This DIY repair manual by Clymer, covers 1993-1996 Yamaha Waverunner personal watercraft (PWC), including:
Book Excerpt: 1993-1996 Yamaha Waverunner 500, 650, 700, 760, 1100 Repair Manual
- Yamaha WR500 | WR650
- Yamaha WRA650 | WRA650A | WRA700
- Yamaha WRB650 | WRB650A | WRB700
- Yamaha SJ650 | SJ700 | SJ700A
- Yamaha FX700
- Yamaha RA700 | RA700A | RA700B | RA760 | RA1100
- Yamaha WB700 | WB700A | WB760
- Yamaha WVT700 | WVT1100
CRANKCASE AND CRANKSHAFT
Disassembly of the crankcase - splitting the cases - and removal of the crankshaft assembly requires engine removal from the hull. However, the cylinder head, cylinder and all other attached assemblies should be removed with the engine in the hull.
The crankcase is made in 2 halves of precision diecast aluminum alloy and is of the thin-walled type (Figure 85). To avoid damage to them do not hammer or pry on any of the interior or exterior projected walls.
These areas are easily damaged if stressed beyond what they are designed for. They are assembled without a gasket: only gasket sealer is used while dowel pins align the crankcase halves when they are bolted together. The crankcase halves are sold as a matched set only (Figure 86).
If one crankcase half is damaged, both must be replaced.
The procedure which follows is presented as a complete, step-by-step major lower end overhaul.
When splitting the crankcase assembly, a few special tools are required. These tools allow easy disassembly and reassembly of the engine without prying or hammer use. Remember, the crankcase halves can be easily damaged by improper disassembly or reassembly techniques.
a. Yamaha coupling holder (or equivalent) part No. YW-38741 (760cc models) or part No. YW-06547 (all other models). See Figure 87. This tool is used to remove and install the coupling half from the end of the crankshaft or drive shaft. Because the couplings are made of cast aluminum, they can be easily damaged by the use of improper tools or removal procedure.
Subject: 1993, 1994, 1995, 1996 Yamaha PWC Water Vehicles service, maintenance, repair. ISBN-10: 0892876867 | ISBN-13: 9780892876860 | Clymer W806