Polaris Virage TX 2000 User manual

The Way Out.
2000 Virage TX, SLX, Pro 1200,
Genesis FFI ™ PERSONAL WATERCRAFT
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. Certain procedures require the use of special tools.
Use only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary impor
tance.
This manual includes procedures for disassembly and reassembly, inspection, maintenance, component identifi
cation and unit repair, along with service specifications for 2000 Virage TX, SLX, Genesis, Genesis FFI™, and
Pro 1200 Polaris personal watercraft. A table of contents is placed at the beginning of each chapter to aid the
user in locating specific areas of information. The alphabetic index at the end of the manual will help the user
find specific information quickly.
Care is taken to ensure that all information in this manual was technically correct at the time of publication. How
ever, all materials and specifications are subject to change without notice.
Comments or suggestions about this manual may be directed to: Engineering Services, Technical Writer, Polaris
Sales Inc., 2100 Highway 55, Medina, MN 55340.
Technical Training Center
Minneapolis, MN 55447
2000 Virage TX, SLX, Pro 1200, Genesis, Genesis FFI
Personal Watercraft Service Manual (PN 9916290)
Copyright2000 Polaris Sales Inc., Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
j\ The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the operator, passenger, bystander
or person inspecting or servicing the watercraft.
A WARNING
Failure to follow WARNING instructions could result in severe injury or death to the operator, passenger, bystand
er or person inspecting or servicing the watercraft.
CAUTION:
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
Torx, Trademark of Textron
Teflon, Trademark of DuPont
Alemite, Trademark of Alemite Corporation

CHAPTER 1
GENERAL INFORMATION
Publication Numbers and FFI™ Tools .1.1
FFI ™ Special Tools 1.2
2000 Model Identification 1.3
2000 Model Specifications 1.4 - 1.5
Standard Torque Specifications 1.6
Decimal Equivalents 1.7
Conversion Tables 1.8
Tap Drill Charts 1.9
Glossary of Terms 1.10-1.11
Service Tips 1.12

GENERAL INFORMATION
Publication Numbers/Paint Codes
Watercraft Publication Part Numbers
Paint Codes
Dealer orders can be placed through Midwest Industrial Coatings using the Polaris "P" number. Phone
(763-942-1840). Mix as directed.
Special Tools
Polaris Sales Inc.
1.1
3100

GENERAL INFORMATION
Publication Numbers/Paint Codes
FFI ™ Fuel Injection Special Tools
2872454 - EMM Lap Top Com Cord
2872604 - Engine Bumper Tool
2872602 - Schrader Valve
2872456 - EMM Service
Power Connector
2872621 - Fuel Pump Ring Spanner
300
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Polaris Sales Inc.

GENERAL INFORMATION
Model Identification
Identification Numbers
The engine I.D. number and hull I.D. number are used to register the watercraft. They are unique numbers that
distinguish each watercraft from others of the same model.
If the watercraft is ever stolen these numbers will help identify it. The owner should keep a record of these
numbers in a place other than the watercraft.
lumber Identifjj^tipii;;' ■; .;',, •": '■&•" /.";
if^dtyr^l^r:" Serial /^/l^otith'ofV" t TY^rof '- " ^
Month Code: A = January; B = February; etc.
Year Of Manufacture: 9 = 1999; 0 = 2000; etc.
Starter Cover
Engine I.D. Number
(Polaris Domestic Engine)
Polaris Sales Inc.
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3/00

