Polaris 2003 Freedom Owner'S Safety And Maintenance Manual Download

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FEATURES

RPM Limiter

Some Polaris watercraft are equipped with a device that will limit

engine RPM if the engine overheats. This feature is designed to help

prevent engine damage caused by engine overheating.
If the high temperature indicator light or “hot” warning message

displays (and the engine RPM is limited), stop the engine immediately.
Clean the jet pump and impeller as outlined on page 24. If the cause of

the of the overheating is identified and corrected, normal operation can

be resumed by releasing and reapplying the throttle.
If the engine continues to overheat after cleaning the jet pump and

impeller, take the watercraft to an authorized Polaris dealer for service.

A clogged intake and/or impeller can cause overheating and/or

damage to the jet pump and impeller parts. Always keep the

intake and/or impeller free of debris and weeds.

CAUTION

Summary of Contents for 2003 Freedom

Page 1: ...2003 Owner s Safety And Maintenance Manual MODELS INCLUDE Genesis i Virage i Virage Freedom ...

Page 2: ...WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm ...

Page 3: ...ated a web site just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out www polarisindustries com owner ...

Page 4: ...2 ...

Page 5: ...craft making it the finest vehicle we ve ever produced For safe and enjoyable operation of your watercraft be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Tec...

Page 6: ...6 SAFETY 7 23 CONTROLS 24 25 FEATURES 26 41 OPERATION 42 77 MAINTENANCE AND LUBRICATION 78 99 ENGINE TROUBLESHOOTING 100 102 POLARIS RECOMMENDED PRODUCTS 103 SPECIFICATIONS 104 105 WARRANTY 106 109 NOTE Illustrations used in this manual are for general representation only Your model may differ ...

Page 7: ...l aspects of your vehicle including safe operating procedures Familiarize yourself with all boating laws and regulations concerning the operation of the vehicle in your area Safety Training When you purchased your new Polaris watercraft your dealer provided a watercraft safety video and the Polaris 2003 Universal Watercraft Owner s Manual for Safety and Maintenance Please review this information o...

Page 8: ...number is located at the front of the engine near the stator cover 2 Record your vehicle s ID numbers in the spaces provided and in another location away from the vehicle If the vehicle is destroyed or stolen you ll have the ID numbers required by insurance and or law enforcement NOTE Check with your insurance agent about obtaining insurance coverage for your watercraft or see your Polaris dealer ...

Page 9: ...mbol on your vehicle or in this manual alerts you to the potential for personal injury The safety alert warning indicates a potential hazard that may result in serious injury or death The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION NOTE A note will alert you to important information or instructions A caution indicates ...

Page 10: ...eneral Safety Warning Decal This decal is located at the rear of the watercraft just below the seat General Safety Warning Decal Text To reduce the risk of SEVERE INJURY or DEATH Wear A Personal Flotation Device PFD All riders must wear a Coast guard approved PFD that is suitable for personal watercraft PWC use Wear Protective Clothing Severe internal injuries can occur if water is forced into bod...

Page 11: ... high performance boat not a toy Sharp turns or jumping wakes or waves can increase the risk of back spinal injury paralysis facial injuries and broken legs ankles and other bones Do not jump wakes or waves Do Not Apply Throttle When Anyone Is At Rear Of PWC Turn engine off or keep engine at idle Water and or debris exiting jet thrust nozzle can cause severe injury Do Not Overload It will signific...

Page 12: ...om open flames or sparks S Do not overfill tank S Pull up seat and open engine compart ment before starting engine Push down and latch compartment cover and replace seat before restarting engine S Do not start engine if gasoline or vapors are present Every time you refuel check engine oil Running engine without oil will cause major engine damage CAUTION WARNING RIGHTING CAPSIZED BOAT 7073865 S To ...

Page 13: ...p a safe distance away from people objects and other watercraft S Do not follow directly behind PWCs or other boats S Do not go near others to spray or splash them with water S Avoid sharp turns or other maneuvers that make it hard for others to avoid you or understand where you are going S Avoid areas with submerged objects or shallow water Take Early Action to avoid collisions Remember PWCs and ...

Page 14: ... Boat Is Not Required To Comply With The Following U S Coast Guard Safety Standards In Effect On The Date Of Certification DDisplay of Capacity Information DSafe Loading DFlotation DElectrical System DFuel System DPowered Ventilation As Authorized By U S Coast Guard Grant Of Exemption CGB 91 013 ...

Page 15: ...shroud Located on the engine water manifold 7073734 PUSH TO RESET 7078260 FIRE EXTINGUISHER CONTAINER LOCATED INSIDE 7074963 GREASE LUBRICANT FITTING LOCATED BELOW SHROUD SEE OWNER S MANUAL FOR INSTRUCTIONS Do Not Remove Electrical Part When Starting Or During Operation High Voltage Shock Hazard 7075383 WARNING ...

