1992-1998 Polaris Personal Watercraft Service Manual PN 9912201

This is a complete Service Manual in English for the 1992-1998 Polaris Personal Watercraft.
This is the same manual that dealers and professional mechanics use to repair your PWC.

Manual part number: 9912201

Models covered in this manual:

Service manual is searchable and indexed. It includes hi-resolution images, diagrams and detailed description of procedures to service and repair your PWC.

To find information in PDF file please use "Ctrl+F" or "Command+F" for Mac and enter keywords you need to find in a manual.

File will be available for download in minutes!

"1992-1998 Polaris Personal Watercraft Service Manual PN 9912201" manual can be saved to any computer hard drive, flash storage, burned to a CD or DVD ROM or any other digital media.

This Manual PDF file is:

• + Printable: Yes
• + Viewable on: MS Windows, Mac, Android, iOS, Linux
• + Requires: Adobe Acrobat/Preview

Once manual is downloaded any number of pages could be printed or it could be printed in whole.
Manual could be opened in Adobe Acrobat on any mobile device (like iPad, iPhone or Android device etc.) any computer capable of viewing a PDF files including IBM compatible computers running Windows, Linux (or any other flavor of UNIX). Apple Computers have native support for PDF files.

Write a Review

Full list of manual chapters:

CHAPTER 1GENERAL INFORMATION
    Publication Numbers 1.1
    Service Bulletin Index By Bulletin Number 1.2 - 1.4
    Service Bulletin Index By Model 1.4a - 1.4b
    Paint Codes 1.5 - 1.6a
    Model Identification 1.7
    Model Specifications 1992 - 1993 1.8
    Model Specifications 1994 - 1995 1.9 - 1.11
    Model Specifications 1996 - 1997 1.12 - 1.14c
    Model Specifications 1998 1.14d - 1.14e
    Standard Torque Specifications 1.15
    Decimal Equivalents 1.16
    Conversion Table 1.17
    Tap Drill Charts 1.18
    Glossary of Terms 1.19 - 1.20
    Special Tools 1.21 - 1.26
    Service Tips 1.27
    Warranty Policy 1.28
CHAPTER 2MAINTENANCE/TUNE UP
    Periodic Maintenance Schedule 2.1 - 2.1a
    Recommended Lubricants and Accessories 2.2
    Electrical 2.7 - 2.10
    Engine / Exhaust System 2.11 - 2.18
    Cable Adjustments 2.19 - 2.25
    Air Intake / Fuel System 2.25 - 2.32
    Cooling System Maintenance/Storage 2.33 - 2.36
    Fuel System Storage/Engine Fogging 2.37 - 2.39
    Cleaning 2.39
    Bilge Siphon System 2.40
    Electric Trim Adjustment 2.41
    Submerged Engine (Hydrolocked) 2.42
    Pump/Impeller 2.43
    Hull/Deck 2.44 - 2.47
    Troubleshooting 2.48 - 2.53
CHAPTER 3FUEL SYSTEM/CARBURETION
    Carburetor Specifications and Initial Settings 3.1 - 3.5c
    Carburetor Jet Part Numbers 3.6
    High Elevation Recommendations 3.7 - 3.7a
    Vent/Fuel Delivery Exploded View 3.8 - 3.17
    Fuel Tank/Fuel Pickup Exploded View 3.18 - 3.29
    Air Intake Silencer and Water Separator 3.30 - 3.39
    Carburetor Assembly Exploded View 3.40 - 3.45
    Oil Tank Removal 3.46
    Oil Tank Exploded View 3.47 - 3.50
    Oil Pump Assembly Exploded View 3.51 - 3.52
    Carburetor Fuel Hose Connections - Keihin 3.52a - 3.52b
    Carburetor System Operation, Mikuni 3.53 - 3.55
    Carburetor System Operation, Keihin 3.56 - 3.58
    Fuel Pump Operation 3.59 - 3.60
