REPAIR MANUALS YAMAHA POLARIS SYSTEMS FUEL GASKETS ENGINE/ EXHAUST DRIVE LINE. Part No. W Part No. W801 HANDLING SUPER BN MANUAL
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1 REPAIR MANUALS SEA DOO KAWASAKI SUPER BN MANUAL For the watercraft tuner working with Super BN series carburetors. Mikuni Manual Sea Doo Water Vehicles Standard GT, GTS, GTX, SP, SPi, XP W809-3 Sea Doo Water Vehicles GS/GSI/GSX/GSX RFI/ GSX Ltd./GTI/GTS/GTX GTX DI/GTX RFI/GTX Ltd. HX/LRV/RX/RX DI SP/SPX/XP Ltd. W810 YAMAHA Kawasaki Jet Ski JS300, JS550, JS300SX, JS550SX, JS400, JF650X-2, JS440, JS650SX, JF650TS, JL650SC, JB650TS Jet Mate W801 Kawasaki Jet Ski JS440, JS550, JS550SX, JB650 Jet Mate, JF650X-2, JF650TS, JL650SC, JS650SX, JH750SS, JS750SX, JH750Xi, JT750ST, JH750XIR W802 EXHAUST DRIVE LINE ELECTRICAL WATERLINE Yamaha Water Vehicles Kawasaki Jet Ski Performance Manual, all models WJ500, WRA650, WR500, SJ650, WR650 W805 Yamaha Water Vehicles WR500, SJ650, WR650, WRA650, WRA650A, WRB650, WRB650A, FX700, SJ700, RA700, RA700A, RA700B, WB700A, WRA700, WRB700, WVT700, RA760, WB760, RA1100, WVT100 W804 POLARIS Polaris Water Vehicles BODY ACCESSORIES SERVICE TOOLS W806 SL650, SL750, SLT750 W819 CHEMICAL FREESTYLE 2006 WORLD FINALS LAKE HAVASU, AZ PHOTO COURTESY OF JIN OMURA Polaris Water Vehicles SL650, SL750, SLT750 W
2 STAINLESS STEEL HEX BOLT PACKS 6 x 10 6 x 12 6 x 14 6 x 16 6 x 18 6 x 20 6 x 25 6 x 30 6 x x 40 6 x 45 6 x 50 6 x 60 6 x 70 6 x 80 8 x 18 8 x x 25 8 x 30 8 x 35 8 x 40 8 x 50 8 x 60 8 x x EXHAUST STAINLESS STEEL ALLEN HEAD BOLT PACKS DRIVE LINE ELECTRICAL 4 x 30 4 x 16 5 x 10 5 x 25 6 x 10 6 x 12 6 x x 16 6 x 20 6 x 25 6 x 30 6 x 35 6 x 40 6 x x 60 8 x 20 8 x 25 8 x 30 8 x 50 8 x x WATERLINE STAINLESS STEEL NUTS STAINLESS STUD PACKS Size 6mm 8mm X BODY ACCESSORIES SERVICE TOOLS CHEMICAL STAINLESS STEEL FLAT WASHERS Size 6mm 8mm 10mm ZIP TIES PLASTIC FITTINGS STAINLESS STEEL SPRING WASHERS Size 6mm 8mm 10mm FREESTYLE 168 Color 3 x.090 Black 7 1/4 x Black (Sold in Packages of 100) Plastic T Fitting 3/8 x 3/8 x 3/8 1/2 x 1/2 x 1/2 Plastic Y Fitting 3/8 x 3/8 x 3/8 (white) 1/4 x 1/4 x 1/4 (white) 1/4 x 1/4 x 1/4 (black)
3 BRASS FITTINGS Straight Hose Barbed 1/8 Thread 1/4 Hose 1/8 Thread 3/8 Hose 1/4 Thread 1/2 Hose Barb Connector 1/4 I.D. Hose 1/4 I.D. Hose 3/8 I.D. Hose 3/8 I.D. Hose 1/2 I.D. Hose 1/2 I.D. Hose Brass Push in Nipple 1/8 Straight 1/4 Straight EXHAUST DRIVE LINE 90 Degree 1/8 Pipe thread 3/8 Hose 1/4 Pipe thread 1/2 Hose 1/8 Pipe thread 1/4 Hose Garden Hose Adapter 3/8 1/ Press-in 90 Degree Fuel Inlet 1/4 90 Degree 44 ELECTRICAL WATERLINE 45 Degree 1/8 Pipe thread 1/4 Hose 1/8 Pipe thread 3/8 Hose 1/4 Pipe thread 1/2 Hose Brass Fitting 1/8 Pipe threaded junction 1/8 to 1/4 Adapter 9mm Yamaha Flush Adapter BODY ACCESSORIES SERVICE TOOLS CHEMICAL FREESTYLE T-Fitting Primer Fitting 1/8 x 1/8 x 1/8 Primer 1/4 x 1/4 x 1/8 Fuel Line 1/4 x 1/4 x 1/ Brass Threaded Plug 1/8 Threaded Plug 1/4 Threaded Plug WORLD FINALS LAKE HAVASU, AZ PHOTO COURTESY OF JIN OMURA 169
