Polaris 0964588 Owner'S Safety And Maintenance Manual Download Page 1

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Summary of Contents for 0964588

Page 1: ...SAFETY AND N d4NCE MANUAL ...

Page 2: ...The engine exhaust from this product contains chemicals known to cause cancer birth de fects or other reproducti eharm ...

Page 3: ...ou have purchased this vehicle from someone other than a Polaris dealer you can still obtain information and service from any authorized Polaris dealer If your Owner s Manual is misplaced you should get a replacement copy from your Polaris dealer Anyone who operates this watercraft musthavereadthe Owner s Manualprovided with this machine Failure to follow the warnings and precautions contained in ...

Page 4: ...ENTSAND CONTROLS 20 23 FUEL AND OIL RECOMMENDATIONS 24 25 OIL INJECTION SYSTEM 26 WATERCRAFT EQUlPMENT 27 28 PRE OPERATION CHECK 29 35 ENGINE BREAK IN PROCEDURE 36 OPERATION 37 48 SPECIAL PROCEDURES 49 54 EXTENDEDSTORAGE AND WINTERIZATION 55 57 MAINTENANCE 58 74 TROUBLESHOOTING 75 76 ACCESSORIES 77 78 WIRING DIAGRAM 79 SPECIFICATIONS 80 OBTAINING SERVICE AND WARRANTY ASSISTANCE 81 WARRANTY POLICY ...

Page 5: ...ge 2 for location of numbers Any reprinting or unauthorized use without permission of Polaris Industries Inc is prohibited Questions or comments about this publication may be directed to any authorized Polaris watercraft dealer PURCHASE DATE POLARIS MODEL NUMBER SLT780 0964588 DEALER IMPRINT HULL I D NUMBER ENGINE I D NUMBER POLARIS INDUSTRIES INC 1996 SLT780 Watercraft Owner s Safety k Maintenanc...

Page 6: ...mbers will help identify it Keep a record of these number in a place other than the watercraft as well as in the spaces provided on page 1 INSURANCE Check with your own insurance agent regarding insurance cover age of your personal watercraft Your dealer may have marine in surance available He or she should know the requirements of your state and can help you with the proper policy to protect your...

Page 7: ...ll resultinsevere injury or deathtothe op erator passenger bystander or person inspecting or repairing the watercraft FailuretofollowWARNING instructionscould result in severe injury or deathto the operator passenger bystander or person inspecting or repairing the watercraft A CAUTION indicates special precautions that must be taken to avoid minor per sonal injury or watercraft or property damage ...

Page 8: ...PUSH ROD FORWARD TO RELEASE Located near support for storage compartment Located on electrical box inside engine compartment See page 67 for exact location DO NOT REMOVE ELECTRICAL PARTSWHEN STARTING OR Located on the engine water manifold Push to Reset LOCATED BELOW SHROUD SEE OWNER S MANUAL FOR INSTRUCTIONS Located on shroud Located on engine water out manifold FIRE EXTINGUISHER CONTAINER LOCATE...

Page 9: ...injury do not place hands or objects into pump inlet To prevent major engine damage Make sure engine is stopped by pulling lanyard from engine stop switch and turn boat to upright position in a clockwise direction 7073865 Locatedat rear of watercraft and positioned upside down allowing the operator to read it when the boat is in the capsized position ...

Page 10: ...ause accidents Never engage the reverse system when the watercraft is movingfaster than idle speed or damage to the reverse system or severe injury could occur Drowning Hazard A personal flotation device PFD must be worn by operator and passengers Polaris recommends that operator and passengers wear a vest type PFD Type 1 2 or 3 at all times o The stream of water produced by the jet pump and falli...

Page 11: ...Ridewith anotherwatercraftwhen going intoremoteareas or largeareasof open water Useextracautionwhen ridinginunfamiliarareas Collision with underwa ter obstacles can cause severe injury or death Jumping Hazard Do notjump wakes from other boats or operate this watercraft in a mannerthat will limitthe visibility or reactiontime to avoid obstacles or other oncomingwatercraft Do notattempttojump rampso...

