Polaris Personal Watercraft (PWC) Repair Service Manual 1992-1998

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This workshop service repair manual PDF download for the 1992-1998 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.

APPLICABLE MODELS :

1992 SL650 B924058
1993 SL650 B934058
1993 SL750 B934070
1994 SL650 B944058
1994 SL750 B944070
1994 SLT750 B944170
1995 SL650 B954058 (1954058)
1995 SL650 STD B954358 (1954358)
1995 SL750 B954070 (1954070)
1995 SLT750 B954170 (1954170)
1995 SLX780 B954287 (I954287)
1996 SL700 B964066 (1964066)
1996 SLT700 B964166 (1964166)
1996 Hurricane B964466 (I964466)
1996 SL780 B964087 (1964087)
1996 SLX780 B964287 (I964287)
1996 SLT780 B964588 (I964588)
1996 SL900 B964291 (1964291)
1996 SLTX B964590 (I964590)
1997 SL700 B974071
1997 SL700 Deluxe B974072
1997 SLT700 B974572
1997 Hurricane B974473
1997 SL780 B974088
1997 SLT780 B974588
1997 SL900 B974091
1997 SL 1050 B974090
1997 SLTX B974590
1998 SLH B984673
1998 SLTH B984573
1998 SLXH B984690
1998 SLTX B984590

TABLE OF CONTENTS :

1992-1998 Personal Watercraft Service Manual
CHAPTER 1 GENERAL INFORMATION
CHAPTER 2 MAINTENANCE/TUNE UP
CHAPTER 3 FUEL SYSTEM/CARBURETION
CHAPTER 4 ENGINE/COOLING
CHAPTER 5 FINAL DRIVE/JET PUMP
CHAPTER 6 HULL/DECK, STEERING AND CONTROLS
CHAPTER 7 ELECTRICAL
Wiring Diagrams
Index for 1992-1998 (except Pro 785)

1997-1998 SERVICE MANUAL SUPPLEMENT for SLX Pro785
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, STEERINGAND CONTROLS
CHAPTER 7 ELECTRICAL

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9912201
Total Pages : 582

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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1992-1998 Personal Watercraft Service Manual (PN 9912201)
1997-1998 SERVICE MANUAL SUPPLEMENT for SLX Pro785
CHAPTER 1 GENERAL INFORMATION

Watercraft Publication Part Numbers
Service Bulletin Index
Service/Information Bulletins -1992
Service/Information Bulletins -1993
Service/Information Bulletins -1994
Service/Information Bulletins -1995
Service/Information Bulletins -1995 (Cont.)
Service/Information Bulletins -1996
Service Bulletins -1997
Service Bulletins -1998
1996 PWC Bulletin Index By Model
1997 PWC Bulletin Index By Model
1998 PWC Bulletin Index By Model
Paint Codes
2-Part Structural Adhesive – For repair of SMC hulls and decks
Model Identification
Identification Numbers
Model Specifications
1992, 1993
1994
1995
1996
1997
1998

Standard Torque Specifications
Decimal Equivalents
Conversion Table
Tap Drill Charts
Glossary Of Terms
Special Tools
Service Tips
Warranty Policy
CHAPTER 2 MAINTENANCE/TUNE UP
Periodic Maintenance Schedule
Recommended Lubricants
Maintenance Products
Lubrication
Throttle Cable And Choke Cable
Choke Knob
Steering Cable
Steering Nozzle Pivot
Steering (Handlebar) Pivot Shaft
Seat Latch And Hooks
Throttle and Choke Shaft
Steering Nozzle Pivot
Carburetor and Oil Injection Pump
Drive Shaft Lubrication
Models With Bonded Rubber Coupler (1996-Current)
Bearing Housing
Electrical
Electrical Connections
Terminal Board, Typical
Handlebar Switch Tightening Sequence
Circuit Breaker
Battery

