charts for starting and running faults.

• Hull and controls: Steering and reverse-cable adjustments, water-lock inspection, engine-hood service, and fiberglass scratch and puncture repairs.

• Maintenance references: Periodic maintenance charts, compression checks, lubrication points and storage procedures, with component torque tables and wear specifications.

Written for mechanics, these manuals present Yamaha dealer service procedures with the measuring equipment and special tools required for the work.

Power-Unit Inspection and Fuel-System Service

The power-unit chapters go beyond removal and installation. They cover cylinder-bore measurements, piston-ring inspection, reed-valve checks and crankshaft deflection, followed by crankcase assembly and staged tightening specifications.

Engine installation includes coupling alignment and the original mounting-shim locations. These details matter when reconnecting the engine to the intermediate shaft after removal.

Carburetor coverage includes the fuel pump, diaphragms, needle valve and float arm. The Fuel System Diagram and Oil Injection System Diagram identify hose connections and routing, while lubrication references specify Yamalube two-stroke outboard oil for applicable assemblies.

The carburetor cleaning cautions explain how unsuitable solvents can damage synthetic rubber parts and how compressed air can damage diaphragms.

Jet Pump, Control Cables and Hull Repairs

The jet-pump instructions identify the impeller’s left-hand thread and cover drive-shaft bearings, oil seals and impeller-to-housing clearance. Intermediate-shaft service references include the YW-38741 coupler wrench and YW-38742 shaft holder.

The Cable Routing Diagram supports steering, throttle, choke and reverse-control work. In the WRA700 section, the Cooling System Diagram distinguishes cooling-water, exhaust and bilge paths.

Hull repair procedures address gel-coat scratches and punctured fiberglass. Related sections cover bilge strainers, water locks, exhaust hoses and sealing, along with gunwale, mat and deck components.

Electrical Tests and Fault Isolation

The troubleshooting charts distinguish a starter that does not turn from an engine that cranks without starting. Separate fuel, ignition and compression checks help narrow the fault before selecting a component test or repair.

Electrical sections provide lead-specific resistance checks for the CDI unit, ignition coils and rectifier-regulator. The CDI tables also explain that readings can vary with the tester and unit characteristics.

Starter-motor repair extends to brushes, the commutator, armature continuity and reassembly. Disassembly notes warn that the factory thread-locked through-bolt heads can strip easily.

Follow the manual’s ventilation and fuel-handling precautions before fuel or electrical work.

Piston-Clearance and Battery-Check Examples

For the WRA650D engine, the piston inspection section specifies a piston-to-cylinder clearance of 0.080–0.085 mm and a 0.1 mm wear limit. The WRA700 section specifies 0.070–0.075 mm, making the distinction important when selecting the appropriate inspection data.

Battery inspection data lists electrolyte specific gravity of 1.28 at 20°C (68°F), alongside battery-condition checks and charging specifications.

Text Search, Bookmarks and Printable PDF

Finding procedures and diagrams: OCR text supports searches across the service sections, though recognition errors and some index or chapter-divider pages limit search coverage. Embedded bookmarks organize all five manuals. Small wiring color codes and connector details require zooming.

The collection comes as one printable, English-language PDF with 804 pages total: 793 service-manual pages, a five-page storage extract and six additional cover/end pages, all included in that total.