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INTRODUCTION
These manuals contains an introductory description on and procedures for the inspection, service and overhaul of its main components. General knowledge information is not included. Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning your personal watercraft PWC in the manual. Read and refer to the other sections in this manual for information regarding proper inspection and service procedures.
• These manuals have been prepared using the latest information available at the time of publication. If a modification has been made since then, differences may exist between the content of these manuals and the actual PWC personal water craft.
• Illustrations in these manuals are used to show the basic principles of operation and work procedures of the actual personal watercraft and components in exact detail.
• These manuals are intended for use by technicians who already possess the basic knowledge and skills to service a personal watercraft motors and components. Persons without such knowledge and skills should attempt with caution to service any component or engine by relying on this manual only. Never attempt to perform any work with out the assistance of a service manual.
Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may or may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the engine unsafe for the watercraft operator and passengers.
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POLARIS WATERCRAFT SERVICE MANUALS AVAILABLE:
1992 1998 Polaris PWC WaterCraft Service Manual (Water Craft)
Service Manual Application: Polaris 1992, 1993, 1994, 1995, 1996, 1997 & 1998 WaterCraft (Water craft) PWC. Models covered in this manual: 1992: SL650 (SL-650) - 1993: SL650 (SL-650), SL750, SLT - 1994: SL650, SL750 (SL-750), SLT - 1995: SL650 (SL650 International), SL650 STD (SL650 STD International), SL750 (SL750 International). SLTl50 (SLTl50 International), SLX780 (SLX-780 International) - 1996: SL700 (SL-700 International), SLTlOO (SLTlOO International), SL780 (SL780 International), SL900 (SL-900 International), SLX780 (SLX780 International), SLTl80 (SLTl80 International), Hurricane (Hurricane International), SLTX (SLTX International) - 1997: SL700, SL700 Deluxe, SLT700 Hurricane, SL780, SLTl80, SLX PRO 785, SL900, SL1050 SLTX - 1998: SLH, SLTH, SLXH, SLTX
1999 Polaris Genesis X 45 & Ficht Service Manual PWC
Service Manual Application: Polaris 1999 Genesis, 1999, Genesis Ficht and 1999 X-45 WaterCraft (Water craft) PWC. Models covered in this manual: Genesis, Genesis Ficht & X-45.
2000 Polaris Virage TX SLX Genesis & Pro 1200 Service Manual
Service Manual Application: 2000 Polaris Virage TX, SLX, Pro 1200, Genesis, Genesis FFI WaterCraft (Water craft) PWC. Models covered in this manual: 2000 Polaris Virage TX, 2000 Polaris SLX, 2000 Polaris Pro 1200, 2000 Polaris Genesis, 2000 Polaris Genesis FFI.
2001 Polaris Service Manual Genesis SLX Virage & Pro 1200
Service Manual Application: 2001 Polaris SLX, PRO 1200, Virage TX, Genesis, Virage TXi, Genesis i WaterCraft (Water craft) PWC. Models covered in this manual: 2001 Polaris SLX, 2001 PRO 1200, 2001 Virage TX, 2001 Genesis, 2001 Virage TXi, 2001 Genesis i
2001 Polaris SLH & Virage Service Manual PWC WaterCraft
Service Manual Application: 2001 Polaris SLH, Virage PWC Factory Service Manual Personal WaterCraft (Water craft) PWC. Models covered in this manual: 2001 Polaris SLH, 2001 Polaris Virage.
2002 Polaris Service Manual Freedom Genesis Virage
Service Manual Application: 2002 02' Polaris Freedom, Virage, Virage TX, Virage i, Virage TXi, Genesis, Genesis i PWC Factory Service Manual Personal WaterCraft (Water craft) PWC. Models covered in this manual: 2002 Freedom W025297D, 2002 Virage W025197D, 2002 Virage TX W025199D, 2002 Virage i W025101D, 2002 Virage TXi W025198D, 2002 Genesis W025099D, 2002 Genesis i W025098D
2003 Polaris Service Manual FREEDOM GENESIS VIRAGE
Service Manual Application: 2003 03' Polaris Freedom, Virage, Virage i, Genesis i PWC Factory Service Manual Personal WaterCraft (Water craft). Models covered in this manual: Freedom W035297DA, Virage W035197DA, Virage i W035101CA, Genesis i W035098CA.
2004 Polaris Service Manual MSX110 MSX150 (MSX-110 MSX-150)
Service Manual Application: 2004 04' Polaris MSX110 (MSX-110) MSX150 (MSX-150) PWC Factory Service Manual Personal WaterCraft (Water craft). Models covered in this manual: 2004 Polaris MSX110 (MSX-110), 2004 Polaris MSX150 (MSX-150).
