Polaris WATERCRAFT Freedom Service Manual
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Polaris WATERCRAFT Freedom Service Manual

Polaris WATERCRAFT Freedom Service Manual

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Freedom
Virage
Virage
Virage TX
Virage TX
Virage i
Virage i
Virage TXi
Genesis
Genesis i
2002 Personal Watercraft Service Manual
2002 Personal Watercraft Service Manual
Part Number 9917370
Part Number 9917370

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Summary of Contents for Polaris WATERCRAFT Freedom

  • Page 1 Freedom Virage Virage Virage TX Virage TX Virage i Virage i Virage TXi Genesis Genesis i 2002 Personal Watercraft Service Manual 2002 Personal Watercraft Service Manual Part Number 9917370 Part Number 9917370...
  • Page 3 SERVICE MANUAL Foreword 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.
  • Page 4 A CAUTION indicates special precautions that must be taken to avoid minor personal injury, or watercraft or prop- erty damage. NOTE: A NOTE provides key information to clarify instructions. Polaris acknowledges the following products mentioned in this manual: Loctite, Registered Trademark of the Loctite Corporation FLEXLOC, Registered Trademark of SPS Technologies MityVac, Registered Trademark of Neward Enterprises...
  • Page 5 Chapter 1 ... . . General Information Chapter 2 ... . . Maintenance Chapter 3 ... . . Engine / Cooling Chapter 4 .

  • Page 7: Table Of Contents

    2002 PWC Identification Numbers ........2002 PWC Publication Part Numbers .

  • Page 9: 2002 Pwc Identification Numbers

    Month of Country of Number Manufacture of Craft Manufacture Manufacture Month Code: A = January; B = February; etc. Year Of Manufacture: 1 = 2001; 2 = 2002; etc. HULL I.D. NUMBER Starter Cover Engine I.D. Number (Polaris Domestic Engine)

  • Page 10: 2002 Pwc Publication Part Numbers

    General Information 2002 PWC Publication Part Numbers Model Model Number Owner’s Manual Parts Book Microfiche Freedom W025297D/I 9917547 9917548 Virage W025197D/I 9917129 9917130 Virage TX W025199D/I 9917132 9917133 Virage i W025101D/C/I 9917138 9917139 9917128 Virage TXi W025198D/C/I 9917135 9917136 Genesis W025099D/I 9917141 9917142...

  • Page 11: Service Tools

    General Information Personal Watercraft Service Tools Part Number Tool (Must Order From Polaris Tool Vendor) Piston Pin Puller 2870386 Piston Pin Puller Adapter 2871445 (Works with 2870386) Piston Support Block 2870390 C--Clip Installation Tool 2870773 Piston Pin Puller (800 / 1200cc Engines)
  • Page 12 General Information 2002 Freedom W025297D Length: ..120.3 in. (305.6 cm.) Width: ..49.3 in. (125.2 cm.) Height: ..39 in. (99.1 cm.) Draft: ..9 in.
  • Page 13 General Information 2002 Freedom Model Number W025297D Engine Platform Polaris Marine 700 LE Engine Model Number W70- -SCSP- -05A Engine Displacement 701cc Number of Cylinders Bore & Stroke (mm) 81x68 Compression Ratio (Full Stroke) 7.0:1 Horsepower Maximum Torque 69.2 Cooling System Water Cooled / Thermostat Pop- -Off, self- -draining, Direct From Propulsion.
  • Page 14 General Information 2002 Virage W025197D Length: ..124.3 in. (305.6 cm.) Width: ..49.3 in. (125.2 cm.) Height: ..39 in. (99.1 cm.) Draft: ..9 in.
  • Page 15 General Information 2002 Virage Model Number W025197D Engine Platform Polaris Marine 700 LE Engine Model Number W70- -SCSP- -05A Engine Displacement 701cc Number of Cylinders Bore & Stroke (mm) 81x68 Compression Ratio (Full Stroke) 7.0:1 Horsepower Maximum Torque 69.2 Cooling System Water Cooled / Thermostat Pop- -Off, self- -draining, Direct From Propulsion.
  • Page 16 General Information 2002 Virage TX W025199D Length: ..124.3 in. (305.6 cm.) Width: ..49.3 in. (125.2 cm.) Height: ..39 in. (99.1 cm.) Draft: ..9 in.
  • Page 17 General Information 2002 Virage TX Model Number W025199D Engine Platform Polaris Marine 1200 Engine Model Number W120- -TCSP- -04 Engine Displacement 1165cc Number of Cylinders Bore & Stroke (mm) 84x70 Compression Ratio (Full Stroke) 6.7:1 Maximum Horsepower Maximum Torque Cooling System Water Cooled / Thermostat Pop- -Off, self- -draining, Direct From Propulsion.
  • Page 18 General Information 2002 Virage i W025101D Length: ..124.3 in. (305.6 cm.) Width: ..49.3 in. (125.2 cm.) Height: ..39 in. (99.1 cm.) Draft: ..9 in.
  • Page 19 General Information 2002 Virage i Model Number W025101D Engine Platform Polaris Marine 800 DIt Engine Model Number W77- -DFI- -01A Engine Displacement 777cc Number of Cylinders Bore & Stroke (mm) 84x70 Compression Ratio (Full Stroke) Maximum Horsepower Maximum Torque 72 ft. lbs.
  • Page 20 General Information 2002 Virage TXi W025198D Length: ..124.3 in. (305.6 cm.) Width: ..49.3 in. (125.2 cm.) Height: ..39 in. (99.1 cm.) Draft: ..9 in.
  • Page 21 General Information 2002 Virage TX i Model Number W025198D Engine Platform Polaris Marine 1200 DIt Engine Model Number W120- -DFI- -04A Engine Displacement 1165cc Number of Cylinders Bore & Stroke (mm) 84x70 Compression Ratio (Full Stroke) 6.5/6.5/6.2:1(MAG, CTR, PTO) Maximum Horsepower...
  • Page 22 General Information 2002 Genesis W025099D Length: ..131.1 in. (330.5 cm.) Width: ..49.3 in. (125.2 cm.) Height: ..40.4 in. (102.6 cm.) Draft: ..9 in.
  • Page 23 Pivoting Angle 30° Impeller Type Progressive Pitch Radial Blade Impeller Diameter 5.8 in. Reverse System PERCt (Polaris Electronic Reverse Control) Hull / Body Hull Design Modified Full V Hull Material FRC (Fiberglass Reinforced Composite) Top Deck Material FRC (Fiberglass Reinforced Composite)
  • Page 24 General Information 2002 Genesis i W025098D Length: ..131.1 in. (330.5 cm.) Width: ..49.3 in. (125.2 cm.) Height: ..40.4 in. (102.6 cm.) Draft: ..9 in.
  • Page 25 Pivoting Angle 30° Impeller Type Progressive Pitch Radial Blade Impeller Diameter 5.8 in. Reverse System PERCt (Polaris Electronic Reverse Control) Hull / Body Hull Design Modified Full V Hull Material FRC (Fiberglass Reinforced Composite) Top Deck Material FRC (Fiberglass Reinforced Composite)

  • Page 26: Standard Torque Specifications

    General Information Standard Torque Specifications The following torque specifications are to be used as a general guideline. Use standard torque values for the appropriate size fastener when torque values are not specified. Always consult the specific manual section for torque values of fasteners and use of locking agent. RECOMMENDED TORQUE SPECIFICATION STAINLESS STEEL FASTENERS (SAE) Bolt Size...
  • Page 27 General Information Decimal Equivalent Chart 1/64 ......0156 1/32 ..... .0312 .
  • Page 28 General Information Conversion Chart Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m x .7376 = ft. lbs. kg-m x 7.233 = ft.

  • Page 29: Decimal Equivalent Charts

    General Information SAE Tap Drill Sizes Thread Size Drill Size Thread Size Drill Size #0-80 3/64 1/2-13 27/64 #1-64 1/2-20 29/64 #1-72 9/16-12 31/64 #2-56 9/16-18 33/64 #2-64 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 3/4-10 21/32 #4-40 3/4-16 11/16 #4-48 7/8-9 49/64...

  • Page 30: Service Glossary

    General Information Service Glossary ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. Bow: The front of a watercraft C: Celsius CC: Cubic centimeters.
  • Page 31 Short Circuit: An electrical circuit which is completed before the current reaches the intended component. (e.g. a bare wire touching a grounded component. Spark Plug Reach: Length of threaded portion of spark plug. Polaris uses 3/4” (2 cm) reach plugs. Static Timing: Ignition timing when engine is at zero RPM.

  • Page 32: Service Guidelines

    Polaris recommends the use of Polaris lubricants and greases, which have been specially formulated for the top performance and best protection of our machines. In some applications, such as the engine, warranty coverage may become void if other brands are substituted.
  • Page 33 Recommended Maintenance Products ......Periodic Maintenance Schedule ........2.2 -- 2.3 PWC Specific Maintenance Products .

  • Page 35: Recommended Maintenance Products

    Maintenance Recommended Maintenance Products Oil and Lubricants VES Synthetic 2--Cycle Oil Quart 2872927 Gallon 2872925 16 Gallon 2873918 55 Gallon 2872924 330 Gallon 2873303 Nature Oil Biodegradable 2--Cycle Oil Gallon 2872607 55 Gallon 2872926 Fuel System Maintenance Products Carbon Clean Plus 2871326 Isopropyl Fuel De- -Icer 2870505...

  • Page 36: Periodic Maintenance Schedule

    Maintenance Periodic Maintenance Schedule NOTE: Maintenance intervals are based upon average operating conditions. Watercraft operated in saltwater require daily corrosion protection and engine flushing, and more frequent maintenance and lubrication. DESCRIPTION Pre- Pre- 1 Mo./ 3 Mo./ 6 Mo./ Tune ride sea- Daily...
  • Page 37 Aggressive riding requires more frequent service. Fogging kits should be added to all Polaris watercraft. The engine should be fogged if the PWC will not be used for more than 48 hours.

  • Page 38: Pwc Specific Maintenance Products

    -Engine ground connection at mount plate, reed cage, etc. Marine Grade -Pump inlet scoop Silicone Sealant -Pump mating surfaces (PN 8560054) -Ride plate -Area where cables pass through hull, -All underwater areas, T-9 Metal -All external metal parts protectant (For internal engine protection use Polaris fogging oil)

  • Page 39: General Lubrication

    Verify that seals are installed in proper Oil Pump location after oiling. Cable Throttle Cable Polaris Premium Grease PN 2871423 Steering Cable / Steering Joints 1. Expose inner cable and apply lubricant. Lubricate NOTE: Cable seal can be moved to allow grease into cable.
  • Page 40 Maintenance General Lubrication - - Continued Steering Nozzle* Lubricate 1. Lubricate nozzle pivot and trim pivot. NOTE: Picture depicts model with reverse gate. Polaris Premium Grease Lubricate PN 2871423 Reverse System 1. Generously lubricate reverse cable. Polaris Premium Grease PN 2871423...
  • Page 41 1. Lubricate seat latches and mounting posts. Seat Latch Steering Pivot Shaft 1. Lubricate steering pivot shaft and bushing with Polaris Premium Marine Grease. Premium All Season Grease PN 2871423 Throttle / Choke Shafts* 1. Grease springs, exposed sections of cable,...
  • Page 42 Maintenance General Lubrication - - Continued Drive Shaft Lubrication WARNING The plastic driveshaft shroud is designed to protect you from dangerous moving parts. It must be rotated out of the way to lubricate the driveshaft coupler. Follow the instructions below in order to avoid personal injury. CAUTION: Grease drive shaft coupler and bearing housing anytime water in the craft has been at or above the coupler level to avoid damage to these parts.

  • Page 43: Battery Safety

    Maintenance Electrical Components Battery Safety When removing and installing the battery, or when performing battery maintenance always heed the following warnings and cautions: WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with the skin, eyes or clothing.

  • Page 44: Battery Charging / Maintenance

    Maintenance Electrical Components - - Continued Replenishing Battery Fluid The fluid level should be kept between the upper and low- er level marks. To refill use only distilled water. Tap water contains miner- Maintain als which are harmful to a battery. Between Battery Connections Upper and...

  • Page 45: Battery Installation / Storage

    Maintenance Electrical Components - - Continued Battery Installation WARNING Always connect battery cables in the order specified. Red (positive) cable first, black (negative) cable last. 1. Install battery in its holder. 2. Install battery vent tube. It must be free from kinks, obstructions, or restrictions and securely installed.
  • Page 46 Maintenance Electrical Components - - Continued Electrical Connections Apply Nyogelt grease to battery posts and exposed cable connections. Inspect electrical box for moisture, check wire sealing grommets, and apply Nyogelt grease to terminal board connections. Nyogelt Grease PN 2871329 Terminal Board NOTE: Verify that terminal board clips hold fuses securely.

  • Page 47: Spark Plugs

    Maintenance Electrical Components - - Continued Spark Plugs 1. Disconnect high tension leads and remove spark plugs. 2. Inspect electrodes for wear, carbon buildup, or fouling (wet oily residue). Replace plugs if edges of electrodes are rounded or eroded. CAUTION: Severe engine damage may occur if the incorrect spark plug is used.

