Download a Polaris PWC service manual directly to your computer in seconds!

PREVIEW A SAMPLE PAGE OF A TYPICAL WATERCRAFT SERVICE MANUAL

 

SELECT A SERVICE MANUAL TO DOWNLOAD



INTRODUCTION

These manuals contains an introductory description on and procedures for the inspection, service and overhaul of its main components. General knowledge information is not included. Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning your personal watercraft PWC in the manual. Read and refer to the other sections in this manual for information regarding proper inspection and service procedures.

• These manuals have been prepared using the latest information available at the time of publication. If a modification has been made since then, differences may exist between the content of
these manuals and the actual PWC personal water craft.

• Illustrations in these manuals are used to show the basic principles of operation and work procedures of the actual personal watercraft and components in exact detail.

• These manuals are intended for use by technicians who already possess the basic knowledge and skills to service a personal watercraft motors and components. Persons without such knowledge and skills should attempt with caution to service any component or engine by relying on this manual only. Never attempt to perform any work with out the assistance of a service manual.

Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may or may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the engine unsafe for the watercraft operator and passengers.


POLARIS WATERCRAFT SERVICE MANUALS AVAILABLE:

1992 1998 Polaris PWC WaterCraft Service Manual (Water Craft)

Service Manual Application: Polaris 1992, 1993, 1994, 1995, 1996, 1997 & 1998 WaterCraft (Water craft) PWC. Models covered in this manual: 1992: SL650 (SL-650) - 1993: SL650 (SL-650), SL750, SLT - 1994: SL650, SL750 (SL-750), SLT - 1995: SL650 (SL650 International), SL650 STD (SL650 STD International), SL750 (SL750 International). SLTl50 (SLTl50 International), SLX780 (SLX-780 International) - 1996: SL700 (SL-700 International), SLTlOO (SLTlOO International), SL780 (SL780 International), SL900 (SL-900 International), SLX780 (SLX780 International), SLTl80 (SLTl80 International), Hurricane (Hurricane International), SLTX (SLTX International) - 1997: SL700, SL700 Deluxe, SLT700 Hurricane, SL780, SLTl80, SLX PRO 785, SL900, SL1050 SLTX - 1998: SLH, SLTH, SLXH, SLTX

1999 Polaris Genesis X 45 & Ficht Service Manual PWC

Service Manual Application: Polaris 1999 Genesis, 1999, Genesis Ficht and 1999 X-45 WaterCraft (Water craft) PWC. Models covered in this manual: Genesis, Genesis Ficht & X-45.

2000 Polaris Virage TX SLX Genesis & Pro 1200 Service Manual

Service Manual Application: 2000 Polaris Virage TX, SLX, Pro 1200, Genesis, Genesis FFI WaterCraft (Water craft) PWC. Models covered in this manual: 2000 Polaris Virage TX, 2000 Polaris SLX, 2000 Polaris Pro 1200, 2000 Polaris Genesis, 2000 Polaris Genesis FFI.

2001 Polaris Service Manual Genesis SLX Virage & Pro 1200

Service Manual Application: 2001 Polaris SLX, PRO 1200, Virage TX, Genesis, Virage TXi, Genesis i WaterCraft (Water craft) PWC. Models covered in this manual: 2001 Polaris SLX, 2001 PRO 1200, 2001 Virage TX, 2001 Genesis, 2001 Virage TXi, 2001 Genesis i

2001 Polaris SLH & Virage Service Manual PWC WaterCraft

Service Manual Application: 2001 Polaris SLH, Virage PWC Factory Service Manual Personal WaterCraft (Water craft) PWC. Models covered in this manual: 2001 Polaris SLH, 2001 Polaris Virage.

2002 Polaris Service Manual Freedom Genesis Virage

Service Manual Application: 2002 02' Polaris Freedom, Virage, Virage TX, Virage i, Virage TXi, Genesis, Genesis i PWC Factory Service Manual Personal WaterCraft (Water craft) PWC. Models covered in this manual: 2002 Freedom W025297D, 2002 Virage W025197D, 2002 Virage TX W025199D, 2002 Virage i W025101D, 2002 Virage TXi W025198D, 2002 Genesis W025099D, 2002 Genesis i W025098D

2003 Polaris Service Manual FREEDOM GENESIS VIRAGE

Service Manual Application: 2003 03' Polaris Freedom, Virage, Virage i, Genesis i PWC Factory Service Manual Personal WaterCraft (Water craft). Models covered in this manual: Freedom W035297DA, Virage W035197DA, Virage i W035101CA, Genesis i W035098CA.

