Polaris SLT PWC 1993 1994 Workshop Service Manual

beerdart / LRRIS I N DUSTRIES Inc. 1992 • 1998 PERSONAL WATERCRAFT SERVICE MANUAL Foreword This manual is designed primarily for use by Polaris personal watercraft service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. The technician should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary impor- tance . This manual includes procedures for disassembly and reassembly, inspection, maintenance, component identification and unit repair, along with service specifications for all 1992 - 1998 Polaris personal watercraft . A table of contents is placed at the beginning of each chapter to aid the user in locating specific areas of information. The alphabetic index at the end of the manual will help the user find specific information quickly. Care is take"n to ensure that all information in this manual was technically correct at the time of publication. How- -- ever, all materials and specifications are subject to change without notice. Comments or suggestions about this manual may be directed to: Service Publications, Supervisor, Polaris Industries Inc., 1225 Highway 169 North, Minneapolis, MN 55441-5078. Technical Training Center Minneapolis, MN 55441 1992-1998 Personal Watercraft Service Manual (PN 9912201) Printed in U.S.A.

beerdart UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols : '&'The Safety Alert Symbol means ATTENTION! BECOME ALERT' YOUR SAFETY IS INVOLVED' A DANGER Failure to follow DANGER instructions will result in severe injury or death to the operator, passen ger, bystander or person inspecting or servicing the watercraft. A WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator, passenger, bystander or person inspecting or servicing the watercraft. A CAUTION indicates special precautions that must be taken to avoid minor personal injury, or watercraft or prop- erty damage. NOTE: A NOTE provides key information to clarify instructions. Polaris acknowledges the following products mentioned in this manual: Loctite, Registered Trademark of the Loctite Corporation FLEXLOC, Registered Trademark of SPS Technologies MityVac, Registered Trademark of Neward Enterprises Torx, Trademark of Textron Teflon, Trademark of DuPont Vortex, Trademark of Ocean Pro Alemite, Trademark of Alemite Corporation SPECIAL TOOLS Special tools described in this manual may be ordered directly from the Victor Specialty Tool Company. The toll free order FAX number is 1-800-716-3938 (orders only please). Phone 716-742-1790. Address: Victor Specialty Tool Co 66 School St. Victor, NY 14564

beerdart CHAPTER 1 GENERAL 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

beerdart r Watercraft Publication Part Numbers GENERAL INFORMATION Publication Numbers Year Model Model No. Owner's Parts Book Micro- (International) Manual Fiche (Set) 1992 SL650 8924058 9912153 9912292 9913434 1993 SL650 8934058 9912443 9912473 (9913435) SL750 8934070 9912443 9912475 SLT 8934170 9912484 9912594 1994 SL650 8944058 9912645 9912699 (9913436) SL750 8944070 9912645 9912701 SLT 8944170 9912484 9912594 1995 SL650 (SL650 International) 8954058 (1954058) 9912969 9913048 (9913437) SL650 STD (SL650 STD International) 8954358 (1954358) 9912969/ 9913292 9913375' SL750 (SL750 International) 8954070 (1954070) 9912969 9913052 SLTl50 (SLTl50 International) 8954170 (1954170) 9912993 9913056 SLX780 (SLX780 International) 8954287 (1954287) 9913290 9913395 1996 SL700 (SL700 International) 8964066 (1964066) 9913562 9913563 (9913438) SLTlOO (SLTlOO International) 8964166 (1964166) 9913287 9913392 SL780 (SL780 International) 8964087 (1964087) 9913551 9913552 SL900 (SL900 International) 8964291 (1964291) 9913557 9913558 SLX780 (SLX780 International) 8964287 (1964287) 9913551 9913744 SLTl80 (SLTl80 International) 8964588 (1964588) 9913567 9913568 Hurricane (Hurricane International) 8964466 (1964466) 9913572 9913573 SLTX (SLTX International) 8964590 (1964590) 9913577 9913578 1997 SL700 8974071 9913919 9914087 (9914732) SL700 Deluxe 8974072 9913919 9914087 SLT700 8974572 9914111 9914112 Hurricane 8974473 9913926 9914104 SL780 8974088 9914091 9914092 SLTl80 8974588 9914116 9914117 SLX PRO 785 8974978 9913923 9914125 SL900 8974091 9914102 9914097 SL1050 8974090 9914096 9914097 SLTX 8974590 9914120 9914121 1998 SLH 8984673 9914731 9914516 9914517 SLTH 8984573 9914731 9914655 9914656 SLXH 8984690 9914731 9914511 9914512 SLTX 8984590 9914731 9914631 9914632 , Addendum Polaris Industries Inc. 1.1 5/98