Battery Safety
Battery Removal
Battery Connections
Battery Charging
Battery Installation
Battery Storage
Engine Mounts
Compression Test
Spark Plugs
Ignition Timing Specifications and Degrees to Piston Position Conversion Chart
Cylinder Head Re-Torque (Fuji)
Cylinder Base Gasket Re-Torque
Exhaust Manifold
Exhaust Cooling Orifice/Screen Cleaning
Thermostat/Pop Off Valve Cleaning
Idle Speed
Throttle Lever Freeplay
Oil Filter
Oil Pump Adjustment – Fuji Engines
Oil Pump Adjustment – Polaris Engines
Throttle Cable Inspection/Adjustment
Choke Cable Inspection
Choke Cable Adjustment
Steering Cable Adjustment
Reverse Cable Adjustment
Fuel System
Carb Air Intake – Vortex™ Style
Carb Air Intake – Single Element
Fuel/Water Separator
Fuel Lines/Vent Lines
Fuel Filter
Carburetor Adjustments
Idle Speed
Carburetor Synchronization – Manometer
Manual Carburetor Synchronization
Cooling System Flushing and Salt Water Maintenance
Flushing Procedure
Flushing Procedure 1992 Models
Flushing Procedure 1993 Models
1994 to Current Models
External Engine Corrosion Prevention
Storage
Off Season Storage Procedures
Engine Draining 1992-1993
Freezing Temperature Procedure1992-1993 Models
Engine Draining 1994 to Current
Fuel System Storage
Engine Fogging Procedure
1992-1995 (Except SLX780)
Engine Fogging – SLX780 / Hurricane
Engine Fogging Procedure SL700, SLTH, SLT700, SLT780, SL780, SL900 SL1050,SLXH,SLTX
Cleaning
Fire Extinguisher
Bilge Siphon System
Bilge Drain Plug
Electric Trim Adjustment
Trim Linkage Adjustment
1993-1994 Mechanical Trim Indicator
1995 – Current Models with Multi-Function Display (MFD)
Submerged Engine (Hydrolocked)
Pump/Impeller
Cooling Water Pickup Screen (1995 Models)
Fasteners
Scoop/Ride Plate/Intake Grate
Impeller Clearance
Pump Housing Inspection
Hull/Deck
Sacrificial Anode
Handlebars/Hand Grips
Fasteners/Parts/Hoses
Seat Seal Inspection/Seat Adjustment
Seat Adjustment – SL and SLX Models
Seat Adjustment – SLT Models
Storage Compartment Door Adjustment
Compartment Door Alignment – SLT Models
Compartment Door Latch Adjustment – SLT Models
Compartment Door Alignment – SL and SLX Models
Door Latch Adjustment
1992-1993 Models
1994-1995 Models
Hull Extension Adjustment (Hurricane)
Troubleshooting
Lean Condition
Poor Performance
Rich Fuel Mixture
Piston Damage
Engine Overheating/Misc.
Electrical
Vibration / Pump
Hydrolock
CHAPTER 3 FUEL SYSTEM/CARBURETION
Carburetor Specifications and Initial Settings
1992 SL650
1993 SL65O
1993 SL750