2004 Polaris Service Manual FREEDOM GENESIS VIRAGE
Service Manual Application: 2004 04' Polaris Freedom, Freedom, Virage, Virage i, Genesis i, MSX 140 PWC Factory Service Manual Personal WaterCraft (Water craft). Models covered in this manual: Freedom W045297DA, Freedom International W045297IA, Virage W045197DA, Virage International W045197IA, Virage i W045101CA, Virage i International W045101IA, Genesis i W045098CA, Genesis i International W045098IA, MSX140 W045303CA, MSX 140 International W045303IA |
BELOW IS A GENERAL OUTLINE OF A TYPICAL WATERCRAFT SERVICE MANUAL SUBJECTS MAY DIFFER DEPENDING ON YEAR AND MODEL |
GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL SYSTEM POWER UNIT JET PUMP UNIT PUMP ELECTRICAL SYSTEM HULL AND HOOD HOOD TROUBLE ANALYSIS
CHAPTER 1 GENERAL INFORMATION
IDENTIFICATION NUMBERS PRIMARY l.D. NUMBER ENGINE SERIAL NUMBER JET PUMP UNIT SERIAL NUMBER HULL IDENTIFICATION NUMBER (H.l.N.) SAFETY WHILE WORKING FIRE PREVENTION VENTILATION SELF-PROTECTION OILS, GREASES AND SEALING FLUIDS GOOD WORKING PRACTICES DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS MEASURING
CHAPTER 2 SPECIFICATIONS
GENERAL SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE JET PUMP UNIT HULL AND HOOD ELECTRICAL TIGHTENING TORQUES SPECIFIED TORQUES GENERAL TORQUE CABLE AND HOSE ROUTING
CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT
Maintenance chart ivterval & Periodic service Control system Steering column inspection Steering cable inspection and adjustment Throttle cable inspection and adjustment Choke cable inspection and adjustment QSTS cable inspection and adjustment YPVS cable adjustment Fuel System Fuel line inspection Trolling speed check and adjustment Oil Injection System Oil line inspection Power Unit Spark plug inspection Electrical Battery inspection Jet pump Unit Impeller inspection Water inlet strainer inspection Bilge strainer inspection Drain plug inspection Lubrication points
CHAPTER 4 FUEL SYSTEM
Fuel cock and fuel filter Fuel filter inspection Fuel cock inspection Oil tank Exploded diagram Removal and installation chart Oil line inspection Oil level sensor inspection Oil tank inspection Fuel tank Check valve inspection Fuel level sensor inspection Fuel tank inspection Pipe joint inspection Intake silencer Carburetor unit Throttle valve synchronization inspection and adjustment Choke cable and throttle cable installation Oil pump cable installation Carburetor assembly Carburetor Diaphragm inspection Accelerator pump body inspection Arm inspection Regulator body inspection Needle valve inspection Jet and carburetor body inspection Carburetor assembly Fuel Pump Fuel pump inspection Fuel filter inspection Oil pump Oil pump inspection Oil hose inspection Check valve inspection Oil pump cable adjustment Oil injection pump air bleeding
CHAPTER 5 POWER UNIT
Engine unit Shim removal Engine mount inspection Coupling clearance inspection Exhaust chamber assembly Exhaust chamber joint Exhaust manifold Reed valves Reed valve inspection YPVS YPVS valve inspection YPVS valve installation Cylinder head Cylinders Cylinder head inspection Cylinder inspection Pistons Piston pin clip removal and installation Piston inspection Cylinder and piston combination Piston ring inspection Piston pin and bearing inspection Starter motor Flywheel magneto Drive coupling removal and installation Flywheel magneto removal and installation Drive coupling inspection Flywheel magneto inspection Starter clutch assembly inspection Crankcase Crankcase inspection Crankcase installation Crankshaft Crankshaft inspection
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CHAPTER 6 JET PUMP UNIT
Jet pump unit Nozzle deflector and nozzle ring Impeller duct, impeller housing and intake duct Impeller duct and drive shaft Drive shaft removal Impeller inspection Drive shaft inspection Drive shaft installation Transom plate and hoses Bilge strainer inspection Bilge hose inspection Bearing housing Driven coupling removal and installation Intermediate drive shaft removal Bearing removal Bearing, driven coupling shaft, and grease hose inspection Driven coupling inspection Bearing installation Oil seal installation Intermediate housing installation
CHAPTER 7 ELECTRICAL SYSTEM
Electrical components Electrical box Electrical analysis Digital tester Peak voltage measurement Peak voltage adaptor Test harness Ignition system Wiring diagram, diagrams Ignition spark gap Ignition system peak voltage Spark plugs Spark plug caps Spark plug gap Ignition coil Engine stop switch Thermoswitch Starting system Battery Wiring connections Fuses and fuse Starter switch Starter relay Starter motor Armature inspection Brush holder inspection Starter motor front cover inspection Charging system Rectifier, regulator peak voltage Lighting coil peak voltage Pickup coil CDI unit YPVS servomotor YPVS cable removal and installation YPVS cable inspection YPVS servomotor inspection YPVS cable adjustment INDICATION SYSTEM Buzzer Oil level sensor Fuel level sensor Oil level sensor Multifuction meter/removal Display function Fuel level gauge Oil level gauge Overheat warning indicator Speed meter Speed sensor
CHAPTER 8 HULL AND HOOD
