Polaris SLH, SLTH, SLX, SLTX, PRO 785 PWC Repair Service Manual 1999

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This workshop service repair manual PDF download for the 1999 SLH, SLTH, SLX, SLTX, PRO 785 Polaris Personal Watercraft has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


Polaris SLH – 8994673
Polaris SLTH – 8994573
Polaris SLTX – 8994590
Polaris SLX – 8994690
Polaris Pro 785 – 8994978


Chapter 1 – General Information
Chapter 2 – Maintenance / Tune Up
Chapter 3 – Fuel System / Carburetion
Chapter 4 – Engine / Cooling
Chapter 5 – Final Drive / Jet Pump / Bilge System
Chapter 6 – Hull / Deck, Steering and Controls
Chapter 7 – Electrical
Index A-W


File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9915085
Total Pages : 347

This polaris watercraft manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.

This polaris service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Cover 1999 Service Manual 9915085
Chapter 1 – General Information
Publication Numbers/Paint Codes
Service Bulletin Index By Model
Model Identification
Model Specifications
1999 SLH
1999 SLTH
1999 SLX
1999 SLTX
1999 Pro 785
Standard Torque Specifications
Glossary Of Terms
Service Tips
Chapter 2 – Maintenance / Tune Up
Periodic Maintenance Schedule
Recommended Lubricants
Throttle Cable And Choke Cable
Steering Cable
Steering Nozzle Pivot
Reverse Cable
Steering (Handlebar) Pivot Shaft
Seat Latch And Hooks
Throttle and Choke Shaft
Carburetor and Oil Injection Pump
Drive Shaft Lubrication
Solid Coupler
Bonded Rubber Coupler
Through-Hull Bearing Housing
Electrical Connections
Terminal Board
Battery Safety
Battery Removal
Battery Connections
Battery Charging
Battery Installation
Battery Storage
Circuit Breaker
Engine Mounts
Compression Test
Spark Plugs
Ignition Timing Specifications
Degrees to Piston Position Conversion Chart
Cylinder Head Re-Torque
Cylinder Base Gasket Re-Torque
Exhaust Manifold
Exhaust Cooling Orifice/Screen Cleaning
Engine – Pro 785 cooling diagram
Thermostat/Pop Off Valve Cleaning
Idle Speed
Throttle Lever Freeplay
Oil Filter
Oil Pump Adjustment – Pro 785
Oil Pump Adjustment – Polaris domestic Engines
Throttle Cable Inspection/Adjustment
Choke Cable Inspection/Adjustment
Steering Cable Inspection
Steering Cable Adjustment
Reverse Cable Adjustment
Carb Air Intake – Vortex™ Style
Carb Air Intake – Single Element
Fuel System
Fuel/Water Separator
Fuel Lines/Vent Lines
Fuel Filter
Carburetor Adjustments
Idle Speed
Manual Carburetor Synchronization
Cooling System Maintenance/Storage
Cooling System Flushing and Salt Water Maintenance
Flushing Procedure
Off Season Storage Procedures
Engine Draining
Fuel System Storage
Engine Fogging Procedure
Engine Fogging – Vortex™ Air Intake
Engine Fogging Procedure – Standard Air Intake
Fire Extinguisher
Bilge Siphon System
Bilge Drain Plug
Electric Trim Adjustment
Models with Multi-Function Display (MFD)
Submerged Engine (Hydrolocked)
Jet Pump/Impeller
Cooling Water Pickup Screen
Scoop/Ride Plate/Intake Grate
Impeller Clearance
Jet Pump Housing Inspection
Sacrificial Anode
Handlebars/Hand Grips
Seat Seal Inspection/Seat Adjustment
Seat Adjustment – SL Models
Seat Adjustment – SLT Models
Storage Compartment Door Adjustment
Lean Condition
Poor Performance
Rich Fuel Mixture
Piston Damage
Engine Overheating/Misc.
Troubleshooting – Electrical/Final Drive
Vibration / Jet Pump
Chapter 3 – Fuel System / Carburetion
Carburetor Specifications and Initial Settings