1994 SL650
1994 SL650
1994 SL750/SLT750
1994 SL750/SLT750
1995 SL650/SL650 STD
1995 SL650/SL650 STD
1995 SL750/SLT750
1995 SLX780
1996 SL700/SLT700
1996 Hurricane
1996 SL780, SLT 780
1996 SLX780
1996 SL900
1996 SLTX
1997 SL/SLT700/SL700Deluxe
1997 Hurricane
1997 SL780/SLT780
1997 SL900
1997 SL1050/SLTX
1998 SLH/SLTH
1998 SLXH/SLTX
Carburetor Jet Part Numbers
Keihin Carburetor Jet Part Numbers
Mikuni Carburetor Jet Part Numbers
High Elevation Recommendations
1998 Model High Elevation Recommendations
Vent/Fuel Delivery Exploded View
1992-1993 Models
1994 SL650, SL750
1994 SLT750
1995 SL650, SL650 STD, SL750 (Early Production)
1995 SL650, SL650 STD, SL750 (Late Production)
1995 SLT750
1995 SLX780
1996 SL700/SL700 Deluxe/SLT700
1997 SLT 700
1996 -1997 SL780, SLX780
1997 SL 700/SL 700 Deluxe
1998 SL/SLTH
1996 SLTX
1996 SL900
1997 SLTX / SL1050 / SL 900
1998 SLXH/SLTX
Fuel Tank/Fuel Pickup Exploded View
1992-1994 SL650,1995 SL650 STD
1995 SL650
1993-1994 SL750
1995 SL750
1994 SLT750 and Early Production 1995 SLT750
1995 SLT750 (Late Production)
1995 SLX780
1996 SL700
1996 SLT700
1997 SL700 / SL 700 Deluxe
1998 SLH
1997 SLT 700/1998 SLTH
1997 SL 780 / SL 900 / SL 1050
1998 SLXH
1996/1997 Hurricane
1996 SL780, SLX780, SL900
1996 to Current SLTX
Air Intake Silencer and Water Separator
1992-1994 SL650.SL750
1995 SL650, SL650 STD, SL750
1994-1995 SLT750
1995 -1996 SLX780 /1998 SLH
1996 SL700,1996 -1997 SLT700,1997 SL700 Deluxe /1998 SLTH
1997 SL700
1996-1997 Hurricane
1996 -1997 SL780 / SLT780
1996 to Current SLTX
1996 – 1997 SL900, SL1050 / 1998 SLXH
Carburetor Assembly Exploded View
1992-1993 Models
1994-1995 Models (Except SLX780)
1995 SLX780
1996 -1997 SL700 and SL700 Deluxe, SLT700, Hurricane /1998 SLH, SLTH
SL700 – (Single) 40mm Carburetor
1996 SL780, SLT780, SLX780
1996-1997 SL900, SL1050, SLTX
Oil Tank Removal/Exploded View
1992-1995 SL650,SL750
Oil Tank Removal Procedure
1994-1995 SLT750,1996 SLT700
1996 SL700, SL780, SLX780, SL900
1996 Hurricane
1996 SLT780, SLTX
1995 SL650, SL750, SLT750,1996 SL780, SLT780, SLX780
Oil Pump Assembly Exploded View
1996 to Current SL700, SLT700, Hurricane, SL900, SL1050, SLTX
Fuel Line Connections – Keihin
1996 SLTX

1996 / 1997 SL900, 1997 SL1050, 1997 SLTX, 1998 SLXH/SLTX

System Operation – Mikuni Carburetor
Carburetor System Operation, 1992 to 1998
Pop Off Pressure
Needle Valve/Diaphragm Operation
Testing Needle and Seat Pop Off Pressure
System Operation – Keihin Carburetor
Air Metering System
Inlet Needle Valve System/Fuel Chamber
Idle (Slow) System
Mid-Range System
High Speed System
Keihin CDK II Carburetor diagram