2004 Polaris Service Manual MSX110 MSX150 (MSX-110 MSX-150)

Service Manual Application: 2004 04' Polaris MSX110 (MSX-110) MSX150 (MSX-150) PWC Factory Service Manual Personal WaterCraft (Water craft). Models covered in this manual: 2004 Polaris MSX110 (MSX-110), 2004 Polaris MSX150 (MSX-150).

2004 Polaris Service Manual FREEDOM GENESIS VIRAGE

Service Manual Application: 2004 04' Polaris Freedom, Freedom, Virage, Virage i, Genesis i, MSX 140 PWC Factory Service Manual Personal WaterCraft (Water craft). Models covered in this manual: Freedom W045297DA, Freedom International W045297IA, Virage W045197DA, Virage International W045197IA, Virage i W045101CA, Virage i International W045101IA, Genesis i W045098CA, Genesis i International W045098IA, MSX140 W045303CA, MSX 140 International W045303IA


BELOW IS A GENERAL OUTLINE OF A TYPICAL WATERCRAFT SERVICE MANUAL
                     SUBJECTS MAY DIFFER DEPENDING ON YEAR AND MODEL


GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND ADJUSTMENT
FUEL SYSTEM
POWER UNIT
JET PUMP UNIT
PUMP
ELECTRICAL SYSTEM
HULL AND HOOD HOOD
TROUBLE ANALYSIS

CHAPTER 1
GENERAL INFORMATION

IDENTIFICATION NUMBERS
PRIMARY l.D. NUMBER
ENGINE SERIAL NUMBER
JET PUMP UNIT SERIAL NUMBER
HULL IDENTIFICATION NUMBER (H.l.N.)
SAFETY WHILE WORKING
FIRE PREVENTION
VENTILATION
SELF-PROTECTION
OILS, GREASES AND SEALING FLUIDS
GOOD WORKING PRACTICES
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS
MEASURING

CHAPTER 2
SPECIFICATIONS

GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
JET PUMP UNIT
HULL AND HOOD
ELECTRICAL
TIGHTENING TORQUES
SPECIFIED TORQUES
GENERAL TORQUE
CABLE AND HOSE ROUTING

CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENT

Maintenance chart ivterval & Periodic service
Control system
Steering column inspection
Steering cable inspection and adjustment
Throttle cable inspection and adjustment
Choke cable inspection and adjustment
QSTS cable inspection and adjustment
YPVS cable adjustment
Fuel System
Fuel line inspection
Trolling speed check and adjustment
Oil Injection System
Oil line inspection
Power Unit
Spark plug inspection
Electrical
Battery inspection
Jet pump Unit
Impeller inspection
Water inlet strainer inspection
Bilge strainer inspection
Drain plug inspection
Lubrication points

CHAPTER 4
FUEL SYSTEM

Fuel cock and fuel filter
Fuel filter inspection
Fuel cock inspection
Oil tank
Exploded diagram
Removal and installation chart
Oil line inspection
Oil level sensor inspection
Oil tank inspection
Fuel tank
Check valve inspection
Fuel level sensor inspection
Fuel tank inspection
Pipe joint inspection
Intake silencer
Carburetor unit
Throttle valve synchronization inspection and adjustment
Choke cable and throttle cable installation
Oil pump cable installation
Carburetor assembly
Carburetor
Diaphragm inspection
Accelerator pump body inspection
Arm inspection
Regulator body inspection
Needle valve inspection
Jet and carburetor body inspection
Carburetor assembly
Fuel Pump
Fuel pump inspection
Fuel filter inspection
Oil pump
Oil pump inspection
Oil hose inspection
Check valve inspection
Oil pump cable adjustment
Oil injection pump air bleeding

