1986–1993 Yamaha WaveRunner 500 / WR500 Marine Jet 500T Service Manual (P/N E10700-0)

• A 580-page PDF containing Yamaha service-manual sections for the WaveRunner 500 (WR500) and WaveJammer 500 (WJ500), with additional WR650 WaveRunner LX and MJ650T material.
• Engine removal, internal inspection and reassembly extend to reed-valve service, crankshaft checks and engine and coupling alignment.
• Diaphragm carburetor and fuel-pump repair covers needle valves, float-arm inspection, mixture adjustment and model-specific fuel hose routing diagrams.
• Jet pump overhaul includes impeller removal, driveshaft bearings and seals, with shim-selection charts for impeller-to-housing clearance.
• Electrical documentation pairs wiring diagrams and CDI circuit diagrams with ignition testing, starter motor repair and rectifier-regulator checks.
• Steering procedures distinguish the WJ500 steering post from the WR500/WR650 column assemblies. Later sections add ride-plate angle adjustment and bilge-system inspection.

Written for Yamaha dealers and their mechanics, these service procedures call for the measuring equipment and special tools identified in the manuals.

Model Coverage and Manual Sections

The PDF combines four service-manual sections and a separate storage insert:

WJ500-specific service is concentrated in the first two sections. Identification pages give hull identification, primary I.D. and engine serial-number locations, together with section-specific starting numbers. For example, the 1992 WR500 section lists primary I.D. EU0-813601 onward and engine serial number 6K8-070745 onward.

The compilation has gaps in the original page sequences: engine disassembly page 4-5 in the 1987–1989 section; carburetor inspection page 4-9 and WR650 disassembly page 5-9 in the 1990–1991 section; and engine/intermediate-shaft pages 5-48–5-49 in the 1993 section.

Engine and Fuel-System Details

The engine chapters distinguish the 6K8-powered WR500/WJ500 from the 6M6-powered WR650/MJ650T. Cylinder bore limits, piston-to-cylinder clearances and crankcase assembly data are supported by piston-ring checks, bearing inspection and water-jacket examination. Separate assembly sections address the different engine layouts.

Fuel-system illustrations distinguish ON, RES, supply and return connections, with hose identification guides that vary between sections. Carburetor cautions explain how unsuitable cleaning solvents and methods can damage synthetic rubber parts and diaphragms.

Special-tool references include flywheel puller YB-6117 and, in the later tool list, WR500 gauge block YW-06367 and CDI tester YU-91022-B. Exploded assembly views identify component relationships and the specified lubrication and sealing points.

Electrical Diagnosis and Specifications

Troubleshooting charts separate an engine that will not crank from one that cranks without starting, then address weak spark, irregular running, stalling and failure to shut off. Component checks extend to charge and pulser coils, starter brushes and armature, and the overheat thermo switch.

Torque values for engine fasteners, fuel system components, and jet pump assemblies are documented alongside wear limits and electrical test specifications. The later Cooling System Diagram distinguishes cooling water, exhaust and bilge paths; the Ventilation System Diagram identifies fresh-air, vapor and drain-water routes.

Hull, Hood and Seasonal Service

Hull repair coverage addresses light and deep scratches, punctures, graphic replacement and damaged insert-nut mountings. Later chapters document gunwale and mat replacement, hood hinges and latches, and deck hardware. The separate Water Vehicle FRP Repair Manual referenced for insert-nut repairs is not part of this collection.

The WJ500 steering-post section warns that incorrect tightening can loosen the mounts and crack the post. Ride-plate stopper notes also reference MJ500T, MJ500S and MJ650T configurations.

Routine maintenance schedules are included, together with greasing points and a storage insert covering cooling-system flushing, engine fogging, fuel treatment and battery care. Follow the manual’s precautions for gasoline vapors and rotating jet-pump parts, and consult a qualified technician if you are unsure about a complex repair.