Page 16: ...ll applicable boating rules and regulations This watercraft does not have brakes The watercraft is stopped by releasing the throttle The vehicle will glide to a stop due to the natural drag of the water Allow a minimum of 300 feet 90 m to coast to a stop from full throttle Jet thrust is required to steer and turn the vehicle Never completely release the throttle and attempt to turn at more than a ...

Page 17: ...g Do not allow passengers to stand on the boarding platform while the watercraft is running or in motion Passengers should always remain seated Never travel over a ski jump or attempt to jump waves wakes or other objects in the water Doing so may severely damage the watercraft and cause personal injury due to the hard impact a temporary loss of visibility possible loss of control and reduced react...

Page 18: ...ure and unknown hazards in the water such as debris and hidden objects Riding gloves may also be considered NOTE A helmet may provide increased personal injury protection in some situations such as impact with the watercraft or during a collision with other watercraft or an obstacle However a helmet may not provide adequate protection against all foreseeable impacts and may aggravate some injuries...

Page 19: ...l regulation requires that all watercraft carry an approved fire extinguisher Do not operate the watercraft without a fire extinguisher on board Know how to reach the fire extinguisher quickly in case of fire and know how to use it before you operate the personal watercraft If you have any doubts about your ability to extinguish a fire swim away from the craft as quickly as possible Immediately se...

Page 20: ...other watercraft when operating in remote areas or in large areas of open water Carry a flare gun on board to signal for help if necessary Protective Apparel Normal swimming attire may not provide adequate protection while riding a watercraft At the rear of the watercraft the jet pump emits a forceful stream of water that can injure body orifices such as mouth eyes ears rectum and vagina In additi...

Page 21: ... the back of the machine up and down in at least two feet of water If the craft has been beached flush the cooling system Turning and Accelerating Turning and accelerating without checking for other boats and objects in your path can cause an accident and result in severe injury or death Always look behind the watercraft and to each side before accelerating and before making sudden turns Always be...

Page 22: ...enance and service recommendations outlined in this manual Jet Pump Water Intake Safety Contact with the jet pump or driveline components of the watercraft can result in severe injury death or drowning Do not allow hands feet ropes straps clothing or long hair to come in contact with the jet pump water intake 1 on the bottom of the watercraft while the engine is running Never insert any object int...

Page 23: ...r s waist except in towing situations when the spotter faces the rear and uses the grab handle to hold on Lifting the Watercraft Severe back injury or other injury could result from attempting to lift the watercraft without assistance Never attempt to lift the watercraft without the aid of a trailer and winch or another heavy lifting device Operator Awareness A collision can cause severe injury or...

Page 24: ...ically able to reboard if the need arises Boating Under the Influence Operating any watercraft while under the influence of alcohol or drugs could result in an accident and lead to severe injury or death More than half of all the people who drown have consumed alcohol prior to their accident Even if you re not intoxicated any amount of alcohol can be a threat to your safety and the safety of other...

Page 25: ...ect against exposure to weather elements Hypothermia Your life may depend on a clear understanding of the effects of cold water on the human body Many suspected drowning victims actually died from cold exposure hypothermia rather than drowning Hypothermia can begin in water as warm as 80 F 27 C It s a condition in which the body loses heat faster than it can produce it Violent shivering develops w...

Page 26: ... detailed explanation of multi function instrument MFI 6 Bilge Button The bilge button is the gray button on top of the switch assembly Whenever the engine is running the bilge pump will be running When the engine is shut down pushing and holding this button will operate the bilge pump This should be used if water is discovered in the hull during the pre operation inspection and prior to restartin...

Page 27: ...25 CONTROLS 1 3 6 4 7 5 2 8 10 11 9 ...

Page 28: ...top 3 Seat Latch The seat latch secures the seat in position When re leased it provides access to the engine compartment NOTE The num ber of latches will depend on the model Some boats have one latch and others have two latches 4 Boarding Platform Footwell Pads The boarding platform assists riders while boarding The footwell pads are the place for the operator s and passenger s feet while riding t...

Page 29: ...27 FEATURES 7 2 5 5 1 3 2 1 5 5 4 6 7 3 6 4 Freedom Virage Models Genesis i ...

Page 30: ... clockwise to replace 7 Grab Handle The grab handle assists riders while boarding the craft or riding as a passenger 8 Warning Light All models are equipped with an oil level gauge on the multi function instrument MFI panel The red light will flash if oil is low The MFI will also provide an LCD message LOW FUEL 9 Fuel Valve if equipped ON allows fuel to operate the water craft OFF stops the fuel s...