CHAPTER 5
POWER UNIT

Engine unit
Shim removal
Engine mount inspection
Coupling clearance inspection
Exhaust chamber assembly
Exhaust chamber joint
Exhaust manifold
Reed valves
Reed valve inspection
YPVS
YPVS valve inspection
YPVS valve installation
Cylinder head
Cylinders
Cylinder head inspection
Cylinder inspection
Pistons
Piston pin clip removal and installation
Piston inspection
Cylinder and piston combination
Piston ring inspection
Piston pin and bearing inspection
Starter motor
Flywheel magneto
Drive coupling removal and installation
Flywheel magneto removal and installation
Drive coupling inspection
Flywheel magneto inspection
Starter clutch assembly inspection
Crankcase
Crankcase inspection
Crankcase installation
Crankshaft
Crankshaft inspection

CHAPTER 6
JET PUMP UNIT

Jet pump unit
Nozzle deflector and nozzle ring
Impeller duct, impeller housing and intake duct
Impeller duct and drive shaft
Drive shaft removal
Impeller inspection
Drive shaft inspection
Drive shaft installation
Transom plate and hoses
Bilge strainer inspection
Bilge hose inspection
Bearing housing
Driven coupling removal and installation
Intermediate drive shaft removal
Bearing removal
Bearing, driven coupling shaft, and grease hose inspection
Driven coupling inspection
Bearing installation
Oil seal installation
Intermediate housing installation


CHAPTER 7
ELECTRICAL SYSTEM

Electrical components
Electrical box
Electrical analysis
Digital tester
Peak voltage measurement
Peak voltage adaptor
Test harness
Ignition system
Wiring diagram, diagrams
Ignition spark gap
Ignition system peak voltage
Spark plugs
Spark plug caps
Spark plug gap
Ignition coil
Engine stop switch
Thermoswitch
Starting system
Battery
Wiring connections
Fuses and fuse
Starter switch
Starter relay
Starter motor
Armature inspection
Brush holder inspection
Starter motor front cover inspection
Charging system
Rectifier, regulator peak voltage
Lighting coil peak voltage
Pickup coil
CDI unit
YPVS servomotor
YPVS cable removal and installation
YPVS cable inspection
YPVS servomotor inspection
YPVS cable adjustment
INDICATION SYSTEM
Buzzer
Oil level sensor
Fuel level sensor
Oil level sensor
Multifuction meter/removal
Display function
Fuel level gauge
Oil level gauge
Overheat warning indicator
Speed meter
Speed sensor

CHAPTER 8
HULL AND HOOD

Handlebar
Handlebar inspection
Handlebar switch inspection
Handlebar assembly installation
QSTS GRIP
QSTS cable inspection
QSTS grip inspection
Steering colum
Steering column bushing inspection
Remote control cables and speed sensor lead
Remote control cables inspection
Steering cable (jet pump side) installation
Steering cable stopper installation
QSTS cable (jet pump side) installation
QSTS cable stopper installation
Front hood
Steering console cover
Buzzer and hood lock
Hoses
Check valve inspection
Ventilation hose installation
Seats and hand grip
Battery box
Exhaust system
Seat lock inspection
Exhaust system inspection
Exhaust component parts sub-assembly
Deck and hull
Engine mount
Hull repair
Shallow scratches
Deep scratches
Cracks and punctures
Insert nut
Graphic & Decal, Decals removal
Graphic installation

CHAPTER 9
TROUBLE ANALYSIS

Troubleshooting & analysis
Trouble analysis chart


COMMON POLARIS TROUBLESHOOTING SEARCHES FOR  (A T V'S)

ENGINE

Engine Turns Over But Fails to Start

• No fuel
• Dirt in fuel line or filter
• Fuel will not pass through fuel valve
• Fuel pump inoperative/restricted
• Tank vent plugged
• Carb starter circuit
• Engine flooded
• Low compression (high cylinder leakage)
• No spark (Spark plug fouled)

Engine Does Not Turn Over

• Dead battery
• Starter motor does not turn
• Engine seized, rusted, or mechanical failure

