Polaris WATERCRAFT Freedom User manual

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
2002 Personal Watercraft Service Manual

2002 Freedom, Virage, Virage TX, Virage i,
Virage TXi, Genesis, Genesis i
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 the 2002 Freedom, Virage, Virage TX, Virage i, Virage
TXi, Genesis, and Genesis i 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.
2002 Personal Watercraft Service Manual (PN 9917370 )
Copyright 2001 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:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow DANGER instructions will result in severe injury or death to the operator, passenger, bystander
or person inspecting or servicing the watercraft.
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.............
Chapter 2 Maintenance.............
Chapter 3 Engine / Cooling.............
Chapter 4 Carburetion / Exhaust.............
Chapter 5 Final Drive / Propulsion.............
Chapter 6 Hull / Control Systems.............
Chapter 7 Electrical Systems.............
Chapter 8 Fuel Injection System /.............
Software

2002 PWC Identification Numbers 1.1..................................
2002 PWC Publication Part Numbers 1.2...............................
Service Tools 1.3....................................................
Freedom Specifications 1.4 -- 1.5...........................................
Virage Specifications 1.6 -- 1.7.............................................
Virage TX Specifications 1.8 -- 1.9..........................................
Virage i Specifications 1.10 -- 1.11............................................
Virage TXi Specifications 1.12 -- 1.13..........................................
Genesis Specifications 1.14 -- 1.15............................................
Genesis i Specifications 1.16 -- 1.17...........................................
Standard Torque Specifications 1.18....................................
Decimal Equivalent Charts 1.19........................................
Conversion Chart 1.20................................................
Tap Drill Size Charts 1.21..............................................
Service Glossary 1.22 -- 1.23.................................................
Service Guidelines 1.24...............................................

PLE 00000 A 0 02
Manufacturers I.D. Serial
Number
Month of
Manufacture
Year of
Manufacture
Model Year
of Craft
Hull Number Identification
US
Country of
Manufacture
HULL I.D. NUMBER
Engine I.D. Number
(Polaris Domestic Engine)
Starter Cover
General Information
1.1
2002 PWC 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 num-
bers in a place other than the watercraft.
Month Code: A = January; B = February; etc.
Year Of Manufacture: 1 = 2001; 2 = 2002; etc.

General Information
1.2
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 9917128 9917138 9917139
Virage TXi W025198D/C/I 9917135 9917136
Genesis W025099D/I 9917141 9917142
Genesis i W025098D/C/I 9917144 9917145
D = US/Canada C = California I = International
Watercraft Service Manual Part Numbers
Book Part Number
2002 All Models 9917370
2002 PWC Wallcharts 9917372
2002 PWC Flat Rate Manual 9917371
2001 SLH / Virage 9917163
2001 1200s
(SLX, Virage TX, Genesis, PRO 1200, Virage
TXi, Genesis i)
9917164
2001 PWC Wallcharts 9917166
2000 700 / 785 9916289
2000 1200 9916290
FFItDiagnostic Guide 9916771
1999 1200 9915673
1999 PWC Volume II 9915085
1995 Supplement 9913365
1992 -- 1996 PWC Volume I 9912201
Watercraft Service Video Part Numbers
Video Part Number
Introduction to FICHTÒFuel Injection 9915680
FICHTÒDiagnostics 9915891
PWC Jet Pump Service 9915819
Generation III Ignition Troubleshooting 9917441

General Information
1.3
Personal Watercraft Service Tools
Tool Part Number
(Must Order From Polaris Tool Vendor)
Piston Pin Puller 2870386
Piston Pin Puller Adapter (Works with 2870386) 2871445
Piston Support Block 2870390
C--Clip Installation Tool 2870773
Piston Pin Puller (800 / 1200cc Engines) PU--45255
Piston Pin Puller Adapter (800 / 1200cc Engines) PU--45248
Timing Adjustment Tool 2872290
EMM Laptop Communication Cable 2872454
Deutsch--to--Packard Comm. Adapter 2874061
1999 to Current DItDiagnostic Software 2874118
Service Code Light 2872455
EMM Service Power Connector 2872456
TPS Jumper Tool 2872603
Bump Stop Tool 2872604
Fuel Injector Jumper 2872623
Impeller Removal Tool (Rubber Coupler Remover) 2871036
Steel Coupler Removal Tool 2871037
Pump Alignment Tool 2871343
Through--Hull Fitting Tool 2871425
Static Timing Tool 2871745
Heavy Duty Flywheel Puller 2871043
2002 TPS Test Tool 2201519
2002 TPS Test Tool Adapter
(Allows connection of tool to both snowmo
bile and PWC TPS sensors.)
TBD
Use Diagnostic Software

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. (22.9 cm.)......
Dry Weight: 590 lbs..
Category: Sport..
Riders: 1to3.....
Fuel Capacity:17 US Gallons (64.4 L)
Oil Capacity: 6 US Quarts (5.8 L)
General Information
1.4