4 EXHAUST WATERLINE DRIVE LINE ELECTRICAL STAINLESS STEEL HOSE CLAMPS T-BOLT CLAMPS Clamps #5 #36 #48 #60 #72 #80 Max. Size (for waterline) /16 3 1/2-2 9/16 4 1/4-3 5/ /16 5 1/2-4 9/ Size 3 3-1/4 4-1/ /4 5-1/2 Width SQUEEZE ON STAINLESS STEEL CLAMPS HOSE SHEARS Scissor-action cutter for hose. BODY Hose Shears ACCESSORIES SERVICE TOOLS CHEMICAL Pincer Tool Clamp for 1/4 Hose (10 pcs/pk) Clamp for 3/8 Water Line (10 pcs/pk) Clamp for 1/2 Water Line (10 pcs/pk) FREESTYLE 170 3/8 Blue 1/2 Black 1/2 Blue WATER LINE HOSE Sold per foot FEED AND VENT HOSE Designed to meet fuel hose specification for SAE J1527 and ISO This hose meets all the requirements of the USCG, NMMA, ABYC. 25 feet/pk. 1/4 Fuel Feed & Vent Hose 5/16 Fuel Feed & Vent Hose LINE Fuel line is made from a thick walled polyurethane tubing. Sold per foot. or 25 feet/pk Blue (1/4 ) per foot Blue (1/4 ) 25 feet/pk Primer Line (1/8 ) per foot Primer Line (1/8 ) 25 feet/pk
5 SYSTEM SERVICE TOOLS CARB SCREW ADJUSTING TOOL Angled head for the hard-to-reach carb adjustment screws Carb Screw Adjusting Tool DEGREE 1/4 HEX DRIVER Precision made of high-grade aluminum & stainless steel. Designed for hardto-reach pilot screw. Gear driven 1/4 hex. Includes 1/4 hex bits, straight slot, Phillips, D-shaped pilot screw bit, 6mm hex jet bit and 1/4 -hex-to-1/4 drive bit. 90 Degree 1/4 Hex Driver EXHAUST DRIVE LINE ONE-HANDED OPERATION HOSE PINCHER Clamps and holds hoses up to inside diameter. Angled jaws close to create a complete seal every time. Jaws are offset for hard-to-reach areas. The handles lock firmly to hold the jaws in closed position. Hose Pinchers MIKUNI TOOL KIT This handy little kit contains all the tools necessary to make jetting change, perform normal maintenance as well as disassemble and rebuild any Mikuni carburetor Mikuni Tool Kit LS BLACK GRIPPER JAW TUBE HOSE REMOVAL PLIERS For easy removal of 5/32 to 1/2 (4mm to 14mm) hoses. Engage the tube (line) with the black jaw.this sharpened jaw actually digs into the tube to grip it! Squeeze, and the hose is easily pushed off by the silver jaw. Hose Removal Pliers HAND REAMER JET SET Cleans jets the right way. 6pcs Reamer Jet Set SILVER PUSHER JAW HOSE BEING REMOVED LS ROTARY VALVE TIMING WHEEL Rotary Valve Timing Wheel HOSE PINCHERS Quick, easy way to pinch off fuel lines, etc. without damaging the line. Sold two per set. Hose Pinchers POP-OFF GAUGE For Accurate adjustment of pop off pressure levels. A Mikuni Gauge 30 Lbs. 60 Lbs. 100 Lbs. B Aftermarket Thumb Operated Gauge LS22850 A B ELECTRICAL WATERLINE BODY ACCESSORIES SERVICE TOOLS CHEMICAL FREESTYLE 171
6 ENGINE / EXHAUST SYSTEM SERVICE TOOLS EXHAUST DRIVE LINE QUICK RELEASE RING COMPRESSOR Ring Compressor makes it easy to remove ring from piston. Range is from 2-1/8 5 (54mm 127mm). Quick Release Ring Compressor LS19000 HEAD PULLER FOR KAWASAKI HEADS Pull straight up from the spark plug hole while using the studs for leverage. Head Puller for Kawasaki /2 WIRE CUP BRUSH Removes weld scale, rust, paint and corrosion from metal surfaces. Made with.014 carbon steel wire and designed for light duty use with an electric drill. Maximum safe free speed is 4500rpm. 2-1/2 Wire Cup Brush LS14020 ELECTRICAL WATERLINE WRINKLE BAND RING COMPRESSOR Wrinkle band cuts friction in half. Rings slide in easily 3 5 (76.2mm 127mm). Wrinkle Band Ring Compressor RINGS SLIDE IN EASILY RANGE 3 TO 5 (76.2 to 127mm) LS21700 SEAL PULLER Simply insert the tip of the tool behind the oil or grease seal, press and pull. Leverage works for you. Two size tips reach in and fit nearly all seal applications. Seal Puller LS56750 KNOT STYLE CRIMPED STYLE 1 WIRE END BRUSHES Made with.020 industrial heat-tempered wire. Use with portable electric and air tools. 