    Fuel Shut Off Valve Disassembly/Inspection 3.61
    FuellWater Separator 3.62
    Mixture Screw Adjustment, Mikuni 3.63 - 3.66
    Carburetor Removal, Mikuni " 3.67
    Carburetor Disassembly, Mikuni 3.68 - 3.71
    Carburetor Assembly, Mikuni 3.72
    Carburetor Removal, Keihin 3.73 - 3.75
    Carburetor Disassembly/Inspection, Keihin 3.76 - 3.82
    Carburetor Assembly, Keihin 3.83 - 3.86
    Carburetor Installation, Keihin 3.87 - 3.88
    Carburetor Adjustment and Service, Keihin 3.89 - 3.90
    Cable Adjustment 3.91
    Mixture Screw Adjustment - Keihin 3.92 - 3.93
    Fuel Tank Vent System 3.94 - 3.95
    Fuel Tank Vent Line Routing 3.96 - 3.97
    Fuel Tank Check Valve Testing 3.98
    Fuel Pump Operation 3.99
    Fuel Pump Maintenance 3.100
    Reed Valve Removal/Inspection, Mikuni 3.101 - 3.102
    Reed Cage and Intake Manifold Installation, Mikuni 3.103
    Reed Valve Removal/Inspection, Keihin 3.104
    Reed Valve Assembly, Keihin 3.105
    Testing 3.106 - 3.107
CHAPTER 4ENGINE/COOLING
    Engine Specifications 1993 - 1994 4.1
    Engine Specifications 1995 - 1996 4.2 - 4.4
    Engine Specifications 1997 4.4a - 4.4b
    Engine Specifications 1998 4.4c
    Torque Chart 4.5
    Torque Patterns 4.6 - 4.10
    Engine and Mount Assembly Exploded View 4.11 - 4.15
    Cylinder and Manifold Exploded View 4.16 - 4.20
    Crankshaft/Piston Exploded View 4.21 - 4.25
    Crankcase Exploded View 4.26 - 4.30
    Oil Pump Exploded View 4.31 - 4.33
    Engine Removal, Fuji " 4.34 - 4.36
    Engine Disassembly/Inspection, Fuji 4.37 - 4.41
    Engine Assembly, Fuji 4.42 - 4.47
    Engine Installation, Fuji 4.48
    Engine Disassembly/Inspection, 780cc 4.49 - 4.62
    Engine Assembly, 780cc 4.63 - 4.70
    Engine Removal, Polaris 4.71 - 4.72
    Engine Disassembly/Inspection, Polaris 4.73 - 4.82
    Engine Assembly, Polaris 4.83 - 4.98
    Engine Installation, Polaris 4.99
    Cylinder Honing / Port Chamfering 4.100 - 4.101
    Oil Pump, Fuji 4.102 - 4.103
    Cooling System Exploded View 4.104 - 4.107
    Thermostat and Coolant Filter, Fuji 4.108
    Thermostat and Coolant Filter, Polaris 4.109
    Crankshaft Indexing 4.110- 4.111
CHAPTER 5FINAL DRIVE/JET PUMP/
    Torque Specifications / Special Tools 5.1
    1996 to Current Pump Data 5.2 - 5.2a
    Impeller Part Numbers 5.3
    High Elevation Specifications 5.4
    DriveshaftiCoupler Exploded View 5.5 - 5.6
    Pump Assembly Exploded View 5.7 - 5.12
    Pump Intake Exploded View 5.13 - 5.16
    Pump Removal, 1992-1993 5.17
    Pump Disassembly/Inspection, 1992-1993 5.18 - 5.20
    Drive Shaft Inspection, 1992-1993 5.21
    Pump Assembly, 1992-1993 5.22
    Intake Scoop and Ride Plate Installation 5.23
    Pump Installation, 1992-1993 5.24
    Pump Removal, 1994-1996 5.25 - 5.26
    Pump Disassembly/Inspection, 1994-1996 5.27 - 5.30
    Pump Assembly, 1994-1996 5.31
    Pump Installation, 1994-1996 5.32 - 5.34
    Pump Housing Removal, 1994-1996 5.35
    Pump Housing Installation, 1994-1996 5.36
    Pump Drive Shaft Alignment 5.37 - 5.37d
    Drive Shaft Lubrication 5.38 - 5.39
    Coupler Removal 5.40
    Ventilation/Cavitation Diagnostics 5.41
CHAPTER 6 HULL/DECK, STEERING AND CONTROLS
    Seat Assembly Exploded View. 6.1 - 6.4b
    Steering Assembly Exploded View 6.5 - 6.12
    Deck Assembly Exploded View 6.13 - 6.21