Page 12: ...ble and explosive A fire or explosion can cause severe injury or death Stop en gine before refueling Refuel in a well ventilated area Never refuel while smoking or inthe vicinityof an open flame or sparks o Check engine oil every time you refuel Oil fill is under front compartment door Running the engine without oil will cause major engine damage ...

Page 13: ...can result from ignor ing warnings or improper use of watercraft 0 Minimum operator age 16 Operators between 16 and 18 years of age require close adult supervision Operator and passenger must wear a Coast Guard approved vest type personal flotation device at all times Always attach the engine stop switch lanyard to the operator s wrist before operating watercraft ...

Page 14: ...rakes The watercraft is stopped by re leasing the throttle andgliding to astop by the naturaldrag of the water Jet thrust is requiredto steerandturn thevehicle Releasingthethrottleeliminates the abilitytosteerthe watercraft Nevercompletelyreleasethethrottleandattempt to turn at more than a trolling speed becausethe watercraft will notturn Sufficient jet thrust is required to turn Use enough thrott...

Page 15: ... at all times because water spray can interferewith vision Vest Type Personal Flotation Device Foot Protection w Beforestartingthe watercraft the operator must always attach the lanyardcord to hislher left wrist or PFD ensuringit ssnug This will immediate ly stop the engine if the operator falls off Be sure the lanyard is free and not wrapped around the handlebars or controls When the watercraft i...

Page 16: ...a sub normal body temperature which can result in severe injury or death in a very short time Hypothermia can begin inwater as warm as 80 F 27 C Ridewith anotherwatercraft when go ing into remote areas or large areas of open water Take along a flare gun when going into remote areas to signal for help if necessary A Re boardingthe watercraft indeepwater can bestrenuous Practiceboard ing in chest de...

Page 17: ... is less than two feet 60 cm deep Do not operate at morethan an idle speed inwater that is lessthan six feet deep Ingesting sandintothe coolingsystemwill causethe engineto overheat resulting inpossible severe engine damage nAlways perform the pre operation check beginning on page 29 before startingand riding the watercraft Check fuel and oil levels and all controls especially the throttle lever ha...

Page 18: ...llow the prescribed mainte nanceandservice recommendationsin this manual Havean authorized Polar is dealer perform the service work aWhile the engine is running do not allow hands feet ropes straps clothing or long hair to come in contact with the jet pump water intake on the bottom of the watercraft Never insert any object into the intake or outlet of the jet pump Never start or operate the water...

Page 19: ...our feet from objects in the water The passenger should face forward and firmly hang onto the operator s waist aNever operate the watercraft after sunset or before sunrise It is NOT equippedto be ridden inthe dark which makes it unsafe and illegal to oper ate nBe aware of other watercraft people swimming and other obstacles while operatingthe watercraft and maintain a safe distance This is especia...

Page 20: ...and wind produces fatigue which makes you act as if you were legally intoxicated Ifyoucombinealcoholconsumptionwiththis boatingfatiguecondition itintensifies the effects and increases your accident risk So remember don t drink alcohol or take drugs if you are planning to have fun in or on the water Cold Water SurwivaO Your life may depend on a better understanding of cold water Many suspected drow...

Page 21: ...In nautical terms the stand on privileged vessel has the right of way and the give way burdened vessel must yield or give way Stand on Vessel The vesselwith the right of way hasthe duty to continue its course and speed ex cept to avoid an immediate collision By maintaining course and speed other ves sels should be able to determine how best to avoid you Give way Vessel The vessel which does not ha...

Page 22: ... vessel The other vessel isexpected to maintain itscourse and speed You must stay out of itsway untilyou are past it The same would be true if you were the stand on vessel Maintain your course and speed until the other vessel has passed you Meeting If you are meeting another power vessel head on and you are close enough to possibly collide neither vessel has the right of way Both vessels must alte...

Page 23: ...ls Ina narrowchannel a non motorized craft should not interfere with the safe pas sage of a power vessel Fishing Vessel Right of way All vessels which are fishing with nets lines or trawls are considered fishing ves sels under International Rules Vessels with trolling lines are not considered fish ing vessels Fishing vessels have the right of way regardless of position They cannot interfere with t...

