1999 Polaris SLH SLTH SLX SLTX Pro 785 Personal Watercraft Repair Manual

\ POLRRI SBLES IRC. 1999 SLH, SLTH, SLX, SLTX, PRO 785 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 identifi cation and unit repair, along with service specifications for 1999 SLH, SLTH, SLX, SLTX, and Pro 785 Polaris personal watercraft. A table of contents is placed at the beginning of each chapter to aid the user in locating spe cific areas of information. The alphabetic index at the end of the manual will help the user find specific information quickly. Care is taken 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: Engineering Services, Technical Writer, Polaris Sales Inc., 1225 Hwy 169 N, Minneapolis, MN 55441-5078. Technical Training Center Minneapolis, MN 55441 1999 SLH, SLTH, SLX, SLTX, and Pro 785 Personal Watercraft Service Manual (PN 9915085) Copyright 1999 Polaris Sales Inc. Printed in U.S.A.

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, passenger, 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, bystand er or person inspecting or servicing the watercraft. I CAUT.ON: I 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

CHAPTER 1 GENERAL INFORMATION Publication Numbers 1.1 Paint Codes 1.1 Bulletin Index by Model 1.2 Service Bulletins -1998 1.2 Model Identification Numbers 1.3 Model Specifications 1.4 -1.5 Standard Torque Specifications 1.6 Decimal Equivalents 1.7 Conversion Table 1.8 Tap Drill Charts 1.9 Glossary of Terms 1.10-1.11 Service Tips 1.12

GENERAL INFORMATION Publication Numbers/Paint Codes Watercraft Publication Part Numbers Year 1999 Model SLH SLTH SLTX SLX Pro 785 Model No. B994673 B994573 B994590 B994690 B994978 Parts Book 9915133 9915139 9915142 9915136 9915151 Micro- Fiche 9915134 9915140 9915143 9915137 9915152 Owner's Manual 9915132 9915132 9915132 9915132 9915132 Paint Codes Model SLH SLTH SLTX SLX Pro 785 Color Bright White (P133) Teal Metallic (P168) Black (P070) Bright White (P133) Pearlstone (P277) Bright White (P133) Classic Red Pearl (P294) Black (P070) Bright White (P133) Black Metallic (P177) Screamin' Yellow (P216) Bright White (P133) Black Metallic (P177) Havasu Red (P292) Polaris Sales Inc. 1.1 2/99

GENERAL INFORMATION Service Bulletin Index By Model 1999 PWC Bulletin Index By Model Model Bulletin # Type Notes All 1999 Models 1999SLH 1999 SLTH 1999 SLTX 1999 SLX 1999 Pro 785 1998 PWC Bulletin Index By Model Model All 1998 Models 1998 SLTX 1998SLXH 1998 SLH 1998 SLTH 1998 SLX Pro785 Bulletin # PWC-98-02 PWC-98-02 PWC-98-03 PWC-98-03 S-98-01 Type Service Service Safety Safety Service Notes Hard Starting and/or Lean Condition at Part Throttle Hard Starting and/or Lean Condition at Part Throttle Handlebar Clamp Bolts Handlebar Clamp Bolts Cooling Water Outlet Hose Restrictor Service Bulletins -1998 PWC-98-01 1998 SLX Pro 785 Cooling Water Outlet Hose Restrictor PWC-98-02 1998 SLTX; SLXH Hard Starting and/or Lean Condition at Part Throttle PWC-98-03 Safety Alert 1998 SLH; SLXH Handlebar Clamp Bolts 2/99 1.2 Polaris Sales Inc.

GENERAL INFORMATION Model Identification Identification Numbers The engine I.D. number and hull I.D. number are used to register the watercraft. They are unique numbers that distinguish each watercraft from others of the same model. If the watercraft is ever stolen these numbers will help identify it. The owner should keep a record of these numbers in a place other than the watercraft. Hull Number Identification US Country of Manufacture PLE 00000 Manufacturers I.D. Serial ■'/• Number A Month of Manufacture Year of Manufacture 99 Model Year of Craft Month Code: A = January; B = February; etc. Year Of Manufacture: 8 = 1998; 9 = 1999; etc. loi J"X n, \O u 0/ \ 0 0 ZoP) —r—__ \ \ A—- _——J Engine I.D. Number (Polaris / Fuji Engine) Starter Cover Engine I.D. Number (Polaris Domestic Engine) Polaris Sales Inc. 1.3 2/99