  • Page 48: Engine Compression / Break In

    Carbureted Models: Breaking in a new engine is critical! Carbureted Polaris watercraft utilize oil injection, how- ever,you must add oil to the fuel in the fuel tank for the first tank of fuel only. Mix Polaris Premium 2 cycle oil, or Polaris Premium Gold Synthetic oil, or Nature Oil with the first tank of fuel at a 40:1 ratio.
  • Page 49 Maintenance Engine - - Continued Cylinder Head Re-Torque* With engine at room temperature (68° F or 20° C), re- torque cylinder heads in a criss-cross pattern de- scribed in the Engine Section. Cylinder Base Gasket Re-Torque* With engine at room temperature (68° F or 20° C), re- torque cylinder base nuts following the pattern de- scribed in the Engine Section.
  • Page 50 Maintenance Engine - - Continued Exhaust Cooling Orifice/Screen Cleaning The exhaust pipe rubber hoses and muffler are cooled by injecting a small amount of water through an orifice from the main cooling system into the exhaust stream. The orifice and screen should be inspected and cleaned periodically to ensure proper cooling of the exhaust muffler and connector hoses.
  • Page 51 Maintenance Engine - - Continued Thermostat/Pop Off Valve Cleaning 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.
  • Page 52 Maintenance Engine - - Continued Oil Filter The oil filter is located in-line between the oil tank and the oil pump on all models. The in-line oil filter is a special type and must not be substituted. Replace the oil filter annually or whenever water or debris has entered the oil tank.

  • Page 53: Throttle / Choke Cable Adjustment

    Maintenance Engine - - Continued Throttle / Choke Cable Inspection 1. Check for smooth throttle opening and closing in all handlebar positions. Throttle operation should be smooth and lever must return freely without binding. 2. Inspect cable for proper routing, kinks, or damage. 3.

  • Page 54: Gasoline Safety

    Maintenance Gasoline Safety WARNING Gasoline is highly flammable and explosive under certain conditions. ¨ Always exercise extreme caution whenever handling gasoline. ¨ Always refuel with the engine stopped and outdoors or in a well ventilated area. ¨ Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
  • Page 55 Maintenance Fuel System - - Continued Fuel / Water Separator - - Continued 2. Turn off fuel valve and remove battery ground cable. 3. Wrap a shop towel around top of bowl. 4. Remove bowl slowly by turning counterclockwise. Take care not to spill fuel while removing. Wipe up spills immediately with a shop cloth.
  • Page 56 Maintenance Fuel System - - Continued Fuel Lines / Vent Lines 1. Check fuel lines and vent lines for signs of wear, deterioration, damage or leakage. Replace if necessary. Ensure that clamps are tight. 2. Be sure all lines are routed properly and secured with cable ties away from any moving parts.

  • Page 57: Carburetor Adjustment

    Maintenance Fuel System - - Continued Carburetor Adjustments CAUTION: DO NOT attempt to perform carburetor adjustments with the engine attached to a flush kit or inaccurate adjust- ment will result. Idle speed and low speed mixture screw adjustments should only be performed in a test tank or in the water while secured to a trailer or dock.
  • Page 58 Maintenance Fuel System - - Continued Carburetor Air Intake 1. Remove nuts and washers, and remove each air All 700cc Engines intake. Cover carburetor with a clean shop towel to prevent foreign material from entering. 2. Clean element with high flash point solvent, followed by hot soapy water.

  • Page 59: Cooling System Maintenance

    Maintenance Cooling System Cooling System Flushing and Salt Water Maintenance Flushing the cooling system with fresh water is necessary to neutralize the corroding effects of salt water or water with impurities like silt, sand, alkali, and other particles as well as to flush out other residue left in the passages of the watercraft cooling system.
  • Page 60 Storage / Exterior Care Off Season Storage Procedures NOTE: DIt models use the same off season storage procedures as all Polaris watercraft, however, because the EMM and stator housing used on the DIt are water-cooled, it is recommended that DIt models are stored 10°...
  • Page 61 Polaris highly recommends the regular use of Polaris fogging oil. The engine should be fogged daily when operated in salt water. Fogging kits should be added to all Polaris watercraft. The engine should be fogged if the PWC will not be used for more than 48 hours.
  • Page 62 5. After cleaning, protect and shine watercraft using a regular furniture polish or non-abrasive silicone wax. Protect seat and handlebar unit with a vinyl protector. 6. Cover watercraft with a Polaris cover and store in a clean, dry place. Do not use plastic or coated materials as condensation and corrosion may occur.

  • Page 63: Bilge System

    Maintenance Bilge System Bilge Siphon System 1. Clean bilge siphon pickup screen whenever debris is present. View From Inside Hull Screen 2. Inspect the .040² hole in fitting elbow. It must be clear to prevent siphoning of water into bilge. .040²...
  • Page 64 Maintenance Final Drive / Propulsion Cooling Water Pickup Screen Inspect the screen in the pump stationary nozzle for de- bris and clean if necessary. Screen Fasteners Inspect all fasteners in the pump area and make sure they are tight. These include the steering nozzle mount- ing bolts, steering cable bolt, trim nozzle mounting bolts (where applicable), and all reverse mechanism fasteners (where applicable).

  • Page 65: Final Drive / Propulsion Maintenance

    Maintenance Final Drive / Propulsion Sacrificial Anode A zinc sacrificial anode is in place on all models on the pump housing. The purpose of these anodes is to prevent corrosion of metal parts due to electrolysis. The mounting surfaces must be clean and the mounting bolt tight to main- tain a good connection between the pump and anode.

  • Page 66: Seat Adjustment

    Maintenance Hull / Control Systems Handlebars/Hand Grips Handlebar w/grips 1. Pull and twist on hand grips to ensure they are not loose. If loose or wore, the handlebar with grip assembly must be replaced. 2. Check steering support hub fasteners and make sure they are tight.
  • Page 67 Maintenance Hull / Control Systems - - Continued Steering Cable Inspection 1. Check handlebars for free movement throughout their full range. Visually inspect steering control cable for damage. Check cable ends for damage. 2. Make sure cable is routed and secured properly. Inspect fasteners at ends of cable and re-torque.

  • Page 68: Steering Cable Maintenance / Adjustment

    Maintenance Hull / Control Systems - - Continued Steering Cable Adjustment Insert drill bit or dowel into hole to lock 1. Open front compartment door and then tool kit door. lock steering in center position. 2. Locate alignment hole on the bottom of the steering post.
  • Page 69 Maintenance Hull / Control Systems - - Continued Steering Cable Adjustment Procedure 1. Minor adjustments can be made using the steering 8 ft. lbs. Small adjustments cable rod end(s). Loosen jam nut on rod end(s). can be made with rod Remove end from top of steering nozzle.

  • Page 70: Reverse Cable Adjustment

    Maintenance Hull / Control Systems - - Continued Adjustment Procedure - - Continued 5. Use main cable adjuster nuts to make major adjustments. Adjuster nuts are located at forward end of cable near steering pod. Open front compartment and remove storage tray for access to bottom nut.