Fuel Pump Operation
Fuel Pump Operation, 1992 to 1998 650 and 750 Fuji Engines Only
Fuel Pump Operation, 1995 SLX780 1996 SL780, SLT780
Fuel Shut Off Valve Disassembly and Inspection
Fuel Filter
Fuel Water Separator
Carburetor Adjustment and Service – Mikuni
Carburetor Synchronization
Manual Carburetor Synchronization
Carburetor Adjustment and Service – All
Carburetor Mixture Screw Adjustment
Low Speed Mixture Screw Adjustment (Mikuni and Keihin)
1992-1994 Carburetor Removal
1995 to 1998 650, 750 and 780 Carburetor Removal
Carburetor Disassembly – Mikuni
Carburetor Assembly – Mikuni
Choke Plate Centering
Carburetor Removal – Keihin
Carburetor Disassembly/Inspection – Keihin
Cleaning
Carburetor Assembly – Keihin
Carburetor Installation – Keihin
Carburetor Adjustment and Service – Keihin
Carburetor Synchronization – Twin Cylinder Models
Carburetor Synchronization – Three Cylinder Models
Cable Adjustment
Throttle Cable
Choke Cable
Oil Pump Cable
Mixture Screw Settings
Idle Speed
Mixture Screw Adjustment – Base Setting
Mixture Screw Adjustment – Tuning
Fuel Tank Vent System
1992-1993 Models
1994 Models
1995 Models (And 1994 Models with PN 2200620 Vent Kit Installed)
Fuel Tank Vent Line Routing
1994 SL650, SL750 Pressure Relief Valve Location(With Vent Kit PN 2200620 Installed)
1994 SLT (With Vent Kit PN 2200620 Installed)
1995SLT
SLT Models
SL Models
Fuel Tank Check Valve Testing
Fuel Pump Operation, SL700, SLT700, Hurricane, SL900, SLTX
Fuel Pump Maintenance, SL700, SLT700, Hurricane, SL900, SLTX
Disassembly/Inspection
Reed Valve Removal – Mikuni Carburetor
Reed Valve Removal, 1992-1993 Models
1994 to Present
Reed Valve Inspection – Mikuni Carburetor
Reed Cage and Intake Manifold Installation – Mikuni Carburetor
1992-1993 Models
1994 to Present
Reed Valve Removal/Inspection – Keihin Carburetor
Inspection
Reed Valve Assembly – Keihin Carburetor
Testing
Fuel Line Air Leak Testing
Oil Check Valve Testing
Accelerator Pump Testing
CHAPTER 4 ENGINE/COOLING
Engine Specifications
1992 SL650
1993 SL650
1993 SL750
1994 SL650
1994 SL750&SLT750
1995 SL650&SL650STD
1995 SL750 & SLT750
1995 SLX780
1996 SL700, SLT700
1996 Hurricane
1996 SL780
1996 SLT780
1996 SLX780
1996 SL900
1996 SLTX
1997 SL700
1997 SL700 Deluxe, SLT700
1997 Hurricane
1997 SL780, SLT780
1997 SL900
1997 SL1050
1997 SLTX
1998 SLH, SLTH
1998 SLXH, SLTX
Specific Torque Chart
Torque Chart – Engine Fasteners
Torque Patterns-Fuji Engine
Torque Patterns – Polaris Domestic Engine
Engine and Mount Assembly
1992-1993 SL 650, SL750 Models
1994-1995 Models (Except SLX780)
1995 SLX780,1996 to Current SL, SLT, SLX780
1996 to Current SL700, SLT700, Hurricane
1996 to Current SL900, SL1050, SLTX
Cylinder and Manifold
1992-1993 SL 650, SL750 Models
1994-1995 Models (Except SLX780)
1995 SLX780,1996 SL780, SLX780
1996 to Current SL700, SL 700 Deluxe, SLT700, Hurricane
1996 to Current SL900, SL1050, SLTX
Crankshaft/Piston
1992 -1993 SL650, SL750 Models
1994 -1995 SL650, SL750 Models (Except SLX780)
1994 -1995 All Models, 1996 SL780, SLT780, SLX780
1996 to Current SL700, SL700 Deluxe, SLT700, Hurricane
1996 to Current SL900, SL1050, SLTX
Crankcase
1992 -1993 SL650, SL750 Models
1994 -1995 Models (Except SLX780)
1995 SLX780,1996 to Current SL780, SLT780, SLX780
1996 to Current SL700, SL700 Deluxe, SLT700, Hurricane
1996 to Current SL900, SL1050, SLTX
Oil Pump
1992-1994 Models
1995 SL650, SL750, SLT750,1996 to Current SL780, SLT780, SLX780
Oil Pump Assembly Exploded View
1996 to Current SL700, SL700 Deluxe, SLT700, Hurricane, SL900, SLTX
Engine Removal – Fuji
Disassembly / Inspection – Fuji
1992-1995 (Except SLX780)
Assembly – Fuji
Reed Valve and Intake Manifold Installation
1992-1993 Models
1994 to Present
Oil Pump Installation
Engine Installation
Disassembly / Inspection – 780cc Models
Reed Valve Inspection
Cylinder Measurement
Piston Pin / Needle Bearing Inspection
Connecting Rod Small End Inspection
Piston Ring Installed Gap
Flywheel Inspection
Crankshaft Bearing Inspection
Crankshaft Truing
Crankshaft Installation
Cylinder Installation
Flywheel Installation
Engine Removal – Polaris Domestic

Piston Pin / Needle Bearing Inspection
Connecting Rod Small End Inspection
Piston Inspection/Measurement
Crankshaft Main Bearing Inspection
Connecting Rod (Big End)
Assembly – Polaris Domestic Engine