20,000rpm maximum safe speed. 1 Knot Wire End Brush LS Crimped Wire End Brush LS14060 BODY ACCESSORIES SERVICE TOOLS CHEMICAL FREESTYLE 172 PISTON RING INSTALLER Piston Ring Installer PISTON PIN PULLER Universal piston pin puller easily removes all sizes of piston pins without any damage to the piston. Piston Pin Puller LS O RING AND SEAL PICK Quickly removes and installs O rings and seals. Tips are hardened to stay sharp. O Ring and Seal Pick Carbide Gasket Scraper Replacement Carbide Blade LS31840 CARBIDE GASKET SCRAPER Six-sided carbide blade cuts smoother and lasts longer. LS51650 LS51660 CONVERSION TABLE Unit Linear Measure centimeter (cm.) meter (m.) kilometer (km.) Conversion inch feet / yards mile inch (in.) 2.54 centimeters foot (ft.) = 12 inches centimeters yard (yd.) = 3 feet centimeters rod (rd.) = 5.5. yards meters chain (ch.) = 4 rods meters furlong (fur.) = 10 chains meters mile (m., mi.) = 8 furlongs kilometers league (l.) = 3 miles kilometers Aviordupois Weight Gram (g.) oz. avdp. kilogram (kg.) = 1,00 grams lb. avdp metric ton (M.T.) short tons long ton grain (gr.) gram dram (dr. avdp.) = grains grams ounce (oz.avdp.) = 16 drams grams pound (lb. avpd) = 16 ounces kilogram hundredweight (cwt.) (US) = 100 pounds kilograms (UK) = 112 pounds kilograms ton (t., tn.) (US) = short ton =2,000 pounds metric ton (UK) = short ton =2,240 pounds metric ton
7 ENGINE / ELECTRICAL SYSTEM SERVICE TOOLS BEARING RACE AND SEAL DRIVER MASTER SET Make it easier to insert bearing race and seals without damage to race. This master set includes nine drivers to fit most standard bearings. Bearing Race and Seal Drive Handle Mini pouched SET INCLUDES ONE OF EACH OF THE FOLLOWING DRIVERS: DRIVER PART NO. SIZE LS12980 LS12660 SPARK PLUG WRENCH SET 3/8 10mm / 12mm / 14mm Extensions 15mm / 30mm A. B. SPARK PLUG TOOLS A. Plug Wrench B. Ratchet Plug SPARK PLUG HOLE THREAD CHASER Cleans threads in spark plug hole. Use with 13/16 spark plug socket. Double-ended for both 14mm and 18mm threads. Spark Plug Hole Thread Chaser GAPPING Spark Plug Gauge and Gapper LS20200 GAUGING STANDARD/HIGH ENERGY SPARK PLUG GAUGE AND GAPPER Gauge and gap all types of spark plugs from.020 to.110 (.50mm to 2.53mm). LS67870 EXHAUST DRIVE LINE ELECTRICAL WATERLINE COMPRESSION TESTER Contains hoses for 10, 12 & 14mm spark plug applications. Features a quick disconnect with a pressure release valve and a 300lbs. Gauge. Packed in a convenient carry box. Made in USA. Compression Tester TELESCOPING MIRROR Enables you to see around corner. 2-1/4 diameter mirror swivels to any position. Length extends from 10 to 14. Telescoping Mirror LS32050 SPARK PLUG WIRE TESTER Now you can check spark plug wires without piercing the wires. Light flashes indicating sound wire. Spark Plug Wire Tester Replacement Bulb Assembly IGNITION SYSTEM SPARK TESTER This ignition system tester checks the integrity and strength of your system by gauging your systems spark. Ignition System Spark Tester LS26900 LS LOW CIRCUIT TESTER Quick check both AC and DC current up to 28 volts with power on. Helps locate shorts or breaks in wiring. Complete with insulated grounding grip. Low Circuit Tester Replacement Bulb UL APPROVED BATTERY CHARGER Made in Japan. LS26250 LS26270 Battery Charger BODY ACCESSORIES SERVICE TOOLS CHEMICAL FREESTYLE 173