beerdart GENERAL INFORMATION Service Bulletin Index Service/Information Bulletins· 1992 PWC-92-01 PWC-92-02 PWC-92- 03 PWC-92-04 PWC-92-05 PWC-92-06 PWC-92-07 PWC-92-08 PWC-92-09 PWC-92-10 1. Driveshaft Coupler Lubrication Interval 2. Flame Arrestor Intake Cover Sealing on Craft Before Ser. # 00097 3. Storage Cover Hinges and Insert Bolt Torque Dnveshaft Seal/Bearing Housing Oil Reservoir Tube Engine Oil Injection Line Damage SL 650 Carburetion Setup and Adjustments 1. Paint Codes and Refinishing Procedure for SL 650 2. SL 650 Cylinder Head Gasket Positioning 3. Optional Jet Pump Impeller for SL 650 SL 650 Engine Cooling System Revision SL 650 Engine Cooling System Check Valve Installation Lanyard Cord Switch Adjustment SL650 Engine Spark Plugs SL650 Engine Draining Procedures for Cold Weather Storage Service/Information Bulletins· 1993 PWC-93-01 PWC-93-02 PWC-93-03 PWC-93-04 PWC-93-05 PWC-93-06 PWC-93-07 PWC-93-08 PWC-93-09 Incorrect Ride Plate Installed on Some 1993 SL750 Model Watercraft 1992 SL650 Fuel Tank Drop Tube Retaining Cap 1992 SL650 Update Kit PN 2200475 Lanyard Cord Switch Adjustment 1993 Model PWCs with Low Oil Warning Buzzers That Remain On After Oil Tank Has Been Filled Air Intake Silencer Mounting Bolts 1993 SL650 Model #B934058 (all) 1993 SL750 Model #B934070 through Serial #PLE07000C393 1. All 1992 and 1993 SL650 and SL750 Fuel Tank Drop Tube Retaining Cap 2. Fuel Tank Drop Tube Lines and Clamps 3. Oil Tank Lower Elbow Fitting Inspection 1. Speedometer Kit Installation on 1992 SL650 Watercraft 2. Quick Trim System not Staying in Set Position 3. Inspection of Oil System, Fuel System Vent Lines and Check Valves Oil Tank Lower Elbow Fitting Replacement 4/96 1.2 Polaris Industries Inc .

beerdart GENERAL INFORMATION Service Bulletin Index Service/Information Bulletins - 1994 PWC-94-01 PWC-94-02 PWC-94-03 PWC-94-04 PWC-94-05 PWC-94-06 PWC-94-07 PWC-94-08 PWC-94-09 PWC-94-10 PWC-94-11 PWC-94-12 PWC-94-13 1. Spark Plug Caps Improperly Installed on the Coil High Tension Leads 2. Insufficient Torque on Cylinder Head Nuts 3. Spark Plug Type Listed Incorrectly in Owner's Manual Retention of the air Intake Duct Drain Hose 1. Fiberglass Gel Coat Surface Crazing (Spider Webbing) 2. A Limited Number of 1994 SLTs may need Fiberglass Trimmed from the area below the rub rails in the rear corners Possible Water Leak on SLT Drive Shaft Through-hull Fitting Engine Cooling Water Inlet Hose 1. Exhaust Manifold Fasteners 2. Prevention of Water Leakage 1994 SLT Seat and Compartment Door Seals Front Seat Latch Plate Wear Into Gel Coat on some 1994 SLTs All 1994 SL650, SL750 & SLT, Fuel Tank Drop Tube Retaining Cap 1994 SL750 Power Trim Nozzle Fasteners 1. 1994 SLT Water Leaks at Steering and Reverse Cable 2. All 1994 Watercraft. Rear Muffler Bracket may wear through water supply hose All 1994 Watercraft. Possible water ingestion through the air intake 1994 SLT Fuel Tank Vent Relocation Service/Information Bulletins - 1995 /' PWC-95-01 PWC-95-02 PWC-95-03 PWC-95-04 PWC-95-05 PWC-95-06 PWC-95-07 PWC-95-08 PWC-95-09 PWC-95-10 PWC-95-11 PWC-95-12 PWC-95-13 Polaris Industries Inc. 1994 SLT - Reinforcement Of Driveshaft Through Hull Fitting 1994 SLT - Fuel Tank Vent System Update All 1994 Models - Failure Of Vacuum Controlled Fuel Valve 1995 SLT - Loose Hose Clamp On Exhaust Cross-Over Hose All 1995 Models - Cracked Or Broken Stems On Fuel Tank Pick-up/Sender Un i t All 1995 Models - Defective Oil Tank Fitting All 1995 Models - Kinked Fuel Lines 1995 SL650/750 - Incorrect Fuel Line Routing 1995 SL650/750 - Loose Front Bumper All 1995 Models - Bilge Siphon Fitting Restricted Or Plugged All 1995 Models - Steering Cable Adjustment Procedure All 1995 Models - Grab Handle Cracking 1995 SLX 780 - Intermittent Hard Starting 1.3 4/96

