1992-1998 Polaris Personal Watercraft Service Manual PN 9912201
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- 1992 1998 Polaris PWC Service Manual
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:
1992: | SL650 | |
1993: | SL650 SL750 SLT | |
1994: | SL650 SL750 SLT | |
1995: | SL650 (SL650 International) SL650 STD (SL650 STD International) SL750 (SL750 International) SLTl50 (SLTl50 International) SLX780 (SLX780 International) | |
1996: | SL700 (SL700 International) SLTlOO (SLTlOO International) SL780 (SL780 International) SL900 (SL900 International) SLX780 (SLX780 International) SLTl80 (SLTl80 International) Hurricane (Hurricane International) SLTX (SLTX International) | |
1997: | SL700 SL700 Deluxe SLT700 Hurricane SL780 SLTl80 SLX PRO 785 SL900 SL1050 SLTX | |
1998: | SLH SLTH SLXH SLTX |
Service manual is searchable and indexed. It includes hi-resolution images, diagrams and detailed description of procedures to service and repair your PWC.
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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