1992-1998 Polaris SL650 SL750 SLT750 SLX780 SL700 SLT700 Hurricane SL780 SLT780 SL900 SLTX SL1050 SLX Pro 785 watercraft repair manual

Table of Contents

1- Description and Operation

• Brief History
• Principles of Operation
• Engine and Jet Drive
  • Cooling System
  • Bilge Breather
• Impellers
• Replacement Parts
• Debris Removal and Engine Overheating
• Reverse Capability
• Special Features
  • RPM Limiter
  • Other Warning Systems
  • Self-Circling Mode

2- Safety

• Introduction
• Craft Classification Information
• Minimum Legal Requirements for Equipment
  • Personal Flotation Devices
  • Bells, Horns and Whistles
  • Fire Extinguisher
  • Visual Distress Signals
• Minimum Legal Requirements for Craft
• Safety Practices
• Boating Accident Reports
• Security

3- Tuning

• Introduction
• Tune-up Sequence
• Compression Check
• Spark Plug Inspection
• Electrical Power Supply
• Carburetor Adjustment
• Fuel Pumps
  • Remote Fuel Pump
  • Integral Fuel Pump
• Cranking Motor
• Jet Pump
  • Gate Position
  • Impeller

4- Maintenance

• Introduction
• Initial Tasks
  • After Use Tasks
  • Cooling
  • Cooling System Flushing
  • Controlling Corrosion
  • Pump Impeller
• Serial Numbers
• Lubrication -- Complete Unit
  • Throttle & Choke Cable
  • Steering Cable
  • Lubrication Table
  • "Break-in" Lubrication
  • Jet Pump
• Inspection and Service
  • Fuel Tank Check Valve
  • Air Inlet Check Valve
  • Fuel/Water Separator
  • Fuel Filter
  • Oil Filter
  • Drain Plug
• Flushing -- Cooling and Bilge Systems
• Impeller-to-Pump Case Clearance
• Pre-Season Preparation
• Sealants, Adhesives, Lubricants, & Fuel Stabilizers
• Fiberglass Hulls
• Submerged Engine Service
  • Salt Water Submersion
  • Fresh Water Submersion
• Winter Storage
• Pre-Season Check

5- Troubleshooting

• Introduction
• General Problems
  • Low Engine rpm
  • High Engine rpm
  • Engine Troubleshooting
  • Cranking System Test
  • Ignition System Test
  • Compression Test
• Mechanical Engine Problems
  • Twisted Crankshaft
  • Engine Noises
  • Leak Down Procedure
• Fuel System Problems
  • Engine Surge
  • Rough Engine Idle
  • Spark Plug Evaluation
• Cranking System Failures
• Charging System Malfunctions
  • Charging System Testing
  • Unregulated Voltage
  • Charging System Testing
  • Regulated Voltage
• Troubleshooting Charts

6- Fuel and Oil

• Introduction
• General Carburetor Info
  • Diaphragm Carburetors
  • Fuel Flow Through System
• Fuel Components and Available Gas
  • Leaded Gasoline
  • Air/Fuel Mixture
  • Throttle & Choke Valves
• Fuel Pump
  • Remote Fuel Pump
  • Integral Fuel Pump
  • Fuel/Oil Mixture
• Removing Fuel From System
• Troubleshooting
  • Fuel Filter & Sediment Bowl
  • "Sour" Fuel
  • Choke Problems

7- Ignition

• Introduction and Chapter Coverage
• Spark Plug Evaluation
• CDI and Charging System
  • Description & Operation -- Ignition
  • Troubleshooting -- CDI System
  • Testing Ignition Components
  • Resistance Charts
• Timing Adjustments
  • Timing Table
  • Static Timing
  • Dynamic Timing
• Charging Circuit
  • Description & Operation
  • Testing -- Regulated Voltage

8- Engine

• Introduction and Chapter Organization
• Two-Cycle Engine Operation
• Complete Service -- Three-Cylinder Engine
  • Preliminary Tasks
  • Engine Removal
  • Disassembling 3-Cylinder Engine
  • Cleaning & Inspecting
  • Assembling & Installation
  • Engine Support Equipment
• Complete Service -- Two-Cylinder Engine
  • Removal
  • Disassembling 2-Cylinder Engine
  • Cleaning & Inspecting
  • Assembling and Installation
  • Engine Support Equipment
• Cleaning and Inspecting All Engines
• Sealants, Adhesives, Lubricants & Fuel Stabilizers

9- Electrical

• Introduction
• Batteries
• Tachometer
• Electrical System - General Information
• Cranking Motor Circuit Service
  • Description
  • Cranking Motor Noises
  • Troubleshooting
• Testing Other Electrical Components
  • Temperature Warning Circuit
  • Temperature Sensor Test
  • RPM Limiter
  • Fuel Sender Unit Test
  • Oil Level Sender
  • Trim System Motor Test
  • Electric Bilge Pump

10- Jet Pump

• Introduction
• Impellers
• Jet Pump Service
  • Removal & Disassembling
  • Cleaning & Inspecting
  • Assembling
• Bearing Housing and Driveshaft Service

11- Control Adjustments

• Introduction
• Steering Cable Adjustment
• Reverse Cable Adjustment
• Trim Nozzle
• Speedometer Inspection

Appendix

• Metric Conversion Chart
• Tap Drill Sizes
• Engine Torque Values
• Engine Specifications
• Tune-Up Adjustments
• Carburetor Installation and Bench Adjustments
• Wiring Diagrams and Color Code Identification

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