beerdart GENERAL INFORMATION Service Bulletin Index Service/Information Bulletins - 1995 (Cont.) PWC-95-14 PWC-95-15 PWC-95-16 PWC-95-17 PWC-95-18 PWC-95-19 PWC-95-20 PWC-97-05 1995 SL650/SL650 STD - Piston Damage Or Lean Condition At High Throttle Settings All 1992-1995 SL650; SL650 STD; SL750; SLX780 - Improved Seat Sea l Kit All 1993-1995 Model Watercraft - Cooling Water Hose Damage 1995 SL650 STD; 1995 SLX 780 - Threaded Through Hull Fitting May Loosen All 1992-1995 Model Watercraft - Fuel Valve Restriction May Cause Lean Condition 1994 - 1995 SLT 750 - Fuel Cap Cracking All 1995 Watercraft - Improved Steering Cable Retention All 1995-1996 Watercraft Fuel Inlet and Cap Replacement Service/Information Bulletins - 1996 PWC-96-01 PWC-96-02 PWC-96-03 PWC-96-04 PWC-96-05 PWC-96-06 PWC-96-07 PWC-96-08 PWC-96-09 PWC-96-10 PWC-96-11 PWC-96-12 PWC-96-13 PWC-96-14 PWC-96-15 PWC-97-05 1996 SLT700 - Flywheel Replacement and Cylinder Head Bracket Installation All Except SUSLT 700 - MFD Malfunction SLTX - Temperature Sensors Incorrect Or Missing All 1996 PWC - Loose Handgrips 1996 SL900 and SLTX - Improved Throttle Response On Initial Acceleration 1996 SLT 780 - Steering Cable May Contact The Drive Coupler All 1992-1995 Models; All 1996700,780, & Hurricane Models - Fuel Valve Restriction May Cause Lean Condition 1996 SLTX - Revised Carburetor Jetting For SLTX 1996 Hurricane - Loose Engine Mounting Bolts and Air Filter Mounting Studs All 1996 Model Watercraft (Except Hurricane) - Leaks At Bilge Plug 1996 SL700; SLT700; Hurricane; SL900; - Oil Pump a-Ring Leakage 1996 SL700; SLT700; Hurricane; SL900; SLTX; - Loose Or Broken Cylinder Head Bolts 1996 Hurricane - Handlebars May Develop Cracks 1996 SL780; SLT780; SLX 780 - Carburetor Hi/Low Screw Settings 1996 Hurricane - Hood Seal Replacement All 1995-1996 Watercraft Fuel Inlet and Cap Replacement Service Bulletins - 1997 PWC-97-01 PWC-97-02 PWC-97-03 PWC-97-04 PWC-97-05 1997 SL1050 - Quality Assurance Upgrades To Engine And Pump 1997 SLTX - Quality Assurance Upgrades To Engine, Pump, and Compartment Door 1997 SLTX Compartment Door Latch Plate Replacement 1997 SLX Pro 785 Compartment Door Latch Plate Replacement All 1995-1996 Watercraft Fuel Inlet and Cap Replacement Service Bulletins - 1998 5/98 PWC-98-01 1998 SLX Pro 785 Cooling Water Outlet Hose Restrictor 1.4 Polaris Industries Inc .