Page 31: ...29 FEATURES Freedom and Virage Models 9 6 7 1 2 3 4 5 10 1 2 4 3 7 12 8 13 10 8 13 5 14 11 11 15 15 ...

Page 32: ...enti late the engine compartment 6 Fuel Tank Cap Turn the cap counterclockwise to remove and clockwise to replace 7 Grab Handle The grab handle assists riders while boarding or while riding as a passenger 8 Warning Light All models are equipped with an oil level gauge on the multi function instrument MFI panel The red light will flash if oil is low The MFI will also provide an LCD message LOW FUEL...

Page 33: ...31 FEATURES Genesis i Model 1 2 3 4 5 6 7 8 12 9 10 11 13 ...

Page 34: ...ter temperature sensor 5 Exhaust cooling hose 6 Exhaust silencer 7 Engine water outlet hose underneath thermostat assembly 8 Water manifold 9 Thermostat assembly 10 Electrical box circuit breaker and fuses 11 Fuel water separator 12 Exhaust coolant filter 13 Air filter 14 Battery 15 Bilge pump 16 Starter solenoid ...

Page 35: ...33 FEATURES Engine Components 12 1 3 5 6 10 7 9 8 Freedom Virage 11 2 14 15 16 13 4 ...

Page 36: ...er temperature sensor 5 Exhaust cooling hose 6 Exhaust silencer 7 Engine water outlet hose underneath thermostat assembly 8 Water manifold 9 Thermostat assembly 10 Exhaust coolant filter 11 Air filter 12 Battery 13 Capacitor 14 Starter solenoid 15 EMM Engine Management Module found only on Direct In jected models ...

Page 37: ...35 FEATURES Engine Components 1 8 6 9 7 Genesis i 2 11 13 12 15 Virage i 1 2 11 15 6 8 12 7 9 14 3 4 10 5 5 14 4 10 3 13 ...

Page 38: ...ne immediately Clean the jet pump and impeller as outlined on page 24 If the cause of the of the overheating is identified and corrected normal operation can be resumed by releasing and reapplying the throttle If the engine continues to overheat after cleaning the jet pump and impeller take the watercraft to an authorized Polaris dealer for service A clogged intake and or impeller can cause overhe...

Page 39: ...splay LCD display on the left a function numeric keypad in the center and an electronically driven analog speedometer and reverse PERCt indicator on the right The LCD contains a highly responsive analog tachometer fuel and oil gauges a 16 point compass clock battery voltmeter resettable distance meter and non volatile engine hour meter To the right and under the fuel and oil gauges is a digital de...

Page 40: ...H GAUGE An optional transducer kit is required Before activating the DEPTH GAUGE function the depth sensor must first be installed After installation is complete press and hold both the 3 8 and 4 9 buttons simultaneously for several seconds to activate the DEPTH GAUGE function The display will read SONAR ON and the depth digits under the fuel and oil gauges will display depth in either feet or met...

Page 41: ...d even when power is removed due to nonvolatile EEPROM memory SPEEDOMETER The right side of the MFI contains an analog speedometer While the speedometer is traditional in appearance it is actually controlled by the system microprocessor and is extremely accurate SECURITY LOCK Briefly pressing and releasing the LOCK button will cause the lock status to be displayed either LOCKED or UNLOCKED Pressin...

Page 42: ...display for several seconds if the second entry of the new code matches the first If the second code entered does not match the first INVALID CODE will be displayed and the CODE SET MODE is cancelled DISPLAY Pressing the DISPLAY button toggles the MFI between NORMAL DISPLAY mode and DIGITAL DISPLAY mode The lower display will show VOLTS DISTANCE HOURS when in NORMAL mode and real time digital RPM ...

Page 43: ...xtinguisher UL 5 B C Rating PN 2871012 S Registration numbers see your Polaris watercraft dealer S Tow rope for emergency use PN 2871310 S Flare gun for emergency use PN 2871533 S Safety and riding gear including approved personal flotation devices for operator and passenger see your Polaris watercraft dealer S Emergency Signal Kit PN 2871206 S Emergency Survival Kit PN 2871204 S Pliers PN 2872761...

Page 44: ...ult Always inspect the vehicle as outlined in the checklist before each use to ensure it s in proper and safe operating condition See page 78 for additional inspection information Always remove the lanyard from the engine stop switch before performing the pre operation inspection WARNING Starting or operating the watercraft with a fuel leak can result in an explosion causing serious injury or deat...