Page 24: ...ccess to fire extinguisher and additional storage space 6 Air IntakeOpenings Air enters here to supply engine and ventilate engine compartment 7 Fuel Tank Cap Turn the cap counterclockwise to remove and clockwise to replace 8 Grab Handles Used to assist the riders while boarding 9 Fuel Valve This is a three position rotating valve with ON OFF and RES reserve ON allows fuel to operate the watercraf...

Page 25: ...choke is usedto help instartingacold engine Itisnotto be used when starting a warm engine 14 Throttle Controls the speed of the watercraft When squeezed the engine accelerates when fully released the engine returns to an idle 15 Engine Stop Button The red engine stop button on the left handlebar will stop the engine when necessary The engine stop button is a component of the engine stop switch Pre...

Page 26: ...partment 20 Boarding PlatformlFootrest To assist riderswhile boarding The placefor operator and passenger s feet while riding the watercraft 21 Drain Plug Whenwater gets intothe bilge itcan bedrainedthroughthis plug Remove the watercraft from the water before draining the bilge Be sure the plug is securely closed before launching the watercraft 22 Jet Pump lntake Grate The grate protects the impel...

Page 27: ... Driveshaft shroud See page 56 for detail 4 Exhaust pipe 5 Water temperature sensor 6 Exhaust cooling hose 7 Exhaust silencer 8 Enginewater outlet hose underneath thermostat assembly 9 Water manifold 10 Thermostat assembly 11 Electrical box battery underneath 12 Fuellwater separator mounted to underside of hull ...

Page 28: ...g is performed or where gasoline is stored Do not over fill the tank Do not fill the tank neck Ifyou get asoline on your skin or clothing immediatelywash if off with soap and water andgchange clothing Neverstartthe engineor let it run inan enclosedarea Gasoline poweredengine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time Shut off fuel valve whenever the w...

Page 29: ...e gasolineandoil The only deviationfromthis isduringthe engine break in peri od see page 36 Refueling Keepthe watercraft horizontal while fueling Shut fuel valve off Carefully remove the gas cap Use fresh seasonal gasoline which has been stored in a clean container To get the best performance from gasoline only purchase what is needed for a month or less of operation Always stop the engine before ...

Page 30: ...necessary Donot overfill Wipe up any oil spillage im mediately Visually inspect the oil for water orforeign matter Ifeither ispres ent change the oil Oil Fill Cap The SLT780 is equipped with an oil level gauge on the multi function meter The gauge will flash OIL and a red light if low The use of unrecommended oil could result in engine damage or poor perfor mance It will also void your warranty If...

Page 31: ...er possible provide part numbers You Will Need To Supply U S Coast Guard approved fire extinguisher UL 5 B C Rating PN 2871012 Registrationnumbers Tow rope for emergency use Flare gun for emergency use Safetyand ridinggear includingapproved personalflotation devices for operator and passenger see page 11 TC W3 Oil PN 2871098 case quarts PN 2871097 case gallons Polariscable lubricant PN 2870510 Pol...

Page 32: ...edlPurplelYellowlBlack XL 2850826 M 2850829 L 06 Size 2856132 XXL 2850827 S 02 Neoprene Performance Lifevest PurplelBlacWRed L 2850830 M 03 XL 09 XXL 12 S 02 Size 2856133 Life Jacket with Race Flags RedlBluelPurple XL 2850831 L 06 M 03 L 06 Size 2856134 XXL 2850832 S 02 Youth Lifevest RedlPurplelBlue XL 09 M 03 XL 09 Size 2856135 XXL 12 XXL 12 S 02 Universal Three Belt Life Vest PN 2850843 28 M 03...

Page 33: ...ng Fire extinguisher Storage compartment Battery Hull IDrain pluglbilge Inspect and clean it should not sure it is tiaht and secure Inspect and remove debris if present be sure intake grate is secure push rear of watercraft up and down to flush sand out of water intake before starting Check for proper operation Check for proper operation visually in spect control cable Inspect condition and expira...