beerdart , 1996 PWC Bulletin Index By Model GENERAL INFORMATION Service Bulletin Index - By Model Model Bulletin # Type Notes All 1996 Models PWC-96 -04 Service Loose Hand Grips - All 1996 Models PWC-96-10 Information Leaks At Bilge Plug (Except Hurricane) PWC-97-05 Service Fuel Inlet and Cap Replacement 1996 SLTX PWC-96-02 Service Multi Function Display- Erratic RPM / Water Damage PWC-96-03 Service Engine Temp Sensor Incorrect Or Missing PWC-96-04 Service Loose Hand Grips - All 1996 Models PWC-96-05 Service Improved Throttle Response On Initial Acceleration PWC-96-08 Service Revised Carburetor Jetting For SLTX PWC-96-10 Information Leaks At Bilge Plug (Except Hurricane) PWC-96-11 Service Oil Pump a-Ring Leakage PWC -96-12 Information Loose Or Broken Cylinder Head Bolts 1996 SL 900 PWC-96-02 Service Multi Function Display-Erratic RPM / Water Damage PWC-96-04 Service Loose Hand Grips - All 1996 Models PWC-96-05 Service Improved Throttle Response On Initial Acceleration PWC-96-10 Information Leaks At Bilge Plug (Except Hurricane) PWC-96-11 Service Oil Pump a-Ring Leakage PWC- 96-12 Information Loose Or Broken Cylinder Head Bolts 1996 SLX 780 PWC-96-02 Service Multi Function Display-Erratic RPM / Water Damage PWC-96-04 Service Loose Hand Grips - All 1996 Models PWC-96-07 Information Fuel Valve Restriction May Cause Lean Condition PWC-96-10 Information Leaks At Bilge Plug (Except Hurricane) PWC-96-14 Service Carburetor High/Low Screw Settings 1996 SLT780 PWC-96-02 Service Multi Function Display- Erratic RPM / Water Damage PWC-96-04 Service Loose Hand Grips - All 1996 Models PWC-96-06 Service Steering Cable May Contact Drive Coupler PWC-96-07 Information Fuel Valve Restriction May Cause Lean Condition PWC-96-10 Information Leaks At Bilge Plug (Except Hurricane) PWC-96-14 Service Carburetor High/Low Screw Settings 1996 SL780 PWC-96-02 Service Multi Function Display-Erratic RPM / Water Damage PWC-96-04 Service Loose Hand Grips - All 1996 Models PWC-96-07 Information Fuel Valve Restriction May Cause Lean Condition PWC-96-10 Information Leaks At Bilge Plug (Except Hurricane) PWC-96-14 Service Carburetor High/Low Screw Settings Polaris Industries Inc . 1.4a 5/98

beerdart GENERAL INFORMATION Service Bulletin Index By Model 1996 PWC Bulletin Index By Model (Cont.) Model Bulletin # Type Notes 1996 SLT700 PWC-96-01 Service Flywheel Replacement And Cyl. Head Bracket PWC-96-04 Service Loose Hand Grips - All 1996 Models PWC-96-07 Information Fuel Valve Restriction May Cause Lean Condition PWC-96-10 Information Leaks At Bilge Plug (Except Hurricane) PWC-96-11 Service Oil Pump a-Ring Leakage PWC-96-12 Information Loose Or Broken Cylinder Head Bolts 1996 SL700 PWC-96-04 Service Loose Hand Grips - All 1996 Models PWC-96-07 Information Fuel Valve Restriction May Cause Lean Condition PWC-96-10 Information Leaks At Bilge Plug (Except Hurricane) PWC-96-11 Service Oil Pump a-Ring Leakage PWC-96-12 Information Loose Or Broken Cylinder Head Bolts 1996 Hurricane PWC-96-02 Service Multi Function Display-Erratic RPM / Water Damage PWC-96-04 Service Loose Hand Grips - All 1996 Models PWC-96 -07 Information Fuel Valve Restriction May Cause Lean Condition PWC-96-09 Service Loose Engine Mounting Bolts And Air Filter Mount- ing Studs PWC-96-11 Service Oil Pump a-Ring Leakage PWC-96 - 12 Information Loose Or Broken Cylinder Head Bolts PWC-96-13 Safety Alert Handlebars May Develop Cracks PWC-96·· 15 Service Seat Seal Replacement - 1996 Hurricane 1997 PWC Bulletin Index By Model Model Bulletin # Type Notes All 1997 Models 1997 SLTX PWC-97 -02 Service Quality Assurance Upgrades To Engine, Pump, Door PWC-97-03 Service Compartment Door Latch Plate Replacement 1997 SL1050 PWC-97 -01 Service Quality Assurance Upgrades To Engine and Pump 1997 SL900 1997 SLT780 1997 SL780 1997 SLT700 1997 SL700/Deluxe Hurricane 1998 PWC Bulletin Index By Model Model Bulletin # Type Notes All 1998 Models 1998 SLTX 1998 SLXH 1998 SLH 1998 SLTH 1998 SLX Pro785 S-98-01 Service Cooling Water Outlet Hose Restrictor 5/98 1.4b Polaris Industries Inc .