  • Page 71: General Troubleshooting

    Maintenance General Troubleshooting The following information is provided to help you identify possible causes for conditions/symptoms listed. Always verify tune-up adjustments and all related basic maintenance has been performed. These items are randomly listed, and are not necessarily in order of most common occurrence. Lean Condition Symptoms: Hard starting;...
  • Page 72 Maintenance General Troubleshooting - - Continued Rich Fuel Mixture Symptoms: Fouled spark plugs; black sooty exhaust; rough idle, idle unstable; poor fuel economy; rough running (four cycling); misses; poor performance; bogs; loads up; backfires (plug fouling). Thermostat/pop--off leak, dirty or damaged Carburetor mixture needles damaged or adjusted incorrectly Needle and seat damaged Misuse of choke...
  • Page 73 Maintenance General Troubleshooting - - Continued Piston Damage Symptoms: Hole in piston. Water in carburetors or fuel Lean fuel mixture (see lean condition troubleshooting) Detonation from incorrect ignition timing, poor quality fuel, modified cylinder heads, excessive carbon buildup, etc. Incorrect spark plug Overheated engine Flywheel key sheared, keyway damaged, flywheel damage Crankshaft out of index...
  • Page 74 Maintenance General Troubleshooting - - Continued Engine Overheating / Misc. Symptoms: Engine overheats. Cooling water passages in pump restricted (check screen and passages) Impeller or pump housing damage Pump housing passage plugs missing Thermostat/pop--off valve restricted Cooling water passages in engine restricted with sand or debris Loose or damaged cooling hoses or clamps Collapsed exhaust hose or pipe (restricted) Symptoms: Hard starting (engine turns over with electric starter but engine won’t start)
  • Page 75 Terminal board or connectors corroded Poor grounds or connections in electrical box or at engine mount plate Poor connections at primary winding of secondary coil (blk/blk-white on Polaris-Fuji engines) Faulty ignition coil Faulty exciter coil, trigger, or pulser coil (test stator) Excessive crankshaft runout on Magneto end (digital CDI only) (>...
  • Page 76 Maintenance General Troubleshooting - - Continued Hydrolock When an engine has been hydrolocked from water or fuel it is important to find the cause and inspect all compo- nents which may have been damaged. Be sure to check the items on this list to ensure maximum service life from the engine.
  • Page 77 2002 Engine Specifications ........3.1 -- 3.2 Engine Torque Specifications .
  • Page 79 .014 - - .019 (.36 - - .48mm) Maximum Horsepower Maximum Torque 69.2 Oil Requirement Polaris TC- -W3 RPM Limiter 7200 RPM Compression (Sea Level) 120 - - 150 lbs./sq.in. (8.40 - - 10.5 kg/sq. in.) No greater than 5% between cylinders.
  • Page 80 .019in. ± .003in. Ring End Gap Inches Maximum Horsepower Maximum Torque Oil Requirement Polaris TC- -W3 RPM Limiter 7200 RPM Compression (Sea Level) 120 - - 150 lbs./sq.in. (8.40 - - 10.5 kg/sq. in.) No greater than 5% between cylinders.
  • Page 81 Engine / Cooling 700cc Engine Torque Specifications - - Freedom / Virage Engine Fasteners Ft.lbs. Apply: Air Intake Cover Nut 5ft.lbs. 7 Nm Loctite 242 Air Intake Cover Studs to Carburetor 9ft.lbs. 12 Nm Loctite 242 Carburetor Mounting Bolts 9ft.lbs. 12 Nm Loctite 242 Air Intake Manifold Mounting Bolts...
  • Page 82 Engine / Cooling Polaris 800cc / 1200cc Engines - - Carbureted / DIt Torque Specifications Virage TX / Virage i / Virage TXi / Genesis / Genesis i Engine Fasteners Foot lbs. Apply: Air Intake Cover Bolts 22 ft. lbs.
  • Page 83 Engine / Cooling 700cc / 800cc Engine Torque Sequences - - Freedom / Virage / Virage i Crankcase Bolts (Bottom View) Mag End PTO End Cylinder Base Nuts (Top View) PTO End Mag End Exhaust Manifold...
  • Page 84 Engine / Cooling 700cc Engine Torque Sequences - - Freedom / Virage / Virage i Intake Manifold Cylinder Head Cylinder Head Cover Cylinder Head - 800cc...
  • Page 85 Engine / Cooling 1200cc Engine - - Carbureted / DIt Torque Sequences - - Virage TX / Virage TXi Genesis / Genesis i Crankcase Bolts (Bottom View) Mag End PTO End Cylinder Base Nuts (Top View) PTO End Mag End Exhaust Manifold...
  • Page 86 Engine / Cooling 1200 Engine - - Carbureted / DIt Torque Sequences - - Virage TX / Virage TXi Genesis / Genesis i Cylinder Head - All Cylinder Head Cover - Carbureted Models Intake Manifold...
  • Page 87 Engine / Cooling All Engines - - Carbureted / DIt Torque Sequences NOTE: When disassembling the water jacket / flywheel cover, take note of the water inlet and outlet pipes for proper assembly. Attach and tighten the lower hose first. NOTE: Non--DIt engines will not have a water jacket.
  • Page 88 Engine / Cooling 700cc / 800cc Engine Mount Assembly Torque Specifications . . . 9ft.lbs. (12Nm) . . . Clean thoroughly and tighten securely..50ft.lbs. (68Nm) Apply Loctitet 262 to threads..14ft.lbs. (19Nm) Apply Loctitet 262 to threads. .
  • Page 89 Engine / Cooling 700cc Crankcase Assembly Torque Specifications . . . 28ft.lbs. (38Nm) Apply Loctitet 242 to threads..22ft.lbs. (30Nm) Apply Loctitet 242 to threads..22ft.lbs. (30Nm) Apply Loctitet 242 to threads..9ft.lbs.
  • Page 90 Engine / Cooling 700cc Cylinder and Manifold Assembly Torque Specifications . . . 9ft.lbs. (12Nm) . . . Apply Loctitet Pipe Sealant 56531 . . . 22ft.lbs. (30Nm) . . . 20ft.lbs. (27Nm) . . . 32ft.lbs. (43Nm) . . . 18ft.lbs.
  • Page 91 Engine / Cooling 700cc Crankshaft and Piston Assembly C Clip “ L Ring” Connecting Rod Keystone Ring Piston Piston Pin Rod Small End Bearing Rod Big End Bearing Crank Pin Circlip A Spacer Thrust Washer O--Ring Bearings Seals Collar Torque Specifications .
  • Page 92 Engine / Cooling 800cc Engine Crankcase Assembly Torque Specifications . . . 28 ft.lbs. (38Nm) Apply Loctitet 242 to Threads..22 ft.lbs. (30Nm) Apply Loctitet 242 to Threads..10 ft.lbs. (13Nm) Apply Marine- - Grade Silicone to Threads. .
  • Page 93 Engine / Cooling 800cc Flywheel and Magneto Housing Torque Specifications . . . 22ft.lbs. (30Nm) . . . 9ft.lbs. (12Nm) . . . Apply 3 Bond 1215 Sealant to sealing surfaces..Apply Starter Grease to teeth and shafts. Insert shims in quantity and position as noted in disassembly.
  • Page 94 Engine / Cooling 800cc Engine Cylinder / Manifold / Ignition Assembly Torque Specifications . . . 9 ft.lbs. (12Nm) . . . 20 ft.lbs. (27Nm) Apply Loctitet 242 to Threads..18 ft.lbs. (24Nm) Apply Loctitet 242 to Threads. .
  • Page 95 Engine / Cooling 800cc Engine Throttle Body Assembly Torque Specifications . . . 20 ft.lbs. (27Nm) . . . 9 ft.lbs. (12Nm) . . . 5 ft.lbs. (7Nm) . . . Verify that Fogging Plugs are Installed Prior to Operation. .
  • Page 96 Engine / Cooling 800cc Engine Crankshaft Assembly Piston Assemblies Oil Pump Drive Cap Flywheel Nut Seal MAG Bearings Needle Bearings Washer Bushing PTO Bearings Flywheel Key Crankshaft Assembly Spacer Bushing O--ring Seals Torque Specifications . . . 80- -100 ft.lbs. (108- -136Nm) Apply Loctitet 242 to Threads. .
  • Page 97 Engine / Cooling 1200cc Engine Mount Assembly Torque Specifications . . . 9ft.lbs. (12Nm) . . . Clean thoroughly and tighten securely. Apply Nyogelt to Threads..50ft.lbs. (68Nm) Apply Loctitet 262 to threads..14ft.lbs. (19Nm) Apply Loctitet 262 to threads. .
  • Page 98 Engine / Cooling 1200cc Crankcase Assembly - - Carbureted Models Torque Specifications . . . 28ft.lbs. (38Nm) Apply Loctitet 242 to threads..22ft.lbs. (30Nm) Apply Loctitet 242 to threads..22ft.lbs. (30Nm) . . . 9ft.lbs.
  • Page 99 Engine / Cooling 1200cc Crankcase Assembly - - DIt Models Torque Specifications . . . 28ft.lbs. (38Nm) Apply Loctitet 242 to threads..22ft.lbs. (30Nm) Apply Loctitet 242 to threads..22ft.lbs. (30Nm) . . . 9ft.lbs.
  • Page 100 Engine / Cooling 1200cc Cylinder and Manifold Assembly - - Carbureted Models Torque Specifications . . . 9ft.lbs. (12Nm) . . . Apply 3 Bond 1215 Sealant . . . 22ft.lbs. (30Nm) . . . 20ft.lbs. (27Nm) . . . 32ft.lbs.
  • Page 101 Engine / Cooling 1200cc Manifold / Ignition Assembly - - DIt Models Ignition Coils Torque Specifications . . . 9ft.lbs. (12Nm) WARNING: DO NOT OVERTIGHTEN COIL MOUNTING BOLTS..Apply 3 Bond 1215 Sealant . . . 18ft.lbs. (24Nm) Apply Anti- - Seize Compound to Threads. .
  • Page 102 Engine / Cooling 1200cc Throttle Body Assembly - - DIt Models Torque Specifications . . . 5ft.lbs. (7Nm) . . . 5ft.lbs. (7Nm) DO NOT APPLY NYOGEL TO CONNECTOR. 3.24...
  • Page 103 Engine / Cooling 1200cc Crankshaft and Piston Assembly C Clip “ L Ring” Keystone Ring Connecting Rod Piston Piston Pin Rod Small End Bearing Rod Big End Bearing Circlip A Crank Pin Thrust Washer Spacer Circlip B O--Ring Bearings Seals Collar Torque Specifications .
  • Page 104 Engine / Cooling Oil Pump Assembly - - All Engines Torque Specifications . . . 5ft.lbs. (7Nm) . . . Replace O- - ring whenever oil pump is removed. 3.26...
  • Page 105 Do not allow any wires or hoses to get pinched between the hull and engine mount straps. Reference the appropriate chapter in routing the steering cables and throttle cables. The first tank of fuel for carbureted models should be pre--mixed with Polaris 2 cycle engine oil at a 40:1 ratio. WARNING Do not install the battery ground (--) cable until all other fuel and electrical connections are done.
  • Page 106 Engine / Cooling Engine Disassembly - - All Engines 1. Remove spark plugs. 2. Remove water outlet manifold. Discard gaskets. 3. Remove intake manifold. 3.28...
  • Page 107 Engine / Cooling Engine Disassembly - - All Engines 4. Remove the reed valves from the intake tracks. Note the order of the valves, gaskets, and reed stuffers for reassembly. Inspect sealing surface for damage that may cause an air leak. 5.
  • Page 108 Engine / Cooling Engine Disassembly - - All Engines 7. Using a strap or adjustable wrench to hold coupler, and socket to hold flywheel nut, remove the flywheel nut and washer. 8. Install flywheel puller on flywheel. Remove flywheel. When flywheel is removed, inspect flywheel key and keyway in flywheel for damage.
  • Page 109 Engine / Cooling Engine Disassembly - - All Engines 10. Loosen the three stator mounting allen screws, and stator harness allen screw. 11. Loosen the wire protection plate bolt. Remove the stator assembly from the stator housing. Three(3) stator mounting bolts. (A) Stator harness retaining shield bolt.
  • Page 110 Engine / Cooling Engine Disassembly - - All Engines 13. Remove the two starter mounting bolts, and remove the starter. NOTE: Use extreme care when removing the starter. Do not break the starter boss. 14. Tap lightly on the stator housing with a soft--faced hammer and remove housing.
  • Page 111 Engine / Cooling Engine Disassembly - - All Engines 17. Remove the four cylinder head cover bolts. 18. Remove the cylinder heads. (DIt models) Discard o rings. 19. On carbureted models, loosen the cylinder head bolts. Remove each cylinder head from the engine. discard o rings.
  • Page 112 Engine / Cooling Engine Disassembly - - All Engines 21. Using a small screwdriver, pry the circlips out of each piston. CAUTION: The circlip is under tension. Wear eye protection. Keep your thumb on the edge of the clip to prevent it from springing out.
  • Page 113 Engine / Cooling Engine Disassembly 25. Remove crankcase bolts. 26. Turn crankcase over. Using a soft--faced hammer, separate the upper half from lower. 27. Photo depicts crankshaft assembly parts. Discard seals, O--ring, and bearing retainer clip. NOTE: Some engines will be manufactured with crank- shafts that feature a center guide snap ring.
  • Page 114 Engine Assembly - - All Engines CAUTION: The cylinder mounting studs on Polaris engines are used to secure crankcase halves along with the crankcase bolts. Cylinder base nuts must be temporarily installed and torqued to maintain even pressure on the crankcase sealing surfaces during top end assembly.
  • Page 115 Engine Assembly - - All Engines 1. Install PTO O--ring and spacer onto crankshaft. Lubricate O--ring with Polaris Premium 2 Cycle oil. 2. Install the (2) PTO seals on crankshaft. Inner seal lip towards bearings, outer seal lip towards threads.
  • Page 116 Engine / Cooling Engine Assembly - - All Engines 4. Insert bearing retainer clip on MAG side of crankshaft. Open end of clip is positioned upward. 5. Apply a thin, even layer of sealer to entire surface of lower crankcase half. CAUTION: Do not allow sealer to dry.
  • Page 117 Rotate crankshaft to verify that crankshaft rotates freely without binding. 9. Bend locking tabs flat and up against bolt heads. 10. Lubricate main bearing holes with Polaris Premium 2 Cycle engine oil and rotate crankshaft to distribute oil evenly.
  • Page 118 Engine / Cooling Engine Assembly - - All Engines 11. Install one circlip in piston with gap facing upward or downward. Verify that clip is fully seated before proceeding. Circlip Installation Tool PN 2870773 12. Lubricate and install piston rings on piston. Letter on end of each ring faces upward.
  • Page 119 Engine / Cooling Engine Assembly - - All Engines 14. Install each piston with arrow facing exhaust side. Ring locating pins should be facing intake side. 15. Install remaining circlips into pistons using circlip installation tool. Again verify that gap is either upward or downward and clip is fully seated.
  • Page 120 Engine / Cooling Engine Assembly - - All Engines 17. Align ring end gaps with locating pins on each piston and compress rings. Install each cylinder carefully using a gentle front--to--back motion. Install cylinder base nuts loosely. CAUTION: Do not twist or force cylinder during installation. IMPORTANT: To prevent possible water leaks at ex- haust manifold, the cylinders must be aligned be- fore the base nuts are tightened.
  • Page 121 Engine / Cooling Engine Assembly - - All Engines 20. Verify that O--ring grooves in cylinders are clean. Inspect surfaces of cylinder and cylinder head for nicks or scratches. 21. Lightly oil new cylinder head O--rings and install in grooves. Be sure O--ring is properly positioned and groove is clean and free from debris.
  • Page 122 Engine / Cooling Engine Assembly - - All Engines 27. Hand tighten the cylinder cover bracket bolts first, then remove the water outlet rail. Hand tighten the remaining cover bolts. 28. Torque cylinder cover bolts to specifications. Cylinder Cover Bolt Torque 22ft.lbs.
  • Page 123 Apply a thin, even layer of crankcase sealer to the polished surfaces of the housing. 32. Lubricate the seal and crankshaft with a light film of Polaris Premium All Season grease. 33. Install the stator housing to the engine. Only (3) bolts can be installed at this time.
  • Page 124 Engine / Cooling Engine Assembly - - All Engines 36. Apply a light film of Loctitet 262 to crankshaft taper. Install flywheel on flywheel key. 37. Using a flywheel holder tool, PN 8700229, tighten the flywheel nut to specification. 38. Visually inspect the stator housing to make sure wires are not coming into contact with the flywheel or starter drive.
  • Page 125 Engine / Cooling Engine Assembly - - All Engines 41. Place a new O--ring on the oil pump. Install oil pump on flywheel cover. Torque to specification. Verify that oil pump spade lines up with the drive slot in the flywheel cover.
  • Page 126 Engine / Cooling Engine Assembly - - All Engines 45. Insert reed valves into intake tracks. Assembly is reverse of disassembly. 46. Attach intake manifold to engine. Tighten to specifications. Intake Manifold Bolt Torque 9ft.lbs. (12Nm) 3.48...
  • Page 127 Engine / Cooling Engine Inspection - - All Engines 1. Inspect the starter drive. Starter Drive Bushing I.D. .4735²-.4740² (12.03-12.04mm) Std. Shaft O.D. .470²-.472² (11.94-11.99mm) Starter Drive Bushing Clearance: Std: .0015²-.004² (.04-.10 mm) Service Limit: .010² (.25 mm) 2. Check each cylinder head for warping as shown. (Carbureted Models) Replace cylinder head if warp exceeds service limit.
  • Page 128 Engine / Cooling Engine Inspection - - All Engines 4. Inspect each cylinder for wear, scratches, or damage. If no damage is evident, measure cylinder for taper and out of round with a telescoping gauge and micrometer or a dial bore gauge. Measure bore 1/2² down from top of cylinder in two directions - in line with piston pin and 90°...
  • Page 129 Engine / Cooling Engine Inspection - - All Engines Connecting Rod Small End Inspection 1. Clean small end of connecting rod and inspect inner bore with a magnifying glass. Look for any surface irregularities including pitting, wear, or dents. 2. Run your fingernail around the inside of the rod and check for rough spots, galling, or wear.
  • Page 130 Service Limit: .028² (.71mm) Crankshaft Main Bearing Inspection 1. Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris Premium 2 cycle engine oil. Carefully check each main bearing on the shaft. NOTE: Due to extremely close tolerances, the bearings must be inspected visually, and by feel. Look for signs of discoloration, scoring or galling.
  • Page 131 Service Limit: .0021² (.053mm) NOTE: Specialized equipment and a sound knowledge of crankshaft repair and straightening is required to per- form crankshaft work safely and correctly. Crankshaft repair should be performed by trained Polaris service tech- nicians in a properly equipped shop.
  • Page 132 Selecting a hone which will straighten as well as remove material from the cylinder is very important. Honing a cylinder with a spring loaded glaze breaker is never advised. Polaris recommends using a rigid type hone which also has the capability of oversizing. These hones are manufactured by such companies as Sunnen Products Company of St.
  • Page 133 Rinse the cylinders in clear water and dry thoroughly with compressed air. Immediately apply Polaris Premium 2 Cycle Lubricant or 2-stroke engine oil to all areas of the cylinder sleeve to prevent rust. Wipe cylinders with an oil coated shop towel to clean all remaining honing material from the cross hatch of the cylinder bore, and re-oil.
  • Page 134 Engine / Cooling Engine Inspection - - All Engines Crankshaft Truing Lubricate the bearings and clamp the crankshaft securely in the holding fixture. On three cylinder crankshafts, straighten one of the ends (Magneto or PTO) and then straighten the center section. Place the center section in the holding fixture and then straighten the remaining end.
  • Page 135 Engine / Cooling Crankshaft Indexing - - 700cc Engines Polaris Watercraft crankshafts are pressed together or (indexed) so the connecting rod journal center lines are .100 ATDC Dial Indicator 120° apart from each other (180° on twin cylinders). It is sometimes necessary to check multi-cylinder crank- shafts to verify that one cylinder has not been forced out of position relative to the other cylinder or cylinders.
  • Page 136 Engine / Cooling Crankshaft Indexing - - 1200cc Carbureted Engines Polaris Watercraft crankshafts are pressed together or (indexed) so the connecting rod journal center lines are 120° apart from each other. .100 ATDC Dial Indicator It is sometimes necessary to check multi-cylinder crank- shafts to verify that one cylinder has not been forced out of position relative to the other cylinder or cylinders.
  • Page 137 Crankshaft Indexing - DIt Engines NOTE: Domestic Twin Timing Marks: 180° Domestic Triple Timing Marks: 120° Polaris DIt engines have a fuel injector mounted in place Rotate until of the standard spark plug hole. The spark plugs on DIt resistance engines are mounted on the side of the cylinder heads.
  • Page 138 Engine / Cooling Cooling System - - Freedom / Virage Water Inlet Hose Water Outlet Hose Indicates Water Flow 3.60...
  • Page 139 Engine / Cooling Cooling System - - Virage TX Water Inlet Hose Water Outlet Hose Indicates Water Flow 3.61...
  • Page 140 Engine / Cooling Cooling System - - Virage i Water Outlet Hose Water Solenoid Water Inlet Hose Stator Exhaust Housing Thru- - Hull Indicates Water Flow 3.62...
  • Page 141 Engine / Cooling Cooling System - - Genesis Indicates Water Flow 3.63...
  • Page 142 Engine / Cooling Cooling System - - Virage TXi / Genesis i Stator Exhaust Housing Thru- - Hull Indicates Water Flow 3.64...
  • Page 143 Engine / Cooling Cooling System Overview Thermostat Pop Off Assembly 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.
  • Page 144 Engine / Cooling Exhaust Cooling Orifice / Screen Cleaning The exhaust pipe rubber hoses and muffler are cooled by injecting a small amount of water through an orifice from the main cooling system into the exhaust stream. The orifice and screen should be inspected and cleaned periodically to ensure proper cooling of the exhaust muffler and connector hoses.
  • Page 145 2002 Freedom / Virage Carburetor Specifications ....2002 Virage TX Carburetor Specifications ......2002 Genesis Carburetor Specifications .