Page 34: ...rclockwise and remove it to look insidethe oil tank You can also remove the storage tray inside the storage compartment to view the oil level in the oil tank Add recom mended oil as necessary Visually inspect the oil for water or other contaminants If either of these is present have the oil changed and bleedthe system to re move all contaminants NOTE Read the oil recommendations found on page25 fo...

Page 35: ...ake of water Dam age could occur if the intake is clogged causing engine over heatingandjet pump damage If any obstruction cannot be removed have an au thorized Polarisdealer service it immediately 11 Ride Plate Intake Grate Drive Shaft Impeller After launching walk the watercraft into water at least 2 feet 60 cm deep and bouncethe back of the watercraft upand down several times to flush out any s...

Page 36: ...at it is in working condition Loose PartsIHoses Inspectthe watercraft for any loose nuts bolts fasteners and hoses Be surethat all hose clamps are tight Replace cracked or deteriorating hoses Fire Extinguisher The operator of this watercraft is re quired by law to carry a fire extin guisher on board Be sure a fire ex tinguisher is inside the compartment designed for its containment lo cated inside...

Page 37: ...tery can leave you stranded Neveroperate the water craft with a battery that is too weak to start the engine on its own or shows signs of loss of power HIGH Maintain Between Upper and Lower Level u Marks Be sure the battery is securely fastened in its mounting position Check the battery fluid level and add distilled water if level is low It should be be tween the upper and lower level See that ter...

Page 38: ...in plug Once the watercraft is launched re move the seat and check for leaks Loose Staaps RopeslClothinglkong Hair Be sure there are no loose straps ropes cords or belt like objects hanging from the watercraft or riders Long hair should be tied back and secured These objects can becometangled inthejet pump impeller andcause severe inju ry or death Seat Removingthe seat allows access to the engine ...

Page 39: ...ter leaks and have them repaired if present Do notridethe watercraft until leaksare repaired Start the engine and let it run for a few seconds Remove the lanyard lock plate from the engine shut off switch The engine should sto im mediately If it doesn t pulI the chokeleveruntilthe enginedies Do not ride the watercraft and have it serviced by an authorized Polaris dealer before riding it again Star...

Page 40: ...ry a passenger during the break in period When starting the engine be sure the watercraft is in water at least 2 feet 60cm deep Ifthe engine is run inwater lessthantwo feetdeep sand weeds anddebris may be sucked into the jet intake and damage the impeller or injure bystanders Ingestionof sand intothe cooling systemwill cause the engine to overheat result ing in possible severe engine damage 1 Laun...

Page 41: ...eleased You must havethrust to turn Keepthe throttle depressedto maintain thrust and control to aid in steering and avoiding potential contact with objects or people in the water The morethe throttle is depressed while turning the sharper the turn will be Prac tice these maneuvers in open water to understand and acquire a feel for turning The watercraft behaves differently with a passenger on boar...

Page 42: ...is started in shallower water sand and pebbles may be sucked into the jet pump intake anddamage the impel ler or cooling system 3 Turn the fuel valve to on 4 Carefully board the watercraft and sit down 5 Attach the lanyardwrist bandto your left wrist or PFD 6 Fastenthe lanyard lock plateto the engine stop switch on the handlebars by pushing the lock plate around the barrel of the switch just below...

Page 43: ...e fuellwater separator bowldrained it maytake two or three attempts to start Do not run the starter for morethan ten seconds at a time as damage to the starter may result Starting the engine immediately generates forward thrust Be seated and alert when starting the watercraft If The Engine Does Not Start If the engine does not start within 10 seconds release the starter switch Wait 10 seconds befo...

Page 44: ...the engine has stopped you will lose all steering control of the watercraft Be sure there is at least 2 feet 60 cm of water under the watercraft when stopping to make sure dam aging debris isn t sucked into the impeller or cooling system Remove the lanyard lock plate Neverleavethe lanyardattachedto an unattended watercraft Launching The Watercraft 2 60cm Minimum Before launching be aware of weathe...