beerdart GENERAL INFORMATION Paint Codes Paint Codes' Year Model Model No. Color Polaris PPG I Ditzler (See Note Below) Reference No. Number 1992 SL650 B924058 Bright White (P133) 8520113 2185 / 91473 1993 SL650 B934058 Bright White (P133) 8520113 2185 / 91473 SL750 B934070 Bright White (P133) 8520113 2185 / 91473 Carnation Pink (P189) 8520121 N/ A I N/A 1994 SL650 B944058 Bright White (P133) 8520113 2185/91473 Rubine Red (P182) 8520129 N/A I N/A SL750 B944070 Bright White (P133) 8520113 2185/91473 Black Metallic (P177) 8520106 9000 1 N/A SLT B944170 White (Gel Coat Repair Kit) 2871287 Caribbean Blue (P196) 8520133 N/A / 19717 1995 SL650 B954058 Rubine Red (P182) 8520129 N/A 1 N/ A SL650 STD B954358 Bright White (P133) 8520113 2185 / 91473 SL750 B954070 Purple Ve l vet (P194) 8520160 N/A 1 N/ A SLT750 B954170 Caribbean Blue (P196) 8520133 N/A / 19717 SLX780 B954287 Bright White (P133) 8520113 2185 / 91473 Rubine Red (P182) 8520129 N/A 1 N/A Black Metallic (P177) 8520106 9000 1 N/A 1996 SL700 B964066 Bright White (P133) 8520113 2185 / 91473 Lazer Blue (P217) 8520231 N/A 1 N/A SLT700 B964166 Bright White (P133) 8520113 2185/91473 Caribbean Blue (P196) 8520133 N/ A 1 19717 Purple Velvet (P194) 8520160 N/A 1 N/A Hurricane B964466 Bright White (P133) 8520113 2185 / 91473 Porsche Red (P136) 8520066 N/A 172060 SL780 B964087 Bright White (P133) 8520113 2185 / 91473 Porsche Red (P136) 8520066 N/A 172060 SLT780 B964588 Bright White (P133) 8520113 2185 / 91473 Purple Wave (P214) 8520230 N/A 152113 Caribbean Blue (P196) 8520133 N/ A / 19717 SLX780 B964287 Bright White (P133) 8520113 2185 / 91473 Black Metallic (P177) 8520106 90001 N/A Porsche Red (P136) 8520066 N/A 172060 SL900 B964291 Bright White (P133) 8520113 2185 / 91473 Porsche Red (P136) 8520066 N/A 1 72060 SLTX B964590 Bright White (P133) 8520113 2185/91473 Purple Wave (P214) 8520230 N/A / 52113 Caribbean Blue (P196) 8520133 N/A / 19717 *Includes International models *. Bright White (P133) Is Ditzler #91473 or PPG 2185 NOTE: Order Polaris "P" Number from Midwest Industrial Coatings (612)-934-8252 . Mix as directed . N/A = Not Available Polaris Industries Inc . 1.5 4/97

Polaris SLT PWC 1993 1994 Workshop Service Manual

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