Polaris Genesis 2000 Service Manual Download Page 1

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Summary of Contents for Genesis 2000

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Page 2: ... maintenance component identifi cation and unit repair along with service specifications for 2000 Virage TX SLX Genesis Genesis FFI and Pro 1200 Polaris personal watercraft A table of contents is placed at the beginning of each chapter to aid the user in locating specific areas of information The alphabetic index at the end of the manual will help the user find specific information quickly Care is...

Page 3: ...tions 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...

Page 4: ...and FFI Tools 1 1 FFI Special Tools 1 2 2000 Model Identification 1 3 2000 Model Specifications 1 4 1 5 Standard Torque Specifications 1 6 Decimal Equivalents 1 7 Conversion Tables 1 8 Tap Drill Charts 1 9 Glossary of Terms 1 10 1 11 Service Tips 1 12 ...

Page 5: ...Numbers Paint Codes Watercraft Publication Part Numbers Paint Codes Dealer orders can be placed through Midwest Industrial Coatings using the Polaris P number Phone 763 942 1840 Mix as directed Special Tools Polaris Sales Inc 1 1 3100 ...

Page 6: ...tion Numbers Paint Codes FFI Fuel Injection Special Tools 2872454 EMM Lap Top Com Cord 2872604 Engine Bumper Tool 2872602 Schrader Valve 2872456 EMM Service Power Connector 2872621 Fuel Pump Ring Spanner 300 1 2 Polaris Sales Inc ...

Page 7: ...rom others of the same model If the watercraft is ever stolen these numbers will help identify it The owner should keep a record of these numbers in a place other than the watercraft lumber Identifjj tipii if dtyr l r Serial l otith ofV t TY rof Month Code A January B February etc Year Of Manufacture 9 1999 0 2000 etc Starter Cover Engine I D Number Polaris Domestic Engine Polaris Sales Inc 1 3 3 ...

Page 8: ...mium Gold Polaris TC W3 Premium Polaris TC W3 Premium Gold Synthetic or Nature Oil Gold Synthetic or Nature Synthetic or Nature Oil Oil RPM Limiter Operation 7200 RPM 100 7200 RPM 100 7200 RPM 100 Carburetion Carburetors 3 40mm Keihin CDK 3 40mm Keihin CDK 3 FICHT Fuel Injectors Fuel Type Regular Unleaded Gasoline Regular Unleaded Regular Unleaded Gasoline 87 Octane or 89 if Gasoline 87 Octane or ...

Page 9: ...remium Gold Polaris TC W3 Premium Gold Synthetic or Nature Oil Synthetic or Nature Oil RPM Limiter Operation 7200 RPM 100 7200 RPM 100 Carburetion Carburetors 3 40mm Keihin CDK 3 40mm Keihin CDK FuelType Regular Unleaded Gasoline Regular Unleaded Gasoline 87 Octane or 89 if 87 Octane or 89 if oxygenated oxygenated Idle Speed In Water 135Q 100 1350 100 Electrical Magneto Generator Output 8 5A 60W a...

Page 10: ...e values for the appropriate size fastener when torque values are not specified Always consult the specific manual section for torque values of fasteners and use of locking agent To convert in lbs to ft lbs divide by 12 To convert ft lbs to Nm multiply foot pounds by 1 356 To convert Nm to ft lbs multiply Nm by 7376 3 00 1 6 Polaris Sales Inc ...

Page 11: ...13 32 4063 27 64 4219 11 mm 4331 7 16 4375 29 64 4531 15 32 4688 12 mm 4724 31 64 4844 1 2 5 13 mm 5118 33 64 5156 17 32 5313 35 64 5469 14 mm 5512 9 16 5625 37 64 5781 15 mm 5906 19 32 5938 39 64 6094 5 8 625 16 mm 6299 41 64 6406 21 32 6563 17 mm 6693 43 64 6719 11 16 6875 45 64 7031 18 mm 7087 23 32 7188 47 64 7344 19 mm 7480 3 4 75 49 64 7656 25 32 7813 20 mm 7874 51 64 7969 13 16 8125 21 mm 8...

Page 12: ...GENERAL INFORMATION Conversion Table C to F 9 C 40 5 40 F F to C 5 F 40 9 40 C 300 1 8 Polaris Sales Inc ...

Page 13: ...GENERAL INFORMATION Tap Drill Charts SAE Tap Drill Sizes Metric Tap Drill Sizes Polaris Sales Inc 1 9 3 00 ...