8 ELECTRIC SYSTEM SERVICE TOOLS EXHAUST WATERPROOF TERMINAL REPAIR KIT Japanese OEM Type Connector Kit PERMA-SEAL FLYWHEEL PULLER CONNECTOR KIT MSD Perma-Seal Connector Kit 4377 Sea Doo 800/951 38mm x 1.5 DS#57 Kawasaki 900/ mm x 1.5 DS#29 DRIVE LINE A. B. ELECTRICAL WATERLINE BODY ACCESSORIES SERVICE TOOLS CHEMICAL PRO-CRIMP TOOL To do a job right, it is important to have the right tools. If you custom build a lot of plug wires, the Pro-Crimp is the right tool for you! The Pro-Crimp features a hardened steel frame, molded hand grips and built-in rachet action that is also adjustable. The tool is supplied with jaws to fit MSD s Super Conductor Spark Plug wires and can be removed to use additional jaws (sold separately) for crimping common wiring terminals. MSD Pro Crimp Tool 3505 Spark Plug Dies 3508 Amp Pins 3506 Amp Lug Dies 3507 Weathertight Dies 3509 Deutsch Terminal Dies 3510 TERMINAL DETENT TOOL The hollow barrel allows you to depress the tab on the terminal end and to remove the wire from the connector without damaging its ends. Terminal Detent Tool TIMIMG LIGHTS MSD offers a heavy duty top quality timing light. This timing light is supplied in a heavy duty metal housing and features a high output Linear Xenon strobe with a focused fresnel lens that produces a light that s bright enough to use outdoors. It is equipped with a 6 foot lead and uses a metal inductive pickup that clamps to the spark plug wire. Timing Light 8990 TDC DIAL INDICATOR KIT Perfect for indicating TDC (Top Dead Center) when setting ignition and rotary valve timing. CNC-machined spark plug hole (14mm) adapter. 1 travel dial indicator. Rotating Bezel. Measures in.001 increments. TDC Indicator MT-DIAL MAGNETO FLYWHEEL PULLER Sea Doo A. 580/650/720 DS#34 3 Hole Disc 8mm Bolts Polaris B. Polaris ALL & Universal DS#37 Universal 12 Hole Disc 8mm Bolts C. D. MAGNETO FLYWHEEL PULLER YAMAHA C. 500/650/Pre DS#26 3 Hole Disc 8mm Bolts D. 701/760/800/1100/1200 DS#22 3 Hole Disc 8mm Bolts E. F. FREESTYLE 174 TERMINAL REMOVAL TOOL Includes six different shaped blades. Terminal Removal Tool LS14900 TIMING DEGREE WHEEL Set total loss timing with no guess work. Check crank shaft timing to exact degree. A must for porting and port timing. Timing Degree Wheel MAGNETO FLYWHEEL PULLER KAWASAKI E. 300/440/550/650 DS#22 3 Hole Disc 8mm Bolts F. 750 DS#36 Special 18mm x 1.5 Right Hand Bolt
9 PUMP SYSTEM SERVICE TOOLS AND SHOP TOOLS A. K. B. IMPELLER HOLDER TOOL Sea Doo A. 580/650/720/800/951 All DS#23 18mm spline POLARIS B. Polaris ALL & long reach univ. DS#38 C. D. E. IMPELLER HOLDER TOOL Sea Doo K. GTX 4Tec Super Charged DS#70 L. RXP DS#71 L. A3250 SHOP LANYARD Not legal for riding. For shop testing only. KPTW, Yamaha, Sea Doo KPTW, Yamaha, Sea Doo DESS A3240 A3240 A3250 EXHAUST DRIVE LINE CABLE LUBBER Installs quickly and helps free up corroded or tight IMPELLER SHAFT HOLDER TOOL cables. Note; Damaged cable should be replaced. FOR YAMAHA Yamaha C. WR500, WJ650LX DS#27 16mm spline D. 650/701/760/1100/1200 DS#32 18mm spline E. GP1200R DS#56 20mm spline Cable Lubber RATIO CUP & LID Ratio Cup Lid ELECTRICAL WATERLINE F. G. IMPELLER HOLDER TOOL Kawasaki F. 440/ DS#24 16mm spline G. 650/750/900/1100 DS#23 18mm spline DRIVE COUPLER TOOLS Use to remove drive coupler from crankshaft and sub-shaft. 