GENERAL INFORMATION
Model Specifications
Polaris reserves the right to change specifications at 2000 Wage TX 2000 GeneSJS 2000 GeneSJS FF1™
any time without incurring obligations. *
Model Number W005199D W005099D W005098D
Dimensions/Materials/Capacities
Length 120.3" (305.56cm) 131.1" (330.5cm) 131.1" (330.5cm)
Width 49.3" (125.22cm) 49.3" (125.22cm) 49.3" (125.2cm)
Height 39" (99.06cm) 40.4" (102.6cm) 40.4" (102.6cm)
Dry Weight 620 (280 kg) 625 (282 kg) 625 (282 kg)
Rider Capacity 3 person/500 lbs. (227 kg) 4 person/600 lbs. (272 4 person/600 lbs. (272 kg)
kg)
Rated Fuel Capacity including reserve .... 17 U.S. Gal (64.4L) 17 U.S. Gal (64.4L) 17 U.S. Gal (64.4L)
Fuel Reserve N/A N/A N/A
Oil Reservoir Capacity - U.S. quarts 6.0 (5.68L) 6.0 (5.68L) 6.0 (5.68L)
Hull Material Sheet Molded Compound Fiberglass Reinforced Fiberglass Reinforced
(SMC) Composite (FRC) Composite (FRC)
Top Deck Material Fiberglass Reinforced Fiberglass Reinforced Fiberglass Reinforced
Composite (FRC) Composite (FRC) Composite (FRC)
Engine/Cooling
Engine Model No W120-TCSP-02B1 W120-TCSP-02B2 W120-DFI-02B
Engine Displacement 1165cc 1165cc 1165cc
Engine Type (# Of Cylinders) Polaris Marine 1200 (3) Polaris Marine 1200 (3) Polaris Marine 1200 FFI® (3)
Bore & Stroke 84mm x 70mm 84mm x 70mm 84mm x 70mm
Compression Ratio (Full Stroke) 6.8:1 6.8:1 6.8:1
Horsepower 135 HP @ 6700 RPM 135 HP @ 6700 RPM 135 HP @ 6700 RPM
Cooling System Water cooled Water cooled Water cooled
Thermostat Open 140°F (60°C) 140°F (60°C) 140°F (60°C)
Overheat Warning 3500 Rev Limit @ 237°F 3500 Rev Limit @ 237°F S.L.O.W.™/Warning Light
(114°C) (114°C)
Induction Type Case Reed Case Reed Case Reed
Lubrication Oil Injected Oil Injected Oil Injected
Oil Type Polaris TC-W3, Premium Gold Polaris TC-W3, Premium Polaris TC-W3, Premium Gold
Synthetic or Nature Oil Gold Synthetic or Nature Synthetic or Nature Oil
Oil
RPM Limiter Operation 7200 RPM ±100 7200 RPM ±100 7200 RPM ±100
Carburetion
Carburetors 3-40mm, Keihin CDK 3-40mm, Keihin CDK 3-FICHT® Fuel Injectors
Fuel Type Regular Unleaded Gasoline Regular Unleaded Regular Unleaded Gasoline
(87 Octane or 89 if Gasoline (87 Octane or (87 Octane or 89 if
oxygenated) 89 if oxygenated) oxygenated)
Idle Speed (In Water) 1350±100 1350± 100 1150±50
Electrical
Magneto Generator Output 8.5A / 60W at 4500 RPM 8.5A / 60W at 4500 RPM 12A /160W at 4500 RPM
Ignition System Digital CDI Digital CDI FICHT®
Spark Plug Type NGK BR9ES NGK BR9ES NGK PZFR6H
Spark Plug Gap (inches) 028" (0.7mm) .028" (0.7mm) .032" (0.8mm)
Timing Degrees BTDC 23°±1 @3000 23°±1 @3000 N/A
15°±1 @6500 15°±1 @6500
Battery 12V19AYB16CL-B 12V19AYB16CL-B 12V19AYB16CL-B
Starting System Electric Electric Electric
Fuse 15A resettable circuit breaker 15A resettable circuit 15A resettable circuit breaker
breaker
Propulsion
Jet Pump Type Single Stage Axial Flow Single Stage Axial Flow Single Stage Axial Flow
Dominator Style Dominator Style Dominator Style
ImpellerRotation Counterclockwise Counterclockwise Counterclockwise
Couplingtype Rubber Rubber Rubber
Bilge Pump Type Electric Electric Electric
Minimum Water Level For Jet Pump 2 Feet (60cm) 2 Feet (60cm) 2 Feet (60cm)
Pivoting Angle 30° 30° 30°
ImpellerType Progressive Pitch Slim Hub Progressive Pitch Radial Progressive Pitch Radial 3
Stainless 3 Blade NuJet 7.0 3 Blade Skat Trak Blade Skat Trak
ImpellerDiameter 5.8" (14.73cm) 5.8" (14.73cm) 5.8" (14.73cm)
Reverse System Std Std Std
*MFD / MFI includes: Speedometer, Peak Speed, Peak RPM, Tachometer, Clock, Hour Meter, Oil Level, Trip Meter, Low
Oil Warning, Fuel Level, Volts, Low Fuel Warning, Hot Engine Warning, Compass.
300
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Polaris Sales Inc.