  • Page 147: 2002 Freedom / Virage Carburetor Specifications

    Fuel / Exhaust 2002 Freedom / Virage Carburetor Specifications Carburetor Manufacture Keihin Size 40mm / 38mm Venturi Fuel Regulator System Diaphragm Float Arm Level 1.5mm Starter System Choke Main System Primary Main Jet: 148 Secondary Main Jet: 120 Mid Range System Pilot System Low Speed Screw 1 3/4 Turns Out From Lightly Seated...

  • Page 148: 2002 Virage Tx Carburetor Specifications

    Fuel / Exhaust 2002 Virage TX Carburetor Specifications Carburetor Manufacturer Keihin Size 40mm / 35mm Venturi Fuel Regulator System Diaphragm Float Arm Level 1.5mm Starter System Choke Main System MAG:#140 CTR:#142 PTO:#135 Mid Range System Pilot System Low Speed Screw 1 1/8 Turns Out From Lightly Seated Idle Speed (In Water) 1350±100...

  • Page 149: 2002 Genesis Carburetor Specifications

    Fuel / Exhaust 2002 Genesis Carburetor Specifications Carburetor Manufacturer Keihin Size 40mm / 35mm Venturi Fuel Regulator System Diaphragm Float Arm Level 1.5mm Starter System Choke Main System MAG:#132 CTR:#138 PTO:#142 Mid Range System Pilot System Low Speed Screw 1 1/8 Turns Out From Lightly Seated Idle Speed (In Water) 1350±100 Needle &...

  • Page 150: Keihin Carburetor Jet Part Numbers

    Fuel / Exhaust WARNING Gasoline is highly flammable and explosive under certain conditions. ¨ Always exercise extreme caution whenever handling gasoline. ¨ Always refuel with the engine stopped and outdoors or in a well ventilated area. ¨ Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 151: Keihin Carburetor System Overview

    Fuel / Exhaust Keihin Carburetor System Overview The Keihin carburetor is a floatless diaphragm type. Several separate but overlapping systems are used to meter fuel and air properly. 1. Air Metering System The metering of air is controlled by the throttle plate. The position of the throttle plate determines which fuel deliv- ery system or systems supply fuel from the fuel chamber to the engine.
  • Page 152 S Leaking needle seat O-Ring S Corrosion on lever arm, lever arm pin, and/or return spring S Incorrect lever arm return spring (Use only genuine Polaris parts) S Fuel return line kinked or return restrictor orifice plugged (in carburetors or in return line)
  • Page 153 Fuel / Exhaust Keihin 40mm LE Carburetor w/Accelerator Pump - - Freedom / Virage Accelerator Pump Assembly Needle Valve Assembly Mid Range Check Valve Diaphragm Carburetor Body Jet Block O Ring & Retainer Check Valve Fuel Pump Gaskets Low Speed Screw Idle Stop Screw Fuel Pump...
  • Page 154 Fuel / Exhaust Keihin 40mm CDK Carburetor w/Accelerator Pump - - Virage TX / Genesis Accelerator Pump Assembly Jet Block Needle Valve Assembly Mid Range Check Valve Fuel Pump Gaskets Diaphragm Main Check Valve Fuel Pump Synchronizing Screw Idle Stop Screw Low Speed Screw...
  • Page 155 Fuel / Exhaust Keihin Carburetor System Vapor Anti-Siphon Separator Valve Restrictor Main Main Jet Fuel Discharge Return Nozzle Mid-range Fuel Inlet Seat Needle Valve Control Mid-range Port Atmospheric Filter Vent Transfer Throttle Bypass Plate Control Arm Check Holes Spring Valves Fuel Chamber Slow...
  • Page 156 Fuel / Exhaust Air Intake Cover Assembly Exploded View - - 700 Engines Torque Specifications . . . 5ft.lbs. (9Nm) . . . 9ft.lbs. (12Nm) . . . 9ft.lbs. (12Nm) If model is equipped with fogging plugs, verify that plugs are installed prior to opera- tion.
  • Page 157 Fuel / Exhaust Air Intake Cover Assembly - - Exploded View - - 800 / 1200 Engines 800cc = One Bolt Torque Specifications . . . 9ft.lbs. (12Nm) 800 DIt uses one mounting bolt. If model is equipped with fogging plugs, verify that plugs are installed prior to opera- tion.
  • Page 158 Fuel / Exhaust Vent / Fuel Line Delivery Exploded View - - Freedom / Virage Fuel In Fuel Return Torque Specifications All Micro Hose Clamps 22in.lbs (2.5Nm). 4.12...
  • Page 159 Fuel / Exhaust Vent / Fuel Delivery Exploded View - - All 1200cc Carbureted Engines Fuel In Fuel Return Impulse Lines Torque Specifications All Micro Hose Clamps 22in.lbs. (2.5 Nm) 4.13...
  • Page 160 Fuel / Exhaust Vent / Fuel Delivery Exploded View - - All DIt Models Fuel Vent Line Virage TXi / Genesis i Only Fuel Return Fuel Supply Torque Specifications All Micro Hose Clamps 22in.lbs. (2.5 Nm) WARNING: Never re- - use Oetikert Clamps During Reassembly 4.14...
  • Page 161 Fuel / Exhaust Oil Tank - - All Models Torque Specifications All Micro Hose Clamps 22in.lbs. (2.5Nm) All Large Hose Clamps 35in.lbs. (4Nm) 4.15...
  • Page 162 Fuel / Exhaust Fuel Tank - - All Models Torque Specifications = Genesis Models Only . . . 14ft.lbs. (19Nm) Apply Loctitet 242 to Threads..10 - - 15ft.lbs. (14 - - 20Nm) . . . 36 - - 44ft.lbs. (50 - - 61Nm) Large Worm Gear Clamps .

  • Page 163: Carburetor Pop--Off Valve Testing

    S Inlet needle stuck in seat S Corrosion on lever arm, lever arm pin, and/or return spring S Incorrect lever arm return spring (Use only genuine Polaris parts) S Fuel return line orifice missing Testing Needle and Seat Pop Off Pressure Attach pump to fuel inlet.
  • Page 164 Fuel / Exhaust Gasoline Safety WARNING Gasoline is highly flammable and explosive under certain conditions. ¨ Always exercise extreme caution whenever handling gasoline. ¨ Always refuel with the engine stopped and outdoors or in a well ventilated area. ¨ Do not smoke or allow open flames or sparks in or near the area where refueling, maintenance, or repair work is performed or where gasoline is stored.
  • Page 165 Fuel / Exhaust Fuel / Water Seaparator IMPORTANT: Prior to performing any adjustments to car- Filter buretors check the following: S Verify that no water is present in the fuel system. Check the water trap for presence of water. S Check for proper choke operation. S Verify all fuel and vent lines are routed and secured properly.
  • Page 166 Fuel / Exhaust Fuel / Water Separator - - DIt Models The DIt models utilize a water separating filter that is located inside the tank. This unique filter separates water from fuel, allowing only fuel to enter the fuel pump and fuel lines.
  • Page 167 Fuel / Exhaust Mixture Screw Inspection and Adjustment Carburetor mixture screws pre-adjusted at the factory and usually no adjustment is necessary. Exceptions would be after cleaning or overhaul, or when minor adjustments are required for altitude. Refer to carburetor specifica- tions at the beginning of this section and perform the following adjustments.

  • Page 168: Carburetor Disassembly / Inspection

    Fuel / Exhaust Carburetor Disassembly / Inspection NOTE: Because the mechanical differences between a single--carburetor and triple--carburetor are few, the dis- assembly, inspection, and assembly sections will cover both systems. Differences will be noted in the text. 1. Complete carburetor assembly and related mounting hardware.
  • Page 169 Fuel / Exhaust Carburetor Disassembly / Inspection - - Continued 3. Inspect the jet block and pop--off valve assembly for obstructions. 4. Measure control arm height from machined surface to top of plastic button on control arm. .060² Remove screw and remove control arm and inlet 1.5 mm needle.
  • Page 170 Fuel / Exhaust Carburetor Disassembly / Inspection - - Continued 6. Loosen jet block screw, (if present). Carefully separate the jet block from the assembly. 7. Inspect needle seat O--rings for damage. Replace O--rings upon assembly. Clean screen of debris or replace if torn or damaged.
  • Page 171 Fuel / Exhaust Carburetor Disassembly / Inspection - - Continued 9. Remove both check valves. The valves must lay flat against the plate to seal properly. Replace if distorted or bent. Replace gasket if torn or damaged. 10. With check valves, needle valve, and O--rings removed, thoroughly inspect the carburetor casting for debris and cracking.
  • Page 172 Fuel / Exhaust Carburetor Disassembly / Inspection - - Continued 13. Remove accelerator pump components including spring, diaphragm, dust boot, and O-ring. Check guide bushing in pump body and replace front carburetor jet block assembly if worn. The bushing is not replaceable. 14.
  • Page 173 Fuel / Exhaust Carburetor Cleaning 1. Thoroughly clean all passages with carburetor cleaner or electrical contact cleaner. WARNING Wear eye protection when using compressed air or chemical spray cleaners. If you get cleaner in your eyes or if you swallow cleaner, see your doctor immediately. Some carburetor cleaners are extremely caustic and ex- tended periods of soaking can loosen the adhesive sealer on passage drill-way plugs.
  • Page 174 Fuel / Exhaust Carburetor Assembly - - Continued 2. Install screen and new O--rings on inlet needle seat. Lubricate O--rings with Polaris Premium 2 Cycle Lubricant. Polaris Premium 2 Cycle Lubricant PN 2871098 - Gallon PN 2872097 - Quart 3. Install set block and tighten screw securely.
  • Page 175 Use care when using Loctitet to ensure it does not enter the carburetor or linkages. 10. Grease all exposed shafts and springs with Polaris Premium All Season Grease. 11. Manually synchronize carburetors. Look down each carb bore and verify throttle plates are just below first bypass hole (not on or above).

  • Page 176: Carburetor Installation

    Fuel / Exhaust Carburetor Installation 1. Prior to installing any carburetor, verify that you have all required parts and gaskets. Perform the installation in a clean environment, and take precaution not to allow any foreign material into the intake manifold during installation.
  • Page 177 Fuel / Exhaust Cable Adjustment Throttle / Choke Cable Inspection 1. Check for smooth throttle opening and closing in all handlebar positions. Throttle operation should be smooth and lever must return freely without binding. 2. Inspect cable for proper routing, kinks, or damage. 3.
  • Page 178 Fuel / Exhaust Choke Cable Adjustment 1. On models with inline adjusters, turn the adjuster in (clockwise) to increase the amount of choke lever Choke Off freeplay. Turn the adjuster out (counterclockwise) to decrease the amount of choke lever freeplay. 2.