Page 45: ...verse while moving forward above planing speed Lossof controlcould occur resulting indamageto the watercraft or severe person al injury to the operator or passenger s Launching In Shallow Water 1 Never operate the watercraft in less than 2 feet 60 cm of water Guide the watercraftto an areathat isdeep enough bounce the rear of the watercraft up and down to flush out the pump then board it from the ...

Page 46: ...tach the lanyard lock plate to the engine stop switch and see that the lanyard wrist band is secure on your left wrist 4 Pull the choke knob all the way out If the engine is already warm do not use the choke 5 Push the starter switch with your left hand while squeezing the throttle with your right hand 6 As soon as the engine starts release the starter switch and throttle enough throttle should be...

Page 47: ... board using the grab handle Both operator and passenger should try to balance the watercraft while the passenger is boarding 4 The operator should see that the passenger is holding on tightly and that their feet are both on the footrests Once this is done start the engine Load Limit The heavier the combined weight of operator and passenger the more difficult it isto balancethe watercraft while bo...

Page 48: ...the watercraft in roughconditions which could make it difficult to get back to and re board the watercraft Turning Turning the watercraft requires us ing the throttle thrust from the jet pump and turning the handlebars High thrust makes the watercraft turn more sharply Lower thrust makes the watercraft turn less sharply Remember releasing the throttle completely eliminates the ability to steer the...

Page 49: ...ercraftas muchas 300 feet 90 m after the throttle is re leasedto come to a stop This distanceis approximate and is supplied only for reference Slow watercraft to an idle be forestoppingthe engine Push the engine stop button when approaching shore and you are close to your intended stopping area This will help prevent sand and debris from enteringthe pump and cooling system causing damage 300 ft 90...

Page 50: ...wly approach the beach and stop the engine in no less than 2 feet 60 cm of water Make sure there are no swimmers boats or other obstacles close to the watercraft Remember turning the watercraft is impossible if the engine is stopped 2 Get off the watercraft andguide it to the beach 3 Before restarting inspect the impellerljet pumparea for sand and debris Move the watercraft to at least 2 feet 60 c...

Page 51: ...s This watercraft is designed to carry one operator and one or two pas sengers and their combined weight shouldnotexceed500 Ibs 227kg The operator should firmly grip the handlebars and have both feet on the footrests The passengers should firmly hang onto the operator s waist or seat strap and should keep both feet on the footrests Do not give a ride to a person whose feet do not reach the footres...

Page 52: ...E If the watercraft is going to be stored block the seat engine compartment open about 112 1 3 cm to provide air circulation and prevent condensation from form ing If the seat is saturated with water stand it on end to drain NOTE Drain and flush the engine See instructions on page 55 5 Clean the impeller of weeds or other debris it may have collected during the ride Be sure lanyard lock plate is r...

Page 53: ...isconnectthe battery cables Acloggedintakeand or impellercan cause overheating andlor damage to jet pump and impeller parts Operation of the engine with the in take system removed could damage the engine Screen On Land Cleaning 1 Shut off the engine and remove the watercraft from the water 2 Remove the lanyard lock plate from the engine stop switch and disconnect the battery cables 3 Carefully cle...

Page 54: ...sized The operator and pas senger must know how to right the watercraft or they could become stranded Se vere engine damage could also result from not righting a capsized watercraft as soon as possible Ifthe watercraft has remained in a 180 capsized position for morethan two min utesall fuel andoil lines mustbe inspectedfor presenceof water and or air Severe enginedamage could result if the engine...

Page 55: ... hand to rotate engine until the water has run out 5 Depressthe starter button for one second at a time until no more water exits the spark plug holes Depressingthe starter turns the engine and pump Stay clear of all moving parts to avoid severe personal injury 6 Upright the watercraft 7 Inspect dry and install new spark plugs Install the air intake 8 Check the battery vent hose for obstruction dr...

Page 56: ... at the bow and stern so it is firmly restrained on the trailer and does not move Use additional cables if necessary There should be no movement between the watercraft and trailer Do not route ropes or tie downs over the seat because they could cause permanent damage to the seat Protect the watercraft body from ropes by putting padding or something similar between the rope and body Make sure the s...