Page 45: ...rage compartment Check for secure latching Engine Cover Check for secure latching Battery Check fluid level and condition vent hose must be clear and open Hull Inspect hull for damage or cracks clean off marine growth Drain plugs bilge Inspect and clean it should not leak be sure it is tight and secure Loose parts hoses Inspect for loose parts hoses and connec tions Seat Check that seat is securel...

Page 46: ...d S Do not overfill the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an enclosed area Gaso line powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time S Turn the fuel valve off if equipped whenever the vehicle is...

Page 47: ... what is needed for a month or less of operation The use of a funnel or flexible spout will help avoid gasoline spillage on the watercraft Always wipe up spills immediately NOTE If the fuel or oil levels become low the Multi Function Instrument MFI will display a flashing warning light Proceed to shore and refuel Refer to the specifications section beginning on page 104 to determine if your craft ...

Page 48: ...ry NOTE Do not overfill Wipe up any oil spills immediately 4 Visually inspect the oil for water or foreign matter If either is present change the oil All models are equipped with an oil level gauge on the instrumentation The gauge will flash a red light if oil is low 1 8 tank or less Add oil immediately Read the oil recommendations found on page 54 for proper lubrication during the break in period...

Page 49: ...down several times to flush out any sand and debris that may be in the pump 1 2 3 4 Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When disconnecting cables always disconnect the negative black cable first When reconnecting always connect the negative black cable last WARNING CAUTION A clogged intake or the ingestion of sand into ...

Page 50: ... to ensure that it s in working condition Throttle Inspection Always check throttle operation prior to starting the engine Pull or squeeze the throttle several times to be sure the throttle lever moves freely through its full range It should spring back to its original position when released Engine and Storage Compartments If the craft is operated in salt water we recommend that you spray the insi...

Page 51: ...tation Device PFD and will not provide life saving flotation Always wear a PFD when operating or riding a watercraft Fire Extinguisher The operator of the watercraft is required by law to carry a fire extinguisher on board Always keep a fully charged and working fire extinguisher inside the fire extinguisher holder 1 which is located inside the storage area under the front compartment door A fire ...

Page 52: ...between the upper and lower marks 1 on the battery Keep the battery in good condition and fully charged at all times as a weak battery can leave you stranded Never operate the watercraft with a battery that s too weak to start the engine on its own or shows signs of loss of power Causing sparks while servicing the battery or servicing the battery when gas fumes are present can result in an explosi...

Page 53: ... plug and carefully flush out the bilge with fresh water Allow the bilge to drain completely Wipe out the bilge with dry shop towels and reinstall the drain plug After launching the craft remove the seat and check for leaks Riding Gear Be sure all operators and passengers have the appropriate riding gear including a PFD See page 16 Make sure all trailing objects are securely tied back or stowed 1 ...

Page 54: ...seconds Remove the lanyard lock plate from the engine shut off switch to test operation The engine should stop immediately If it doesn t press the stop button or pull the choke lever knob out until the engine stops Do not ride the watercraft Have it serviced by an authorized Polaris dealer before operating it again 4 If removing the lanyard lock plate successfully stopped the engine in the previou...

Page 55: ...ule on Direct Injected models It is not serviceable 1 Visually inspect the fuel water separator bowl 1 If water is present at the bottom of the bowl it will appear as a clear liquid 2 Turn off the fuel valve and remove the bowl by turning it counterclockwise NOTE Use care to avoid spilling fuel when removing the bowl Wipe up any spills immediately with a shop towel 3 Empty the bowl and dispose of ...

Page 56: ...reatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully 1 When filling the fuel tank for the first time use a 40 1 gas oil premix to provide additional lubrication during the break in period A 40 1 ratio is one pint 5 l oil to five gallons 19 l of gasoline After the break in period the oil injection system will pr...

Page 57: ... of operation 5 Gradually open the throttle to half speed 6 Vary throttle speeds up to 3 4 speed during the break in period If the engine is run while the watercraft is in very shallow water sand weeds and debris may be sucked into the jet intake and could cause damage to the impeller or injury to bystanders Ingesting sand into the cooling system will cause the engine to overheat which could lead ...

Page 58: ...ileged vessel has the right of way and the give way burdened vessel must yield or give way Stand on Vessel The vessel with the right of way has the duty to continue its course and speed except to avoid an immediate collision By maintaining course and speed other vessels should be able to determine how best to avoid interfering with its course Give way Vessel The give way vessel is responsible for ...

Page 59: ...ssel head on S Crossing traveling across another vessel s path Overtaking Vessels If your watercraft is passing another vessel your craft is the give way vessel The other vessel is expected to maintain its course and speed You must not interfere with its course of travel If your craft is the stand on vessel maintain your course and speed until the other vessel has passed you 1 2 ...