  • Page 179: Idle Speed Adjustment

    Fuel / Exhaust Idle Speed Adjustment 1. Connect tachometer according manufacturer’s instructions. 2. With craft in the water or test tank, start engine and let it idle. 3. Adjust idle speed to specifications by turning the idle speed screw in (clockwise) to increase or out (counterclockwise) to decrease idle speed.
  • Page 180 Fuel / Exhaust Mixture Screw Adjustment and Tuning 1. The low speed mixture screw is located lowermost on carburetor. Remove limiter cap (pull outward). 2. With craft in the water or test tank, adjust idle speed to specifications (see procedure this section).
  • Page 181 Fuel / Exhaust Fuel Pump Operation The pump supplies fuel to carburetors. On three cylinder models two fuel pumps supply fuel to each of the end carburetors and commonly to the center cylinder. When the piston is on the upstroke Ill.
  • Page 182 Fuel / Exhaust Fuel Pump Maintenance The fuel pump does not require any specific scheduled maintenance. However, the following should be observed: S Output: The pump output may be checked by re- moving the fuel supply line from the rear cylinder carburetor (PTO end) and placing it into a container.
  • Page 183 Fuel / Exhaust Accelerator Pump Testing On models equipped with an accelerator pump, verify proper accelerator pump operation use the following proce- dure: CAUTION: Wear eye protection when performing this procedure. 1. Turn engine off. 2. Remove air intake silencer. 3.

  • Page 184: Reed Valve Inspection / Removal

    Fuel / Exhaust Reed Valve Removal 1. Remove air box inlet and hose clamp. Remove air box cover and screen. Remove (9) intake base bolts and intake base. CAUTION: Cover carbs and use care not to drop washers or de- bris into carb openings.

  • Page 185: Fuel Line Air Leak Testing

    Fuel / Exhaust Fuel Line Air Leak Testing Fuel lines may develop air leaks causing the PWC to run lean or be hard to start. If you suspect this to be the case, the following would be suggested areas to check. All fuel line clamps: Carb rack hose connections;...
  • Page 186 Fuel / Exhaust 2002 Exhaust System Exploded View - - Freedom / Virage / Virage i Torque Specifications All Micro Hose Clamps 22in.lbs. (2.5Nm) All Large Hose Clamps 35in.lbs. (4Nm) . . . 44ft.lbs. (60NM) Exhaust manifold- - to- - pipe mounting bolts. .
  • Page 187 Fuel / Exhaust 2002 Exhaust System Exploded View - - Virage TX Torque Specifications All Micro Hose Clamps 22in.lbs. (2.5Nm) All Large Hose Clamps 35in.lbs. (4Nm) . . . 44ft.lbs. (60NM) Exhaust manifold- - to- - exhaust pipe mounting bolts. .
  • Page 188 Fuel / Exhaust 2002 Exhaust System Exploded View - - Virage TXi Torque Specifications All Micro Hose Clamps 22in.lbs. (2.5Nm) All Large Hose Clamps 35in.lbs. (4Nm) . . . 90 in.lbs. (10 Nm) Exhaust hose gear clamps..18 ft.lbs.
  • Page 189 Fuel / Exhaust 2002 Exhaust System Exploded View - - Genesis / Genesis i Torque Specifications All Micro Hose Clamps 22in.lbs. (2.5Nm) All Large Hose Clamps 35in.lbs. (4Nm) . . . 90 in.lbs. (10 Nm) Exhaust hose gear clamps..18 ft.lbs.
  • Page 190 Fuel / Exhaust Exhaust System - - Inspection A complete inspection of exhaust components is critical to proper operating performance. Inspect all hoses for cracks, pinholes, swelling, tears, discoloration, air bubbles, and fatigue. If any of these are evident, the hose MUST be replaced.
  • Page 191 2002 PWC Pump Specifications ........2002 Final Drive / propulsion Quick Reference Maintenance Chart .
  • Page 193 Driveshaft Bumper(s) 5410663 5133375 *Impeller torque for ALL Polaris impellers: 100ft.lbs. (138Nm) Apply Loctitet 242 to threads. **Bonded Rubber Coupler Torque: Hand tight. Apply light film of grease to threads and coupler splines. 2002 Final Drive / Propulsion Quick Reference Guide...

  • Page 194: Ventilation / Cavitation Diagnostics

    Final Drive / Propulsion Ventilation / Cavitation Diagnostics If a watercraft exhibits poor performance during accelerating, high engine RPM with little forward speed or power, inconsistent RPM, or difficulty pulling skiers out of the water, pump ventilation or cavitation may be the cause. Ventilation Ventilation results when air enters the pump inlet tract and is compressed by the impeller, causing a reduction in thrust and an increase in engine RPM.
  • Page 195 Driveshaft end play, (fwd/rear), should be .100 -- .200 in. (2.5 -- 5.0mm) with new bumpers. Driveshaft runout service limit= .005 in. (.13mm). Grease applicable parts with Polaris All Season Grease, PN 2871423..Rubber bumpers must be inspected and in place.
  • Page 196 Driveshaft end play, (fwd/rear), should be .100 -- .200 in. (2.5 -- 5.0mm) with new bumpers. Driveshaft runout service limit= .005 in. (.13mm). Grease applicable parts with Polaris All Season Grease, PN 2871423..Rubber bumpers must be inspected and in place. Double bumpers consist of one bumper with top half of another bumper attached with silicone.
  • Page 197 ..Thicker edge on bottom of pump assembly..Apply Polaris All--Season grease..Sacrificial Anode Bolt Torque: 25 in.lbs. (2.9Nm). Apply Nyogel to threads..
  • Page 198 ..Thicker edge on bottom of pump assembly..Apply Polaris All--Season grease..Sacrificial Anode Bolt Torque: 25 in.lbs. (2.9Nm). Apply Nyogel to threads..
  • Page 199 Final Drive / Propulsion 2002 Pump Induction - - Freedom / Virage Series Pump Housing O- - ring Intake Scoop Intake Grate Ride Plate Pump Induction Notes: ..Apply continuous bead of marine grade silicone to a mating surfaces of the hull, scoop, front and side edges of ride plate, and front and rear sections of the inlet grate.
  • Page 200 Final Drive / Propulsion 2002 Pump Induction - - Genesis Series Pump Housing O- - ring Intake Scoop Intake Grate Ride Plate Pump Induction Notes: ..Apply continuous bead of marine grade silicone to a mating surfaces of the hull, scoop, front and side edges of ride plate, and front and rear sections of the inlet grate.
  • Page 201 Final Drive / Propulsion Reverse System - - Virage / Virage TX / Virage i / Virage TXi Reverse System Notes: . . . 14ft.lbs. (19Nm) . . . 4 - - 6 ft.lbs. (5 - - 8 Nm) . . . 22 in.lbs.
  • Page 202 Final Drive / Propulsion Reverse System - - Genesis Series Reverse System Notes: . . . 14ft.lbs. (19Nm) . . . 20 in.lbs. (2 Nm) . . . 8 ft.lbs (11 Nm) . . . Always use new cotter pin when reassembling. 5.10...

  • Page 203: Pump Removal

    Final Drive / Propulsion Pump Removal 1. Remove lanyard cord. Remove electrical box hold--down straps. Proceed with disconnecting the battery by removing negative(--) cable. 2. Loosen coupler guard worm gear clamp and remove coupler guard. Loosen the two bearing carrier worm gear clamps.
  • Page 204 Final Drive / Propulsion Pump Removal - - Continued 5. Remove the four pump mounting bolts using a criss--cross pattern. 6. Remove the jet nozzle assembly from the watercraft. NOTE: Verify the position of the pump wedge for later use in reassembly.
  • Page 205 Final Drive / Propulsion Pump Removal - - Continued 8. Remove the pump extension housing, if applicable. Remove the driveshaft by pulling straight outward. NOTE: Driveshaft removal is simplified with the help of an assistant pushing the driveshaft outward from inside the engine compartment.

  • Page 206: Pump Assembly / Installation

    Final Drive / Propulsion Pump Assembly / Installation 1. If pump housing was removed, begin by re--attaching to the hull. Refer to pages: 5.5 and 5.8 for bolt torque. NOTE: Completely remove all old silicone from hull and parts prior to installation. Apply Marine Grade Silicone Sealant PN 8560054...
  • Page 207 Final Drive / Propulsion Pump Assembly / Installation - - Continued 3. Liberally grease the driveshaft, driveshaft splines, and O--ring. Insert driveshaft into thru--hull fitting. Verify that the correct bumpers are installed on driveshaft ends and in good condition. 4. Slide bearing carrier hose over thru--hull fitting. Grease bearing carrier seals, and insert carrier into hose.
  • Page 208 Final Drive / Propulsion Pump Assembly / Installation - - Continued 8. Attach steering linkage to steering nozzle. Tighten to specifications. 9. Attach bilge siphon hose(s) to pump assembly. Use panduit strap to secure hose(s). Steering Nozzle Bolt Torque 8ft.lbs. (11Nm) 10.

  • Page 209: Driveshaft Inspection

    Final Drive / Propulsion Drive Shaft Inspection 1. Clean driveshaft and support in V - blocks as shown (C). Measure runout by rotating shaft and Place dial indicator observing dial indicator at point (B). Replace if at (B) runout exceeds the service limit. NOTE: Excessive driveshaft runout can cause vibra- tion, bearing, and spline failure.
  • Page 210 Final Drive / Propulsion Stator Disassembly - - Continued 2. Mount stub shaft flat surfaces in a vise to prevent the impeller and stator from rotating. 3. IInstall impeller removal tool turn Impeller Tool Diameter: counterclockwise to remove. The impeller removal .852²...
  • Page 211 Final Drive / Propulsion Stator Disassembly - - Continued 4. Remove stator assembly from vise. Using a soft--faced hammer, tap stub shaft out of housing. 5. Inspect shaft and collar for wear, scratches, or damage. Install new O--rings upon reassembly. 6.

  • Page 212: Stator Assembly

    Final Drive / Propulsion Stator Assembly NOTE: Seals, bearings, and O-rings should be replaced if removed. Heat the impeller housing evenly with a heat gun to ease removal of bearings in next step. Remove tail cone O-ring before applying heat To ease installa- tion, wrap bearings in wax paper and chill in a freezer for 30 minutes or longer.

  • Page 213: Pump Alignment

    Final Drive / Propulsion Pump Alignment NOTE: Checking the pump alignment is not required if the alignment is not suspect. You need only to verify align- ment if alignment is determined to be incorrect. Symptoms of incorrect pump alignment are, but not limited to: stripped driveshaft, stripped coupler splines, broken engine mounts, and unevenly worn driveshaft, and worn bearing carriers.
  • Page 214 Final Drive / Propulsion Pump Alignment - - Continued Troubleshooting Symptoms Probable Cause Repair Required Splines worn or stripped at engine Engine misaligned to pump Shim engine mounts coupler end of drive shaft or inside Loose or broken engine mounts Tighten or replace mounts of coupler;...
  • Page 215 Final Drive / Propulsion Pump Alignment - - Continued The pump must be mounted flush with the hull and intake scoop to ensure proper driveshaft alignment. Some of the causes of mis-alignment are listed below. A mis-aligned pump increases stress on driveline components such as the impeller and driveshaft (stripped splines), and pump bearings.

  • Page 216: Driveshaft Lubrication

    Front of Craft Grease 5. Lubricate bearing housing at grease fitting until grease purges past the seals. Use only Polaris Premium Marine or All Purpose grease. Engine Polaris Premium All Season Grease Coupler Shroud 14 oz.

  • Page 217: Bearing Housing Removal / Inspection

    Final Drive / Propulsion Driveshaft Lubrication - - Continued 6. Reposition driveshaft shroud (open side down) and torque clamp screw to specifications. Front of Watercraft Drive Shaft Shroud Clamp Torque Grease Fitting 20-25 in. lbs. (2.3-2.9 Nm) Engine 7. Reconnect battery ground (--) cable. Bearing Housing 8.