Page 57: ...ODEselectsthe digit SETadvancesthe digit PressMODEwhen complete to starttheclock colon begins to flash PEAK SPEEDIRPM While inTACH mode pressingthe SET keywill display both the peak speed and maximum sustained RPM since the last reset or auto off oc curred While displayed holdingthe SET key for 4 seconds will reset the peak me mories Key Functions and Display MODE KEY Toggles multi LCD display mod...

Page 58: ...ds while in DlST mode VOLT Secondary display function controls Multi LCD when selected by mode key VOLT annunciator is on when in VOLT mode Voltage is displayed in 1 volt increments from 5 to 18 volts ENGLISHIMETRIC While in the VOLT mode pressing and holding SET will toggle the instrument between MPH and KPH The distance function is automati cally toggled at the same time LOW POWER If batteryvolt...

Page 59: ...n preparing your watercraft for off season storage we recommend that you add 10 oz of fuel conditioner stabilizer such as Gold Eagle brand STA BIL Polaris PN 2870652 to the fuel tank then top off with fresh fuel 2 Fog the engine with rust preventative oil PN 2870791 Follow the recommended procedures on page 56 NOTE Usinga fuel stabilizer and topping off the fuel tank eliminates the need to drain t...

Page 60: ...nal parts for preventionof rust and corrosion which in turn will extend the life of the engine 1 Loosen the two bolts holdingthe air intake cover A and removethe cover 2 Removethe filter element 3 Start the engine and spray Polaris fogging oil into each carburetor throat to ensure that all internal parts are properly coated Spray fogging oil for two to three seconds in each carburetor throat and r...

Page 61: ... degreasers paint thinner acetone window cleaners ammoniaor products containing alcohol They can damage finishes decals vinyl and plastics and accelerate UV breakdown which could cause color change and premature deterioration of parts 5 Aftercleaning protect andshinethewatercraft using aregular furniture polish or non abrasive silicone wax Protectthe seat and handlebar unit with a vinyl protector ...

Page 62: ...ach day Observe all warnings and cautions mentionedthroughout this manualwhich per tain to the work being performed Additional Inspections To keep your watercraft safe and performing in top condition be sure to follow the additional recommended inspections as shown on the following chart Have an authorized Polarisdealer perform their portion or all of the recommended inspections You may do parts o...

Page 63: ...ENANCE Inspection Chart D Dealer performed O Operator performed NOTE See page 29 for additional pre ride information Every month In salt water use Checked lnit ally after three months thereafter as specified ...

Page 64: ... PN2870510 2 Depress the throttle lever and squirt Polaris cable lube onto the cable 3 Push and release the throttle several times to work the lubricant down the cable Steering Cable Joints And inner Wire 1 Lubricate the steering cable joints on the steering nozzle end using Polariscable lube PN 2870510 2 Exposethe steering cable inner cable and apply Polaris cable lubeto it Lubricatethe steering ...

Page 65: ...ut the choke knob and apply Polaris cable lube PN 2870510 to the knob shaft Seat batch And Hooks Grease the locking mechanism of the seat latch at the rear of the seat opening Carburetor And Oil Injec tion Pump Greasesprings exposedportions of cable and shafts at the carburetor Grease often if used in salt water Electrical Connections Apply a dielectric grease on battery posts and exposed cable co...

Page 66: ...aft shroud in place and rotate it 180 See page 22 for location 6 Usingagrease gunwith a needlepoint availablefrom your Polarisdealer PN 2871174 lubricate coupler at the grease fitting until the driveshaft to coupler boot just begins to expand Use premium marine grease PN 2871066 7 Reposition the driveshaft shroud open side down and torque the clamp screw to 20 to 25 in Ibs 8 Reconnect battery grou...

Page 67: ...here is a malfunction with the RPM limiter Alightgrey or whitetip indicates the wrong spark plug wrongheat range is being used carburetoridlespeed mixtureistoo lean there isapluggedfuelfilter orthere is a leaking engine seal or gasket A yellow tip is caused by salt water mist ingestion This is a conductive coating which will eventually cause fouling This is a normal situation If the spark plug tip...