650/701 DS# /800/110/1200 DS#61-5 FOLD-UP SCRAPER The fold-up scraper features three arm positions and a slanted blade for proper scraping. Great for removing decals, etc. Fold-up Scraper J. I. Locks in 3 Different Positions. LS52400 SCRATCH BRUSH Removes rust, scale, paint, and solder from metal surfaces. I. Shoe Handle Scratch Brush LS14180 J. Scratch Brush LS14160 HYDRO-TURF OIL EXTRACTOR The unit uses a small vacuum system, which pumps fluid through a hose to the 6-liter reservoir. It also includes a pour spout to aid in emptying the reservoir. Pump is removable for easy storage. Hydro-Turf Oil Extractor Parts Cleaning Brush OIL01 PARTS CLEANING BRUSH LS14000 BODY ACCESSORIES SERVICE TOOLS CHEMICAL FREESTYLE 175
10 SHOP TOOLS EXHAUST DRIVE LINE ELECTRICAL WATERLINE CHEMICAL STUD BOLT REMOVER SET For easy installation and removal of intake manifold and cylinder stud bolts. 6mm/8mm/10mm/12mm Set T-HANDLE RATCHET Features a compact design that allows it to be used even in tight spaces. 1/4 T-Handle Ratchet /8 T-Handle Ratchet MAGNETIC SOCKET HOLDERS Standard and deep sockets fit on one convenient holder with powerful magnets, securely holding on to any steel surface. Red color only. 1/4 Holder with 26 compartments LS /8 Holder with 28 compartments LS40200 BODY ACCESSORIES SERVICE TOOLS STUD INSTALLATION TOOLS Will Install cylinder and intake manifold studs. Hex head is or 19mm. 6mm x 1.00 Stud Tool mm x 1.25 Stud Tool mm x 1.25 Stud Tool IMPACT DRIVER SET For easy removal of Mikuni Valve body screws without damage. Impact Driver Set BALL END ALLEN SET Made of chrome-vanadium tool steel. Size available 1.5, 2, 2.5, 3, 4, 5, 6, 8, & 10mm. Ball end allows for better access to allen-head bolts (up to 25 degree working angle.) Ball End Allen Set T-HANDLE ALLEN WRENCH 5mm 6 long T-Handle mm 9 long T-Handle mm 9 long T-Handle LS21300 LS21400 MAGNETIC TOOL HOLDERS Powerful magnet holds even heavy hand tools. Ideal for both home and shop. 13 long Magnetic Tool Holder LS long Magnetic Tool Holder LS21400 FREESTYLE 176 TORX SOCKET SET FOR SEA DOO Special Star Sockets for Sea Doo 4-Tec& DI engine bolts are mode from heat-treated vanadium steel and black oxide coated for durability. Sockets are kept in a convenient vinyl holder. Four 3/8 Drive Sockets (T10, T12, T14, T16) Three 1/4 Drive Sockets (T6, T7, T8) Torx Socket Set LS26750 DOC ALLEN S VERSATOOL Lightweight Compact Multi-Function Stainless Steel Use in Tight Places Compact Tool Set VERSATOOL RUBBER-FACED & ALUMINUM VISE JAW PADS These vise jaw pads are designed to protect delicate parts from damage. Sold in pairs. A. Rubber-faced Vise Jaw Pads LS48100 B. Aluminum Vise Jaw Pads LS48000
REPAIR MANUALS YAMAHA KAWASAKI SEA DOO POLARIS STROKE FOUR SYSTEMS INTAKE. Part No. W806 GASKETS ENGINE/ EXHAUST DRIVE LINE. Part No.
REPAIR MANUALS Yamaha Water Vehicles 1993-1996 WR500, SJ650, WR650, WRA650, WRA650A, WRB650, WRB650A, FX700, SJ700, RA700, RA700A, RA700B, WB700A, WRA700, WRB700, WVT700, RA760, WB760, RA1100, WVT100 W806
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