2000 Polaris SLH Virage Pro 785 Personal Watercraft

.I SERVICL PUBLICATIONS I I LH, Virajc, P 785

POLRRI The Way Out. 2000 SLH, VIRAGE, 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 2000 SLH, Virage, and Pro 785 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 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., 2100 Highway 55, Medina, MN 55340. Technical Training Center - Minneapolis, MN 55447 2000 SLH, Virage, and Pro 785 Personal Watercraft Service Manual (PN 9916289) Copyright2000 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: f\ The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! 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. C&UTKSN: 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 Model Identification Numbers 1.1 Model Specifications 1.2 -1.3 Standard Torque Specifications 1.4 Decimal Equivalents 1.5 Conversion Table 1.6 Tap Drill Charts 1.7 Glossary of Terms 1.18 - 1.9 Service Tips 1.10

GENERAL INFORMATION Publication Numbers/Paint Codes Watercraft Publication Part Numbers Year 2000 Model SLH Virage Pro 785 Model No. W004673D W005197D W004978D Parts Book 9915133 9915139 9915151 Micro- Fiche 9915134 9915140 9915152 Owner's Manual 9915132 9915132 9915132 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 PLE 00000 00 Country of Manufacturers I.D, Serial Month of Year of Model Year Manufacture Number Manufacture Manufacture of Craft Month Code: A = January; B = February; etc. Year Of Manufacture: 9 = 1999; 0 = 2000; etc. Engine I.D. Number (Pro 785 Engine) Starter Cover Engine I.D. Number (Polaris Domestic 700 Engine) Polaris Sales Inc. 1.1 3/00

GENERAL INFORMATION Model Specifications Polaris reserves the right to change specifications at any time without OOOO Ql M incurring obligations. ^UUU OLH Model Number W004673D Dimensions/Materials/Capacities Length (inches) 108.5" (276 cm) Width (Inches) 47.5" (120.7 cm) Height (inches) 39.5" (100.3cm) Dry Weight (lbs.) 460 (209 kg) RiderCapacity 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 Fiberglass Reinforced Composite (FRC) Full Throttle Cruising Range (Approx.) 50 miles (80.5 km) Engine/Cooling EngineModel W70-DCSP-02A0 Engine Displacement 701cc Engine Type (# Of Cylinders) Polaris Marine 700 (2) Bore&Stroke 81mmx68mm Compression Ratio (Full Stroke) 11.5:1 Horsepower 95 HP @ 6700 RPM Full Throttle RPM 6600-6700 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 OilType Polaris TC-W3, Polaris Synthetic Gold, or Nature Oil RPM Limiter Operation 7200 RPM ±100 Carburetion Carburetors , 2-40mm, Keihin Fuel Type Regular Unleaded Gasoline (87 Octane or 89 Octane oxygenated) IdleSpeed (In Water) 1350± 100 Electrical Magneto Generator Output 5A/60Wat4500 RPM Ignition System Digital CDI SparkPlugType NGKBPR8ES Spark Plug Gap (inches) 028" (0.7mm) Timing Degrees BTDC 18°±1 at 3000 RPM 13°±1at6000RPM Battery 12V19AYB16CL-B Starting System Electric Fuse 15A resettable circuit breaker Propulsion Jet Pump Type Single Stage Axial Flow ImpellerRotation Counterclockwise Coupling Type Rubber Bilge Pump Type Electric Minimum Water Level For Jet Pump 2 Feet (60cm) PivotingAngle 30° Impeller Type Progressive Pitch Stainless 3 Blade ImpellerDiameter 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 2000 Virage W005197D 120.3" (305.6 cm) 49.3" (125.2 cm) 39" (99.1cm) 595 (270 kg) 3 person/565 lbs. (256 kg) 17.0 U.S. Gal (64.4L) N/A 6.0(5.68L) Sheet Molded Compound (SMC) Fiberglass Reinforced Composite (FRC) 61 miles (98.1 km) W70-SCSP-03B 701 cc Polaris Marine 700 (2) 81 mm x 68mm 11.5:1 95 HP @ 6700 RPM 6600-6700 RPM Water cooled 140°F(60°C) Light(MFI)(On@160°F) Case Reed Oil Injected Polaris TC-W3, Polaris Synthetic Gold, or Nature Oil 7200 RPM ±100 1-40mm, Keihin Regular Unleaded Gasoline (87 Octane or 89 Octane oxygenated) 1350+100 5A/60Wat4500RPM Digital CDI NGKBPR8ES .028" (0.7mm) 23°±1at3000RPM 18°±1at6000RPM 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 3/00 1.2 Polaris Sales Inc.