    Front Compartment Assembly Exploded View 6.22 - 6.24
    Steering Cover/Steering Post Removal 6.25 - 6.27
    Steering Cable Replacement/Adjustment 6.28 - 6.30
    Speedometer Operation and Inspection 6.31
    Dash/Control Panel 6.32
    Decal Replacement 6.32
    Wire Clip Replacement 6.32
    Hull Repair 6.33 - 6.34
    Sponson Removal/Installation 6.35
    Through-Hull Fitting Removal/Installation. . . . . . 6.35
CHAPTER 7ELECTRICAL
    Specifications - Spark Plugs / Alternator 7.1
    Specifications - CDI Box / Ignition Timing 7.1 a
    Warning Systems Operating Characteristics 7.1 b
    Stator Coil/Ignition Component Specifications 7.2
    Ignition System Exploded Views 7.3 - 7.6
    Electrical Box Exploded Views 7.7 - 7.13
    Battery Charging System Testing 7.14 - 7.15
    Switch Testing 7.15
    Battery Testing 7.16 -7.17
    Battery Maintenance 7.18
    Starter Motor Disassembly 7.19 - 7.20
    Starter Motor Brush Replacement 7.21
    Starter Motor Armature Testing 7.21
    Starter Motor Exploded View 7.22
    Starter Motor Assembly 7.22 - 7.23
    Starter System Testing 7.24
    Temperature Warning Operation / Sensor Test 7.25
    Fuel Gauge Operation and Testing 7.26
    RPM Limiter Function / Troubleshooting 7.27 - 7.27b
    Oil Level Sensor System Troubleshooting 7.28
    Quick Trim System Operation / Maintenance 7.29 - 7.30
    Ignition Timing (Degrees-to-Piston PositionConversionChart) 7.31
    Ignition System Testing 7.32 - 7.34c
    Hall Effect Sensor Testing 7.35
    Ignition Timing Adjustment, Fuji 7.36 - 7.37
    Ignition Timing Adjustment, Polaris 7.38 - 7.39
    Multi-Function Display Operation and Modes 7.40 - 7.41
    Multi-Function Display Troubleshooting 7.42
    Weatherproof Connector Servicing 7.43
    Electronic Module Function 7.44
    Bilge Pump 7.45
    Wiring Diagrams 7.47 - 7.71
    INDEX
SLXPro97-98
    CHAPTER 1GENERAL INFORMATION
        Publication Numbers
        Model Specifications
        Standard Torque Specifications
    CHAPTER 2MAINTENANCE/TUNE UP
        Maintenance Schedule
        Recommended Lubricants
        Lubrication
        Ignition Timing Specifications
        Engine
        Exhaust Valve Inspection/Cleaning/Adjustment
        Cooling System Maintenance
        Corrosion Prevention
        Storage
    CHAPTER 3FUEL SYSTEM/CARB'URETION
        Carburetor Specifications and Initial Settings
        Fuel Delivery Exploded View
        Fuel Tank/Fuel Pickup Exploded View
        Carburetor Exploded VIew
        Oil Tank Exploded View
    CHAPTER 4ENGINE/COOLING
        Service Data
        Torque Chart - Engine Fasteners
        Cylinder,Head and Exhaust Valves
        Engine Removal/Disassembly
        Engine Installation
        Cylinder Honing
        Oil Pump
        Cooling
    CHAPTER 5FINAL DRIVE/JET PUMP/BILGE SYSTEM
        Torque Specifications
        Pump Exploded View
        Pump Intake
        Pump Removal
    CHAPTER 6HULL/DECK, STEERINGAND CONTROLS
        Steering Assembly
        RTM Surface Repair Process
        Fiberglass Repair
    CHAPTER 7ELECTRICAL
        Specifications
        Ignition System
        Electrical Box
        Exhaust Valve Motor
        Temperature Warning
        RPM Limiter Circuits
        Ignition System Testing
        Wireing Diagram