Polaris Slt Pwc 1993 – 1994 Workshop Service Manual
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LANGUAGE:ENGLISH
PAGES:577
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Polaris Slt Pwc 1993 – 1994 Workshop Service Manual
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 importance. 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.
TABLE OF CONTENTS:
Polaris Slt Pwc 1993 – 1994 Workshop Service Manual
GENERAL INFORMATION
Publication Numbers 11
Service Bulletin Index By Bulletin Number12 – 14
Service Bulletin Index By Model14a – 14b
Paint Codes 15 – 16a
Model Identification17
Model Specifications 1992 – 1993 18
Model Specifications 1994 – 1995 19 – 111
Model Specifications 1996 – 1997 112 – 114c
Model Specifications 1998114d – 114e
Standard Torque Specifications 115
Decimal Equivalents 116
Conversion Table 117
Tap Drill Charts 118
Glossary of Terms 119 – 120
Special Tools 121 – 126
Service Tips 127
Warranty Policy128
MAINTENANCE/TUNE UP
Periodic Maintenance Schedule 21 – 21a
Recommended Lubricants and Accessories 22
Lubrication 23 – 26
Electrical 27 – 210
Engine / Exhaust System 211 – 218
Cable Adjustments 219 – 225
Air Intake / Fuel System 225 – 232
Cooling System Maintenance/Storage 233 – 236
Fuel System Storage/Engine Fogging 237 – 239
Cleaning239
Bilge Siphon System 240
Electric Trim Adjustment 241
Submerged Engine (Hydrolocked)242
Pump/Impeller243
Hull/Deck 244 – 247
Troubleshooting 248 – 253
FUEL SYSTEM/CARBURETION
Carburetor Specifications and Initial Settings 31 – 35c
Carburetor Jet Part Numbers 36
High Elevation Recommendations 37 – 37a
Vent/Fuel Delivery Exploded View 38 – 317
Fuel Tank/Fuel Pickup Exploded View 318 – 329
Air Intake Silencer and Water Separator 330 – 339
Carburetor Assembly Exploded View 340 – 345
Oil Tank Removal 346
Oil Tank Exploded View 347 – 350
Oil Pump Assembly Exploded View 351 – 352
Carburetor Fuel Hose Connections – Keihin 352a – 352b
Carburetor System Operation, Mikuni 353 – 355
Carburetor System Operation, Keihin 356 – 358
Fuel Pump Operation 359 – 360
Fuel Shut Off Valve Disassembly/Inspection 361
FuellWater Separator 362
Mixture Screw Adjustment, Mikuni 363 – 366
Carburetor Removal, Mikuni ” 367
Carburetor Disassembly, Mikuni 368 – 371
Carburetor Assembly, Mikuni 372
Carburetor Removal, Keihin 373 – 375
Carburetor Disassembly/Inspection, Keihin 376 – 382
Carburetor Assembly, Keihin 383 – 386
Carburetor Installation, Keihin 387 – 388
Carburetor Adjustment and Service, Keihin 389 – 390
Cable Adjustment 391
Mixture Screw Adjustment – Keihin 392 – 393
Fuel Tank Vent System 394 – 395
Fuel Tank Vent Line Routing 396 – 397
Fuel Tank Check Valve Testing 398
Fuel Pump Operation 399
Fuel Pump Maintenance 3100
Reed Valve Removal/Inspection, Mikuni 3101 – 3102
Reed Cage and Intake Manifold Installation, Mikuni 3103
Reed Valve Removal/Inspection, Keihin 3104
Reed Valve Assembly, Keihin 3105
Testing 3106 – 3107
Engine Specifications 1993 – 1994 41
Engine Specifications 1995 – 199642 – 44
Engine Specifications 199744a – 44b
Engine Specifications 1998 44c
Torque Chart 45
Torque Patterns 46 – 410
Engine and Mount Assembly Exploded View 411 – 415
Cylinder and Manifold Exploded View 416 – 420
Crankshaft/Piston Exploded View 421 – 425
Crankcase Exploded View426 – 430