GENERAL INFORMATION Model Specifications Polaris reserves the right to change specifications at any time without -j QQQ SLH incurring obligations. Model Number B994673 Dimensions/Materials/Capacities Length (inches) 108.5" (276 cm) Width (inches) 47.5" (120.7 cm) Height (inches) 39.5" (100.3 cm) Dry Weight (lbs.) 460 (209 kg) Rider Capacity 2 person/370 lbs. (168 kg) Rated Fuel Capacity including reserve 12.5 U.S. Gal (47.3L) Fuel Reserve N/A Oil Reservoir Capacity - U.S. quarts 5 (4.73L) Hull Material Sheet Molded Compound (SMC) Top Deck Material Resin Transfer Molding (RTM) Full Throttle Cruising Range (Approx.) 50 miles (80.5 km) Engine/Cooling Engine Model W70-99DCSP-01A2 Engine Displacement 701 cc Engine Type (# Of Cylinders) Polaris Marine 700 (2) Bore & Stroke 81 mm x 68mm Compression Ratio (Full Stroke) 11.5:1 Horsepower 95 HP @ 6700 RPM Cooling System Water cooled Thermostat Open 140° F (60° C) Overheat/Low Oil Warning Light (MFD)(On@160°F) Induction Type Case Reed Lubrication Oil Injected Oil Type Polaris TC-W3 or Polaris Synthetic Gold RPM Limiter Operation 7200 RPM ± 100 Carburetion Carburetors 2-40mm, CDK Fuel Type Regular Unleaded Gasoline (87 Octane or 89 Octane oxygenated) Idle Speed (In Water) 1400±50 Electrical Magneto Generator Output 5A / 60W at 4500 RPM Ignition System Digital CDI Spark Plug Type NGK BPR8ES Spark Plug Gap (inches) 028" (0.7mm) Timing Degrees BTDC 18°±2 at 3000 RPM 13°+2at6250RPM Battery 12V 19A YB16CL-B Starting System Electric Fuse 15A resettable circuit breaker Propulsion Jet Pump Type Single Stage Axial Flow Impeller Rotation Counterclockwise Coupling Type Rubber Bilge Pump Type Electric Minimum Water Level For Jet Pump 2 Feet (60cm) Pivoting Angle 30° Impeller Type Progressive Pitch Stainless 3 Blade Impeller Diameter 5.83" (14.8cm) Reverse System N/A 'Multi-Function Display includes: Speedometer, Peak Speed, Peak RPM, Tachometer, Clock, Hour Meter, Oil Level, Trip Meter, Low Oil Warning, Fuel Level, Volts, Low Fuel Warning, Hot Engine Warning 1999 SLTH B994573 120.3" (305.6 cm) 49.3" (125.2 cm) 39" (99.1 cm) 595 (270 kg) 3 person/500 lbs. (227 kg) 15.0 U.S. Gal (56.8L) N/A 5.5 (5.20L) Sheet Molded Compound (SMC) Sheet Molded Compound (SMC) 61 miles (98.1 km) W70-99DCSP-01A1 701 CC Polaris Marine 700 (2) 81mm x68mm 11.5:1 95 HP @ 6700 RPM Water cooled 140°F(60°C) Light (MFD)(On@160°F) Case Reed Oil Injected Polaris TC-W3 or Polaris Synthetic Gold 7200 RPM ±100 2-40mm, CDK Regular Unleaded Gasoline (87 Octane or 89 Octane oxygenated) 1400±50 5A / 60W at 4500 RPM Digital CDI NGK BPR8ES .028" (0.7mm) 18°+2at3000RPM 13°±2at6250RPM 12V19AYB16CL-B Electric 15A resettable circuit breaker Single Stage Axial Flow Counterclockwise Rubber Electric 2 Feet (60cm) 30° Progressive Pitch Stainless 3 Blade 5.83" (14.8cm) N/A ~ 2/99 1.4 Polaris Sales Inc.