Cylinder Installation
Engine Installation – Polaris
Cylinder Honing
Exhaust Port Chamfering
Exhaust Port Chamfering – 1050cc Engines
Oil Pump – Fuji
Oil Pump Bleeding
Troubleshooting
Oil Pump Bushing End Play Adjustment
Cooling System Flow Chart
1992 SL650 (After Reverse Flow Cooling Kit)
1993 SL650 and SL 750(1992 with Kit PN 2200475 Similar)
1994 -1995 SL650, SL750, SLT750, SLX780 and all 1996 to Current 780 models
1996 to Current SL700, SL700 Deluxe, SLT700, Hurricane
1996 to Current SL900,1996 SLTX
1997 SLTX, 1997 SL1050
Thermostat and Coolant Filter – All Engines
Thermostat Pop Off Assembly-All Models
Exhaust Coolant Filter – Fuji Engines
Exhaust Coolant Filter – Polaris Engines
Cleaning Procedure
Crankshaft Indexing
Dial Caliper Crankshaft Indexing (Three Cylinder Engines Only)
CHAPTER 5 FINAL DRIVE/JET PUMP
Jet Pump
Final Drive Jet Pump Torque Values
Pump Service Special Tools
1996 Jet Pump Data

1997 Jet Pump Data

1998 Jet Pump Data

Impeller Specifications
Impeller Part Numbers
High Elevation Recommendations
Driveshaft/Coupler
1992-1995 All Models
1996-Current (All Models)
Jet Pump Assembly
1992-1993 Models
1994-1995 Models (Except 1995 SLX)
1995 SLX780
1996 to Current SL700, SLT700, Hurricane
1996 to Current SL780
1996 to Current SLX, SLT780, SL900, SL1050, SLTX
Jet Pump Removal (1992-1993 Models)
Jet Pump Disassembly/Inspection (1992-1993 Models)
Drive Shaft Inspection (1992-1993 Models)
Jet Pump Assembly (1992-1993 Models)
Jet Pump Installation (1992-1993 Models)
Intake Scoop / Ride Plate Installation and Sealing, All Models
Jet Pump Removal -1994 to Current Models
Impeller Clearance
Jet Pump Removal
Pump Disassembly/Inspection -1994 to Current Models
Drive Shaft Inspection
Jet Pump Assembly (1994 to Current)
Jet Pump Installation (1994 to Current Models)