Engine Runs But Will Not Idle

• Restricted carburetor pilot system
• Carburetor misadjusted
• Choke not adjusted properly
• Low compression
• Crankcase breather restricted

Engine Idles But Will Not Rev Up

• Spark plug fouled/weak spark
• Broken throttle cable
• Obstruction in air intake
• Air box removed (reinstall all intake components)
• Incorrect or restricted carburetor jetting
• ETC switch limiting speed
• Reverse speed limiter limiting speed
• Carburetor vacuum slide sticking/diaphragm damaged
• Incorrect ignition timing
• Restricted exhaust system

Engine Has Low Power

• Spark plug fouled
• Cylinder, piston, ring, or valve wear or damage (check compression)
• PVT not operating properly
• Restricted exhaust muffler
• Carburetor vacuum slide sticking/diaphragm damaged
• Dirty carburetor

Piston Failure - Scoring

• Lack of lubrication
• Dirt entering engine through cracks in air filter or ducts
• Engine oil dirty or contaminated

Excessive Smoke and Carbon Buildup

• Excessive piston-to-cylinder clearance
• Wet sumping
• Worn rings, piston, or cylinder
• Worn valves, guides or seals
• Restricted breather
• Air filter dirty or contaminated

Low Compression

• Decompressor stuck
• Cylinder head gasket leak
• No valve clearance or incorrectly adjusted
• Cylinder or piston worn
• Piston rings worn, leaking, broken, or sticking
• Bent valve or stuck valve
• Valve spring broken or weak
• Valve not seating properly (bent or carbon accumulated on sealing surface)
• Rocker arm sticking


Backfiring

• ETC or speed limiter system malfunction
• Fouled spark plug or incorrect plug or plug gap
• Carburetion faulty - lean condition
• Exhaust system air leaks
• Ignition system faulty:

Spark plug cap cracked/broken
Ignition coil faulty
Ignition or kill switch circuit faulty
Ignition timing incorrect
Sheared flywheel key

• Poor connections in ignition system
• System wiring wet
• Valve sticking
• Air leaks in intake
• Lean condition

Spark Plug Fouling

• Spark plug cap loose or faulty
• Choke cable adjustment or plunger/cable sticking
• Foreign material on choke plunger seat or plunger
• Incorrect spark plug heat range or gap
• Carburetor inlet needle and seat worn
• Jet needle and/or needle jet worn or improperly adjusted
• Excessive carburetor vibration (loose or missing needle jet locating pins)
• Loose jets in carburetor or calibration incorrect for altitude/temperature
• Incorrect float level setting
• PVT system calibrated incorrectly or components worn or mis-adjusted
• Fuel quality poor (old) or octane too high
• Low compression
• Restricted exhaust
• Weak ignition (loose coil ground, faulty coil, stator, or ETC switch)
• ETC switch mis-adjusted
• Restricted air filter (main or pre-cleaner)
• Improperly assembled air intake system
• Restricted engine breather system
• Oil contaminated with fuel
• Restricted oil tank vent

Cooling Troubleshooting

Overheating

• Low coolant level
• Air in cooling system
• Wrong type of coolant
• Faulty pressure cap or system leaks
• Restricted system (blocked in radiator, lines, pump, or water jacket)
• Lean mixture (restricted jets, vents, or fuel pump)
• Fuel pump output weak
• Restricted radiator (internally or cooling fins)
• Water pump failure
• Cooling system restriction
• Cooling fan inoperative or turning too slowly
• Ignition timing misadjusted
• Low oil level
• Spark plug incorrect heat range
• Faulty hot light circuit
• Thermostat stuck closed or not opening completely
• Radiator is missing its internal diverter plate not allowing coolant to flow through entire radiator

Temperature Too Low

• Thermostat stuck open

Leak at Water Pump Weep Hole

• Faulty water pump mechanical seal (coolant leak)
• Faulty pump shaft oil seal (oil leak)


Service Manual, Repair Manual, Shop Manual, User's Manual, Workshop Guide, Study Guide, Download PDF Owner's Service Repair Manual, eBook, Learning Book, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 92, 93, 94, 95, 96, 97, 98, 99, 00, 01, 02, 03, 04, 05, 06, 07, 08, 09, 10