1996 Yamaha WaveBlaster WB700A/WB700AU PWC Service Manual Set (P/N LIT-18616-01-54, LIT-18616-00-96)

The 1996 supplement introduces updated WB700AU service procedures and specifications. Yamaha specifies using it together with the included 1993 base manual.

Hull repair scope: Scratch and puncture repairs are covered, but the hull and insert-nut sections also refer to the separate Water Vehicle FRP Repair Manual for additional fiberglass repair detail. That publication is not included.

Engine, Fuel System and Jet Pump Service

• Power unit: Engine removal, reed-valve inspection, cylinder and piston repair, crankcase separation, crankshaft inspection, and reassembly procedures.

• Fuel and oil injection: Carburetor disassembly, throttle and choke valve synchronization, fuel-pump inspection, oil-pump removal, and oil-injection air bleeding.

• Jet pump: Impeller and drive-shaft removal, bearing and oil-seal installation, clearance inspections, and bilge-system service.

• Electrical diagnosis: Wiring diagrams, CDI and charging-system tests, starter-relay checks, starter-motor disassembly, and symptom-based troubleshooting charts.

• Steering, hull and hood: Steering-cable adjustment and replacement, pivot-bearing inspection, hood-latch adjustment, and body-component removal and installation.

• Maintenance and routing: Periodic inspection charts, lubrication points, and pipe routing, cable routing, cooling-system, and ventilation-system diagrams.

Yamaha wrote the base manual primarily for its dealers and trained mechanics, assuming an understanding of the mechanical and electrical concepts involved.

Carburetors and Oil Injection

The supplement covers the paired carburetors, including diaphragm, float-arm, needle-valve, and valve-seat inspection. Front and rear high-speed settings are distinguished, with separate checks for throttle-valve and choke-valve synchronization.

Fuel-pump service points address the diaphragms and filter. The oil-injection material covers pump removal and air bleeding after system disassembly or loss of the oil supply, while the base manual’s Oil Injection System Diagram identifies hose connections.

The carburetor section warns that cleaning jets with steel wire can enlarge their openings and affect performance. Fuel-system service also carries specific precautions for gasoline vapor, pressure release, and ignition sources.

Engine Inspection and Drive Alignment

Internal engine coverage includes cylinder-head warpage, cylinder bore condition, piston-to-cylinder clearance, piston-ring fit, and crankshaft runout. The repair sections pair these inspections with exploded views, removal charts, assembly notes, and component-specific tightening instructions.

The supplement updates several base-manual specifications, including piston-ring clearance and the staged cylinder-head tightening values. These differences matter when selecting the inspection limits and assembly data for the later configuration.

Engine and intermediate-housing installation includes shim identification and coupling-clearance checks. Jet-pump service extends to drive-shaft runout, bearing condition, and oil-seal placement; the tool references include drive shaft holder YB-6049 / 90890-06518.

Electrical Fault Tracing and Watercraft Systems

The troubleshooting charts distinguish a starter that will not turn from a cranking engine that will not fire, then separate fuel, ignition, and compression checks. Other charts address irregular running, stalling, and an engine that will not shut off.

Component tests cover the CDI magneto, ignition coil, rectifier regulator, thermo switch, and starter motor, including brush and commutator inspection. The supplement explains how tester resistance affects low-resistance measurements, helping avoid misleading coil-test results.

The Wiring Diagram identifies circuit connections and wire colors. Routing drawings show the relationships among the fuel and oil lines, control cables, cooling passages, and ventilation hoses. Body service extends to the exhaust water lock, steering column, gunwales, mats, deck fittings, seat, and insert nuts.

A Preview of Carburetor, Piston-Ring and Electrical Specifications

The WB700AU supplement lists a 2.5 mm main nozzle for carburetors stamped 64U00F/R and piston-ring side clearance of 0.01–0.03 mm for both rings. These are supplement specifications, distinct from the base manual’s carburetor and piston-ring data.

For electrical testing, the supplement gives lighting-coil resistance of 1.14–1.40 ohms between the green leads at 20°C (68°F).

The WB700R/WB700S base manual specifies compression pressure of 940 kPa for its warmed-engine test with the craft in water and the throttle fully open during cranking.

Bookmarked PDF and Diagram Readability

Search, navigation and wiring detail: PDF text search is not available. Embedded bookmarks provide access to both publications and their service sections; the “Return to main index” bookmark points to a separate file outside this download. Small wiring labels and dense electrical test tables benefit from zooming.

The download contains one printable English PDF with 203 pages total, including the additional compilation cover. The publication counts above include their front matter and back covers.