GENERAL INFORMATION
Model Specifications
Polaris reserves the right to change specifications at any time without incurring obligations. 2000 SLX 9000 Pro 1900
ModelNumber W004699D W004999D
Dimensions/Materials/Capacities
Len9th 108.5" (276cm) 108.5" (276cm)
Width 47.5" (120.7 cm) 47.5" (120.7cm)
Height 39.5" (100.3cm) 39.5" (100.3cm)
Dry Weight 565(256kg) 625(282kg)
RiderCapacity 2 person/370 lbs. (168 kg) 2 person/370 lbs. (168 kg)
Rated Fuel Capacity including reserve 12.5 U.S. Gal (47.3L) 9.8 U.S. Gal (37.1 L)
Fuel Reserve N/A N/A
Oil Reservoir Capacity - U.S. quarts 5.0 (4.73L) 3.5 (3.31 L)
Hull Material Sheet Molded Compound Fiberglass Reinforced
(SMC) Composite (FRC)
Top Deck Material Fiberglass Reinforced Fiberglass Reinforced
Composite (FRC) Composite (FRC)
Engine/Cooling
EngineModeINo W120-TCSP-02B1 W120-TCSP-02B1
Engine Displacement 1165cc 1165cc
Engine Type (# Of Cylinders) Polaris Marine 1200 (3) Polaris Marine 1200 (3)
Bore&Stroke 84mmx70mm 84mmx70mm
Compression Ratio (Full Stroke) 6.8:1 6.8:1
Horsepower 135 HP @ 6700 RPM 135 HP @ 6700 RPM
CoolingSystem Watercooled Watercooled
Thermostat Open 140°F(60°C) 140°F(60°C)
Overheat Warning 3500 Rev Limit @ 237°F 3500 Rev Limit @ 237°F
(114°C) (114°Q
Induction Type Case Reed Case Reed
Lubrication Oil Injected Oil Injected
Oil Type Polaris TC-W3, Premium Gold Polaris TC-W3, Premium Gold
Synthetic or Nature Oil Synthetic or Nature Oil
RPM Limiter Operation 7200 RPM ±100 7200 RPM ±100
Carburetion
Carburetors 3-40mm, Keihin CDK 3-40mm, Keihin CDK
FuelType Regular Unleaded Gasoline Regular Unleaded Gasoline
(87 Octane or 89 if (87 Octane or 89 if
oxygenated) . oxygenated)
Idle Speed (In Water) 135Q±100 1350±100
Electrical
Magneto Generator Output 8.5A / 60W at 4500 RPM 8.5A / 60W at 4500 RPM
Ignition System DigitalCDI DigitalCDI
SparkPlugType NGKBR9ES NGKBR9ES
Spark Plug Gap (inches) , 028" (0.7mm) .028" (0.7mm)
TimingDegrees BTDC 23°±1 @3000 23°±1 @3000
15°±1 @6500 15°±1 @6500
Battery 12V19A YB16CL-B 12V19A YB16CL-B
Starting System Electric Electric
Fuse 15A resettable circuit breaker 15A resettable circuit breaker
Propulsion
Jet Pump Type Single Stage Axial Flow Single Stage Axial Flow
Dominator Style Dominator Style
ImpellerRotation Counterclockwise Counterclockwise
Couplingtype Rubber Rubber
Bilge Pump Type Electric Electric
Minimum Water Level For Jet Pump 2 Feet (60cm) 2 Feet (60cm)
PivotingAngle 30° 30°
Impeller Type Progressive Pitch Slim Hub Progressive Pitch Radial
Stainless 3 Blade NuJet 7.0 3 Blade NuJet 7.0
ImpellerDiameter 5.8" (14.73cm) 5.8" (14.73cm)
Reverse System N/A N/A
*MFD/ MFI includes: Speedometer, Peak Speed, Peak RPM, Tachometer, Clock, Hour Meter, Oil Level, Trip Meter, Low
Oil Warning, Fuel Level, Volts, Low Fuel Warning, Hot Engine Warning, Compass.
(Some models do not have all features.)
Polaris Sales Inc.
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3/00

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.
To convert in. lbs. to ft. lbs. divide by 12
To convert ft. lbs. to Nm multiply foot pounds by 1.356.
To convert Nm to ft. lbs. multiply Nm by .7376.
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Polaris Sales Inc.

