Polaris Virage TX 2000 Service Manual page 33

MAINTENANCE/TUNE UP
Engine
Thermostat/Pop Off Valve Cleaning (FFI™ Watercraft)
If low end performance of the watercraft begins to deteriorate, and the jet pump intake area is free of debris and
weeds; or if the overheat alarm sounds, the thermostat pop off assembly should be checked for debris and
cleaned. Inspect the thermostat pop off assembly if the watercraft has been stored for more than 30 days or has
been used in salt water.
CAUTION:
Note the location of all parts when cleaning the thermostat/popoff valve assembly. Be sure all parts are positioned
correctly during reassembly, or severe engine damage will result within a very short period of operation. Do not
perform this maintenance while the watercraft is in the water. The thermostat pop off assembly is under tension
from an internal spring. When the screws are removed, the assembly will come apart quickly if not held together
firmly.
1. Using a 3/16" (.5 cm) hexagonal wrench and a flat
screwdriver, remove screws while holding
thermostat pop off assembly firmly together.
Carefully take assembly apart. Be careful npt to
lose any parts.
2. Inspect thermostat pop off assembly for debris,
such as sand or seaweed, and clean thoroughly
with water. Inspect pop off valve for wear. See III. 1.
3. Inspect condition of gaskets and rubber parts.
Replace any parts that appear cracked, damaged,
or distorted.
4. Inspect thermostat and housing for corrosion.
Visually inspect thermostat for damage or
distortion. It should be closed at room temperature.
5. Apply Loctite 242 (Blue) to bolts. Carefully
assemble thermostat pop off assembly in the
correct sequence. Verify proper alignment of all
parts and gasket/O-ring during assembly. The
arrow in the illustration indicates the direction of
water flow (away from engine). See III. 2.
Internal Pop-off Valve x
(Longer End Towards n
Engine) \ ^
Valve Spring
Gasket
Thermostat
Thermostat
Base
Gagftet
/
3100
2.16
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