  • Page 218: Sacrificial Anode

    Final Drive / Propulsion Bearing Housing Removal / Inspection - - Continued 2. Inspect bushings and seals in bearing housing assembly for wear or damage that may allow water Inspect to leak into hull. The housing cannot be rebuilt. Replace as an assembly if wear is evident. 3.
  • Page 219 Final Drive / Propulsion Intake Scoop / Ride Plate Removal and Installation Removal 1. Remove pump assembly as outlined on pages 5.6 to 5.8. 1. Remove the inlet grate and ride plate mounting Inlet Grate Mounting Bolt bolts. 2. Insert a length of 2x4 wood through the water inlet housing from the rear of the watercraft.
  • Page 220 Final Drive / Propulsion Intake Scoop / Ride Plate Removal and Installation - - Continued 1. Insert inlet scoop into pump cavity. Apply marine grade silicone to scoop / ride plate mating surface. Apply Silicone Marine Grade Silicone PN 8560054 2.
  • Page 221 2002 Hull Specifications ......... . 2002 Paint Codes / Colors .
  • Page 223 Hull / Control Systems Hull Specifications Freedom Virage Virage TX Virage i Virage TXi Genesis Genesis i Hull Design Full “V” Modified Full “V” Hull Material / Process Top Deck Material / Process SMC -- Sheet Molded Compound FRC -- Fiberglass Reinforced Composite Paint Codes / Colors Paint Number Freedom...
  • Page 224 Hull / Control Systems Freedom / Virage Series Hull Assembly Torque Specifications . . . 14ft.lbs. (19Nm) . . . 8 - - 10in.lbs. (.9 - - 1.1Nm) . . . 9 - - 11ft.lbs. (12 - - 15Nm) . . . 8ft.lbs.
  • Page 225 Hull / Control Systems Genesis / Genesis i Hull Assembly Standard on Genesis i Optional on Genesis Torque Specifications . . . 14 ft.lbs. (19Nm) . . . 40 in.lbs. (4.6 Nm) . . . 8 ft.lbs. (11 Nm) . . . 48 in.lbs.
  • Page 226 Hull / Control Systems Genesis / Genesis i Hull Assembly - - Continued Torque Specifications . . . 8ft.lbs. (11Nm) . . . 35 in.lbs . . . 8 - - 10 in.lbs. (.9 - - 1.1 Nm) Apply Loctitet 242 to ALL threaded fasteners.
  • Page 227 Hull / Control Systems Freedom / Virage Series - - Front Compartment Door Assembly Torque Specifications . . . 35in.lbs. (4Nm) . . . 40in.lbs. (4Nm) . . . 6 - - 8ft.lbs. (8 - - 11Nm) DO NOT APPLY LOCTITEt TO HOOD FASTENERS.
  • Page 228 Hull / Control Systems Genesis / Genesis i - - Front Compartment Door Assembly Torque Specifications . . . 35in.lbs. (4Nm) . . . 40in.lbs. (4Nm) . . . 6 - - 8ft.lbs. (8 - - 11Nm) . . . 3 in.lbs.
  • Page 229 . . . 22ft.lbs. (30Nm) At least four threads must be visible..8ft.lbs. (11Nm) . . . 15 ft.lbs. (20 Nm) Apply Loctitet 242 to ALL threaded fasteners. Apply Polaris All Season grease to steering post bushings...
  • Page 230 . . . 40in.lbs. (5Nm) . . . Throttle lever- - to- - block clearance = .020 - - .060in. (.5 - - 1.5mm) Apply Loctitet 242 to ALL threaded fasteners. Apply Polaris Lithium- -based grease to steering post bushings.
  • Page 231 Hull / Control Systems Shroud Assembly Mirrors are optional on Freedom Virage i / TXi EMM Bracket Mounting Bolt Torque: 60 in.lbs. (7Nm) Torque Specifications . . . 10in.lbs. (1Nm) . . . 6 - - 8ft.lbs. (8 - - 11Nm) .
  • Page 232 Hull / Control Systems Freedom / Virage Series - - Seat Assembly Torque Specifications . . . 8ft.lbs. (11Nm) Apply Loctitet 242 to ALL threaded fasteners. Apply Polaris Premium Marine Grease to seat posts. Seat on Freedom is One- - Piece. 6.10...
  • Page 233 Hull / Control Systems Genesis / Genesis i Seat Assembly Torque Specifications . . . 8- -12 ft.lbs. (11- -17 Nm) Apply Loctitet 242 to ALL threaded fasteners. Apply Polaris Premium Marine Grease to seat posts. 6.11...

  • Page 234: Handlebar Cover / Steering Post Removal

    Hull / Control Systems Handlebar Cover / Steering Post Removal 1. Remove steering cover (handlebar pad) by loosening the screws located on underside of pad. 2. Spread bottom of cover apart and lift it up and rearward. Note throttle cable and switch wire routing for reassembly.
  • Page 235 Hull / Control Systems Steering Cable Removal / Installation - - All Models WARNING: Failure to properly install the steering cable can result in loss of vehicle control possibly causing se- vere injury or death. 1. Remove seat, front storage compartment (Genesis models), and front bulkhead panel (Genesis models). 2.
  • Page 236 Hull / Control Systems Steering Cable Removal / Installation - - All Models 11. With the upper jam nuts and linkage accessible, remove the eyelet assembly, jamnuts, washers, and thru--hull locknut from the steering cable. NOTE: Always keep the parts in the same order as you re- moved them from the cable.

  • Page 237: Steering Cable Adjustment

    Hull / Control Systems Steering Cable Adjustment Insert drill bit or dowel into hole to lock 1. Open front compartment door and then tool kit door. lock steering in center position. 2. Locate alignment hole on the bottom of the steering post.
  • Page 238 Hull / Control Systems Steering Cable Adjustment - - Continued 6. Minor adjustments can be made using the steering Small adjustments cable rod end(s). Loosen jam nut on rod end(s). can be made with rod 8 ft. lbs. Remove end from top of steering nozzle. Turn rod end(s).

  • Page 239: Reverse Cable Adjustment

    Hull / Control Systems Steering Cable Adjustment - - Continued 8. Use main cable adjuster nuts to make major adjustments. Adjuster nuts are located at forward end of cable near steering pod. Open front compartment and remove storage tray for access to bottom nut.

  • Page 240: Speedometer Operation / Adjustment

    Hull / Control Systems Speedometer Operation / Adjustment The speedometer is operated by water pressure. The pressure is supplied to the back of the speedometer through a hose connected to a fitting located inside the jet pump intake grate area. 1.
  • Page 241 Hull / Control Systems SMC Hull Repair The hull and top deck on some models are constructed of sheet molded compound (SMC) which is an epoxy based, rigid, reinforced material. The processes used to manufacture the hull involve high heat and pressure. Once this process is complete it cannot be reversed.
  • Page 242 Hull / Control Systems FRC Fiberglass Repair Gel Coat Nick or High Spot Repair 1. Lightly sand area using 600 grit paper & water 2. Wipe down with dry cloth 3. Brush on thin film of Aqua Buff 2000t 4. Buff clean FRC Fiberglass Repair (HULL) Some hulls are constructed of hand laid fiberglass.

  • Page 243: Decal Removal / Application

    Hull / Control Systems Decal Removal / Application 1. Clean the original decal and surface with mild detergent or household cleaner. 2. Take the new decal and align it with the old decal. Using a felt--tip marker, outline at three or more points, the position of the new decal.
  • Page 244 Hull / Control Systems Decal Removal / Application - - Continued 4. Pull the old decal away from the hull. 5. Clean the hull surface with Goo Gonet. Take care in not removing the outline marks that were made in step 6.

  • Page 245: Footpad Removal / Application

    Hull / Control Systems Decal Removal / Application - - Continued 8. Apply the decal to the hull from front to back. Once the decal is applied, use a rag to press out any air bubbles. Apply pressure to the areas where the backing material and decal meet.

  • Page 246: Sponson Removal / Installation

    Hull / Control Systems Footpad Removal / Application 4. Peel a small portion of backing material away from the new footwell pad, and immediately apply to deck. 5. Work the pad with your fingertips until the entire pad is pressed onto the deck surface. Constant pressure activates the adhesive and works out any air bubbles out from under the pad.
  • Page 247 Spark Plug / Alternator / Ignition Specifications ..... . Engine Degrees--To--Piston Conversion Chart ..... . . RPM Limiter Systems .
  • Page 249 .024 -- .028 .6 -- .7 Genesis i NGK PZFR6H .028 -- .032 .7 -- .8 WARNING Use only resistor type spark plugs in all Polaris products. 2002 Alternator Specifications Model Alternator Output Freedom 5A / 60W @ 4500 RPM Virage...
  • Page 250 Electrical Systems 700 Domestic Engine Degrees- -to- -Piston Position Conversion Chart 136mm Rod 68mm Stroke Degrees BTDC Inches/MM .025/.64 .031/.78 .037/.93 .043/1.09 .050/1.26 .057/1.45 .065/1.65 .073/1.85 .081/2.06 .090/2.29 .100/2.55 .110/2.81 .121/3.07 .132/3.35 .144/3.64 .155/3.95 .168/4.26 .181/4.58 .194/4.92 800 / 1200 Domestic Engine Degrees- - to- - Piston Position Conversion Chart 136mm Rod 70mm Stroke Degrees BTDC Inches/MM...

  • Page 251: Rpm Limiter Systems

    Genesis -- PERCt Genesis i -- PERCt PERCt = Polaris Electronic Reverse Control The 2002 Virage, Virage TX, Virage i, and Virage TXi are built with a manual reverse system. When the reverse lever is engaged in either neutral or reverse, a switch is contacted, putting the CDI in limiting mode.
  • Page 252 Electrical Systems RPM Limiter System Troubleshooting - - Carb. Models (Except Freedom) - - Overheat RPM Limiter System Troubleshooting flowchart is shown below. Open electrical box. Disconnect temperature sensor 1. Test temperature sensor. Tan wire from terminal board. Does system still limit 2.
  • Page 253 Electrical Systems 2002 Freedom Warning System LR 85 Ground Switched DC Fuel Gauge Pur/W Pur/W Temp. Signal LED Sync. Signal Temp Sensor Fuel Level Signal RPM Limiter Signal (Ground to limit RPM to 3500) Gray Fuel Sender Oil Level BLK/W BLK/Y Oil Sender...
  • Page 254 Electrical Systems 2002 RPM Limiter System Diagram - - Virage / Virage TX RPM Limiter Signal (Ground to limit RPM to 3500) GRY/RD GRY/RD GRY/RD Reverse RPM Limit Switch (Switch closes when lever is shifted to neu- tral or reverse.) Temperature Sensor (Closed When Hot)
  • Page 255 Electrical Systems 2002 RPM Limiter System Diagram - - Virage i / Virage TXi GRY/R GRY/RD Reverse RPM Limit Switch (Switch closes GRY/R when lever is PK/BLK shifted to neutral or reverse.) 13 24 RPM Limiter 40 PIN Signal (Ground to limit RPM to 3500) Water Temperature Sensor...
  • Page 256 Electrical Systems 2002 RPM Limiter System Diagram - - Genesis RPM Limiter Signal (Ground to limit RPM to 3500) GRY/RD GRY/RD GRY/RD Temperature Sensor (Closed When Hot) Reverse Motor...
  • Page 257 Electrical Systems 2002 RPM Limiter System Diagram - - Genesis i GRY/R RPM Limiter Signal (Ground to limit RPM to 3500) GRY/R GRY/R PK/BLK 13 24 40 PIN Reverse Motor Water Temperature Sensor...
  • Page 258 Electrical Systems 2002 Start / Stop Regulator (LR- - 505) The LR--505 module is found on the following 2002 models: Freedom Virage Virage TX Genesis LR- - 505 Wire Designations Wire Color Function Red / Purple Battery (12 volts) Orange Switched DCV* Black / White Starter Solenoid (In)
  • Page 259 Electrical Systems Start / Stop Regulator (LR 505 Module) Troubleshooting Battery (+) Red/Purple Start/Stop- Button Yellow/Red Starter Solenoid CDI unit Coil LR-505 Start/Stop Black/Yellow Black/White Engine run/ Solenoid in Ignition kill Solenoid out Purple/White Tether Switch Ground Battery (+) Red/Purple Charge coil Battery (+)
  • Page 260 Electrical Systems Start / Stop Regulator (LR 503- -1 Module) Troubleshooting Battery (+) Red/Purple Start/Stop- Button Yellow/Red Starter Solenoid unit Coil LR-503- -1 Start/Stop Black/White Black/Yellow Solenoid in Ignition kill Purple/White Solenoid out Yellow Tether Tach switch Ground Battery (+) Pump switch Red/Purple Tach...
  • Page 261 Electrical Systems Start / Stop Regulator Troubleshooting - - Theory Of Operation The LR module provides the following functions that are important to remember: Controls the starting circuit. Provides switched DC voltage once engine has started. Regulated and rectifies AC voltage on CARBURETED MODELS only. Controls the engine kill circuit.
  • Page 262 Electrical Systems 2002 700cc Domestic Ignition System Overview - - Carbureted Models Stator Plate Assembly Flywheel Plug Caps Ignition Coil Pack Starter Solenoid CDI Module 7.14...
  • Page 263 Electrical Systems 2002 1200cc Domestic Ignition System Overview - - Carbureted Models Stator Plate Assembly Magnet Holder Flywheel Ignition Coil Pack Starter Solenoid CDI Module 7.15...

