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. |
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 |
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
You can go here http://www.jetskirepairmanual.com/polaris-jet-ski-repair-manual/ for downloadable Polaris jet-ski repair manuals.
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 |
YAMAHA PWC PERSONAL WATERCRAFT MANUALS AVAILABLE:
You can go here for http://www.jetskirepairmanual.com/yamaha-waverunner-repair-manual/ download repair manuals.
1997 2000 YAMAHA GP1200 (GP 1200) Service Manual
Service Manual Application: 1997, 1998, 1999 & 2000 Yamaha GP1200 (GP-1200) Personal Water Craft (PWC).
1997 2000 Yamaha GP760 (GP 760) Service Manual PWC
Service Manual Application: 1997, 1998, 1999 & 2000 Yamaha GP760 (GP-760) Personal Water Craft (PWC).
1997-2007 Yamaha SJ700AU (SJ700 AU) Service Manual Waverunner
Service Manual Application: 1997-2009 Yamaha SJ700AU, SJ700A, SJ-700-A-AU Super Jet , Superjet Water Craft.
1998 2000 YAMAHA WaveRunner GP800 (GP 800) Service Manual
Service Manual Application: 1998, 1999 & 2000 Yamaha WaveRunner (Wave Runner) GP800 (GP-800) Water Craft
1999-2004 Yamaha SV1200 & SUV1200 Service Manual PWC
Service Manual Application: 1999, 2000, 2001, 2002, 2003 & 2004 Yamaha SV1200 (SV-1200) & SUV, SUV1200 (SUV-1200) WaveRunner (Wave Runner) Water Craft.
1999 2004 YAMAHA Wave Runner XL760 XL1200 Service Manual XL 760/1200
Service Manual Application: Yamaha WaveRunner (Wave Runner) 1999, 2000, 2001, 2002, 2003 & 2004 XL760 (XL-760) & XL1200 (XL-1200).
2000-2002 Yamaha GP1200R (GP-1200-R, GP1200) Service Manual
Service Manual Application: 2000, 2001 & 2002 Yamaha WaveRunner (Wave Runner) GP1200R (GP-1200-R, GP-1200R) Personal Water Craft.
2001-2005 Yamaha GP800R (GP 800 R) Service Manual & Owners Manual
Service Manual & Owners/Operators Manual Application: 2001, 2002, 2003, 2004 & 2005 Yamaha WaveRunner (Wave Runner) GP800R (GP-800R, GP800-R) Personal Water Craft.
2001 2005 YAMAHA WaveRunner XLT1200 (XLT 1200) Service Manual
Service Manual Application: 2001, 2002, 2003, 2004 & 2005 Yamaha WaveRunner (Wave Runner) XLT1200 (XLT-1200) Water Craft.
2002-2004 Yamaha XLT800 (XLT 800) Service Manual PWC
Service Manual Application: 2002, 2003 & 2004 Yamaha WaveRunner (Wave Runner) XLT800 (XLT-800) Personal Water Craft.
2003-2005 Yamaha Waverunner GP1300R Service Manual
Service Manual Application: 2003, 2004, 2005 Yamaha Wave Runner GP1300R, GP1300-R, GP-1300-R PWC Watercraft Service Manual.
2005-2009 Yamaha VX1100 (VX 1100) Service Manual SPORT DELUXE
Service Manual Manual Application: 2005, 2006, 2007, 2008 and 2009 Yamaha WaveRunner (Wave Runner) VX1100 (VX-1100, VX110, VX-110) Sport/Deluxe Personal Water Craft (PWC).
2008 YAMAHA Waverunner FX & FX Cruiser Service Manual FX1100
Service Manual Application: 2008 Yamaha FX High Output, 2008 FX Cruiser High Output WaveRunner (Wave Runner) Water Craft (PWC) FX1100G (FX-1100-G), FX1100LG (FX-1100-LG), FX1100AG (FX-1100-AG), FX1100ALG (FX-1100-ALG).
2008 2009 Yamaha FX SHO & FX Cruiser SHO Service Manual Waverunner
Service Manual Application: 2008-2009 (08, 09) Yamaha FX SHO & FX Cruiser SHO WaveRunner (Wave Runner) Water Craft (PWC).