General Information
1.5
2002 Freedom
Model Number W025297D
Engine
Platform Polaris Marine 700 LE
Engine Model Number W70--SCSP--05A
Engine Displacement 701cc
Number of Cylinders 2
Bore & Stroke (mm) 81x68
Compression Ratio (Full Stroke) 7.0:1
Horsepower 95
Maximum Torque 69.2
Cooling System Water Cooled / Thermostat Pop--Off, self--draining, Direct From Propulsion.
Thermostat Opening Temperature 143°F(62°C)
Overheat Warning Low oil and Overheat / RPM Limit at 3500 RPM
Induction Type Case Reed
Lubrication Oil Injected
Oil Requirements Polaris TC--W3
RPM Limiter 7200 RPM
Exhaust System Water Cooled / Injected 700H
Sound Reduction New Silencer / PLANETt
Carburetion
Fuel Delivery (1) 40mm Keihin LE Carburetor
Fuel Requirement 87 Non--Oxygenated / 89 Oxygenated
Idle Speed (In Water) 1350±100
Electrical
Ignition System Digital CDI / Flywheel Magneto
Magneto Generator Output 5A / 60W @ 4500 RPM
Spark Plug NGK BPR8ES
Spark Plug Gap .024 -- .028 (.6 -- .7mm)
Timing Degrees BTDC 20°@ 3000 RPM
Battery 12V / 19A
Circuit Breaker / (Fuses) 15A Circuit Breaker (3A Bilge Located within electrical box)
Starting Electric (One button start and stop)
Propulsion
Jet Pump Type Extended Big Mouth Reverse, Single Stage Axial Flow w/ Five Vane Aluminum Stator
Impeller Rotation Counter Clockwise (From AFT)
Coupling Type Rubber Coupler
Minimum Depth For Operation 2 ft. (60cm.)
Pivoting Angle 30°
Impeller Type .585°Overlap
Impeller Diameter 5.8 in.
Reverse System N/A
Hull/Body
Hull Design Full V
Hull Material SMC (Sheet Molded Compound)
Top Deck Material FRC (Fiberglass Reinforced Composite)

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. (22.9 cm.)......
Dry Weight: 600 lbs..
Category: Midsize..
Riders: 1to3.....
Fuel Capacity:17 US Gallons (64.4 L)
Oil Capacity: 6 US Quarts (5.8 L)
General Information
1.6

General Information
1.7
2002 Virage
Model Number W025197D
Engine
Platform Polaris Marine 700 LE
Engine Model Number W70--SCSP--05A
Engine Displacement 701cc
Number of Cylinders 2
Bore & Stroke (mm) 81x68
Compression Ratio (Full Stroke) 7.0:1
Horsepower 95
Maximum Torque 69.2
Cooling System Water Cooled / Thermostat Pop--Off, self--draining, Direct From Propulsion.
Thermostat Opening Temperature 143°F(62°C)
Overheat Warning Warning Light / RPM Limit (RPM limit @3500 RPM)
Induction Type Case Reed
Lubrication Oil Injected
Oil Requirements Polaris TC--W3
RPM Limiter 7200 RPM
Exhaust System Water Cooled / Injected 700H
Sound Reduction New Silencer / PLANETt
Carburetion
Fuel Delivery (1) 40mm Keihin LE Carburetor
Fuel Requirement 87 Non--Oxygenated / 89 Oxygenated
Idle Speed (In Water) 1350±100
Electrical
Ignition System Digital CDI / Flywheel Magneto
Magneto Generator Output 5A / 60W @ 4500 RPM
Spark Plug NGK BPR8ES
Spark Plug Gap .024 -- .028 (.6 -- .7mm)
Timing Degrees BTDC 20°@ 3000 RPM
Battery 12V / 19A
Circuit Breaker / (Fuses) 15A Circuit Breaker (1/4A MFD, 3A Bilge Located within electrical box)
Starting Electric (One button start and stop)
Propulsion
Jet Pump Type Extended Big Mouth Reverse, Single Stage Axial Flow w/ Five Vane Aluminum Stator
Impeller Rotation Counter Clockwise (From AFT)
Coupling Type Rubber Coupler
Minimum Depth For Operation 2 ft. (60cm.)
Pivoting Angle 30°
Impeller Type .585°Overlap
Impeller Diameter 5.8 in.
Reverse System Manual Reverse w/RPM Limiter
Hull/Body
Hull Design Full V
Hull Material SMC (Sheet Molded Compound)
Top Deck Material FRC (Fiberglass Reinforced Composite)

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. (22.9 cm.)......
Dry Weight: 625 lbs..
Category: Midsize..
Riders: 1to3.....
Fuel Capacity:17 US Gallons (64.4 L)
Oil Capacity: 6 US Quarts (5.8 L)
General Information
1.8

