2000 Polaris SLH, Virage, Pro 785 Personal Watercraft Service Manual (P/N 9916289)

This Polaris service manual covers the 2000 SLH, Virage, and Pro 785 personal watercraft. P/N 9916289, Rev.01, with service information dated March 2000, contains separate procedures for the Polaris Marine 700 and Polaris/Fuji 785 engines.

The 322-page PDF is a scanned copy with visible watermarks and added annotations on two wiring-diagram pages.

• Engine repair: Engine removal, teardown, inspection, and reassembly, including crankshaft checks, cylinder reconditioning, and Pro 785 exhaust-valve service.

• Fuel and oil systems: Keihin CDKII and Mikuni Super BN carburetor overhaul, synchronization, needle-and-seat testing, fuel-line leak checks, and oil-injection service.

• Cooling and maintenance: Periodic maintenance schedules, thermostat/pop-off valve service, cooling-system flushing, off-season storage, and submerged-engine procedures.

• Jet pump and driveline: Pump removal and rebuilding, impeller inspection, engine-to-pump alignment, and ventilation/cavitation troubleshooting.

• Electrical troubleshooting: Model-specific wiring diagrams, PVL and Fuji ignition diagnosis, starter overhaul, charging-system tests, and MFD/MFI fault finding.

• Hull and controls: Steering cable replacement and adjustment, trim linkage adjustments, seat and hatch fitting, and SMC, RTM, and FRC repair procedures.

Written primarily for Polaris personal watercraft service technicians in a properly equipped shop, this manual assumes mechanical knowledge, tool proficiency, and familiarity with workshop procedures.

Engine Repair and Cooling

Separate overhaul sections cover the 701cc twin-cylinder and 779cc triple-cylinder engine configurations. They include piston and cylinder measurements, ring-gap checks, connecting-rod inspection, and crankshaft truing and indexing. Pro 785 procedures also address Ni-Ca-Sil cylinder honing and exhaust-valve cleaning and adjustment.

General stainless-steel fastener torque tables accompany component-specific specifications and tightening patterns, including the Pro 785's multi-stage cylinder-head sequence. Compression-test data and inspection limits support engine condition assessment.

Cooling: The Cooling System Flow Charts distinguish the Marine 700 thermostat arrangement from the Pro 785 water-distribution manifold and calibrated restrictors. The thermostat/pop-off valve section warns that incorrect reassembly can cause severe engine damage.

Carburetion and Oil Injection

The SLH's dual Keihin setup and the Virage's single-carburetor layout have separate assembly views. Pro 785 coverage includes Mikuni synchronization with a manometer, alongside diaphragm inspection and mixture adjustment.

Vent/Fuel Delivery Exploded Views show model-specific routing. Oil tank and air-intake silencer assemblies are also illustrated, with fuel-pump, vent-valve, and fuel-line testing procedures.

Oil-injection coverage distinguishes the Marine 700 cable adjustment from the Pro 785 fixed-length control rod, with pump bleeding and drive-bushing end-play inspection for the Fuji engine. The reed-valve section warns that reversing a used reed can cause it to break.

Jet Pump, Driveline, and Hull Repair

The pump alignment symptom chart links coupler-end and impeller-end spline wear to different alignment faults, helping locate the cause of recurring driveline damage. Procedures identify Pump Alignment Tool P/N 2871343 and address engine shimming and pump-to-hull alignment separately.

The Cutaway View of Pump Assembly - Sealing Points supports ventilation diagnosis around the intake scoop, ride plate, and through-hull fitting. Pump service covers bearings, seals, and shaft inspection; a worn driveshaft bearing housing requires assembly replacement.

Hull procedures include through-hull fitting bonding, gel-coat surface repair, and sponson installation. Steering service includes nozzle centering, with pressure testing for the speedometer system.

Ignition, Starting, and Instruments

PVL ignition troubleshooting for the Marine 700 engines includes Hall-effect sensor checks. The Polaris timing procedures identify Ignition Point Adjustment Unit P/N 2872290. The Pro 785 has a separate Fuji ignition diagnostic section, while model-specific tables provide spark-plug specifications and electrical test values.

A starter-system test chart addresses no-crank and slow-crank complaints. Other procedures cover Pro 785 exhaust-valve actuator testing, fuel and oil senders, overheat limiting, Quick Trim, and electric bilge-pump diagnosis.

The 2000 SLH, 2000 Virage, and 2000 Pro 785 Wiring Diagrams include wire-color codes and connector views. MFD/MFI troubleshooting distinguishes display faults from sender, power-supply, and connection problems.

Follow the manual's precautions for fuel vapors, electrical isolation, and exposed rotating driveline components.

File Format and Readability

Included pages: 312 chapter pages, six index pages, two cover pages, and two introductory pages containing the foreword/copyright and safety information. All are included in the 322-page total.

Text search and navigation: An embedded OCR layer supports searches through the body text, but small wiring labels and some cover text are not searchable. PDF bookmarks provide access to chapters, individual procedures, wiring diagrams, and the index.

Wiring pages: Small connector numbers and wire codes are readable when enlarged. The SLH and Virage diagrams contain added colored annotations referencing Service Bulletin PWC-00-05 for an engine no-restart condition. These annotations occupy existing pages; a separate bulletin is not included.