  • Page 264: Electrical Testing

    Electrical Systems Electrical Testing Charging System Testing - - Unregulated Voltage - - Carbureted Models 1. Open electrical box to gain access to components. 2. Turn multimeter to Volts AC position. 3. Disconnect the Yellow and Red/Pur wires from the terminal board and CDI module. Connect one of the tester leads to the Yellow stator wire and the other lead to the Red/Pur stator wire.
  • Page 265 Electrical Systems Battery Testing WARNING: Whenever installing batteries, care should be taken to avoid the possibility of explosion, resulting in serious burns. Always connect the positive (red) cable first and the negative (black) cable last. When working with batteries, always wear safety glasses or a face shield and protective gloves. Battery electrolyte contains sulfuric acid and is poisonous! Serious burns can result from contact with the skin, eyes or clothing.
  • Page 266 Electrical Systems Specific Gravity Test A tool such as the battery hydrometer can be used to measure electrolyte strength or specific gravity. As the battery goes through the charge-discharge cycle, the electrolyte goes from a heavy (more acidic) state at full charge to a light (more water) state when discharged.
  • Page 267 Electrical Systems Refilling a Low Battery The normal charge/discharge cycle of a battery causes the cells to give off hydrogen and oxygen. These gases are the ingredients of water. Because of the loss of these gases and the lowering of the electrolyte level, it will be necessary to add pure, clean distilled water to bring the fluid to the proper level.
  • Page 268 Virage i Virage TXi The Polaris Multi-Function Instrument (MFI) simultaneously displays a great deal of important vehicle information such as speed, RPM, fuel and oil levels, clock, compass heading, engine hours, and warning conditions. Addition- ally, the MFI acts as a command center for security and speed limit functions and interfaces to an optional depth sensor to provide a built in digital depth gauge.
  • Page 269 Electrical Systems Multi- -Function Instrument (MFI) - - Continued VOLTMETER: The left side of the multi-purpose display contains the battery VOLTMETER. Battery voltage is displayed from 5 to 18 volts in .1 volt increments. A battery voltage of less than 10.9 volts will trigger the LOW POWER warning message, indicating battery voltage is approaching a no start condition.
  • Page 270 Electrical Systems MFI Troubleshooting If the MFI is not working check the following items: Battery connections for corrosion; Fuse inside electrical box; Pins in MFD / MFI connector for corrosion or loose fit; Power and ground at the connector to the MFD / MFI; Component inputs are functioning properly.
  • Page 271 Electrical Systems MFD / MFI Troubleshooting - - Continued Blowing fuses Power surges or spikes are the most common cause of blown fuses. These power surges can be caused by loose connections in the electrical box, poor ground at the engine mount plate, and even corroded or loose battery terminals (not necessarily visible to the naked eye).
  • Page 272 Electrical Systems MFI Compass Calibration The electronic compass provides eight points of heading information. Its solid-state design utilizes no moving parts, can be electronically calibrated, and unlike mechanical systems, is immune to vibration. The compass will be reasonably accurate without calibration. However, like all compasses, there are many factors which can influ- ence the accuracy, such as geographic location, angle of operation, magnetic characteristics of the watercraft, etc.
  • Page 273 Electrical Systems Dynamic Ignition Timing Adjustment - - All Domestic Carbureted Models WARNING When replacing a CDI box on ANY domestic carbureted model, it is very important to check timing. A new CDI box may be programmed slightly different than the one being replaced, causing ignition timing to be advanced or retarded too far.
  • Page 274 Electrical Systems Dynamic Ignition Timing Adjustment - - All Domestic Carbureted Models - - Continued 12. Point timing light at inspection hole. Be sure to view the mark at 90° to the window to avoid misreading. Note the position of the scribed mark in relation to the pointer.

  • Page 275: Ignition Point Adjustment Unit

    Electrical Systems Ignition Timing Adjustment - - Ignition Point Adjustment Unit 1. Set timing as indicated in previous section. Ignition Point Adjustment Unit 2. Remove battery cover and exhaust hoses as Part Number 2872290 required to access the battery and electrical box. 3.
  • Page 276 Electrical Systems Ignition Timing Adjustment - - Ignition Point Adjustment Unit - - Continued 8. Connect timing to light to MAG high tension wire. Start engine and verify timing with timing light. CAUTION: Never operate the engine for more than 15 seconds while the watercraft is out of the water.

  • Page 277: Trigger Coil Testing (Hall Effect)

    Electrical Systems Trigger Coil Testing - - Generation III PVL Ignition Systems NOTE: The BLUE wire is found only on 1200cc engines. 700cc engines will only have a GREEN and RED wire. All 2001 Carbureted (700cc and 1200cc) The trigger coils are Hall Effect sensors and re- quire a constant DC power source via the brown wire out of the CDI module.

  • Page 278: Pvl Ignition Troubleshooting

    The creation of RFI can disrupt the the micro-processors within the CDI box and cause ignition misfiring. For these reasons it is extremely important that Polaris Domestic Engines utilize the PVL spark plug caps, RESISTOR WIRES and resistor spark plugs.
  • Page 279 Electrical Systems PVL Ignition Troubleshooting - - 700cc Carbureted Domestic Engine CAUTION: Verify spark plugs are RESISTOR TYPE! If the battery voltage is low, cranking rpm will be down. The ignition system may show weak spark with a plug out of the cylinder, but not spark under compression or it may show no spark at all. Install a charger on the battery to ensure good cranking rpm.
  • Page 280 Electrical Systems PVL Ignition Troubleshooting - - 700cc Carbureted Domestic Engine - - Continued 3. Open electrical box. Check the primary side resistance of the ignition coil tabs: Ignition Coil SPECIFICATIONS: (Ill. 3) IGNITION COIL PRIMARY 0.35 OHMS 0.35 ohms Ill.
  • Page 281 Electrical Systems PVL Ignition Troubleshooting - - 700cc Carbureted Domestic Engine - - Continued B. If the readings are still out of range, open the elec- trical box and remove the plug wire(s). Plug wire a. Measure the resistance of the plug wire(s). SPECIFICATION: (Ill.
  • Page 282 Electrical Systems PVL Ignition Troubleshooting - - 700cc Carbureted Domestic Engine - - Continued d. Connect the positive test lead to the purple Stator Purple Wire wire: Stator Black Wire SPECIFICATION: 5.5 ohms (Ill. 8) ohms Ill. 8 e. Connect the positive meter lead to the follow Brown, Red, Green, Gray, and ing wires (one at a time).
  • Page 283 Electrical Systems 700cc Carbureted Domestic Engine Ignition Coils NOTE: The ignition system used on all Polaris 700 per- sonal watercraft engines are simultaneously firing types. Ignition spark on each cylinder occurs at the same time. Air Box Front Combustion only occurs in the cylinder in which the pis- ton is on the compression stroke.
  • Page 284 Electrical Systems PVL Ignition Troubleshooting - - 1200cc Carbureted Domestic Engine CAUTION: Verify spark plugs are RESISTOR TYPE! If the battery voltage is low, cranking RPM will be down. The ignition system may show weak spark with a plug out of the cylinder, but not spark under compression or it may show no spark at all. Install a charger on the battery to ensure good cranking RPM.
  • Page 285 Electrical Systems PVL Ignition Troubleshooting - - 1200cc Carbureted Domestic Engine - - Continued Ignition b.Check the resistance of the coil without the Coil plug wires installed. (do not disconnect the primary side of the coil) SPECIFICATION: 1200 to 1600 ohms (Ill.3) Engin Groun 1200-1600...
  • Page 286 Electrical Systems PVL Ignition Troubleshooting - - 1200cc Carbureted Domestic Engine - - Continued d.Connect the positive test lead to the purple wire: Stator Purple Wire Stator Black Wire SPECIFICATION: 5.5 ohms (Ill. 5) ohms Ill. 5 e. Connect the positive meter lead to the follow Red/Purple and Gray wire ing wires (one at a time).
  • Page 287 Electrical Systems PVL Ignition Troubleshooting 1200cc Carbureted Domestic Engine - - Continued g. Check the primary side resistance of the Ignition Coil ignition coils: Y/Brn Blk/W SPECIFICATIONS: (Ill. 7) (Mag) Magneto Cylinder Blk/Grn Blk/Blu Black/White to Yellow/Brown: 0.35 (PTO) (Cen) ohms 0.35 ohms...
  • Page 288 Electrical Systems 1200cc Carbureted Ignition Coils NOTE: The ignition system used on 1200 carbureted personal watercraft engines are sequential firing types. Ignition spark on each cylinder occurs independently of Air Box Front the others using a separate trigger pulse from each Hall Effect sensor in the stator.
  • Page 289 Electrical Systems Starter Motor - - Disassembly 1. Remove starter motor and disassemble. Mark end covers and housing for proper reassembly. 2. Remove housing through bolts. 3. Remove brush end bushing dust cover and armature thrust washers. Keep washers in order for reassembly.
  • Page 290 Electrical Systems Starter Motor - - Disassembly - - Continued 5. Measure resistance between starter input terminal and insulated brushes. Reading should be .3 ohms or less. Remember to subtract meter lead resistance. 6. Measure resistance between insulated brush and starter housing.
  • Page 291 Electrical Systems Starter Motor - - Inspection Brush Inspection 1. Measure length of each carbon brush. Replace brush assembly when worn to 5/16² (8 mm) or less. The brushes must slide freely in their holders. Carbon Brush Service Limit 5/16² (8mm) Brush Replacement 1.
  • Page 292 Electrical Systems Starter Motor - - Inspection Armature Testing 1. Using a digital multitester, measure resistance between each of the segments of the commutator. The reading should indicate .3 ohms or less. 2. Measure resistance between commutator and armature shaft. Reading should be infinite (OL).
  • Page 293 Electrical Systems Starter Motor - - Assembly Re Qt Description 2 Rubber Ring* 4 Brush Spring 1 Thrust Washer 1 Gear Assembly 1 O-Ring* 1 Brush Complete 1 O-Ring* 8. AR Thrust Washer 1 Shaft Complete 1 Gear Assembly 1 Through Bolt 1 Cover 1 Stopper 1 Snap Ring...
  • Page 294 Electrical Systems Starter Motor - - Assembly - - Continued 6. Be sure wire insulation is in place around positive brush wire and pushed completely into slot on phenolic plate. 7. Using a non-petroleum grease, lubricate brush end bushing and install shims. Nyogelt Grease PN 2871329 8.