General Information
1.9
2002 Virage TX
Model Number W025199D
Engine
Platform Polaris Marine 1200
Engine Model Number W120--TCSP--04
Engine Displacement 1165cc
Number of Cylinders 3
Bore & Stroke (mm) 84x70
Compression Ratio (Full Stroke) 6.7:1
Maximum Horsepower 135
Maximum Torque 110
Cooling System Water Cooled / Thermostat Pop--Off, self--draining, Direct From Propulsion.
Thermostat Opening Temperature 143°F(62°C)
Overheat Warning Warning Light / RPM Limit (RPM limit @3500 RPM)
Induction Type Case Reed
Lubrication Oil Injected
Oil Requirements Polaris TC--W3
RPM Limiter 7200 RPM
Exhaust System Tuned Pipe
Sound Reduction PLANETt
Carburetion
Fuel Delivery (3) 40mm Keihin Carburetors
Fuel Requirement 87 Non--Oxygenated / 89 Oxygenated
Idle Speed (In Water) 1350±100
Electrical
Ignition System CDI / Flywheel Magneto
Magneto Generator Output 5A / 60W @ 4500 RPM
Spark Plug NGK BR9ES
Spark Plug Gap .024 -- .028 (.6 -- .7mm)
Timing Degrees BTDC 23°@ 3000 RPM (PHASED)
Battery 12V / 19A
Circuit Breaker / (Fuses) 15A Circuit Breaker (1/4A MFI, 3A Bilge Located within electrical box)
Starting Electric (One button start/stop)
Propulsion
Jet Pump Type Dominator Reverse, Single Stage Axial Flow w/Six Vane Stainless Steel Stator
Impeller Rotation Counter Clockwise (From AFT)
Coupling Type Rubber Coupler
Minimum Depth For Operation 2 ft. (60cm.)
Pivoting Angle 30°
Impeller Type Progressive Pitch Radial Blade
Impeller Diameter 5.8 in.
Reverse System Manual Reverse w/RPM Limiter
Hull/Body
Hull Design Full V
Hull Material SMC (Sheet Molded Compound)
Top Deck Material FRC (Fiberglass Reinforced Composite)

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. (22.9 cm.)......
Dry Weight: 610 lbs..
Category: Midsize..
Riders: 1to3.....
Fuel Capacity:17 US Gallons (64.4 L)
Oil Capacity: 6 US Quarts (5.8 L)
General Information
1.10

General Information
1.11
2002 Virage i
Model Number W025101D
Engine
Platform Polaris Marine 800 DIt
Engine Model Number W77--DFI--01A
Engine Displacement 777cc
Number of Cylinders 2
Bore & Stroke (mm) 84x70
Compression Ratio (Full Stroke) TBD
Maximum Horsepower 100
Maximum Torque 72 ft. lbs.
Cooling System Water Cooled / Thermostat Pop--Off, self--draining, Direct From Propulsion.
Thermostat Opening Temperature 143°F(62°C)
Overheat Warning S.L.O.W. (Warning Light, RPM Limit)
Induction Type Case Reed
Lubrication Oil Injected
Oil Requirements Polaris TC--W3
RPM Limiter 7200 RPM
Exhaust System Water Cooled and Injected 700H
Sound Reduction New Silencer / PLANETt
Carburetion
Fuel Delivery (2) Injectors (DIt)
Fuel Requirement 87 Non--Oxygenated / 89 Oxygenated
Idle Speed (In Water) 1150 RPM
Electrical
Ignition System EMM (Engine Management Module)
Magneto Generator Output 12A / 160 W @ 4500 RPM
Spark Plug NGK PZFR6H
Spark Plug Gap .028 -- .032 (.7 -- .8mm)
Timing Degrees BTDC Controlled By EMM
Battery 12V / 19Amps
Circuit Breaker / (Fuses) (2) 15A Circuit Breakers (2A MFI, 3A Bilge Located within electrical splice blocks)
Starting Electric (One button start/stop)
Propulsion
Jet Pump Type Dominator Reverse, Single Stage Axial Flow w/five Vane Aluminum Stator
Impeller Rotation Counter Clockwise (From AFT)
Coupling Type Rubber Coupler
Minimum Depth For Operation 2 ft. (60cm.)
Pivoting Angle 30°
Impeller Type Progressive Pitch Radial Blade
Impeller Diameter 5.8 in.
Reverse System Manual Reverse w/RPM Limiter Switch
Hull/Body
Hull Design Full V
Hull Material SMC (Sheet Molded Compound)
Top Deck Material FRC (Fiberglass Reinforced Composite)

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. (22.9 cm.)......
Dry Weight: 635 lbs..
Category: Midsize..
Riders: 1to3.....
Fuel Capacity:17 US Gallons (64.4 L)
Oil Capacity: 6 US Quarts (5.8 L)
General Information
1.12