Page 14: ...ression ratio too high for the fuel octane 2 low octane fuel 3 over advanced ignition timing Dial Bore Gauge A cylinder measuring instrument which uses a dial indicator Good for showing taper and out of round in the cylinder bore End Seals Rubber seals at each end of the crankshaft F Fahrenheit ft Foot feet Foot Pound Ft Ib A force of one pound at the end of a lever one foot in length applied in a...

Page 15: ... the trigger coil the wires from stator plate to CDI box and to the ignition coil primary windings psi Pounds per square inch pts Pint pints PTO Power take off qt Quart quarts RPM Revolutions per minute Resistance In the mechanical sense friction or load In the electrical sense ohms Both result in energy conversion to heat Right Side The right hand side of the vehicle Always Referred to based on n...

Page 16: ...rque value When removing nuts bolts or screws from a part with several fasteners loosen them all about 1 4 turn before removing them If the condition of any gasket or O Ring is in question replace it with a new one Be sure the mating surfaces around the gasket are clean and smooth in order to avoid leaks iK Some procedures will require removal of retaining rings or clips Because removal weakens an...

Page 17: ...rical Maintenance 2 8 2 11 Engine Maintenance 2 12 2 18 Cable Adjustments 2 19 2 25 Fuel System Maintenance 2 25 2 29 Cooling System Maintenance 2 30 2 31 Storage 2 30 2 32 Cleaning 2 33 Bilge System 2 34 MFD MFI Gauges 2 35 Submerged Engine 2 36 Pump Impeller Maintenance 2 37 Hull Deck Maintenance 2 38 2 39 Troubleshooting 2 40 2 45 ...

Page 18: ...month when operated in salt water Perform daily when operated in salt water Bonded rubber couplers Pre Season Annually 100 hrs or when pump is disassembled for maintenance Genesis FFI water separating filter requires no periodic maintenance CD Replace pop off valve spring and seals every 100 hours only not every 6 months 2 Replace water separator filter element and o ring every 100 hours only not ...

Page 19: ...tectants in the engine compartment Do not use petroleum based protectants or lubricants in the engine compartment as most are flammable and also may deteriorate rubber components Engine Break In Carbureted Models Breaking in a new engine is critical All Polaris watercraft utilize oil injection however you must add oil to the fuel in the fuel tank for the first tank of fuel only Mix Polaris Premium...

Page 20: ...ducts As with all watercraft proper lubrication and corrosion protection are necessary to maintain performance and en sure years of trouble free service Use the recommended lubricant for each component as indicated in the chart below Polaris Sales Inc 2 3 3 00 ...

Page 21: ...cable 1 Depress throttle lever and apply lube onto cable 2 Push and release throttle several times to work lubricant down cable NOTE Cable seals can be moved to allow oil into the cable Make sure seals are put back in proper location after oiling Choke Throttle Cable Oil Pump Cable 3 00 2 4 Polaris Sales Inc ...

Page 22: ... Make sure seals are put back in proper location after oiling Steering Handlebar Pivot Shaft Lubricate handle pivot shaft and bushing using Polaris Premium Marine Grease MAINTENANCE TUNE UP Lubrication Steering Nozzle Pivot Reverse Gate Lubricate steering nozzle pivot and reverse gate with grease Reverse Cable Lubrication Lubricate reverse cable at both ends Polaris Sales Inc 2 5 3100 ...

Page 23: ...ed portions of cable idle stop screw and throttle and choke shafts at carburetor NOTE Grease often if used in salt water Keihin Choke Cable Shaft Idle Speed Screw il Pump Cable Throttle Shaft Grease Carburetor and Oil Injection Pump Grease springs exposed portions of cable and shafts at carburetor NOTE Grease often if used in salt water 3 00 2 6 Polaris Sales Inc ...

Page 24: ...upler and Solid Coupler Driveshaft splines should be lubricated during pre sea son maintenance every 100 hours or when pump is dis assembled Sealing O rings at impeller end and inside coupler should be inspected and replaced if worn or damaged Refer to Final Drive section for driveshaft re moval procedure Use Premium All Season Grease Front of Watercraft Shroud Grease Rotate 180 Coupler Boot Shrou...

Page 25: ... connections Inspect electrical box for moisture check wire sealing grommets and apply Nyogel grease to terminal board connections Terminal Board Terminal Board MFD O O O 0LU GRN W BLU f eiu w o O AGW 3 W BLK R PUR AGC i 4 R PUR R PUR O o o o lOR BLK Y R BLK T BLKH Terminal Board MFI 3 00 2 8 Po ar s Sa es nc ...

