Yamaha WaveBlaster PWC 1993–1996 Service Manual Set (P/N LIT-18616-00-96)

Yamaha’s preface states that the WB700AU supplement must be used with the WB700R/WB700S service manual. Both publications are present, so the variant-specific changes can be read alongside the base repair procedures instead of in isolation.

For additional fiberglass-repair information, the hull chapter refers to the separate Yamaha Water Vehicle FRP Repair Manual. That publication is not included.

PDF Bookmarks, Diagram Detail, and Page Count

Search, navigation, and wiring labels: PDF text search is not available. Embedded bookmarks navigate both publications and their service sections; the “Return to main index” bookmark points to a separate file outside this download. Small wiring-diagram labels are readable when enlarged.

The ZIP contains one printable, English-language PDF with 203 pages total, including the one-page compilation cover. The publication counts above include their title, introductory, and back-cover pages.

Power-Unit, Fuel-System, and Jet-Pump Repair

The selected contents below highlight the main repair areas rather than reproduce the complete contents list. Other covered topics include battery inspection and engine-hood latch adjustment.

• Power-unit repair: Step-by-step procedures for engine removal, top-end disassembly, piston and crankshaft inspection, flywheel-magneto service, crankcase assembly, and coupling alignment.

• Fuel and oil injection: Single- and dual-carburetor service, diaphragm and needle-valve inspection, throttle/choke synchronization, oil-pump removal, hose routing, and air bleeding.

• Jet-pump service: Pump removal, impeller and drive-shaft disassembly, bearing and oil-seal installation, clearance checks, reassembly, and bilge-system service.

• Electrical diagnosis: Wiring diagrams, ignition and charging-component tests, thermo-switch inspection, starter-motor overhaul, and troubleshooting charts for starting, running, and shut-off faults.

• Steering and hull: Steering-bearing and cable replacement, exhaust water-lock service, hood and seat work, deck fittings, and fiberglass hull-repair procedures.

• Maintenance references: Periodic inspection schedules, compression testing, lubrication points, component-specific torque tables, wear limits, clearances, and electrical test specifications.

Written primarily for Yamaha dealers and trained mechanics, these manuals assume a basic understanding of mechanical and electrical service work.

Carburetors, Fuel Delivery, and Oil Injection

The base fuel-system chapter covers fuel-tank removal and installation, fuel-cock and filter checks, water-separator inspection, and hose and check-valve connections. The WB700AU supplement adds a separate fuel-pump exploded view with diaphragm and filter inspection.

The supplement distinguishes front and rear high-speed carburetor adjustments. Hose identification, cable-guide position, and oil-line routing help the correct variant go back together without relying on memory.

Oil-system illustrations identify check-valve arrows, the green-end orientation, and the sub-tank “UP” mark. The carburetor section also warns that steel-wire cleaning can enlarge jet openings and affect performance.

Internal Engine Work and Workshop Tools

The base manual describes top-end removal with the engine installed. Inspection extends to cylinder-head water jackets and warpage, cylinder-bore and piston-clearance measurements, piston rings, piston pins, and bearings.

Engine and intermediate-housing shim packs are treated as coupling-alignment items. The removal and installation sections retain their relationship to the mounting and final alignment checks.

Tune-up tool references cover the dial gauge, compression gauge, cylinder gauge set, and engine tachometer YU-8036-A / 90890-06760.

Power-unit and driveline tools include the flywheel holder, flywheel puller YB-6117 / 90890-06521, shaft holder, and coupler wrench YW-38741 / 90890-06425. Slide-hammer, driver-rod, and bearing attachments are also identified, including YB-6156 / 90890-06634.

Jet-Pump Assembly, Steering, and Hull Work

Pump instructions identify the impeller’s left-hand thread and cover drive-shaft runout, bearing pressing, seal orientation, and specified grease fills. The installation details address bearing and seal handling, while the bilge section covers the strainer, hoses, and connections.

Steering work extends to the handle column and bearings, steering-cable adjustment, and throttle/choke cable replacement. Exhaust-system procedures cover the water lock and its hoses.

The hull chapter includes gunwale and mat removal, engine-hood service, deck fittings, seat disassembly, graphic replacement, and insert-nut repair. Its fiberglass section contains procedures for light scratches, deep scratches, and punctured hulls.

Electrical Tests and Fault Isolation

Component tests cover the fuse, starter relay, rectifier/regulator, ignition coil, CDI unit, and pulser, charge, and lighting coils. Starter-motor inspection includes brushes, the commutator, armature continuity, and field-coil checks.

The Electric Wiring Diagram provides circuit connections and wire-color codes, while the CDI terminal-test chart identifies the test leads. Pipe Routing, Oil Injection System, and Cooling System diagrams show the related fluid connections.

Troubleshooting charts separate starter-circuit faults from fuel, ignition, and compression problems. The WB700AU supplement revises coil tests and explains how a tester’s internal resistance affects low-resistance measurements.

Fuel-system work involves gasoline vapors; power-unit and jet-pump service adds rotating-component hazards, and electrical work requires battery isolation. Follow the manual’s ventilation, support, and disconnection precautions, and verify unfamiliar marine power-unit repair work with a qualified Yamaha watercraft technician.

Selected Carburetor and Charge-Coil Inspection Data

The carburetor inspection sections specify a float-arm height of 0–0.2 mm, measured between the carburetor-body surface and the arm’s top surface with the arm resting on, but not compressing, the needle valve.

For charge-coil testing at 20°C (68°F), Brown/White-to-Black resistance is 328.5–401.5 Ω for WB700R/WB700S and 497.7–608.3 Ω for WB700AU.