GENERAL INFORMATION
Decimal Equivalents
1/64 0156
1/32 0312 1 mm = .0394"
3/64 0469
1/16 0625
5/64 0781 2 mm = .0787"
3/32 0938
7/64 1094 3 mm = .1181"
1/8 1250
9/64 1406
5/32 1563 4 mm = .1575"
11/64 1719
3/16 1875 5 mm = .1969"
13/64 2031
7/32 2188
15/64 2344 6 mm = .2362"
1/4 25
17/64 2656 7 mm = .2756"
9/32 2813
19/64 2969
5/16 3125 8 mm = .3150"
21/64 3281
11/32 3438 9 mm = .3543"
23/64 3594
3/8 375
25/64 3906 10 mm = .3937"
13/32 4063
27/64 4219 11 mm = .4331"
7/16 4375
29/64 4531
15/32 4688 12 mm = .4724"
31/64 4844
1/2 5 13 mm = .5118
33/64 5156
17/32 5313
35/64 5469 14 mm = .5512"
9/16 5625
37/64 5781 15 mm = .5906"
19/32 5938
39/64 6094
5/8 625 16 mm = .6299"
41/64 6406
21/32 6563 17 mm = .6693"
43/64 6719
11/16 6875
45/64 7031 18 mm = .7087"
23/32 7188
47/64 7344 19 mm = .7480"
3/4 75
49/64 7656
25/32 7813 20 mm = .7874"
51/64 7969
13/16 8125 21 mm = .8268"
53/64 8281
27/32 8438
55/64 8594 22 mm = .8661"
7/8 875
57/64 8906 23 mm = .9055"
29/32 9063
59/64 9219
15/16 9375 24 mm = .9449"
61/64 9531
31/32 9688 25 mm = .9843
63/64 9844
1 1.0
Polaris Sales Inc. ^~y 3/00

GENERAL INFORMATION
Conversion Table
°C to °F: 9 (°C + 40) - 5 - 40 = °F
°F
to °C: 5 (°F + 40) + 9 - 40 = °C
300
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GENERAL INFORMATION
Tap Drill Charts
SAE Tap Drill Sizes
Metric Tap Drill Sizes
Polaris Sales Inc.
1.9
3/00

GENERAL INFORMATION
Glossary Of Terms
ABDC: After bottom dead center.
ATDC: After top 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.
CDI: Capacitor discharge ignition. Ignition system which stores voltage generated by the stator plate exciter coil
in a capacitor or condenser (in CDI box). At the proper moment a voltage generated by the stator plate pulser coil
closes an electronic switch (thyristor) in the CDI box and allows the voltage in the capacitor to discharge into the
primary windings of the ignition coil.
Cl: Cubic inches.
Condenser/Capacitor: A storage reservoir for electricity, used in both E.T. and CDI systems.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is
supported between centers on V blocks or resting in lower half of crankcase. Measure at various points especially
at the PTO end.
DCV: Direct current voltage.
Detonation: The spontaneous ignition of the unburned fuel/air mixture after normal ignition spark occurs. Piston
looks "hammered" through, rough appearance around hole. Possible causes: 1) Compression ratio too high for
the fuel octane; 2) low octane fuel; 3) over-advanced ignition timing.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and
out-of-round in the cylinder bore.
End Seals: Rubber seals at each end of the crankshaft.
F: Fahrenheit
ft.: Foot/feet.
Foot Pound: Ft. Ib. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system. There are 28 grams in one ounce.
gal.: Gallon.
Head Volume (Uninstalled): Cylinder head capacity in cc, head removed from engine with spark plug installed.
High Tension Lead: The heavy insulated wire which carries the high secondary voltage from the coil to the spark
plug.
Holed Piston: Piston in which a hole has formed on the dome. Possible causes: 1) detonation; 2) pre-ignition.
HP: Horsepower.
ID: Inside diameter.
Ignition Coil: A type of transformer which increases voltage in the primary windings (approx. 200V) to a higher
voltage in the secondary windings (approx. 14KV - 32KV) through induction. Secondary voltage must be high
enough to ionize the air gap at the spark plug.
Ignition Generating Coil: Exciter coil, primary charge coil. Stator plate coil which generates primary ignition
voltage.
in.: Inch/inches.
kg/cm : Kilograms per square centimeter.
Kg-m: Kilogram meters.
Km: Kilometer.
Kilogram meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
300 1.10 Polaris Sales Inc.