Page 60: ...speed 2 Crossing Paths When two power vessels are crossing each other s path close enough to run the risk of collision the vessel having the other on the starboard right side must give way For example if the other vessel 4 is on your vessel s 3 starboard right side you must give way If the other vessel is on your port left side your vessel is the stand on vessel and should maintain its course and ...

Page 61: ... stay clear of fishing vessels S In a narrow channel a non motorized craft should not interfere with the safe passage of a power vessel Fishing Vessel Right of Way All vessels that are fishing with nets lines or trawls are considered fishing vessels under International Rules Vessels with trolling lines are not considered fishing vessels Fishing vessels have the right of way regardless of position ...

Page 62: ...ve brakes DO NOT RELEASE THROTTLE WHEN TRYING TO STEER away from objects You need throttle for proper steering Always check throttle and steering controls for proper operation before starting the craft Follow navigation rules and all state and local laws that apply to personal watercraft Reading Buoys and Markers United States waters are marked for safe navigation through the use of buoys and mark...

Page 63: ...engine until the watercraft has quit moving Your craft requires engine power for steering After the engine has stopped you ll lose all steering control of the watercraft 1 Release the throttle lever When the engine has slowed to an idle push in the stop button 1 with your left thumb The engine should stop immediately You may also stop the engine by pulling the lanyard lock plate 2 off the engine s...

Page 64: ...d the barrel of the switch Be sure the lanyard is not tangled around the handlebars or controls NOTE The engine will not start if the lanyard lock plate is removed from the engine stop switch 3 Move the choke lever clockwise or pull the knob out if equipped with choke If the engine is already warm do not use the choke NOTE Direct injected models do not have a manual choke If the engine is run whil...

Page 65: ... at a time or damage to the starter may result If the Engine Doesn t Start If the engine does not start within 10 seconds release the starter switch Wait 10 seconds before trying again to avoid damaging the starter If the craft is equipped with manual choke either pull the choke lever out or move the choke lever in a clockwise direction If the engine is already warm do not use the choke If the eng...

Page 66: ... the rear of the watercraft Grip the boarding handle near the rear of the seat 2 Pull yourself up onto the boarding platform If your model is equipped use the seat strap for assistance NOTE Some models are equipped with a boarding step for boarding convenience Refer to the specifications section beginning on page 104 3 Move up to the seat and straddle it 4 Attach the lanyard lock plate to the engi...

Page 67: ...he lanyard wrist band to the left wrist or PFD Do not start the engine yet NOTE During boarding the passenger should steady the watercraft while the operator boards The operator can then help balance it while the passenger boards 2 The passenger should move or swim to the rear of the vehicle 3 The passenger should pull him herself on board using the grab handle Both operator and passenger should t...

Page 68: ...y as required to maintain steering control of the watercraft 3 To return to forward depress the forward button labeled FWD until the reverse gate is in the full up position NOTE The reverse gate can be activated without the engine running by depressing the bilge button and operating the up down button for reverse actuation NOTE Engine RPM is limited during reverse operation While in reverse the mu...

Page 69: ...tercraft as much as 300 feet 90 m to come to a stop after the throttle is released This distance is approximate and is supplied only for reference After releasing the throttle coast toward the desired stopping area with the engine idling You may need to use the throttle again for steering control NOTE Push the engine stop button before entering shallow water to prevent sand and debris from enterin...

Page 70: ...o less than two feet 60 cm of water Make sure there are no swimmers boats or other obstacles close to the watercraft as it will be impossible to turn the watercraft after stopping the engine 2 Dismount the watercraft and guide it to the beach 3 Before restarting inspect the impeller jet pump area for sand and debris 4 Move the watercraft to at least two feet 60 cm of water and push the rear of the...

Page 71: ...pe to the eye located on the bow Slowly tow the watercraft to shore NOTE Before towing use a pliers to close off the cooling water inlet hose located at the bottom of the watercraft hull hose from pump box to exhaust pipe to prevent hydrolock Riding the watercraft in rough water conditions could cause loss of control resulting in severe injury or death to the operator and or passenger Avoid riding...

Page 72: ... engine damage could result Follow the procedures for a submerged waterlogged engine on page 76 This watercraft does not right itself if it has been capsized If the operator is unable to right a capsized watercraft operator and passengers may be stranded which could lead to serious injury or death Follow the procedures outlined in the owner s manual and on the capsize decal which is found on the r...

Page 73: ...y gear They should be good swimmers and they should be in good physical condition as reboarding in deep water can be strenuous A passenger should firmly hang on to the operator s PFD or the seat strap and keep both feet on the footwell pads in the gunnel The operator should make sure any passenger is properly seated and holding on before accelerating The operator should also communicate sudden man...