Page 68: ...lugwith a warm engine The exhaustsystem or engine could burn you causing injury When installing or removing spark plugs be careful not to damage the porcelain insulator Wipe off any water on the spark plug or insidethe cap Pushthe cap down on the pluguntil itclicks Usedielectricgrease PN2871066onthe insideof the spark plug cap to prevent corrosion Before installing a used plug wipe off threads and...

Page 69: ...not attempt to clean this filter Thefuel filter and fuel lines should be inspected regularly Special attention should be given to fuel system line condition after periods of storage Nor maldeterioration from weathering andfuel compounds can occur See your dealer if you suspect any deteriorated components Carburetor Adjustment Thecarburetorisvitalto engineoperationandperformance Adjustment ofthe ca...

Page 70: ...press and release the throttle lever It should return to its initial position smoothly If it does not have your authorized Polaris dealer service it 2 Throttle lever free play should not exceed 020 060 5 1 5 rnrn If it does have it corrected by your authorized Polaris dealer Choke Cable lnspection Pull the choke knob toward you to makesure the choke cable operates smoothly When the knob is pulled ...

Page 71: ...etable oil Call a physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilatewhen charging or using inclosed space Always shieldeyes when working near batteries KEEP OUT OF THE REACH OF CHILDREN The battery must be removed from the watercraft for maintenance and charging Battery electr...

Page 72: ...batteryout of the watercraft beingcareful nottotip itsidewaysandspill any electrolyte If an electrolyte spill occurs apply a generous amount of baking soda to the area and then rinse with fresh water Replenishing Battery Fluid A poorly maintained battery will de teriorate rapidly Check the battery fluid level each day the watercraft is ridden The fluid level should be kept be tween the upper and l...

Page 73: ...e inspection When using a battery charger connect the battery to the charger before turning on the charger This prevents the possibility of sparks at the terminals which could ignitethe battery gases Do not connect charger cables to the battery unless the charger is unplugged 1 Remove the caps from the cells Add distilled water if necessary to bringthe electrolyte up to the proper level 2 Connect ...

Page 74: ...ble 5 Apply dielectric grease PN 2871066 to each cable 6 Reinstall the battery cover and electrical box over the battery and reconnect straps 7 Verify that cables are properly routed 8 Verify that the vent hose is not kinked Battery Storage 1 Remove the battery Clean the casing and terminals with baking soda and water one tablespoon of baking soda to one cup water Apply dielectric grease PN 287106...

Page 75: ...olant Filter The exhaust coolant filter is located on the top of the exhaust pipe see page23 for location detail This part filters debris from the coolant water providing an adequate supply of wa ter through the bleed fitting and in suring proper exhaust temperature for cooling and performance Cleaning Procedure 1 Removeclamp connecting hose to fitting 2 Using a 9116 open end wrench remove the fit...

Page 76: ...scooling system for cooling Flushingthe cooling system with fresh water is necessaryto neutralizethe corrod ingeffects of saltwater or water with impuritieslikesilt sand alkaliandotherpartic ulates as well as to flush out other residue left in the water passagesof the water craft cooling system Flushwater passages when the watercraft is not going to be riddenagain that day or if the watercraft is ...

Page 77: ...within 10 seconds 11 Removethe garden hose and reconnect the male plug 12 Wipe off any water which may have spilled on the engine 13 Reinstall seat Adaptor PN 7052104 Thermostat Pop Off Assembly If low end performanceof the watercraft beginsto deteriorate andthe jet pump in take area is free of debris and weeds or if the overheat alarm sounds and or the LED is flashing hol on the MFD the thermosta...

Page 78: ...efully take the assembly apart Be careful not to lose any parts 2 Check the thermostat pop off assembly for debris such as seaweed and clean it out 3 Check the condition of rubber elements Also check the thermostat and housing for corrosion Replace any parts that appear in poor condition 4 Assemble the thermostat pop off assembly in the correct sequence The arrow indicates the direction of water f...