Page 26: ...jury When re installing battery connect black nega tive cable last Whenever installing batteries care should be taken to avoid the possibility of explosion resulting in serious burns Always connect the positive red cable first and the negative black cable last When working with batteries always wear safety glasses or a face shield and protective gloves Battery electrolyte contains sulfuric acid an...

Page 27: ...attery connect black nega tive cable last A WARNING Keep the battery away from sparks and open flames during charging because the battery gives off gases which are explosive If you smell fuel do not attempt to charge the battery 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 ignite t...

Page 28: ...battery cover and electrical box over battery and reconnect straps 8 Verify that cables are properly routed 9 Verify that vent hose is not kinked Battery Storage 1 Remove battery Clean casing and terminals with baking soda and water one tablespoon of baking soda to one cup water Apply dielectric grease to battery terminals and all exposed cable connectors 2 Top off battery with distilled water and...

Page 29: ...uge in cylinder to be tested 3 Using the starter motor turn engine over with throttle wide open until a maximum reading is obtained approximately 3 5 seconds Record reading 4 Repeat for the other cylinders and compare to each other cylinder All readings must be within 5 of each other Compression Open Throttle at Sea Level Standard 120 50 ty in Service JLIijti t a than 5 variance between cylinders ...

Page 30: ...a small amount of anti seize compound 6 Install spark plug and torque to specifications 7 Make sure spark plug caps are screwed completely onto end of plug wire 8 Apply a small amount of Nyogel grease to inside of plug caps and install MAINTENANCE TUNE UP Engine Ignition Timing Specifications Refer to Electrical Section for ignition timing adjustment procedure and timing chart Polaris Sales Inc 2 ...

Page 31: ...ed in the Engine Section Cylinder Base Gasket Re Torque With engine at room temperature 68 F or 20 C re torque cylinder base nuts following the pattern de scribed in the Engine Section Exhaust Manifold With engine at room temperature 68 F or 20 C re torque exhaust manifold bolts following torque pattern shown in Engine section 3100 2 14 Polaris Sales Inc ...

Page 32: ...nd remove line 2 Using a deep well 9 16 socket or flare nut wrench remove fitting from exhaust manifold Inspect fitting for debris or restriction and clean if necessary 3 Inspect and clean orifice and screen 4 Apply pipe thread sealant to threads of fitting and re install Tighten securely 5 Re install air bypass hose and tighten clamp Orifice Size Pro 1200 SLX Virage TX 070 1 8mm If particles are ...

Page 33: ...l come apart quickly if not held together firmly 1 Using a 3 16 5 cm hexagonal wrench and a flat screwdriver remove screws while holding thermostat pop off assembly firmly together Carefully take assembly apart Be careful npt to lose any parts 2 Inspect thermostat pop off assembly for debris such as sand or seaweed and clean thoroughly with water Inspect pop off valve for wear See III 1 3 Inspect ...

Page 34: ... counterclockwise to decrease idle speed 4 Check throttle cable free play and oil pump adjustment and adjust if necessary Idle Speed In Water 1350 100 BPM Throttle Lever Freeplay 1 Start engine and adjust idle speed to specifications Stop engine 2 Adjust throttle lever freeplay to specifications by loosening locknut and turning cable adjuster 3 Adjust oil pump cable as outlined on page 2 18 Check ...

Page 35: ...er with arrow pointing in direction of oil flow towards pump 3 Install new cable tie straps or reinstall clamps on each line and check for leaks Oil Pump Adjustment NOTE Adjust idle speed and throttle lever freeplay be fore performing oil pump adjustment 1 Inspect mark on oil pump lever and index mark on oil pump body The marks should align with throttle released idle speed The lever should move i...

Page 36: ...djuster Turn adjuster in clockwise to increase or out counterclockwise to decrease free play 4 Tighten lock nut securely when adjustment is complete 5 Start engine and turn handlebars to left and right through entire turning range If engine RPM increases re check cable condition routing and lever free play and correct or adjust as necessary Cable Adjustment Virage TX Genesis FFI 1 Set idle speed t...

Page 37: ...etely vertical when the knob or lever is returned to the off position 2 Tighten nuts securely and re check lever free play Turn bars from full left to full right through entire range of motion and verify that at least the minimum lever play is present in all handlebar positions Be sure cable is routed properly through the handlebar pad and down the steering post Choke Cable Adjustment Virage TX Ge...

Page 38: ...for free movement throughout their full range Visually inspect steering control cable for damage Check cable ends for damage 2 Make sure cable is routed and secured properly Inspect fasteners at ends of cable and re torque Inspect steering nozzle bolts and bushings for wear Polaris Sales Inc 2 21 3 00 ...

