This Service Repair Manual covers Yamaha WJ500, WR500, WR650, WRA650, WRB650, and SJ650 models produced between 1987 and 1992. These Pre-WaveRunner personal watercraft are equipped with reliable two-stroke engines, available in 500cc and 650cc displacements, and feature a water-cooled system and a direct drive jet pump transmission. Their robust engineering and straightforward design have established them as durable and capable watercraft for recreational use.
This manual provides comprehensive guidance for owners and technicians, detailing essential maintenance procedures, including 10, 50, and 100-hour service intervals, tune-up adjustments for spark plugs, ignition timing, and carburetors, as well as storage preparation. It also offers in-depth troubleshooting for starting and engine issues, covering fuel, ignition, and charging systems. Technical specifications and repair information for the electrical, fuel, and steering systems are included to ensure optimal performance and longevity of your Yamaha personal watercraft.
Models Covered:
Yamaha WJ500 (1987-1992)
Yamaha WR500 (1987-1992)
Yamaha WR650 (1987-1992)
Yamaha WRA650 (1987-1992)
Yamaha WRB650 (1987-1992)
Yamaha SJ650 (1987-1992)
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
Manual Contents:
CHAPTER ONE/GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Engine operation / Parts replacement / Clearing a submerged vehicle / Torque specifications / Fasteners / Lubricants / RTV gasket sealant / Threadlock / Basic hand tools / Precision measuring tools / Special tools / Mechanics tips / Ball bearing replacement / Oil seals / Specifications
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Emergency troubleshooting / Engine starting / Starting system / Charging system / Ignition system / Fuel system / Engine / Two-stroke pressure testing / Steering / Jet pump
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Break-in procedure / 10-hour inspection / Lubrication / Lubrication system identification / Recommended fuel mixture / Fuel mixing / Oil injection service / Oil pump bleeding / Oil filter / Oil tank drain hose / Check valve / Oil tank / 50 and 100 hour maintenance schedule / Fuel filter / Water separator / Fuel filler cap / Fuel tank pickup / Cooling system flushing / Engine tune-up / Torque cylinder head bolts / Cylinder compression test / Spark plug / Ignition timing / Carburetor adjustment / Storage / Specifications
CHAPTER FOUR / ENGINE (500 CC)
Engine lubrication / Service precautions / Serial numbers / Servicing engine in hull / Special tools / Engine removal installation / Muffler housing and exhaust guide / Specifications
CHAPTER FIVE / ENGINE (650 CC)
Engine lubrication / Service precautions / Serial numbers / Servicing engine in hull / Special tools / Engine removal installation / Muffler housing / Engine top end / Cylinder / Piston, piston pin and piston rings / Crankcase and crankshaft / Specifications
CHAPTER SIX / DRIVE TRAIN
Intermediate shaft and housing / Jet pump / Ride plate adjustment / Specifications
CHAPTER SEVEN / FUEL AND WATER BOX SYSTEMS
Flame arrestor / Intake manifold and reed valve / Type I Type II Carburetor / Type III Carburetor /Fuel tank / Fuel valve / Water box / Specifications
CHAPTER EIGHT / ELECTRICAL SYSTEM
Battery / Charging system / Electric starting system / Flywheel and stator plate / Flywheel, idler gear and stator plate / Electric box / Switches / Fuel sender / Fuse / Wiring diagrams / Specifications
CHAPTER NINE / OIL INJECTION SYSTEM - WRA650 AND WRB650
Oil tank / Sub oil tank / Check valves / Oil tank breather valve / Oil pump / Specifications
CHAPTER TEN / BILGE SYSTEM
CHAPTER ELEVEN / STEERING SYSTEM
Steering assembly / Specifications
INDEX
WIRING DIAGRAMS
Models Covered:
Yamaha WJ500 (1987-1992)
Yamaha WR500 (1987-1992)
Yamaha WR650 (1987-1992)
Yamaha WRA650 (1987-1992)
Yamaha WRB650 (1987-1992)
Yamaha SJ650 (1987-1992)
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
Manual Contents:
CHAPTER ONE/GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Engine operation / Parts replacement / Clearing a submerged vehicle / Torque specifications / Fasteners / Lubricants / RTV gasket sealant / Threadlock / Basic hand tools / Precision measuring tools / Special tools / Mechanics tips / Ball bearing replacement / Oil seals / Specifications
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Emergency troubleshooting / Engine starting / Starting system / Charging system / Ignition system / Fuel system / Engine / Two-stroke pressure testing / Steering / Jet pump
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Break-in procedure / 10-hour inspection / Lubrication / Lubrication system identification / Recommended fuel mixture / Fuel mixing / Oil injection service / Oil pump bleeding / Oil filter / Oil tank drain hose / Check valve / Oil tank / 50 and 100 hour maintenance schedule / Fuel filter / Water separator / Fuel filler cap / Fuel tank pickup / Cooling system flushing / Engine tune-up / Torque cylinder head bolts / Cylinder compression test / Spark plug / Ignition timing / Carburetor adjustment / Storage / Specifications
CHAPTER FOUR / ENGINE (500 CC)
Engine lubrication / Service precautions / Serial numbers / Servicing engine in hull / Special tools / Engine removal installation / Muffler housing and exhaust guide / Specifications
CHAPTER FIVE / ENGINE (650 CC)
Engine lubrication / Service precautions / Serial numbers / Servicing engine in hull / Special tools / Engine removal installation / Muffler housing / Engine top end / Cylinder / Piston, piston pin and piston rings / Crankcase and crankshaft / Specifications
CHAPTER SIX / DRIVE TRAIN
Intermediate shaft and housing / Jet pump / Ride plate adjustment / Specifications
CHAPTER SEVEN / FUEL AND WATER BOX SYSTEMS
Flame arrestor / Intake manifold and reed valve / Type I Type II Carburetor / Type III Carburetor /Fuel tank / Fuel valve / Water box / Specifications
CHAPTER EIGHT / ELECTRICAL SYSTEM
Battery / Charging system / Electric starting system / Flywheel and stator plate / Flywheel, idler gear and stator plate / Electric box / Switches / Fuel sender / Fuse / Wiring diagrams / Specifications
CHAPTER NINE / OIL INJECTION SYSTEM - WRA650 AND WRB650
Oil tank / Sub oil tank / Check valves / Oil tank breather valve / Oil pump / Specifications
CHAPTER TEN / BILGE SYSTEM
CHAPTER ELEVEN / STEERING SYSTEM
Steering assembly / Specifications
INDEX
WIRING DIAGRAMS