GENERAL INFORMATION
Glossary Of Terms
I or Itr: Liter. One liter = 1.0567 U.S. quarts.
lbs/in : Pounds per square inch.
Inch Pound: In. Ib. 12 in. lbs. = 1 ft. Ib.
Left Side: The left hand side of the vehicle. Referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the
windings. This is how mechanical energy is converted to electrical energy in the lighting coil, ignition generating
coils and trigger coil.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = .040".
N-m: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
Open Circuit: An electrical circuit which is incomplete, (e.g. poor connections or broken wire preventing the flow
of current).
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
Piston Erosion: Piston dome melts. Usually occurs at the exhaust port area. Possible causes: 1) lean fuel/air
mixture; 2) improper spark plug heat range.
Pre-lgnition: A problem in combustion where the fuel/air mixture is ignited before normal spark ignition. Piston
looks melted at area of damage. Possible causes: 1) Spark plug heat range incorrect (too hot) 2) spark plug not
properly torqued; 3) "glowing" piece of head gasket, metal burr or carbon in the combustion chamber; 4) lean
fuel/air mixture.
Primary Circuit: This circuit is responsible forthe voltage build up in the GDI capacitor. In a CDI system the parts
include the exciter coil, the trigger coil, the wires from stator plate to CDI box and to the ignition coil primary
windings.
psi.: Pounds per square inch.
pts: Pint/pints
PTO: Power take off.
qt.: Quart/quarts.
RPM: Revolutions per minute.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy
conversion to heat.
Right Side: The right hand side of the vehicle. Always Referred to based on normal operating position of the rider.
Running Time: Ignition timing at specified RPM.
Secondary Circuit: This circuit consists of the ignition coil secondary windings, high tension wire and ground
through the spark plug air gap.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the
cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston
clearance; 4) stuck piston rings.
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.
Stator Plate: The plate mounted under the flywheel supporting the primary ignition components and lighting coil.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Trigger Coil: Pulser coil. Generates the voltage for triggering (closing) the thyristor and timing the spark in CDI
systems. Small coil mounted at the top of the stator plate next to the ignition generating coil.
Voltage Regulator: An electrical device which prevents overcharging of the battery or overloading of electrical
components as engine RPM increases.
Polaris Sales Inc. -| -|-| " 3j0q

GENERAL INFORMATION
Service Tips
In order to perform service work efficiently and to prevent costly errors, the technician should begin by reading the
text in this manual to become familiar with procedures before beginning. Pictures and illustrations have been
included with the text as an aid. Notes, cautions and warnings have also been included for clarification of text and
safety concerns. However, a knowledge of mechanical theory, tool use, and shop procedures is necessary to
perform the service work safely and satisfactorily. Use only genuine Polaris service parts.
nS Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will act
as an abrasive and cause damage to precision parts. Clean the vehicle before beginning service. Clean new parts
before installing.
As Watch for sharp edges which can cause personal injury. Protect hands with gloves when working with sharp
components.
A± If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be
found. If it is necessary to tap the part into place, use a soft face hammer and tap lightly.
nS Some of the fasteners were installed with locking agents. Use of impact drivers or wrenches will help avoid
damage to fasteners.
/K Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious
machine damage or, as in the case of steering components, can result in injury or death for the rider(s).
nS If a torquing sequence is indicated for nuts, bolts or screws, start all fasteners in their holes and hand tighten.
Then, following the method and sequence indicated in this manual, tighten evenly to the specified torque value.
When removing nuts, bolts or screws from a part with several fasteners, loosen them all about 1/4 turn before
removing them.
^ If the condition of any gasket or O-Ring is in question, replace it with a new one. Be sure the mating surfaces
around the gasket are clean and smooth in order to avoid leaks.
iK Some procedures will require removal of retaining rings or clips. Because removal weakens and deforms
these parts, they should always be replaced with new parts. When installing new retaining rings and clips use care
not to expand or compress them beyond what is required for installation.
nS Because removal damages seals, replace any oil or grease seals removed with new parts. A suitable driver
should be used when installing a new seal to prevent distortion or damage.
/K 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.
/K Grease should be cleaned from parts and fresh grease applied before reassembly of components.
Deteriorating grease loses lubricity and may contain abrasive foreign matter.
lK 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. ANTIDOTE: External
- Flush with water. Internal - Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately. Eyes - Flush with water for 15 minutes and get prompt medical
attention.
300 1.12 Polaris Sales Inc.