Page 39: ...n center position 3 Place a straight edge across horizontal center line of steering nozzle or trim nozzle NOTE The trim nozzle mounting bolts can be used as a reference for the center line on models with Quick Trim See III 2 Rear View Of Pump Nozzle Place straight edge across horizontal center line of steering nozzle or trim nozzle III 2 4 Measure distance from straight edge to hull on left and ri...

Page 40: ...be equal See III 1 Adjustment Procedure MAINTENANCE TUNE UP Cable Adjustments Rear View Of Pump Nozzle Measure on horizontal center line from rear of steering or trim nozzle to station ary nozzle Distance should be equal 11 1 1 Minor adjustments can be made using the steering cable rod end s Loosen jam nut on rod end s Remove end from top of steering nozzle Turn rod end in or out to adjust Reinsta...

Page 41: ... front compartment and remove storage tray for access to bottom nut See III 3 4 Using two 11 16 open end wrenches hold one nut and loosen the other Lengthen or shorten cable to adjust nozzle centering Tighten cable nuts securely after adjustment is complete 5 Turn handlebars to left and right through entire steering range The bars should move freely and smoothly without binding If resistance or bi...

Page 42: ...te Reverse gate must float in the notch and should not be forced in 4 Check gate locking by pulling up on gate when in down position 5 Move shift lever to forward position Reverse gate must be above water stream 6 Tighten adjuster nuts securely 7 Seal the cable threads and adjuster nuts with marine grade silicone sealant PN 8560054 and tighten securely Allow sealant to cure fully before operating ...

Page 43: ...ator should be checked daily and or whenever refueling 1 2 2 5 5 cm of water depth in water trap can cause the engine to run poorly due to re stricted fuel flow If water trap fills quickly check for water in the fuel tank A WARNING Gasoline is extremely flammable and explosive under certain conditions Do not smoke or allow flames or sparks in the work area Be sure the work area is well ventilated ...

Page 44: ...ollow all gasoline handling precautions found on page 2 26 5 Clean and inspect all parts Replace O rings if worn damaged or deteriorated Install O ring on bowl 6 Reinstall separator bowl taking care that the O Ring is not damaged and in the proper place 7 Hand tighten securely Turn fuel valve on start engine momentarily and check carefully for fuel leaks around bowl Never operate the engine for mo...

Page 45: ...ed annually or whenever sediment is visible in the filter 1 Loosen line clamps at both ends of filter 2 Remove fuel lines from filter 3 Install new filter with arrow pointed in direction of fuel flow 4 Re install and tighten clamps on fuel line 5 Start engine and inspect for leaks Never operate the engine for more than 15 seconds with out cooling water Severe engine damage may occur from overheati...

Page 46: ...n Genesis FFI see page 3 40 1 Adjust idle speed to specifications 2 Start engine and warm to operating temperature in a test tank or with the craft safely secured to a trailer or dock 3 Install tachometer to one of the spark plug high tension leads Adjust idle speed to specified RPM by turning idle speed screw clockwise to increase or counterclockwise to decrease speed Idle Speed Screw Keihin Carb...

Page 47: ...riveshaft component when the engine is running Severe personal injury or death could result Flushing Procedure Use Flush Kit PN 2871443 1 Attach garden hose to Female Coupler Hose attachment 2 Snap the male and female coupler together Do not turn on water yet 3 Start engine and immediately within 10 seconds open water tap 4 Rev the engine intermittently for one minute to completely flush cooling s...

Page 48: ... water from the exhaust system to prevent any damage from freezing For off season storage remove water hose going to exhaust manifold to allow engine to drain completely Fuel System Storage Top off the fuel tank with fresh fuel and add fuel conditioner stabilizer It is recommended that the craft be operated for approximately 10 15 minutes after stabilizing fuel to ensure treated fuel reaches the e...

Page 49: ...gine parts for prevention of rust and corrosion which in turn will extend the service life of the engine 1 Remove air intake cover and filter 2 Start the engine and spray Polaris fogging oil towards 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 repeat until the engine is flooded with fogging oil...

Page 50: ... outlet and impeller area 4 Inspect entire deck and hull area for damage Inspect rub rails to be sure they are fastened securely T 9 Metal Protectant For Use On External Metal Surfaces PN 2871064 Silicone Spray Non Flammable For Use Inside the Engine Compartment Available Commercially Never clean the watercraft with strong detergents abrasives de greasers paint thinner acetone window cleaners ammo...