GENERAL INFORMATION Model Specifications Polaris reserves the right to change specifications at any time without incurring 2000 PfO 785 obligations. ModelNumber W004978D Dimensions/Materials/Capacities Length (inches) 108.5" (276 cm) Width(inches) 45" (114.3cm) Height (inches) • ■ 39.5" (100.3cm) Dry Weight (lbs.) 480 (218 kg) RiderCapacity 1-2 persons/370 lbs. (168 kg) Rated Fuel Capacity including reserve 9.8 U.S. Gal (37.1 L) Fuel Reserve N/A Oil Reservoir Capacity- U.S. quarts 3.5(3.31L) HullMaterial Fiberglass Reinforced Composite (FRC) Top Deck Material Resin Transfer Molding (RTM) Full Throttle Cruising Range (Approx.) 40 miles (64.4 km) Engine/Cooling EngineModeINo EC78ZPWE01 Engine Displacement 779cc Engine Type (# Of Cylinders) Polaris / Fuji 785 (3) Bore&Stroke 69.7mmx68mm Compression Ratio (Full Stroke) 12.3:1 Horsepower 140 HP @ 7750 RPM CoolingSystem Watercooled Thermostat Open N/A Overheat Warning Rev Limit 4500 @ (82°C) Induction Type Case Reed Lubrication Oil Injected OilType Polaris TC-W3, Polaris Synthetic Gold, VES Oil, or Nature Oil RPM Limiter Operation 7950RPM±100 Carburetion Carburetors (Mikuni) 3-44mm, Venturi Fuel Type Unleaded Gasoline (91 Octane) Idle Speed (In Water) 1350150 Electrical Magneto Generator Output 10A/120Wat4500RPM Ignition System Digital CDI SparkPlugType NGKBR9ES Spark Plug Gap (inches) 028" (0.7mm) Timing Degrees BTDC 36° at 3000 RPM 12° at 7500 RPM Battery 12VYB14A-A2 Starting System Electric Fuse 15A resettable circuit breaker Propulsion Jet Pump Type Single Stage Axial Flow ImpellerRotation Counterclockwise Couplingtype Solid Bilge Pump Type Electric Minimum Water Level For Jet Pump 2 Feet (60cm) PivotingAngle 30° ImpellerType Slim Overlap Stainless 3 Blade ImpellerDiameter 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. Polaris Sales Inc. -| 3 3/00

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. Bolt Size 8 10 1/4 5/16 3/8 3/8 7/16 1/2 1/2 RECOMMENDED TORQUE SPECIFICATION STAINLESS STEEL FASTENERS (SAE) 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 Nm multiply foot pounds by 1.356. To convert Nm to ft. lbs. multiply Nm by .7376. 3100 1.4 Polaris Sales Inc.

GENERAL INFORMATION Decimal Equivalents 1/64 0156 1/32 0312 1 mm = .0394" 3/64 0469 1/16 0625 5/64 0781 2 mm = .0787" 3/32 0938 7/64 1094 3 mm = .1181" 1/8 1250 9/64 1406 5/32 1563 4 mm = .1575" 11/64 1719 3/16 1875 5 mm = .1969" 13/64 2031 7/32 2188 15/64 2344 6 mm = .2362" 1/4 25 17/64 2656 7 mm = .2756" 9/32 2813 19/64 2969 5/16 3125 8 mm = .3150" 21/64 3281 11/32 3438 9 mm = .3543" 23/64 3594 3/8 375 25/64 3906 10 mm = .3937" 13/32 4063 27/64 4219 11 mm = .4331" 7/16 4375 29/64 4531 15/32 4688 12 mm = .4724" 31/64 4844 1/2 5 13 mm = .5118 33/64 5156 17/32 5313 35/64 5469 14 mm = .5512" 9/16 5625 37/64 5781 15 mm = .5906" 19/32 5938 39/64 6094 5/8 625 16 mm = .6299" 41/64 6406 21/32 6563 17 mm = .6693" 43/64 6719 11/16 6875 45/64 7031 18 mm = .7087" 23/32 7188 47/64 7344 19 mm = .7480" 3/4 75 49/64 7656 25/32 7813 20 mm = .7874" 51/64 7969 13/16 8125 21 mm = .8268" 53/64 8281 27/32 8438 55/64 8594 22 mm = .8661" 7/8 875 57/64 8906 23 mm = .9055" 29/32 9063 59/64 9219 15/16 9375 24 mm = .9449" 61/64 9531 31/32 9688 25 mm = .9843 63/64 9844 1 1.0 Polaris Sales Inc. 1 5 3100

GENERAL INFORMATION Conversion Table Unit of Measure ft. lbs. in. lbs. ft. lbs. in. lbs. Nm kg-m kg-m kg-m in. mm in. mile (mi.) km Ounces (oz) Grams (g) Ib. kg Cubic inches (cu in) Cubic centimeters (cc) Imperial pints (Imp pt) Liters (1) Imperial quarts (Imp qt) Liters (1) Imperial quarts (Imp qt) US quarts (US qt) US quarts (US qt) Liters (1) US gallons (US gal) Liters (1) Pounds - force per square inch (psi) Kilopascals (kPa) Kilopascals (kPa) Kilograms - force per square cm Multiplied by x12 x .0833 x 1.356 x.0115 x .7376 x 7.233 x 86.796 x10 X25.4 x .03937 X2.54 X1.6 x.6214 x 28.35 x 0.035 x.454 x 2.2046 x 16.387 x 0.061 x 0.568 X1.76 x 1.137 xO.88 x 1.201 x 0.833 x 0.946 x 1.057 x 3.785 x 0.264 x 6.895 x 0.145 x0.01 X98.1 Converts to = in. lbs. = ft. lbs. = Nm = kg-m = ft. lbs. = ft. lbs. = in. lbs. = Nm =mm = in. = cm = km = mile (mi.) = Grams (g) = Ounces (oz) = kg = lb. = Cubic centimeters (cc) = Cubic inches (cu in) = Liters (I) = Imperial pints (Imp pt) = Liters (I) = Imperial quarts (Imp qt) = US quarts (US qt) = Imperial quarts (Imp qt) = Liters (I) = US quarts (US qt) =Liters (I) = US gallons (US gal) = Kilopascals (kPa) = Pounds - force per square inch (psi) = Kilograms - force per square cm = Kilopascals (kPa) °C to °F: 9 (°C + 40) +■ 5 - 40 = °F °F to °C: 5 (°F + 40) + 9 - 40 = °C 3/00 1.6 Polaris Sales Inc.

2000 Polaris SLH Virage Pro 785 Personal Watercraft

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