Handlebar Handlebar inspection Handlebar switch inspection Handlebar assembly installation QSTS GRIP QSTS cable inspection QSTS grip inspection Steering colum Steering column bushing inspection Remote control cables and speed sensor lead Remote control cables inspection Steering cable (jet pump side) installation Steering cable stopper installation QSTS cable (jet pump side) installation QSTS cable stopper installation Front hood Steering console cover Buzzer and hood lock Hoses Check valve inspection Ventilation hose installation Seats and hand grip Battery box Exhaust system Seat lock inspection Exhaust system inspection Exhaust component parts sub-assembly Deck and hull Engine mount Hull repair Shallow scratches Deep scratches Cracks and punctures Insert nut Graphic & Decal, Decals removal Graphic installation
CHAPTER 9 TROUBLE ANALYSIS
Troubleshooting & analysis Trouble analysis chart
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COMMON POLARIS TROUBLESHOOTING SEARCHES FOR (A T V'S)
ENGINE
Engine Turns Over But Fails to Start
• No fuel • Dirt in fuel line or filter • Fuel will not pass through fuel valve • Fuel pump inoperative/restricted • Tank vent plugged • Carb starter circuit • Engine flooded • Low compression (high cylinder leakage) • No spark (Spark plug fouled)
Engine Does Not Turn Over
• Dead battery • Starter motor does not turn • Engine seized, rusted, or mechanical failure
Engine Runs But Will Not Idle
• Restricted carburetor pilot system • Carburetor misadjusted • Choke not adjusted properly • Low compression • Crankcase breather restricted
Engine Idles But Will Not Rev Up
• Spark plug fouled/weak spark • Broken throttle cable • Obstruction in air intake • Air box removed (reinstall all intake components) • Incorrect or restricted carburetor jetting • ETC switch limiting speed • Reverse speed limiter limiting speed • Carburetor vacuum slide sticking/diaphragm damaged • Incorrect ignition timing • Restricted exhaust system
Engine Has Low Power
• Spark plug fouled • Cylinder, piston, ring, or valve wear or damage (check compression) • PVT not operating properly • Restricted exhaust muffler • Carburetor vacuum slide sticking/diaphragm damaged • Dirty carburetor
Piston Failure - Scoring
• Lack of lubrication • Dirt entering engine through cracks in air filter or ducts • Engine oil dirty or contaminated
Excessive Smoke and Carbon Buildup
• Excessive piston-to-cylinder clearance • Wet sumping • Worn rings, piston, or cylinder • Worn valves, guides or seals • Restricted breather • Air filter dirty or contaminated
Low Compression
• Decompressor stuck • Cylinder head gasket leak • No valve clearance or incorrectly adjusted • Cylinder or piston worn • Piston rings worn, leaking, broken, or sticking • Bent valve or stuck valve • Valve spring broken or weak • Valve not seating properly (bent or carbon accumulated on sealing surface) • Rocker arm sticking |
Backfiring
• ETC or speed limiter system malfunction • Fouled spark plug or incorrect plug or plug gap • Carburetion faulty - lean condition • Exhaust system air leaks • Ignition system faulty:
Spark plug cap cracked/broken Ignition coil faulty Ignition or kill switch circuit faulty Ignition timing incorrect Sheared flywheel key
• Poor connections in ignition system • System wiring wet • Valve sticking • Air leaks in intake • Lean condition
Spark Plug Fouling
• Spark plug cap loose or faulty • Choke cable adjustment or plunger/cable sticking • Foreign material on choke plunger seat or plunger • Incorrect spark plug heat range or gap • Carburetor inlet needle and seat worn • Jet needle and/or needle jet worn or improperly adjusted • Excessive carburetor vibration (loose or missing needle jet locating pins) • Loose jets in carburetor or calibration incorrect for altitude/temperature • Incorrect float level setting • PVT system calibrated incorrectly or components worn or mis-adjusted • Fuel quality poor (old) or octane too high • Low compression • Restricted exhaust • Weak ignition (loose coil ground, faulty coil, stator, or ETC switch) • ETC switch mis-adjusted • Restricted air filter (main or pre-cleaner) • Improperly assembled air intake system • Restricted engine breather system • Oil contaminated with fuel • Restricted oil tank vent
Cooling Troubleshooting
Overheating
• Low coolant level • Air in cooling system • Wrong type of coolant • Faulty pressure cap or system leaks • Restricted system (blocked in radiator, lines, pump, or water jacket) • Lean mixture (restricted jets, vents, or fuel pump) • Fuel pump output weak • Restricted radiator (internally or cooling fins) • Water pump failure • Cooling system restriction • Cooling fan inoperative or turning too slowly • Ignition timing misadjusted • Low oil level • Spark plug incorrect heat range • Faulty hot light circuit • Thermostat stuck closed or not opening completely • Radiator is missing its internal diverter plate not allowing coolant to flow through entire radiator
Temperature Too Low
• Thermostat stuck open
Leak at Water Pump Weep Hole
• Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) |
Service Manual, Repair Manual, Shop Manual, User's Manual, Workshop Guide, Study Guide, Download PDF Owner's Service Repair Manual, eBook, Learning Book, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 92, 93, 94, 95, 96, 97, 98, 99, 00, 01, 02, 03, 04, 05, 06, 07, 08, 09, 10 |
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