GENERAL INFORMATION
1.52004 Four Stroke PWC Service Manual
Service Guidelines -- Safety Warnings
SClean inside and outside of watercraft prior to servicing. Clean all parts before installing. Always use a service apron to
prevent damage to footwell and top--deck fiberglass.
SWatch for sharp edges which can cause personal injury. Protect hands and arms when working with sharp components.
SAlways use a soft--faced hammer and extreme care when removing difficult or stuck components.
SSome fasteners are installed with locking agents or lubricants. Use of impact drivers will aid in fastener removal.
SAlways follow torques specifications located throughout manual. Fasteners secured with either too little or too much torque
may fail and cause severe property damage, injury or death.
SAlways follow torque sequence patterns when found in this manual. Tighten each fastener evenly and to the specified torque
value, and with specified locking agent.
SAlways use new gaskets, o--rings and seals, clips, cir--clips, and snap rings when assembling components.
SNever re--use Nyloktor Flex Locktnuts when assembling components.
SNever re--use Oetikertclamps when removed from fuel lines. Replace with small gear clamps.
SAlways use Polaris--authorized lubricants, greases, and locking agents when assembling components. Failure to do so
may cause severe engine or vehicle damage.
SAlways disconnect the black (--) negative cable first from the battery when removing the battery. When installing the battery,
attach the red (+) positive cable first, then the black (--) negative cable.
SWear appropriate clothing, eye protection, and rubber gloves when working with batteries. Battery acid contains sulfuric
acid and is extremely poisonous. Serious burns can result when in contact with skin, clothing, eyes or internal body compo-
nents.
SIf battery acid is ingested, drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable
oil. Call a physician immediately.
SFlush eyes for15 minutes with water and seek prompt medical attention if acid comes in contact with eyes. Thoroughly wash
affected external body parts that come in contact with battery acid with water.
SKeep hands, arms, legs, feet and hair away from rotating parts, hot engine and exhaust components, drive pump and impel-
ler and engine induction when engine is running.
SNever attempt engine or driveline inspections and/or repairs without first removing lanyard and battery cables.
SGasoline is highly flammable and explosive under certain conditions. Always exercise extreme care when handling gaso-
line. Do not smoke or allow open flames in or near the area where refueling is performed or where gasoline is stored.
SAlways refuel the watercraft outdoors and in a well--ventilated area. Do not fill the tank to the fuel cap.
SIf you get gasoline or oil on your skin or clothing, wash it off immediately with soap and water and change clothing.
SThe engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
Only run engine outdoors or in a well--ventilated area.
SNever run the engine for more than 15 seconds without cooling water supply.
