1997–2010 Yamaha SJ700AU Superjet Service Manual (P/N LIT-18616-01-43)

• SJ700AU / SJ700A factory coverage with Yamaha identification data for GM6 primary I.D. numbers and 64V engine and jet-pump serial-number families, helping match the manual to the machine before repair work begins.
• Covers the 701 cm³ twin-cylinder 2-stroke power unit from reed valves, cylinder head, cylinder, pistons, crankcase, and crankshaft through engine removal, flywheel magneto, starter motor, and intermediate housing service.
• Details the fuel system and 64U00F/R carburetor, including fuel-line and tank service, diaphragm and needle-valve inspection, fuel-pump checks, high/low-speed screw adjustment, and throttle/choke synchronization.
• Provides axial-flow single-stage jet-pump repair for the pump unit, deflector/nozzle/duct, impeller, drive shaft, bearings, oil seals, mounting shims, and bilge system.
• Includes electrical analysis and wiring diagrams for ignition, starting, and charging systems, with factory test specifications for the CDI magneto, coils, switches, starter circuit, battery, and rectifier regulator.
• A 128-page Yamaha factory PDF, first edition January 1996, LIT-18616-01-43, with 36 TOC-listed exploded-diagram/removal-and-installation chart pairs, factory special-tool references, specification tables, and a system-based trouble-analysis chart.

Component and System Documentation

This Yamaha service manual is built around the SJ700AU configuration; the specification tables identify the model as SJ700A. The General Information section gives starting primary I.D. references of GM6 900101, 910101 for France, and 930101 for GUM/AUS, along with starting engine serial 64V 000101 and jet-pump serial 64V 500101. Yamaha states that the manual was prepared primarily for its dealers and trained mechanics, and it assumes a basic understanding of mechanical and electrical service procedures.

Periodic service coverage goes beyond a maintenance checklist. It includes steering-friction and steering-cable adjustment, throttle and choke cable adjustment, fuel-filter inspection, trolling-speed and carburetor adjustment, spark-plug and battery checks, impeller inspection, bilge-strainer inspection, and lubrication points.

The fuel chapter separates the fuel line, tank, carburetor removal, carburetor body, and fuel pump into dedicated repair sections. Carburetor service covers diaphragm, float arm, body, needle valve, jets, high- and low-speed screws, throttle-valve synchronization, choke-valve synchronization, and final assembly. This is useful when a repair involves more than basic external adjustment or a simple parts swap.

Power-unit coverage reaches into the engine itself. The manual documents inspection and service for the reed valve, exhaust ring and chamber, muffler, cylinder head, cylinder, piston and rings, crankcase, crankshaft, flywheel magneto, electrical unit, starter motor, coupling, and intermediate housing. Related pages provide component-specific tightening data, clearances, wear limits, runout checks, and inspection criteria rather than a single generic specification sheet.

Jet Pump, Electrical, and Hull Repair

The jet-pump section covers unit removal, mounting-shim identification, the deflector/nozzle/duct assembly, impeller removal and installation, drive-shaft and bearing work, oil-seal installation, and bilge-system inspection. Yamaha also identifies the special holders, driver tools, bearing attachments, and slide-hammer equipment used in these procedures.

Electrical diagnosis is organized by system. The manual includes separate ignition-system, starting-system, and charging-system wiring diagrams, plus low-resistance measurement guidance and component checks for the spark plug and cap, ignition coil, engine-stop switch, charge coil, pulser coil, thermo switch, CDI unit, starter relay, lighting coil, and rectifier regulator.

Hull and control work is not treated as an afterthought. Dedicated sections cover the battery case and water lock, handle and handle column, steering cable, throttle and choke cables, steering pole and bracket, engine hood, deck, gunwale, mat, and hull. The hull chapter also includes factory repair coverage for light and deep scratching, puncture damage, insert-nut work, and graphic removal/application.

Diagrams, Tools, and Troubleshooting

Representative illustrations include the carburetor exploded diagram, engine-unit removal exploded diagram, impeller and drive-shaft exploded diagram, steering-cable exploded diagram, and the three system wiring diagrams. The special-tool pages identify Yamaha tools by part number, including the coupler wrench, flywheel holder and puller, intermediate-shaft holder, drive-shaft holder, and bearing installation/removal attachments.

The trouble-analysis chart cross-references likely causes for no-start, rough idle, stalling, failure to stop, poor performance, overheating, loose steering, increased bilge water, and poor battery charging back to the relevant repair chapters.

One manual-specific repair trap is called out at the flywheel: Yamaha warns that uneven or incomplete engagement of the flywheel-puller set bolts can damage the engine or tools. The jet-pump removal chart also tells the technician to mark the mounting shim packs before disassembly so the original alignment reference is not lost during reassembly.

The opening safety material covers fire prevention, ventilation, battery/electrical precautions, protective clothing, and safe disassembly practices. Those precautions are especially relevant before fuel-system, electrical, rotating-component, or hot-engine service.