Page 74: ... to drain any water in the bilge 5 Remove the seat and rinse the engine compartment with a generous amount of fresh water After the water has drained wipe the engine compartment bilge dry with clean towels 6 If the craft is used in salt water Polaris recommends that the inside of the hull engine and components be sprayed with T 9 metal protectant after each use See page 103 7 Reinstall the seat 8 ...

Page 75: ...d see your Polaris dealer for service NOTE Whenever possible avoid operating the watercraft in weedy areas If it s unavoidable vary the watercraft speed as weeds tend to accumulate more rapidly at steady and trolling speeds Serious injury and damage to the watercraft will result if the jet pump and impeller are cleaned while the engine is running Always stop the engine remove the lanyard lock plat...

Page 76: ...nd and allow it to dry out 2 When storing the watercraft make sure the nose is positioned upward at a 10_ angle for drainage 3 Check the screen in the pump stationary nozzle for plugging See instructions on page 94 Serious injury and damage to the watercraft will result if the jet pump and impeller are cleaned while the engine is running Always stop the engine remove the lanyard lock plate and dis...

Page 77: ... Be sure the trailer matches the watercraft s weight and design and that it meets trailer laws and regulations in your area We recommend the use of a Polaris watercraft cover for protection from rocks and other debris while transporting 1 Turn the fuel valve off if equipped 2 Tie the watercraft securely to the trailer at the bow and stern Use additional cables if necessary There should be no movem...

Page 78: ...anically experienced individuals should attempt to remove water from a waterlogged engine Use the procedure on page 77 All others should take the watercraft to an authorized Polaris dealer for service If this is not possible call your Polaris dealer for further instructions A weak battery may not be able to start the engine and could leave you stranded which could result in severe injury or death ...

Page 79: ...sistants hold the watercraft in this position turn the driveshaft by hand to rotate the engine and allow the water to run out 5 Upright the watercraft and inspect and dry the spark plug holes Install new spark plugs 6 Install the air intake 7 Check the battery vent hose for obstructions and drain any water from the hose 8 Check the fuel and oil for the presence of water If water is present take th...

Page 80: ...craft protect the metal components with a T9 Metal Protectant or another 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 may also deteriorate rubber components Periodic Maintenance Schedule NOTE Maintenance intervals are based upon average ope...

Page 81: ...off valve as sembly spring I C I C R Water inlet and outlet hoses and clamps I I I R Spark plugs Compression test I I Spark Plugs DI models re place every 100 hours R I R Engine fastener re torque cyl head cyl base exhaust I I Oil pump adjustment where applicable I I FUEL SYSTEM Fuel water separator drain water I C I C Inspect and clean fuel water separator filter I I R Fuel filter and oil filter ...

Page 82: ...r water sep arator drain line s I C JET PUMP Drive shaft coupler and bear ing housing I L I L I L Drive shaft shroud condition I I Bilge system pick up screens and hoses I C I C Cooling water inlet screen hoses clamps I C I C Jet pump intake grate fasten ers and condition I I Impeller condition and impel ler clearance I I Pump Sacrificial Anode I I Reverse mechanism I A I A ELECTRICAL Battery cond...

Page 83: ...I I L A I L A Handlebar steering operation turns fully freely fasteners I I Hull clean and inspect for cracks damage or leaks I C I Drain Plug Condition I I Bilge system inspection should not leak I I I Seat and compartment seals condition of seal I A I A Fire extinguisher I I Inspect and tighten all fas teners including carburetor mounts engine mounts ex haust system all hose clamps inspect muffl...

Page 84: ... cables 2 Depress the throttle lever and squirt grease onto the cable 3 Push and release the throttle several times to work the grease down the cable Steering Cable Joints and Inner Wire 1 Lubricate the steering cable joints on the steering nozzle end 2 Lubricate the steering cable joints on the steering nozzle end 3 Expose the steering cable inner cable and apply grease Lubricate the steering noz...

Page 85: ...n the choke lever and apply grease to the knob shaft NOTE On some models the choke is located on the console Seat Latch And Hooks Grease the locking mechanism of the seat latch at the rear of the seat opening Carburetor And Oil Injection Pump Grease springs exposed portions of cable and shafts at the carburetor s or throttle bodies Grease often if used in salt water Electrical Connections Apply di...

Page 86: ... frequently used in salt water this procedure should be done semi annually Bearing Housing Using a grease gun lubricate the bearing housing at the grease fitting 1 until grease purges past the seals Use Polaris All Season Premium Grease 1 Front of Boat Any time water has been at or above the coupler level grease the drive shaft coupler to prevent damage to these parts Lubrication after every 25 ho...