1999 SLH
1999 SLTH
1999 SLTX
1999 SLX
1999 Pro 785
Carburetor Jet Part Numbers
High Elevation Recommendations
Vent/Fuel Delivery Exploded View
1999 SLH / SLTH
1999 SLX / SLTX
1999 Pro 785
Fuel Tank/Fuel Pickup Exploded View
1998 SLH / SLX
1999 SLTH / SLTX
1999 Pro 785
Air Intake Silencer
1999 SLH
1999 SLTH
1999 SLX / SLTX
1999 Pro 785
Carburetor Assembly Exploded View
Keihin Carburetor -1999 SLH / SLTH
Keihin Carburetor – 1999 SLX / SLTX
Mikuni Carburetor -1999 Pro 785
Oil Tank Exploded View
1999 SLH / SLX
1999 SLTH / SLTX
1999 Pro 785
Fuel Line Connections – Keihin
System Operation – Mikuni Carburetor
System Operation – Mikuni Carburetor
System Operation – Keihin Carburetor
Keihin CDK II Carburetor
Fuel Shut Off Valve Disassembly and Inspection
Fuel Filter
Fuel Shut Off Valve Disassembly and Inspection -Typical
Fuel / Water Separator
Carburetor Adjustment and Service – Mikuni
Carburetor Synchronization
Carburetor Synchronization – Pro 785
Manual Carb Synchronization – Mikuni
Carburetor Adjustment and Service – Pro 785 (Mikuni)
Carburetor Mixture Screw Adjustment
Low Speed Mixture Screw Adjustment (Mikuni and Keihin)
Pro 785 Carburetor Removal
Carburetor Disassembly – Mikuni
Carburetor Assembly – Mikuni
Choke Plate Centering
Carburetor Removal – Keihin
Carburetor Disassembly/Inspection – Keihin
Carburetor Assembly – Keihin
Carburetor Installation – Keihin
Carburetor Adjustment and Service – Keihin
Cable Adjustment
Throttle Cable
Choke Cable
Oil Pump Cable
Mixture Screw Settings – Keihin
Mixture Screw Adjustment – Base Setting
Mixture Screw Adjustment – Tuning
High Speed Mixture Screw
Fuel Tank Vent System
Relief Valve Testing
Fuel Tank Check Valve Testing
Fuel Pump Operation
Fuel Pump Operation, Keihin
Fuel Pump Maintenance
Reed Valve Removal
Reed Valve Inspection
Reed Valve Assembly – Keihin Carburetor
Fuel Line Air Leak Testing
Oil Check Valve Testing
Accelerator Pump Testing
Chapter 4 – Engine / Cooling
Engine Specifications
Torque Chart – Engine Fasteners
Torque Patterns – Fuji Engine
Torque Patterns/Intake Manifold & Exhaust Manifold – Pro 785
Torque Patterns – Polaris Domestic Engine
Engine and Mount Assembly
700 Marine Engine
1050 Marine Engine
Pro 785
Cylinder and Manifold
700 Marine Engine
1050 Marine Engine
Pro 785
700 Marine Engine
1050 Marine Engine
Pro 785
700 Marine Engine
1050 Marine Engine
Pro 785
Oil Pump Assembly Exploded View
700 /1050 Marine Engines
Pro 785
Exhaust Valve Inspection/Cleaning/Adjustment – Pro 785
Exhaust Valve Operation
Exhaust Valve Cleaning Procedure – Pro 785
Engine Removal – Polaris domestic Engines
Disassembly/Inspection – Polaris Engines
Assembly – Polaris Engines
Engine Installation – Polaris Engines
Cylinder Honing
Port Chamfering
Exhaust Port Chamfering – 1050cc Engines
Engine Removal Pro 785
Disassembly / Inspection – Pro 785 Engine
Assembly – Pro 785
Engine Installation – Pro 785
Cylinder Honing – Pro 785
Oil Pump – Pro 785 (Fuji)
Oil Pump Bleeding
Oil Pump Bushing End Play Adjustment
Cooling System Flow Chart
700 Marine Engine
1050 Marine Engine
Cooling System Flow Chart – Pro 785
Thermostat Pop Off Assembly
Thermostat and Coolant Filter – Polaris Engines
Crankshaft Indexing
Dial Caiiper Crankshaft Indexing (Three Cylinder Engines Only)
Chapter 5 – Final Drive / Jet Pump / Bilge System
Final Drive Jet Pump Torque Values
1999 Jet Pump Data
Impeller Part Numbers
High Elevation Recommendations
All Models Except Pro 785
Pro 785
Jet Pump Assembly – Exploded View