2009 2010 Yamaha GX1800 GX1800A Service Manual GX 1800 A FZR/FZS WaveRunner
Service Manual Application: 2009-2010 FZR GX1800 (F2R) FZS & GX1800A (GX-1800-A) (F2C)Yamaha WaveRunner (Wave Runner) Water Craft (PWC). |
KAWASAKI JETSKI JET SKI SERVICE MANUALS AVAILABLE
1985-1989 Kawasaki Jetski Jet ski TS 650 Tandem Sport JF650 Service
1986-1995 Kawasaki Jetski Jet ski X-2 X2 JF650 Service Manual
1991-1995 Kawasaki Jetski Jet ski SC JL650 JL 650 Service Manual
1992-1995 Kawasaki Jetski Jet ski 750SX 750SXi 750 SX SXi JS750 Service Manual
1994 Kawasaki Jetski Jet ski XiR Xi-R JH750 750 Service Manual
1994-1995 Kawasaki Jetski Jet ski ST STS JT750 750 Service Manual
1996-2002 Jetski Jet ski 1100ZXi 1100 ZXi JH1100 Service Manual
1997-2000 Jetski Jet ski 900 STX 900STX JT900 Service Manual
1998 Kawasaki Jetski Jet ski Xi Sport JH750 Service Manual
2001 Kawasaki Jetski Jet ski Ultra 130 DI 130DI JH1100 1100 Service Manual
2001-2002 Kawasaki Jetski Jet ski 900 STX 900STX JT900 Service Manual
2002 2003 Kawasaki Jetski Jet ski 1200 STX-R 1200STX-R JT1200 Service Manual
2003 Kawasaki Jetski Jet ski 900 STX 900STX JT900 Service Manual
2003 Kawasaki Jetski Jet ski 1100 STX DI 1100STX JT1100 Service Manual
2003-2005 Kawasaki Jetski Jet ski Ultra 150 JH1200 Service Manual
2003-2009 Kawasaki Jetski Jet Ski 800 SX-R SXR 800SXR JS800 SJ Service Manual
2004-2005 Kawasaki Jetski Jet ski STX-15F STX 15F JT1500 Service Manual
2004-2006 Kawasaki Jetski Jet ski 900 STX 900STX JT900 Service Manual
2005 Kawasaki Jetski Jet ski STX-12F STX 12F JT1200 Service Manual
2005-2007 Kawasaki Jetski Jet ski X-2 X2 JF800 800 Service Manual
2006-2007 Kawasaki Jetski Jet ski STX-12F STX 12F JT1200 1200 Service Manual
2006-2009 Kawasaki Jetski Jet ski STX-15F STX 15F JT1500 1500 Service Manual
2007-2008 Kawasaki Jetski Jet ski Ultra 250X 250 X JT1500 1500 Service Manual
2007-2009 Kawasaki Jetski Jet ski Ultra LX JT1500 Service Manual
2009-2010 Kawasaki Jetski Jet ski STX 1500 JT1500D Service Manual
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COMMON PWC PERSONAL WATER CRAFT SEARCHES:
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 to exact specifications in the correct year and model service manual. These items are randomly listed, and are not necessarily in order of most common occurrence. Download a service manual to help identify the cause of your problem and the remedy to fix it.
SYMPTOMS: Hard starting; bogging; hesitation; backfire; surging; detonation; engine noise; low power; spark plug light colored or eroded; engine runs hot; high or unstable idle; piston failure; application of choke improves condition. Stalling (may restart immediately or soon afterward; high speed surging; high speed or sharp turns makes condition worse (may hesitate or stall only in turns).
TROUBLESHOOTING SYMPTOMS
LEAN CONDITION POOR PERFORMANCE RICH FUEL MIXTURE ENGINE BACKFIRES ENGINE PINGING OR KNOCKING ENGINE POWER LOSS ENGINE NOISE ENGINE OVERHEATS HARD STARTING ENGINE TURNS OVER BUT WILL NOT START LOW COMPRESSION ERRATIC IDLE OR NO IDLE
- Fuel level low or fuel contaminated
- Restricted fuel filter, fuel pump, or lines
- Water present in fuel system
- Water in carb fuel chambers between diaphragm, jet block and jets
- Kinked or restricted fuel tank vent or fuel lines
- Fuel tank inlet check valve damaged, faulty, or improperly installed
- Vent lines kinked
- Air leak's at fuel pickup connections or lines between pump and tank
- Fuel pickup tube disconnected or loose in tank
- Fuel pump impulse link pinched, kinked, restricted with oil or water or leaking
- Carburetors dirty; main pilot or bypass orifices restricted; fuel inlet screen plugged
- Carburetor synchronization incorrect
- Water separator full or restricted
- Water in fuel tank
- High or low speed screws adjusted incorrectly; jets too small or restricted
- Fuel pump diaphragm or check valve damaged
- Fuel filter restricted
- Carburetor jetting incorrect
- Fuel tank pickup screen plugged
- Air leaks in engine intake tract (carburetor base gaskets, reed gaskets, synchronizing plugs, etc.)