CHAPTER 2
MAINTENANCE/TUNE UP
Maintenance Schedule 2.1 -2.2
Recommended Lubricants / Products 2.3
Lubrication of Components 2.4-2.7
Electrical Maintenance 2.8-2.11
Engine Maintenance 2.12 - 2.18
Cable Adjustments 2.19 - 2.25
Fuel System Maintenance 2.25 - 2.29
Cooling System Maintenance 2.30 - 2.31
Storage 2.30 - 2.32
Cleaning 2.33
Bilge System 2.34
MFD / MFI Gauges 2.35
Submerged Engine 2.36
Pump / Impeller Maintenance 2.37
Hull / Deck Maintenance 2.38 ■ 2.39
Troubleshooting 2.40 - 2.45

MAINTENANCE/TUNE UP
Maintenance Schedule
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.
* Perform every 15 hrs. or one month when operated in salt water. **Perform daily when operated in salt water.
***Bonded rubber couplers-Pre-Season (Annually), 100 hrs, or when pump is disassembled for maintenance.
****Genesis FFI™ water separating filter requires no periodic maintenance.
CD Replace pop-off valve, spring, and seals every 100 hours only (not every 6 months).
[2] Replace water separator filter element and o-ring every 100 hours only (not every 6 months).
Q Replace inlet and outlet hoses and clamps every 100 hours only.
Polaris Sales Inc.
2.1
3/00

MAINTENANCE/TUNE UP
Maintenance Schedule
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.
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.
* Perform every 15 hrs. or one month when operated in salt water. **Perform daily when operated in salt water.
***Bonded rubber couplers-Pre-Season (Annually), 100 hrs, or when pump is disassembled for maintenance.
Q] Replace pop-off valve, spring, and seals
EJReplace water separator filter element and o-ring
KEY
l=lnspect, adjust, service, or replace if necessary A=Adjust
L=Lubricate with recommended lubricant
C=Clean
R=Replace item
After washing the engine compartment of the watercraft, protect the metal components with a heavy duty siiicone
based spray lube or other non-flammable metal protectant. Do not use flammable sprays or protectants in the
engine compartment. Do not use petroleum based protectants or lubricants in the engine compartment, as most
are flammable and also may deteriorate rubber components.
Engine Break-In
Carbureted Models: Breaking in a new engine is critical! All Polaris watercraft utilize oil injection, however,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 with the first tank of fuel at a 40:1 ratio. After the first tank of fuel/oil mixture is gone,
fill fuel tank with recommended octane fuel only. After any repair where pistons, piston rings, cylinders, or crank
shafts are replaced, the first tank of fuel must be mixed with oil in the above fashion.
FF1™ Models: It is not necessary to mix the first tank of fuel with oil. The FFI ™ system utilizes a fuel injector
for each cylinder, therefore, fuel by itself does not enter any part of the crankcase. Oil is injected into the crank-
case via an oil pump and check valves on the throttle bodies. The extra oil that would be added to the fuel tank
would be passed through the fuel injectors and would not reach internal engine parts.
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3/00
2.2
Polaris Sales Inc.

MAINTENANCE/TUNE UP
Recommended Lubricants/Maintenance Products
As with all watercraft, proper lubrication and corrosion protection are necessary to maintain performance and en
sure years of trouble free service. Use the recommended lubricant for each component as indicated in the chart
below.
Polaris Sales Inc.
2.3
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