Page 87: ...idling occurs the carburetor idle speed mixture or high speed mixture is too rich or there is a malfunction with the RPM limiter A light grey or white tip indicates that the wrong spark plug wrong heat range is being used the carburetor idle speed mixture is too lean there is a plugged fuel filter or there is a leaking engine seal or gasket A yellow tip is caused by salt water mist ingestion This ...

Page 88: ...ble 1 4 to 1 2 turn beyond finger tight is close to the correct torque Push the cap down on the plug until it clicks Use dielectric grease on the inside of the spark plug cap to prevent corrosion Before installing a used plug wipe off the threads and apply dielectric grease Also clean the gasket surface Removing a spark plug while the engine or exhaust system is hot could result in serious burns W...

Page 89: ...an occur See your dealer if you suspect any deteriorated components Oil Filter Failure to heed gasoline warnings can result in fire or explosion which could cause serious injury or death See gasoline warnings on page 44 If your machine is equipped with a fuel valve shut it off before servicing fuel components WARNING Substituting a non recommended oil filter could result in damage to the watercraf...

Page 90: ... smoothly If movement is stiff see your authorized Polaris dealer for service 2 Turn the handlebars from lock to lock and check to be sure that the clearances between the steering nozzle and the rear hull are even on both sides If the alignment is not even see your authorized Polaris dealer for service Throttle Cable Inspection 1 Depress and release the throttle lever It should return to its initi...

Page 91: ...l system is protected with a 15 amp circuit breaker NOTE DI models have two 15 amp circuit breakers To reset the circuit breaker locate and push the reset buttons A on top of the electrical box Fuses Carb Models The MFI is protected by a 1 4 amp fuse B and the bilge pump is protected by a 3 amp fuse C Inspect the fuses every season to ensure fuses are not blown There are spare fuses in the electri...

Page 92: ...ery fluid level often The fluid level should be kept between the upper and lower level marks 1 To refill use only distilled water Tap water contains minerals that are harmful to a battery Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Foll...

Page 93: ...gative battery cable first 5 Disconnect the red positive battery cable next 6 Lift the battery out of the watercraft being careful not to tip it sideways and spill any electrolyte Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery ...

Page 94: ...trolyte up to the proper level 2 Connect the battery to the charger Set the charging rate at 1 9 amps plug in the charger and charge the battery for ten hours NOTE If the electrolyte temperature rises above 115 F 45 C during charging reduce the charging rate to lower the temperature Increase the charging time 3 After the battery is charged check the fluid level If it dropped add distilled water to...

Page 95: ...attach the hold down strap s 7 Verify that cables are properly routed NOTE When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Battery Storage 1 Remove the battery Clean the casing and terminals with baking soda and water one...

Page 96: ...ing procedure on page 95 If the screen cannot be cleaned by flushing see your Polaris dealer for additional cleaning EPA Emissions Regulations All Polaris Direct Injection equipped engines manufactured by Polaris Industries are certified to the United States Environmental Protection Agency regulations for the control of air pollution For this reason factory procedures for servicing must be strictl...

Page 97: ...flushing the cooling system 1 Attach a garden hose to the female coupler hose attachment 2 Snap the male and female coupler together 3 Start the watercraft engine and immediately turn on the water faucet 4 Rev the engine intermittently for one minute to completely flush the cooling system 5 Turn off the water faucet 6 When all water has exited the cooling system turn off the engine NOTE This step ...

Page 98: ...bon Clean to the fuel tank then top off with fresh fuel See page 103 for the part numbers of Polaris recommended products 3 Fog the engine with rust preventing oil Follow the recommended procedures on page 97 NOTE Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system If you prefer to drain the fuel tank use the following procedure 1 Drain the fuel tank ...

Page 99: ...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 intake throat and repeat until the engine is flooded with fogging oil Then stop the engine immediately 4 Reinstall filter element s and air intake covers Failure to fog the engine can result in serious engine corrosion d...

Page 100: ...f damage to these areas is visible see your Polaris dealer for service 4 After cleaning protect and polish the watercraft with a regular furniture polish or non abrasive silicone wax Protect the seat and handlebar unit with a vinyl protector 5 Spray the exterior of the engine with T9 metal protectant 6 Cover the watercraft with an opaque tarp or Polaris watercraft cover and store it in a clean dry...

Page 101: ...r Polaris Premium Gold Synthetic 2 cycle oil into each cylinder 2 Inspect and grease the spark plug threads Replace if necessary 3 Lubricate the choke throttle and steering cables See page 82 4 Lubricate all areas recommended in the maintenance section beginning on page 82 5 Remove and store the battery properly See recommendations on pages 90 93 ...