GENERAL INFORMATION Model Specifications Polaris reserves the right to change specifications 1 999 SLX 1 999 SLTX 1999 PlX) 785 at any time without incurring obligations. Model Number B984695 B984595 B994978 Dimensions/Materials/Capacities Length (inches) 108.5" (276 cm) 120.3" (305.56 cm) 108.5" (276 cm) Width (inches) 47.5" (120.7 cm) 49.3" (125.22 cm) 45" (114.3 cm) Height (inches) 39.5" (100.33 cm) 39" (99.06 cm) 39.5" (100.3 cm) Dry Weight (lbs.) 555 (252 kg) 615 (279 kg) 480 (218 kg) Rider Capacity 2 person/370 lbs. (168 kg) 3 person/500 lbs. (227 kg) 2 person/370 lbs. (168 kg) Rated Fuel Capacity including reserve 12.5 U.S. Gal (47.3L) 15(56.8L) 9.8 U.S. Gal (37.1 L) Fuel Reserve N/A N/A N/A Oil Reservoir Capacity - U.S. quarts ... 5 (4.73L) 5.5 (5.20I) 3.5 (3.31 L) Hull Material Sheet Molded Compound Sheet Molded Compound Fiberglass Reinforced (SMC) (SMC) Composite (FRC) Top Deck Material Resin Transfer Molding Sheet Molded Compound Resin Transfer Molding (RTM) (SMC) (RTM) Full Throttle Cruising Range (Approx.) . 40 miles (64.37 km) 55 miles (88.5 km) 40 miles (64.4 km) Engine/Cooling Engine Model No WC105-99TCSP-05 WC105-99TCSP-05 EC78ZPWE01 Engine Displacement 1051cc 1051cc 779cc Engine Type (# Of Cylinders) Polaris Marine 1050 (3) Polaris Marine 1050 (3) Polaris / Fuji 785 (3) Bore & Stroke 81mm x 68mm 81mm x 68mm 69.7mm x 68mm Compression Ratio (Full Stroke) 11.5:1 11.5:1 12.3:1 Horsepower 120 HP @ 6500 RPM 120 HP @ 6500 RPM 140 HP @ 7750 RPM Cooling System Water cooled Water cooled Water cooled Thermostat Open 140° F (60° C) 140°F(60°C) N/A Overheat Warning 4500 Rev Limit © 160°F (71 °C) 4500 Rev Umit @ 160°F (71 °C) Rev Limit 4500 © (82°C) Induction Type Case Reed Case Reed Case Reed Lubrication Oil Injected Oil Injected Oil Injected Oil Type Polaris TC-W3 or Polaris Polaris TC-W3 or Polaris Polaris TC-W3 or Polaris Synthetic Gold Synthetic Gold Synthetic Gold RPM Limiter Operation 7200 RPM ± 100 7200 RPM ± 100 7950 RPM + 100 Carburetion Carburetors (Keihin) 3-40mm, CDK 3-40mm, CDK 3-44mm, 40mm Venturi Fuel Type Regular Unleaded Gasoline Regular Unleaded Gasoline Regular Unleaded Gasoline (87 Octane or 89 Octane (87 Octane or 89 Octane (91 Octane) oxygenated) oxygenated) Idle Speed (In Water) 1350±50 1350±50 1350+50 Electrical Magneto Generator Output 8.5A / 60W at 4500 RPM 8.5A / 60W at 4500 RPM 10A/120W at 4500 RPM Ignition System Digital CDI Digital CDI Digital CDI Spark Plug Type NGK BPR8ES NGK BPR8ES NGK BR9ES Spark Plug Gap (inches) 028" (0.7mm) .028" (0.7mm) .028" (0.7mm) Timing Degrees BTDC 18°+0, -2 ©3000 18°+0,-2 ©3000 36° at 3000 RPM 11 °+0, -2 © 6250 11 °+0, -2 © 6250 12° at 7500 RPM Battery 12V 19A YB16CL-B 12V 19A YB16CL-B 12V 19A YB16CL-B Starting System Electric Electric Electric Fuse 15A resettable circuit breaker 15A resettable circuit breaker 15A resettable circuit breaker Propulsion Jet Pump Type Single Stage Axial Flow Single Stage Axial Flow Single Stage Axial Flow Impeller Rotation Counterclockwise Counterclockwise Counterclockwise Coupling type Rubber Rubber Rubber Bilge Pump Type Electric Electric Electric Minimum Water Level For Jet Pump ... 2 Feet (60cm) 2 Feet (60cm) 2 Feet (60cm) Pivoting Angle 30° 30° 30° Impeller Type Slim Hub Stainless Slim Hub Stainless Slim Overlap Stainless 3 3 Blade 3 Blade Blade Impeller Diameter 5.83" (14.8cm) 5.83" (14.8cm) 5.83" (14.8cm) Reverse System N/A N/A N/A *Multi-Function Display includes: Speedometer, Peak Speed, Peak RPM, Tachometer, Clock, Hour Meter, Oil Level, Trip Meter, Low Oil Warning, Fuel Level, Volts, Low Fuel Warning, Hot Engine Warning, Compass (SLTX only) Polaris Sales Inc. 1.5 2/99

GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used as a general guideline. Use standard torque values for the appropriate size fastener when torque values are not specified. Always consult the specific manual section for torque values of fasteners and use of locking agent. RECOMMENDED TORQUE SPECIFICATION STAINLESS STEEL FASTENERS (SAE) Bolt Size 8 10 1/4 5/16 3/8 3/8 7/16 1/2 1/2 Threads/Inch 18&32 24&32 20&28 18&24 16 24 14 13 20 Torque 28 in. lbs. 40 in. lbs. 8 ft. lbs. 14 ft. lbs. 25 ft. lbs. 28 ft. lbs. 40 ft. lbs. 58 ft. lbs. 70 ft. lbs. RECOMMENDED TORQUE SPECIFICATION STAINLESS STEEL FASTENERS (METRIC) Bolt Size 5mm 6mm 8mm 10mm 12mm Torque 45-52 in. lbs. 66-78 in. lbs. 13-16 ft. lbs. 26-30 ft. lbs. 40-44 ft. lbs. To convert in. lbs. to ft. lbs. divide by 12 To convert ft. lbs. to kg-m multiply foot pounds by .138. To convert kg-m to Nm move the decimal to the right one position. 2/99 1.6 Polaris Sales Inc.

1999 Polaris SLH SLTH SLX SLTX Pro 785 Personal Watercraft Repair Manual

You're Reading a Preview

Recently Viewed