WaveRunner WB800

NOTICE
HOW TO USE THIS MANUAL
MANUAL FORMAT
ILLUSTRATIONS
CROSS REFERENCES
IMPORTANT INFORMATION
HOW TO USE THIS MANUAL
SYMBOLS
INDEX
CHAPTER 1. GENERAL INFORMATION
IDENTIFICATION NUMBERS
PRIMARY I.D. NUMBER
ENGINE SERIAL NUMBER
JET PUMP UNIT SERIAL NUMBER
HULL IDENTIFICATION NUMBER (H.I.N.)
SAFETY WHILE WORKING
FIRE PREVENTION
VENTILATION
SELF-PROTECTION
OILS, GREASES AND SEALING FLUIDS
GOOD WORKING PRACTICES
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS
MEASURING
REMOVAL AND INSTALLATION
CHAPTER 2. SPECIFICATIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
JET PUMP UNIT
HULL AND HOOD
ELECTRICAL
TIGHTENING TORQUES
SPECIFIED TORQUES
GENERAL TORQUE
HOSE ROUTING
CABLE ROUTING
CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT
MAINTENANCE INTERVAL CHART
PERIODIC SERVICE
CONTROL SYSTEM
Steering column bushing inspection
Steering cable inspection and adjustment
Throttle cable inspection and adjustment
Choke cable inspection and adjustment
YPVS cable adjustment
FUEL SYSTEM
Fuel filter inspection
Trolling speed check and adjustment
Carburetor adjustment
OIL INJECTION SYSTEM
Oil filter inspection
Oil pump cable check and adjustment
Oil injection pump air bleeding
POWER UNIT
Spark plug inspection
ELECTRICAL
Battery inspection
JET PUMP UNIT
Impeller inspection
Water inlet filter inspection
Bilge strainer inspection
GENERAL
Drain plug inspection
Greasing points
CHAPTER 4. FUEL SYSTEM
FUEL LINE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Fuel filter inspection
Fuel cock inspection
OIL TANK
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Check valve inspection
Oil filter inspection
Oil level switch inspection
Oil tank inspection
FUEL TANK
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Check valve inspection
Fuel tank inspection
Pipe joint inspection
Pipe joint installation
CARBURETOR UNIT COVER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
CARBURETOR UNIT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Throttle valve synchronization inspection and adjustment
Choke cable and throttle cable installation
Oil pump cable installation
Carburetor assembly
CARBURETOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Diaphragm inspection
Float arm inspection
Regulator body assembly inspection
Needle valve inspection
Jet and carburetor body inspection
High- and low-speed adjusting screw inspection
High- and low-speed adjusting screw adjustment
Carburetor assembly
FUEL PUMP
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Fuel pump inspection
Fuel pump filter inspection
OIL HOSES
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Check valve inspection
OIL PUMP
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Oil pump inspection
Oil hose inspection
Oil pump cable check and adjustment
CHAPTER 5. POWER UNIT
EXHAUST CHAMBER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
ENGINE UNIT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Shim removal
Engine mount inspection
Coupling clearance inspection
MUFFLER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
REED VALVES
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Reed valve inspection
YPVS
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
YPVS valve inspection
CYLINDER HEAD
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Cylinder head inspection
CYLINDERS
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Cylinder inspection
PISTONS
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Piston pin clip removal and installation
Piston inspection
Cylinder and piston selection
Piston ring inspection
Piston pin and bearing inspection
STARTER MOTOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
ELECTRICAL UNIT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
FLYWHEEL MAGNETO
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Drive coupling removal and installation
Flywheel magneto removal and installation
Drive coupling inspection
Flywheel magneto inspection
Idle gear assembly inspection
FLYWHEEL COVER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
CRANKCASE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Crankcase inspection
Crankcase installation
CRANKSHAFT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Crankshaft inspection
INTERMEDIATE HOUSING
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Driven coupling removal and installation
Bearing removal
Bearing, driven coupling shaft, and grease hose inspection
Driven coupling inspection
Intermediate housing inspection
Bearing installation
Oil seal installation
CHAPTER 6. JET PUMP UNIT
JET PUMP UNIT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
NOZZLE DEFLECTOR AND NOZZLE RING
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Intake duct installation
IMPELLER DUCT AND DRIVE SHAFT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Drive shaft removal
Impeller inspection
Drive shaft inspection
Bearing inspection
Drive shaft installation
INTAKE DUCT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Oil seal and bushing removal
Intake duct inspection
Rubber seal inspection
Bushing and oil seal installation
COOLING AND BILGE SYSTEM
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Bilge strainer inspection
Bilge hose inspection
CHAPTER 7. ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
SERVICE POINTS
Spiral tube installation
ELECTRICAL BOX
ELECTRICAL ANALYSIS
INSPECTION
PEAK VOLTAGE MEASUREMENT
LOW RESISTANCE MEASUREMENT
IGNITION SYSTEM
WIRING DIAGRAM
IGNITION SPARK GAP
IGNITION SYSTEM PEAK VOLTAGE
SPARKPLUGS
SPARK PLUG CAPS
THERMO SWITCH
ENGINE STOP SWITCH
IGNITION COIL
CHARGE COIL
PULSER COIL
CDI UNIT
STARTING SYSTEM
WIRING DIAGRAM
BATTERY
WIRING CONNECTIONS
FUSE
STARTER SWITCH
STARTER RELAY
STARTER MOTOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Armature inspection
Brush holder inspection
Starter motor front cover inspection
CHARGING SYSTEM
WIRING DIAGRAM
RECTIFIER/REGULATOR PEAK VOLTAGE
LIGHTING COIL PEAK VOLTAGE
FUSE
BATTERY
RECTIFIER/REGULATOR
LIGHTING COIL
YPVS
WIRING DIAGRAM
FUSE
BATTERY
PULSER COIL
CDI UNIT
YPVS SERVOMOTOR
INDICATION SYSTEM
WIRING DIAGRAM
FUSE
BATTERY
LIGHTING COIL
RECTIFIER/REGULATOR
CDI UNIT
OIL LEVEL SWITCH
METER (OIL LEVEL WARNING LAMP)
CHAPTER 8. HULL AND HOOD
HANDLEBAR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Handlebar inspection
Handlebar switch inspection
Handlebar switch installation
Handlebar assembly installation
ENGINE HOOD COVER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
STEERING COLUMN
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Steering column bushing inspection
Steering column inspection
Steering column clamp installation
ENGINE HOOD
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Hood support inspection
Engine hood inspection
STEERING CABLE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Steering cable inspection
Steering cable (jet pump side) installation
Steering cable adjustment
THROTTLE CABLE AND CHOKE CABLE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Cable inspection
Cable installation
Throttle cable adjustment
Choke cable adjustment
YPVS SERVOMOTOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
YPVS cable removal and installation
YPVS cable inspection
YPVS servomotor inspection
YPVS cable adjustment
SEAT, STORAGE BOX, AND BATTERY BOX
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Seat lock inspection
Storage box inspection
Battery box inspection
EXHAUST SYSTEM
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Exhaust system inspection
DECK
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Hood lock hook inspection
GUNWALE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
MAT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SERVICE POINTS
Mat installation
HULL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
SPONSON
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
HULL REPAIR
Shallow scratches
Deep scratches
Cracks and punctures
Insert nut
Graphic removal
Graphic installation
CHAPTER 9. TROUBLE-ANALYSIS
TROUBLE-ANALYSIS
TROUBLE-ANALYSIS CHART
WIRING DIAGRAM