- Carburetor inlet needle or control lever arm stuck or adjusted incorrectly
- Fuel line "T" restricted
- Inlet needle valve restricted or size to small
- Air leaks at cylinder base, crankcase drain plugs, fuel pump impulse link or fitting, carburetor base gaskets, reed cage gaskets, crankshaft end seals, crankcase mating surfaces
- Rich or lean condition.
- Jet pump impeller damage, pump cavitation/ventilation.
- Ignition timing incorrect, weak or intermittent spark on one or more cylinders, low compression
- RPM is limited or timing retarded due to low fuel or overheatingg
- Crankshaft out of index due to hydro lock by fuel or water, low cylinder compression, damaged flywheel
- Fuel lines connected improperly
- Ignition timing retarded or RPM limited due to overheat or low fuel
- Water leak into exhaust system(i.e. exhaust pipe to manifold; exhaust manifold to cylinders; etc.)Exhaust hose delimitation present
- Thermostat/pop-off leak, dirty or damaged
- Carburetor mixture needles damaged or adjusted incorrectly
- Needle and seat damaged
- Misuse of choke
- Fouled spark plugs
- Fuel pump diaphragm damaged or ruptured
- Carburetor synchronization incorrect
- Needle and seat control arm to high or sticking
- Collapsed exhaust hose or pipe restricted
- Air intake restricted
- Broken, cracked or poorly sealing reed valve
- Low compression
- Ignition problem
- Anti-siphon valve worn or broken
- Exhaust hose delimitation present
- Weak spark from fouled, defective, worn or wrong spark plugs
- Broken reed petals
- Lean fuel mixture
- Poor quality, low octane gasoline
- Incorrect ignition timing
- Spark plug heat range too high
- Weak spark
- Incorrect fuel or fuel mixture
- Water in fuel system or oil tank
- Fuel filter restricted
- Jet intake clogged
- Cooling system clogged
- Detonation (see causes for holed or eroded pistons)
- Excessive piston clearance
- Exhaust leak, loose exhaust pipe or muffler (water box)
- Engine mounts or mount plate loose or rubber mounts broken
- Drive coupler splines dry
- Drive shaft run out excessive
- Driveshaft end play incorrect; rubber dampers worn or missing
- Broken ring or ring land
- Oil pump bushing end play excessive
- Ignition timing incorrect
- Piston pin damaged or bent
- Connecting rod bearing failure (small end or big end)
- Crankshaft main bearing failure or wear flywheel loose
- Colling water passages in pump restricted
- Impeller or pump housing damage
- Pump housing passage plugs missing
- Cooing water passages in engine restricted with sand or debris
- Out of fuel
- Low compression
- Water in fuel
- Choke or throttle closed
- Piston rings stuck or broken, or excessive end gap
- Cylinder worn, improperly honed or bored, damaged
- Idle speed improperly adjusted
- Incorrectly adjusted low speed mixture screw
- Throttle linkage worn or sticking
HYDROLOCK
A hydrolock condition can be caused by either water of fuel ingestion. Most often, water ingestion causes a hydro lock in the watercraft.
A hydro lock occurs when water fills a cylinder when the piston is moving down. When the next piston fires, the piston with the cylinder full of water is forced back upward. Since water will not compress like air, the pressure is released in one or more of the following ways:
Twisting cranksaft out of index. Breaking or bending the connecting rod and/or piston pin. Cracking or breaking the cylinder and/or cylinder head along with water outlet manifold and exhaust manifold. Flywheel Key, starter motor damage.
Water can enter the engine when the water is capsized and not up-righted properly, if the watercraft is submerged while riding where large amounts of water are allowed to enter the air intake thru-hull fittings, improper use of a flush kit, cracks in the hull, or improperly sealed thru-hull components.
In order to properly diagnose a hydrolock condition see your service manual. |
Service Manual, Repair Manual, Shop Manual, User's Manual, Workshop Guide, Study Guide, Download PDF Owner's Service Repair Manual, eBook, Learning Book, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 92, 93, 94, 95, 96, 97, 98, 99, 00, 01, 02, 03, 04, 05, 06, 07, 08, 09, 10 |
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