  • Page 295: Starter Motor Troubleshooting

    Electrical Systems Starter Motor - - Troubleshooting Condition: Starter fails to turn motor or motor turns slowly. CAUTION: Make sure that engine crankshaft is free to turn before proceeding. With the tester on VDC, place the tester black Remove battery, test and/or service. Install a lead on the battery negative (-) terminal and the fully charged shop battery to continue the test.
  • Page 296 Warning light in MFD is activated when temperature switch contacts are closed (overheat condition) and ground path is complete. On Polaris engines, the sensor is located on the exhaust manifold. Ground the sensor wire from MFD with engine running to see if temp light activates. Refer to MFD function/testing in this section.
  • Page 297 Electrical Systems Coolant Temperature Warning Circuit Operation - - DFIt Models The water temperature used on DFIt models reads the temperature of the water jacket located around the ex- haust manifold. The EMM will notify the operator via the MFI gauge when the sensor reads an overheat condition. To test the sensor, measure the resistance between the black and Pk/Blk pins on the sensor.
  • Page 298 Electrical Systems Fuel Level Sensor - - Carbureted Models The fuel gauge is operated through a voltage signal at the fuel tank sending unit. The sending unit resistance changes with the height of the float in the sender. To check for proper sending unit operation connect an ohmmeter to the wires as shown.
  • Page 299 Fuel Level Sensor Wiring Diagram - - DFIt Models NOTE: The wires inside of the fuel pump are different than that shown on the diagrams. Always follow the Polaris wire colors as shown in the diagrams. Always test at the harness and the connector.
  • Page 300 Electrical Systems Oil Level Sensor Problem: No oil level indication and/or low oil warning at MFD. 1. Open electrical box and disconnect oil level sensor wires. Measure resistance of sender wires and compare to specifications. Consult the appropriate wiring diagram for specifications and wire colors. 2.
  • Page 301 Electrical Systems 2002 Polaris Electronic Reverse Control (PERCt) - - Genesis / Genesis i Green/White Black Black Open Red / Grey Black Switches Blue / White Reverse Cam and Switch Assembly Wire Plug Locations Stops rotation at full up position.
  • Page 302 Electrical Systems REVERSE MOTOR ASSEMBLY TEST* Work through the continuity tables below to find fault with the reverse motor / limit switch assembly. The three possible meter reading are: Forward 1. Open (O.L.) Switch 2. Closed (0-.1.5 ) 3. Motor winding resistance (0.5-6.0 ) Push the bilge pump button along with the FWD or REV buttons to change the Sync.
  • Page 303 DIt Components / Sensors ........S.L.O.W.
  • Page 305 Fuel Injection System WARNING It is unlawful to tamper with any system or function of Polaris DI model personal watercraft. Do not modify any part of the watercraft. Doing so may end in a fine and/or imprisonment. Fichtâ Fuel Injection System - - Components...
  • Page 306 Fuel Injection System DIt Service Specifications Fuel System Pressure 20-30 psi (138-207 kPa) Injector Unit Resistance 1.00 W Spark Plug Lead Resistance 450 - 650 W Ignition Coil Primary Resistance 0.05 - 0.15 W Ignition Coil Secondary Resistance 225 - 325 W Crankshaft Position Sensor Resistance 200 W (Maximum) Air Temperature Sensor Resistance@ 77°...
  • Page 307 Fuel Injection System DIt Individual Service Tests Fuel System Pressure Test Install a 0--100 psi (0--690 kPa) gauge to the Schradert valve. Gauge should read 20--30 psi (138--207 kPa) during diagnostic fuel pump test, cranking, and normal operation. Fuel Injector Resistance Measure resistance between both internal injector pins.
  • Page 308 Fuel Injection System DIt Individual Service Tests - - Continued Water Injection Solenoid (Virage i) Measure resistance between internal solenoid pins. Water Temperature Sensor Measure resistance between internal temperature sensor pins. Test in water bath. Reference specifications for specific resistances at given temperatures. Diagnostic software can be used to verify test temperature and actual sensor readings.
  • Page 309 Fuel Injection System DIt System Overview Ignition Coils Fuel Electronic Injectors Engine Management Sensors Module Water Injection Solenoid (Virage i) Power Supply Polaris Accessories Battery RED 12Vdc RED/PUR 12Vdc WHT/RED 45Vdc WHT/RED 45Vdc Capacitor Black Black RED/WHT 12DCV 45Vac Black...
  • Page 310 Fuel Injection System DIt System Overview 40 Pin Connector 15 Check Engine Light (t/o) 36 Reverse RPM Limit Input (gry/red) 24 Overheat (t) Reverse Tether Switch Sync 35 Tach (y) Water 8 Ignition Kill Input (blk/yel) Switch Injection 39 WTR Injection (blu/w) (Virage i Only) LR-503 Fuel...
  • Page 311 Fuel Injection System EMM Connectors EMM 8 Pin Connector EMM 12 Pin Connector 12 Pin Connector 8 Pin Connector Stator Winding #1 (BRN/W) Battery Positive (R/PUR) Stator Winding #2 (BRN/BLK) Injector (W/R) Stator Winding #3 (Y/BLU) Ground (BLK) Stator Winding #4 (Y/PUR) Ground (BLK) Stator Winding #5 (Y/GRN) Ground (BLK)
  • Page 312 Fuel Injection System EMM Connectors 11 12 16 17 14 15 19 20 21 22 24 25 26 27 28 29 30 31 32 36 37 34 35 39 40 EMM 40 Pin Connector Ignition Ground (BLK) Ignition Ground (BLK) Ignition #3 (PTO) (OR/GRN) Ignition #1 (MAG) (OR/BLU) Throttle Position In (GRN)
  • Page 313 Fuel Injection System Service Codes “Hard” Service Code: Failure has occurred and is occurring at this time. “Intermittent” Service Code: Failure occurred at some time during operation, but is not occurring at this time. CODE DESCRIPTION System Okay - No Fault Throttle Position Sensor Circuit Malfunction Throttle Position Sensor Above Expected Range ROM Checksum Error...
  • Page 314 Fuel Injection System Fichtâ Fuel Injection System - - Troubleshooting Symptom Possible Problem Corrective Action Will Not Turn Over Disconnected Battery Connect Battery MFI Security Enabled Enter 4 digit security code on MFI to disable security functions Lanyard Connection Connect Lanyard Battery Cables Verify that positive and negative battery cables are secured and...
  • Page 315 Fuel Injection System Symptom Possible Problem Corrective Action Engine Turns Over But Will Not 8 Pin Power Harness Verify that 8 Pin power harness is Start correctly installed in the EMM. 12 Pin Stator Harness Verify that 12 Pin stator harness is correctly installed in the EMM.
  • Page 316 Fuel Injection System Symptom Possible Problem Corrective Action Engine Turns Over But Will Not MFI Failure Jump PUR/W to BLK at the LR Start module. If engine starts, repair connection or replace the MFI. Starter Motor Check starter motor. Verify that starter motor is rotating engine fast enough to start.
  • Page 317 Fuel Injection System Symptom Possible Problem Corrective Action Engine Starts and Dies Battery / Connections Check battery voltage. Tighten any loose connections. Engine Kill Switch Verify that ALL BLK/YEL circuits are O.L. when lanyard is installed. Fuel Pump / Fuel Delivery Check 15A circuit breaker.
  • Page 318 Fuel Injection System Symptom Possible Problem Corrective Action Engine Starts and Dies Electrical System Disconnect one injector. If voltage on others jumps, check stator out- put. Always check for loose wires, pins, connectors. Check ALL splice blocks and Buss bars. Check circuit breakers and fuses.
  • Page 319 Fuel Injection System Symptom Possible Problem Corrective Action Engine Surges / Runs Rough Fuel System Use clean, fresh fuel. Check for water in the fuel system. Verify operation of the fuel pump. Use diagnostic software to check fuel pump circuit. Check fuel pump pressure.
  • Page 320 Fuel Injection System Symptom Possible Problem Corrective Action Engine Surges / Runs Rough Ignition System Check Vac of the stator. Verify that flywheel key is not sheared. Verify that the water injection sole- noid is operating on Virage i mod- Mechanical Check overall condition of engine.
  • Page 321 Fuel Injection System Symptom Possible Problem Corrective Action Low maximum RPM. EMM System Use diagnostic software to re- trieve any service codes. Check all sensors. Verify that reverse system is in proper working condition and not limiting top--speed. Verify that EMM is not in S.L.O.W. mode.
  • Page 322 Fuel Injection System Fichtâ Fuel Injection System - - Action Steps WARNING Gasoline is highly flammable and explosive under certain conditions. ¨ Always exercise extreme caution whenever handling gasoline. ¨ Always refuel with the engine stopped and outdoors or in a well ventilated area. ¨...
  • Page 323 Fuel Injection System Fichtâ Fuel Injection System - - Action Steps - - Fuel System / Fuel Injectors 5. If fuel pump will not run, check fuel pump circuit: A. Verify that battery voltage is present on RED/W wire at all times. B.
  • Page 324 Fuel Injection System Fichtâ Fuel Injection System - - Action Steps - - Fuel System / Fuel Injectors NOTE: Remember these important facts regarding the fuel injectors: During cranking, Vdc should “step--up” from 12V, to 22V. If this does not occur, check the stator and/or EMM regulator/rectifier.
  • Page 325 DO NOT connect A.C. powered computers to the watercraft. The Polaris Diagnostic Software will operate on a wide range of laptop computers. It has been tested on laptops using 286, 386, 486, Celeront and Pentiumt-class processors, including AMDÒ. At least 400 kilobytes (K) of DOS memory must be available for the program to run.
  • Page 326 Fuel Injection System Fichtâ Fuel Injection System - - Diagnostic Software Installing the Polaris Diagnostic Software - - Continued 5. Clicking on the “START” button will bring up the start menu window. 6. Click on the “RUN” option. The “RUN” window will allow you to explore the files and folders on your laptop.
  • Page 327 Fuel Injection System Laptop- -To- -EMM Connections Troubleshooting communication problems must begin with verifying the proper connections are made between the EMM and laptop. Additional troubleshooting techniques are provided at the end of the chapter. Understanding the EMM communication cable. The EMM communication cable located inside the watercraft performs two important tasks.
  • Page 328 Fuel Injection System Fichtâ Fuel Injection System - - Diagnostic Software Using the Polaris Diagnostic Software: PODIAG 1. Turn on your laptop, and allow the operating system to boot--up. 2. Double--click on the PODIAG MSDOS icon located on the desktop.
  • Page 329 Fuel Injection System Error Messages If the program doesn’t start, an error message will ap- pear explaining the problem. If the program doesn’t start, AND doesn’t display an error message, the prob- ERROR OPENING PORT NUMBER: 4 lem is most likely insufficient computer memory. PRESS ANY KEY TO TRY AGAIN This error message indicates that the communication port will not open.
  • Page 330 Fuel Injection System Program Select Menu The screen shown is the Program Select Menu. It’s displayed as soon as the DI software starts. Program Select Menu FFI DIAGNOSTICS Option “1”: FFI Diagnostics SERVICE UTILITIES (REPORTS / INJECTORS / EMM) This screen allows you to retrieve stored Service EXIT PROGRAM Codes from the EMM, helps you diagnose problems with the engine that are causing a Service Code, and...
  • Page 331 Fuel Injection System MAIN MENU - OPTION 1 -FFI DIAGNOSTICS The photo to the right is the FFI Diagnostics main menu screen. From this screen, you can: Enter the Diagnostic Session Enter Static Test Perform Cylinder Drop Tests Verify Timing View EMM Information Review RPM Profiles Service Code Review Screen...
  • Page 332 Fuel Injection System Service Code Screens Illustration at right is a Service Code screen. Code screens are displayed in the same sequence as pre- CODE # 14 CLASS: INTERMITTENT sented on the Service Code Review screen. You get # OF EVENTS LAST EVENT AT 13 HRS to them by pressing any key at the Service Code Re- # 3 OF 3 CODES...
  • Page 333 Fuel Injection System Retest Option Some Hard Codes have a Retest and/or associated Static Test option. If these tests are available, Press CODE # 43 CLASS: HARD S for Static Test or Press R to Retest is displayed at the # OF EVENTS LAST EVENT AT 13 HRS bottom of the Code screen.
  • Page 334 Fuel Injection System Session Completion / Code Clearing The Session Completion screen is displayed after you SESSION COMPLETION have seen the last Service Code screen. The Session Completion screen provides three options: Please choose one of the following options to complete this diagnostics session before test- ing engine.
  • Page 335 Fuel Injection System FFIt Diagnostics - - Static Tests - - Continued If the engine is running, a warning screen will be dis- played and the software will not advance to the Static Test screen. If this happens, you must press the ES- CAPE key to return to the Main Menu, or shut the en- NOTE!!! gine off.
  • Page 336 Fuel Injection System FFIt Diagnostics - - Static Tests - - Continued Testing Ignition System NOTE: Do not start the engine during any static test. Doing so will cause erratic operation until you shut off the engine. Remove all spark plug leads and connect them to a spark tester set at air gap specified in the Type 2 and press the ENTER key to test the ignition...
  • Page 337 Fuel Injection System FFIt Diagnostics - - Static Tests - - Continued Testing Electric Fuel Pump NOTE: Do not start the engine during any static test. Doing so will cause erratic operation until FUEL PUMP TEST IS you shut off the engine. RUNNING NOTE: Do not run fuel pump with fuel tank empty or damage to fuel pump may occur.
  • Page 338 Fuel Injection System FFIt Diagnostics - - Cylinder Drop Tests - - Continued When the engine is running above 2000 RPM, the Cylin- der Drop Testing Menu will be displayed. The screen will CYLINDER DROP TESTING MENU also show engine RPM so it can be noted before conduct- ing a drop test.
  • Page 339 Fuel Injection System FFIt Diagnostics - Timing Verification Pro- cedure To enter the Timing Verification Program, type²4² on the FFI Diagnostics menu. Press <ESC> to exit the Timing Verification Procedure. The timing verification screen, displayed to the right, will allow the user to verify proper engine timing. In order to perform the test correctly, engine RPM must be between 700 and 1500 RPM, and in forward mode.
  • Page 340 Fuel Injection System MAIN MENU OPTION 2 -SERVICE UTILITIES MENU Main Menu option 2 is the Service Utilities Menu. This option is new for the 2000 model year. Within this menu, the user may: view past and current EMM re- ports and injector serial numbers, replace the injec- tor(s) or EMM, and view real-time engine monitoring.
  • Page 341 PLE54321 list. NOTE: Polaris recommends for simplicity, you enter the universal manufacture ID and the serial number for each watercraft you are connected to. An example would be: PLE12345. The file name can be no longer than eight characters and contain no special characters.
  • Page 342 DIt Diagnostic software is compatible with 1999 Polaris Genesis DIt watercraft, the DIt diagnostic software will not be able to perform the functions contained in this section on 1999 Polaris Genesis DIt watercraft. The injector Information option allows the user to view the...
  • Page 343 Fuel Injection System Service and Utilities Menu -Option 3 - Service EMM The service EMM program will copy the faulty EMM’s software on your laptop, and then transfer this information to the replacement EMM. WARNING DO NOT TURN OFF YOU LAPTOP WHEN PERFORMING THE OPERATION. TURN OFF ALL OTHER PRO- GRAMS THAT MAY BE RUNNING DURING THIS PROCEDURE.
  • Page 344 Fuel Injection System Engine Monitoring EMM On Time: 0:0:46 Run Time: 12:58:25 ENGINE MONITORING RESULTS SENSORS °F °C ENGINE SPEED VOLTS %OPEN IGNITION TIMING 1.90 SPARK DURATION WATER 2.47 5.00 °BTDC FUEL TIMING 1.25 FUEL PULSE WIDTH 5.33 TPS CAL. BARO PRESSURE 29.61 In HG...
  • Page 345 Fuel Injection System Engine Monitoring EMM On Time: 0:0:46 Run Time: 12:58:25 ENGINE MONITORING RESULTS SENSORS °F °C ENGINE SPEED VOLTS %OPEN IGNITION TIMING 1.90 SPARK DURATION WATER 2.47 5.00 °BTDC FUEL TIMING 1.25 FUEL PULSE WIDTH 5.33 TPS CAL. BARO PRESSURE 29.61 In HG...
  • Page 346 5) EMM Information Screen 5) Return To Program Select Menu 6) RPM Profile X) Exit Program Polaris Diagnostic Software “Site Map” - - Session Breakdown 1) Service Reports 1) Diagnostic Session - - View Current EMM Report - - View / Clear Service Codes...
  • Page 347 EMM and you have performed the above--mentioned trouble--shooting procedures. The Polaris diagnostic software, PN 2874118, has the ability to start the laptop in diagnostic mode without starting the laptop’s operating system. To perform the boot function, follow these procedures.
  • Page 348 EMM. Polaris recommends that if you attempt all of the communication procedures outlined in this service manual with- out success, you then contact the manufacture of your laptop for further assistance. Often times, the manufacture of the laptop will have software patches or hardware updates that will allow your laptop to establish communica- tion.
  • Page 360 2002 Polaris Sales Inc. PN 9917370...

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