Jet Pump Housing Removal (1994 to Current Models)
Intake Scoop / Ride Plate Installation and Sealing
Jet Pump Housing Installation (1994 to Current)
Jet Pump Drive Shaft Alignment (All Models)
Jet Pump Alignment Inspection Procedure
Engine Alignment Inspection (Vertical)
Pump-To-Hull Alignment Inspection
Jet Pump Stud Installation
Driveshaft Lubrication (All Models)
Driveshaft Coupler / Bearing Housing Lubrication
Bearing Housing Removal/Inspection
Driveshaft Coupler Removal
Sacrificial Anode
Ventilation/Cavitation Diagnostics
Ventilation
Cavitation
Jet Pump Intake
1992 -1995 Models (Except SLX780)
1995 SLX780
1996 to Current – All Models Except Hurricane and SLX
1996 to Current Hurricane, 1996 SLX
CHAPTER 6 HULL/DECK, STEERING AND CONTROLS
Seat Assembly
1992-1995 SL650, SL650 STD, SL750,1996 to Current SL700, SL780
1994/1995 SLT750,1996 to Current SLT Models
1996 to Current SL900 Models
1996 to Current Hurricane
1997-1998 SLTX / SLH Models
1998 SLXH
Steering Assembly
1992 -1994 SL650, SL750 Models
1994 -1995 SLT750 Models
1995 SL650, SL750, SLX780 Models
1996 to Current SL700 / SL700 DIx
1996 to Current Hurricane
1996 to Current SLT700
1996 SLX780,1996 to Current SL780, SL900, SL1050
1996 to Current SLTX, SLT780
Deck Assembly
1992SL650
1993-1994 SL650.SL750
1995 SL650, SL750, SLX780
1994-1995 SLT750
1994-1995 SLT750
1996 to Current SL700, SL700 Dlx, SL900
1996 to Current SLTX, SLT780
1996 to Current Hurricane
Front Compartment Assembly
1992 to Current SL650, SL750, SLX780,1996 to Current SL Models
1994-1995 SLT750,1996 to Current SLT Models
1996 to Current Hurricane
Steering Cover/Steering Post
Steering Cover/Steering Post (Handlebar) Removal
SL Models
SLT Models
Hurricane Handlebar Replacement Procedure
Installation
Hand Grip Replacement – All Models
Steering Cable Replacement
Steering Cable Adjustment
Alternate Method Of Measuring Nozzle
Adjustment Procedure
Speedometer Operation and Inspection
Dash/Control Panel
Decal Replacement
Hull Repair
SMC Hull Repair (All Except 1994-1995 SLT and 1996 SLT700 Models)
1995 SL650 STD Hull Repair
Fiberglass Repair – SLT750,1996 SLT700
Trim Repair
Sponson Removal/Installation
Threaded Through-Hull Fitting (1995 SLX780and SL650 Std.)
CHAPTER 7 ELECTRICAL
Specifications
Spark Plugs / Alternator
CDI Box Identification
Warning Systems Operating Characteristics
Stator Plate Assembly And Ignition System Test Specifications
Fuji Engines
Polaris Engines
Ignition System-Exploded View
1992/1993 -All Models
1994-1995 All Models, 1996 SL780, SLX780
1996 to Current SL700, SL700 Dlx, SLT 700, Hurricane
1996 to Current SL900,SLTX, SL1050
Electrical Box
1992/1993 -SL650.SL750
1994/1995 SL650
1994/1995 SL750.SLT750
1995SLX780
1996 SL700, SLT700, Hurricane
1996 to Current SL780, SLT780, SLX780
1996 to Current SL900, SLTX
Charging System
Electrical Testing
Charging System Testing (Unregulated Voltage)
Charging System Testing (Regulated Voltage)
Start Switch Testing
Engine Stop Switch Testing
Battery Testing
OCV – Open Circuit Voltage Test
Load Test
Battery Maintenance
Off-season Storage
Charging Procedure
Starter Motor
Starter Motor Disassembly
Brush Inspection
Brush Replacement
Cleaning
Armature Testing
Starter Assembly
Starter Solenoid Bench Test
Electric Starter System Testing
Temperature Warning
Coolant Temperature Warning Circuit Operation
Temperature Warning Circuit Test
Temperature Sensor Test
Fuel Gauge
Fuel Gauge Operation and Sender Testing
Fuel Gauge Testing (Analog Gauge)
RPM Limiter/ Ignition Timing Retard Circuit
RPM Limiter Function (1995 SLX780,1996 SL780, SLT780, SLX780)
Ignition Timing Retard Circuit (1996 SL900, SLTX)
RPM Limiter Function (1997 SL780, SLT780, SLTX, SL1050)
RPM Limiter System Troubleshooting
1995 SLX780T1996 SL780. SLT780. SLX780 – Limits to 4200 RPM
1996 SL900 and SLTX – Retards ignition timing to 8° BTDC
1997 SL780, SLT780 (Limits to 4200 RPM)
1997/98 SL1050, SLTX, SLXH (Limits to 4500 RPM)
Oil Level Sensor Testing
All models with buzzer
Oil Level Sensor Troubleshooting – Models with Multi-Function Display (MFD)
Quick Trim
Polaris Electric Quick Trim System Operation
Trim Motor Operation Check
Indicator Cable Replacement – Non-MFD Models
Ignition Timing Chart
Fuji Engines
Polaris Engines
Ignition System Testing
Ignition System Testing – Fuji Engines
No Spark
PVL Ignition Troubleshooting (700, 900,1050 Engines)
Ignition Coil Identification
900/1050cc Ignition Coils
To Determine Wire Sequence
Trigger Coil Testing
Trigger Coil (Hall Effect Sensor) Testing -Polaris Engines
Alternate Method Of Testing Hall Effect Sensors – Polaris Engines
Ignition Timing Adjustment – Fuji
Ignition Timing Adjustment – Polaris
Dynamic (Running) Ignition Timing – Polaris Engines
Ignition Timing Adjustment
Static Ignition Timing Adjustment
Multi-Function Display
Operation and Modes

MFD Troubleshooting
Electrical Connector Service

Weatherproof Connector Servicing – Fuji Engines
LR Electronic Module Function
Terminal Board, Typical
Bilge Pump
Wiring Diagrams
1992 SL650
1993 SL650
1993 SL750
1994 SL650
1994 SL750
1994 SLT750
1995 SL650
1995 SL650 STD
1995 SL750
1995 SLT750
1995 SLX780
1996 SL700
1996 SLT700
1996 Hurricane
1996 SL780, SLT780, SLX780
1996 SL900
1996 SLTX
1997 SL700
1997 SLT700, SL700 Deluxe
1997 Hurricane
1997 SL780, SLT780
1997 SL900
1997 SL1050, SLTX
1998 SLH, SLTH
1998 SLXH, SLTX

