Description

Polaris Personal Watercraft Service Manual (1992-1998 Models)

This comprehensive Polaris Service Manual (P/N f5004613) covers maintenance, diagnostics, and repair procedures for 1992-1998 Polaris watercraft models, including SL650, SL750, SLT750, and SL780 series. Features detailed specifications for Fuji marine engines (648cc, 744cc, and 779cc twin-cylinder configurations) with peak outputs ranging from 62-90 HP at 6500 RPM.

Technical Coverage Includes:

• Complete engine service procedures for Fuji twin-cylinder powerplants, including 648cc (bore: 76mm, stroke: 71mm), timing specifications (22° BTDC), cylinder head torque sequences (18-22 ft-lbs), and rebuild tolerances (0.004″ piston clearance)
• Mikuni SBN-44 carburetor tuning specifications, 60 LPH high-pressure fuel pump service, and 3/8″ marine-grade fuel line inspection protocols
• CDI ignition system diagnostics with 280W charging system specifications, complete MPEM (Multi-Purpose Electronic Module) troubleshooting, and voltage regulation parameters (14.2V ±0.4V)
• SMC composite hull and deck repair procedures, including 2.5mm gelcoat applications, structural grid reinforcement specs, and 1.5oz mat/24oz woven roving layup sequences
• 155mm axial-flow jet pump specifications, 15/21 pitch stainless steel impeller maintenance, 0.030″ wear ring clearances, and splined shaft alignment procedures
• UFLEX M66 cable steering system maintenance, 33° maximum nozzle deflection specs, and handlebar pivot adjustment procedures
• Closed-loop cooling system service, including 4.5 GPM water pump specifications, 135°F thermostat testing, and intercooler maintenance
• Factory maintenance intervals and critical torque specifications for all major assemblies

Professional Features:

• OEM repair procedures with Polaris factory specifications and clearances
• Technical illustrations including hull structure diagrams and MPEM schematics
• Advanced diagnostic procedures for electrical and fuel system troubleshooting
• Complete BOM (Bill of Materials) with OEM part numbers and assembly sequences
• USCG safety compliance information and service warning protocols

This manual is an essential resource for marine service professionals, experienced watercraft technicians, and maintenance-oriented owners. All procedures comply with ABYC (American Boat & Yacht Council) standards and NMMA (National Marine Manufacturers Association) guidelines. The manual’s professional-grade content ensures proper maintenance of critical systems including the 14-gallon fuel capacity, 7.8″ draft clearance, and 105.5″ LOA specifications while maintaining the craft’s peak performance of 55+ MPH capability.