Page 102: ...alve is turned off carb models Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plugs Inspect plugs replace if necessary Crankcase filled with water or fuel See your Polaris dealer Overuse of choke Inspect clean and or replace spark plugs Clogged fuel filter Replace the filter Low battery voltage Recharge battery to 12 5 VDC Mechanical failure See ...

Page 103: ...contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of choke Inspect clean and or replace spark plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your Polaris dealer Engine Backfires Pos...

Page 104: ...Clogged jet pump intake Clean intake Clogged exhaust and or cooling system Clean exhaust flush cooling system Hydrolock See your Polaris dealer Too much load weight on craft Reduce load per vehicle specifications Mechanical failure See your Polaris dealer Engine RPM is Too High With Limited Speed Possible Cause Solution Clogged jet pump intake Clean intake Cavitation impeller damaged or worn See y...

Page 105: ...e 3 oz 4 pack 2871322 14 oz Tube 2871423 Starter Grease 2871460 Nyogel Grease 2871329 General Maintenance Products Fogging Oil 12 oz Aerosol 2870791 1 Quart 2871517 Carb Throttle Body Cleaner 2872890 Multi Purpose Lubricant 2872891 Electrical Contact Cleaner 2872892 Engine Degreaser 2872893 Revival Detailing Kit 2871589 Restore Swirl Scuff Eliminator 2871966 Finish Wax 2871965 Vinyl and Rubber Pro...

Page 106: ...R6H NGK PZFR6H Spark Plug Gap 028 7mm 028 7mm 032 8mm 032 8mm Starting System Electric Starter Electric Starter Electric Starter Electric Starter Battery 12V 19A 12V 19A 12V 19A 12V 19A COOLING Engine Cooling Water cooled thermostat pop off Water cooled thermostat pop off Water cooled thermostat pop off Water cooled thermostat pop off Overheat Warning Warning Light RPM Limit Warning Light RPM Limi...

Page 107: ...m 2 feet 60 cm Impeller Diameter 5 83 in 14 80 cm 5 83 in 14 80 cm 5 83 in 14 80 cm 5 83 in 14 80 cm FEATURES Instrumentation 3 Function Gauge 22 Function MFI 23 Function MFI 25 Function MFI Fuel Gauge Standard Standard Standard On MFI Oil Level Sensor Single Level Multi Level Multi Level Multi Level Tachometer N A On MFI On MFI On MFI Reverse System N A Standard Standard PERCt Voltage Meter N A O...

Page 108: ...e on changes modifications and tips on personal watercraft maintenance that may supersede information contained in this manual Your dealer is familiar with Polaris policies and procedures and will be happy to assist you When inquiring about parts service or warranty always include the following information 1 Serial number 2 Model number 3 Dealer name 4 Date of purchase 5 Details of trouble experie...

Page 109: ...s the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR PERSONAL WATERCRAFT IS REGISTERED WITH POLARIS AND YOU HAVE CONFIRMED THAT YOU HAVE WATCHED THE SAFETY AND OPERATION VIDEO AND REVIEWED THE SUMMARY TRAINI...

Page 110: ...ll and deck The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION ...

Page 111: ...l rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by ...

Page 112: ...ns Regulations 94 109 Equipment 41 Extended Storage 96 99 FEATURES 26 41 Fire Extinguisher 49 Fire Safety 17 Fishing Vessel Right of Way 59 Footwell Pads 26 Fuel 44 45 Fuel Lines 87 Fuel Tank 87 Fuel Water Separator 53 Fuses 89 Gasoline Warning Decal 10 General Maintenance 78 Give way 56 Give way Vessel 56 Glove Box 30 Hull 51 Hypothermia 23 IDENTIFICATION NUMBERS 6 Jet Pump Intake 47 Jet Pump Wat...

Page 113: ...gs 85 86 SPECIFICATIONS 104 105 Stand on Vessel 56 Starting In Deep Water 64 Starting the Engine 62 63 Steering Cable 82 Steering Cable Inspection 88 Steering Inspection 48 Stop Switch 24 Stopping the Watercraft 67 Storage 74 96 Storage Compartment 48 Submerged Engine 76 Switches Buttons 52 TABLE OF CONTENTS 4 Temporary Storage 74 Throttle Cable 82 Throttle Cable Inspection 88 Throttle Inspection ...

Page 114: ...Printed in USA Part 9918123 Rev 02 Read and understand all warning labels and Owner s Manual before operation Severe injury 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 WATERCRAFT IN ITS STORAGE BAG AT ALL TIMES ...

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Polaris 2003 Freedom, Owner'S Safety And Maintenance Manual

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