Index for 1992-1998 (except Pro 785)

1997-1998 SERVICE MANUAL SUPPLEMENT for SLX Pro785
Chapter 1 GENERAL INFORMATION

Watercraft Publication Part Numbers
Paint Codes
Model Specifications
Standard Torque Specifications
CHAPTER 2 MAINTENANCE/TUNE UP
Periodic Maintenance Schedule
Recommended Lubricants
Maintenance Products
Drive Shaft Lubrication (The SLX Pro785 Uses a Solid Coupler)
Bearing Housing
Ignition Timing Specifications
Spark Plugs
Engine
Cylinder Head
Exhaust Manifold
Idle Speed
Oil Pump Adjustment
Carb Air Intake
Exhaust Valve Inspection/Cleaning/Adjustment
Exhaust Valve Operation
Exhaust Valve Cleaning Procedure
Cooling System Flushing and Salt Water Maintenance
Flushing Procedure
External Engine Corrosion Prevention
Cleaning
Fire Extinguisher
Off Season Storage Procedures
Freezing Temperature Procedure
Fuel System Storage
Engine Fogging Procedure
Adjusting Trim Display for the Multi-Function Display (MFD)
Submerged Engine (Hydrolocked)
Sacrificial Anode
Hull/Deck
Handlebars/Hand Grips
Seat Adjustment
Compartment Door Alignment
CHAPTER 3 FUEL SYSTEM/CARBURETION
Carburetor Specifications and Initial Settings
1997 SLX PRO 785
1998 SLX PRO 785
Fuel Delivery Exploded View
Vent/Fuel Delivery Exploded View
Fuel Tank/Fuel Pickup Exploded View
Air Intake Silencer and Water Separator
Carburetor Exploded View
Carburetor Parts Description
Oil Tank Exploded View
Fuel Pump Operation
CHAPTER 4 ENGINE/COOLING
Service Data
1997/1998 SLX PRO 785
Torque Chart – Engine Fasteners
Torque Pattems/Crankcase & Cylinder Head
Torque Patterns/Intake Manifold & Exhaust Manifold
Engine and Mount Assembly
Cylinder.Head & Exhaust Valves
Engine Removal
Cylinder Measurement
Exhaust Valve Inspection
Connecting Rod Small End Inspection
Piston Inspection/Measurement
Piston Ring Installed Gap
Engine Installation – Fuji
Cylinder Honing
Oil Pump – Fuji
Oil Pump Bleeding
Troubleshooting
Oil Pump Bushing End Play Adjustment
Water hose routing, cleaning locations

Exhaust Cooling Hoses
1998 SLX Pro 785 Coolant Hose Restrictor
Orientation of the exhaust stinger cooling hoses

Thermostat and Coolant Filter – Fuji
Thermostat Pop Off Assembly
CHAPTER 5 FINAL DRIVE/JET PUMP/BILGE SYSTEM
Final Drive Jet Pump Torque Values
1997 /1998 SLX PRO 785 Pump Data
Jet Pump Exploded View

Jet Pump Intake

Jet Pump Removal

CHAPTER 6 HULL/DECK, STEERINGAND CONTROLS
Steering Assembly
Front Compartment Assembly
RTM Surface Repair Process
Fiberglass Repair
CHAPTER 7 ELECTRICAL
Specifications
CDI Box Identification
Stator Plate Assembly Test Specifications
Ignition System diagram
Electrical Box
Exhaust Valve Motor Assembly
Temperature Warning
Coolant Temperature Warning Circuit Operation
Temperature Warning Circuit Test
Temperature Sensor Test
RPM Limiter Circuits
RPM Limiter Function
RPM Limiter System Troubleshooting
Exhaust Valve Electrical Control System Troubleshooting
Ignition System Testing
No Spark
Ignition Timing Chart
LR-31 Electronic Module Function
Terminal Board, Typical
Pro 785 Wiring Diagrams
1997 Pro 785 Wiring Diagram
1998 Pro 785 Wiring Diagram

 

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