Oil Pump Exploded View431 – 433
Engine Removal, Fuji ” 434 – 436
Engine Disassembly/Inspection, Fuji 437 – 441
Engine Assembly, Fuji 442 – 447
Engine Installation, Fuji 448
Engine Disassembly/Inspection, 780cc 449 – 462
Engine Assembly, 780cc 463 – 470
Engine Removal, Polaris 471 – 472
Engine Disassembly/Inspection, Polaris 473 – 482
Engine Assembly, Polaris 483 – 498
Engine Installation, Polaris 499
Cylinder Honing / Port Chamfering 4100 – 4101
Oil Pump, Fuji 4102 – 4103
Cooling System Exploded View 4104 – 4107
Thermostat and Coolant Filter, Fuji 4108
Thermostat and Coolant Filter, Polaris 4109
Crankshaft Indexing 4110
Torque Specifications / Special Tools 51
1996 to Current Pump Data 52 – 52a
Impeller Part Numbers53
High Elevation Specifications 54
DriveshaftiCoupler Exploded View 55 – 56
Pump Assembly Exploded View 57 – 512
Pump Intake Exploded View 513 – 516
Pump Removal, 1992-1993 517
Pump Disassembly/Inspection, 1992-1993 518 – 520
Drive Shaft Inspection, 1992-1993 521
Pump Assembly, 1992-1993 522
Intake Scoop and Ride Plate Installation 523
Pump Installation, 1992-1993 524
Pump Removal, 1994-1996 525 – 526
Pump Disassembly/Inspection, 1994-1996 527 – 530
Pump Assembly, 1994-1996 531
Pump Installation, 1994-1996532 – 534
Pump Housing Removal, 1994-1996535
Pump Housing Installation, 1994-1996 536
Pump Drive Shaft Alignment 537 – 537d
Drive Shaft Lubrication538 – 539
Coupler Removal 540
Ventilation/Cavitation Diagnostics 541
Seat Assembly Exploded View 61 – 64b
Steering Assembly Exploded View 65 – 612
Deck Assembly Exploded View 613 – 621
Front Compartment Assembly Exploded View , , 622 – 624
Steering Cover/Steering Post Removal625 – 627
Steering Cable Replacement/Adjustment ” 628 – 630
Speedometer Operation and Inspection 631
Dash/Control Panel 632
Decal Replacement 632
Wire Clip Replacement 632
Hull Repair 633 – 634
Sponson Removal/Installation 635
Through-Hull Fitting Removal/Installation635
Specifications – Spark Plugs / Alternator 71
Specifications – CDI Box / Ignition Timing 71 a
Warning Systems Operating Characteristics 71 b
Stator Coil/Ignition Component Specifications 72
Ignition System Exploded Views 73 – 76
Electrical Box Exploded Views 77 – 713
Battery Charging System Testing 714 – 715
Switch Testing 715
Battery Testing 716 -717
Battery Maintenance 718
Starter Motor Disassembly 719 – 720
Starter Motor Brush Replacement 721
Starter Motor Armature Testing 721
Starter Motor Exploded View 722
Starter Motor Assembly 722 – 723
Starter System Testing 724
Temperature Warning Operation / Sensor Test 725
Fuel Gauge Operation and Testing 726
RPM Limiter Function / Troubleshooting 727 – 727b
Oil Level Sensor System Troubleshooting 728
Quick Trim System Operation / Maintenance 729 – 730
Ignition Timing (Degrees-to-Piston Position
ConversionChart) 731
Ignition System Testing 732 – 734c
Hall Effect Sensor Testing 735
Ignition Timing Adjustment, Fuji 736 – 737
Ignition Timing Adjustment, Polaris 738 – 739
Multi-Function Display Operation and Modes 740 – 741
Multi-Function Display Troubleshooting 742
Weatherproof Connector Servicing 743
Electronic Module Function 744
Bilge Pump 745
Wiring Diagrams 747 – 771
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
Elijah Michael –
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