Page 79: ...ill not start Enginewill not start Engineruns irregularly stalls or mis fires Engineruns irregularly stalls or mis fires Engineback fires Probable Cause Engine does not turn over circuit breaker is tripped battery voltage low battery connections loose hydrolocked Engine turns over fuel empty or contaminated spark plugs fouled or defective crankcase filled with water or fuel misuse of choke fuel fi...

Page 80: ... remov ing gas cap fuel filter clogged jet intake is clogged cooling system clogged see Engine runs irregularly stalls or misfires watercraft can t reach top speed cavitation impeller damaged or worn jet pump water intake is clogged weeds or debris lodged in impeller driveshaft damaged bearings damaged in pump lack of lubrication on coupler or bearing carrier hose kinked check valve clogged clean ...

Page 81: ...y Net 15x30 2871184 Bungy Net 28x28 2871448 Dry Storage Pouch 2871450 Seat Bag 2871455 Saddle Bags 2871454 Storage Cooler Bag 2871449 Handlebar Pouch 2871466 28 Sponson Kit 2871484 SMC Repair Kit 2 oz 2871483 SMC Repair Kit Quart 2871523 Hull to Deck Adhesive 2871529 Inlet Scoop 2871452 Docking Rope 2871443 Flush Kit 2871012 Marine Fire Extinguisher 2871456 Extreme Service KitIOcean Pro Flame Arre...

Page 82: ...rplelBluelBlack L 06 Size 2856141 I size 2856142 M 03 S 02 Men s Shorty Wetsuit PurplelBlack XL 09 s 02 XXL 12 L 06 Women s Shorty Wetsuit PurplelBluelBlack XL 09 M 03 M 03 Size 2856143 XXL 12 L 06 S 02 Neoprene Shorts PurplelBlack Universal Men s Sizing L 06 XL 09 L 06 M 03 Size 2856144 S 02 Size 2856145 One Piece Drysuit PurplelBlacWRed xL 09 XL 09 M 03 S 02 XXL 12 XXL 12 Size 2856146 M 03 S 02 ...

Page 83: ......

Page 84: ...ettable circuit breaker Carburetion Fuel type Regular unleaded 87 octane or 89 oct oxygenated Carburetor type and number 3 diaphragm type 38 mm throttle bore 34 mm venturi Carburetion idle speed 1250 100 RPM Propulsion Propulsion system Jet drive Jet pump type Axial flow single stage Impeller rotation seen from rear Counterclockwise Transmission Direct drive Couplingtype Rubber Pivotingangle of di...

Page 85: ...nchanges modifications andtips on personalwatercraft maintenancewhich may supersede informationcontained inthis manual HeIShe isfamiliar with our policies and pro cedures and will be happy to assist you When writing about parts service or warranty always include the following in formation 1 Serialnumber 2 Model number 3 Dealer name 4 Date of purchase 5 Details of trouble experienced 6 Length of ti...

Page 86: ...RANTY COVERAGE AND EXCLUSIONS LIMl BBP18MSOF WARRANTIES AND REMEDIES This Polaris limited warranty covers all parts and components except for impeller damagecaused by ingestionof rocks sand or gravelor any other damagecaused by operation in shallow water The warranty also excludes any other failures that are not caused by a defect in material or workmanship This warranty does not cover accidental ...

Page 87: ...u if incon sistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your personal watercraft requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTA TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris sug gests that you use your orig...

Page 88: ...ng 18 Multi function Display 53 Navigational Rules 17 Non motorized Craft 19 Oil Filter 65 Oil Injection System 26 Oil Recommendations 24 25 Oil Tank Levels 30 Operating And Safety Information 10 19 Beaching 46 Boarding In Deep Water 41 42 Boarding With A Passenger 43 If The Engine Does Not Start 39 Jumping 44 LaunchingThe Watercraft 40 LoadLimit 43 Post Oeration Check And Care 48 Principles Of Op...

Page 89: ...MAINTENANCE RECORD ...

Page 90: ...ury or death can result from ignoring warnings or improper use Never permit a guest to operate this watercraft unless the guest has read and understands all warning labels and the Owner s Manual THIS MANUAL SHOULD REMAIN WITH THE WATER CRAFT AT THE TIME OF RESALE National Safe Boating Co ncil C ...

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