Pro 785
Jet Pump Intake
Pro 785
Intake Scoop / Ride Plate Installation and Sealing, All Models
Jet Pump Removal
Impeller Clearance
Jet Pump Disassembly/Inspection
Drive Shaft Inspection
Jet Pump Assembly
Jet Pump Installation
Jet Pump Housing Removal
Intake Scoop / Ride Plate Installation and Sealing
Jet Pump Housing Installation
Jet Pump Alignment Inspection
Engine Alignment Inspection
Jet Pump Stud Installation
Jet Pump-To-Hull Alignment Inspection
Driveshaft Lubrication (All Models)
Driveshaft Coupler/ Bearing Housing Lubrication
Through-Hull Bearing Housing Removal/Inspection
Driveshaft Coupler Removal
Sacrificial Anode
Jet Pump Ventilation/Cavitation Diagnostics
Chapter 6 – Hull / Deck, Steering and Controls
Seat Assembly
Pro 785
Decal Replacement
Pro 785
Front Compartment Assembly
Deck Assembly
Pro 785
Steering Assembly
SLTH / SLTX / Pro 785
Steering Cover/Steering Post
Steering Cable Replacement
Steering Cable Adjustment
Speedometer Operation and Inspection
Steering Cover/Steering Post (Handlebar) Removal
SLTH / SLTX / Pro 785
SMC Hull Repair
RTM Surface Repair Process
FRC Fiberglass Repair
Sponsor) Removal / Installation
Chapter 7 – Electrical
Spark Plugs / Alternator
Alternate Spark Plugs
CDI Box Identification
Warning Systems Operating Characteristics
Stator Plate Assembly And Ignition System Test Specifications
1999 Pro 785 (Fuji Engine)
1999 Polaris Engines
Ignition System
700 Marine Engine
1050 Marine Engine
Pro 785
Electrical Box
Pro 785
Charging System
Electrical Testing
Charging System Testing (Unregulated Voltage)
Charging System Testing (Regulated Voltage)
Start Switch Testing
Engine Stop Switch Testing
Battery Testing
Battery Maintenance
Off-season Storage
Charging Procedure
Starter Motor
Starter Solenoid Bench Test
Starter Motor Disassembly
Brush Inspection
Brush Replacement
Armature Testing
Starter Assembly
Electric Starter System Testing
Temperature Warning
Coolant Temperature Warning Circuit Operation
Temperature Warning Circuit Test
Temperature Sensor Test
Fuel Sender Operation and Sender Testing
RPM Limiter Circuits
RPM Limiter Function
RPM Limiter System Troubleshooting
Exhaust Valve Motor Assembly
Exhaust Valve Electrical Control System Troubleshooting
RPM Limiter / Ignition Timing Retard Troubleshooting
Oil Level Sensor Troubleshooting
Polaris Electric Quick Trim System Operation
Polaris Quick Trim System Maintenance
Motor Operation Check
Ignition Timing Chart
Ignition System
Ignition System Testing
Ignition System Testing – 785 Fuji Engine
Condition: No Spark
PVL Ignition Troubleshooting (700 and 1050 Engines)
Ignition Coils – Polaris domestic engine
To Determine Wire Sequence
PVL Ignition Troubleshooting (700 and 1050 Engines)
Trigger Coil (Hall Effect Sensor) Testing -Polaris Engines
Alternate Method Of Testing Hall Effect Sensors – Polaris Engines
Ignition Timing Adjustment – Fuji
Ignition Timing Adjustment
Dynamic (Running) Ignition Timing – Polaris Engines
Ignition Timing Adjustment
Static Ignition Timing Adjustment
Multi-Function Display
MFD Troubleshooting
Weatherproof Connector Servicing – Pro 785 Fuji Engine
Bilge Pump
Wiring Diagrams
1999 SLH / SLTH Wiring Diagram
1999 SLX Wiring Schematic
1999 SLTX Wiring Schematic
1999 Pro 785 Wiring Diagram
Index A-W
Back Cover 9915085


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Polaris SLH, SLTH, SLX, SLTX, PRO 785 PWC Repair Service Manual 1999.pdf

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