Page 51: ...e sure they are tight and in position Bilge Drain Plug 1 Inspect bilge plug for cracks or damage from over tightening 2 Periodically inspect sealing O ring and replace if worn or damaged Inspect drain plug gasket keeper strap and tightness of screws View From Inside Hull Screen 040 hole must be clear to prevent siphoning water into bilge To pump fitting Bilge Siphon Keeper Strap Gasket Bilge Plug ...

Page 52: ...MAINTENANCE TUNE UP 2000 MFD MFI Gauges 2000 MFD MFI Fit Chart NOTE Refer to chapter seven Electrical for MFD MFI diagnostics repair and compass calibration Polaris Sales Inc 2 35 3 00 ...

Page 53: ...Attach spark plug wires to ground on engine and depress starter button for one second at a time until no more water exits the spark plug holes WARNING Depressing the starter turns the engine and pump Stay clear of all moving parts to avoid severe personal injury 8 Upright the watercraft 9 Inspect dry anjJ install new spark plugs 10 Check battery vent hose for obstruction drain water from hose if p...

Page 54: ...ate a leak in the sealant around the scoop Even a small leak will ventilate the pump area creating cavita tion of the pump and reducing performance If a leak is evident remove the scoop and re seal Refer to Final Drive Jet Pump section for procedures Excess silicone sealant can be trimmed until flush with edges Impeller Clearance A WARNING Be sure the lanyard cord and lock plate are removed from t...

Page 55: ...on pump and anode 3 Apply dielectric grease to bolt threads and contact surfaces 4 Tighten bolt securely Handlebars Hand Grips 1 Pull and twist on hand grips to ensure they are not loose If loose or wore the handlebar with grip assembly must be replaced 2 Check steering support hub fasteners and make sure they are tight Check handlebars and hub for cracks or damage Replace if cracked or damaged 3 ...

Page 56: ...n lock nut on rear post 2 Turn clockwise to provide more seal pressure and counterclockwise to reduce pressure if seat is too tight or new seal installed 3 Repeat steps one and two for center post 4 Reinstall seat and make sure it latches securely with no up and down movement at front or rear Polaris Sales Inc 2 39 3 00 ...

Page 57: ...be disconnected or loose in tank Fuel pump impulse line pinched kinked restricted with oil or water or leaking Carburetors dirty main pilot or bypass orifices restricted fuel inlet screen plugged Carburetor synchronization incorrect Water separator full or restricted Water in fuel tank High or low speed screws adjusted incorrectly jets too small or restricted Fuel pump diaphragm or check valve dam...

Page 58: ...e worn or wrong spark plugs Broken reed petals Symptoms Engine pinging or knocking Lean fuel mixture Poor quality low octane gasoline Incorrect ignition timing Spark plug heat range too high Symptoms Engine power loss Weak spark Incorrect fuel or fuel mixture Water in fuel system or oil tank Fuel filter restricted Jet intake clogged Cooling system clogged Symptoms Engine noise Detonation see cause...

Page 59: ...incorrect ignition timing poor quality fuel modified cylinder heads excessive carbon buildup etc Engine overheating inspect cooling system Crankshaft out of index see engine section Flywheel key sheared Symptoms Seized or scuffed piston Water in oil Oil pump failure Oil tank vent problem restricted check valve in backward Pinched or restricted lines Lean fuel mixture see carburetion Poor quality f...

Page 60: ...lean mixture troubleshooting Choke inoperative or not closing completely Fouled spark plug s Water in fuel Worn broken or cracked reeds Restricted or plugged low speed idle passages Symptoms Low compression Choke or throttle closed both must be wide open for test Loose cylinder head or head gasket failure Rings stuck or broken or excessive end gap Piston damage see piston damage Cylinder worn impr...

Page 61: ... incorrect or disconnected Terminal board or connectors corroded Poor grounds or connections in electrical box or at engine mount plate Poor connections at primary winding of secondary coil blk blk white on Polaris Fuji engines Faulty ignition coil Faulty exciter coil trigger or pulser coil test stator Excessive crankshaft runout on Magneto end digital CDI only 004 or 10 mm Vibration Pump Damaged ...

Page 62: ...ing water supply through hull etc Was the engine left running when the craft capsized Engine Compression verify within specifications See Engine Section Reeds inspect for damage See Carburetion Section Fuel Tank Venting check fuel tank and vent system for water Crankshaft Indexing verify crankshaft has not been forced out of index See Engine Section Flywheel and Key Inspect flywheel key and keyway...

Page 63: ... 14 Keihin System Operation 3 15 3 17 Fuel Shut Off Disassembly Inspection 3 18 Fuel Water Separator 3 19 3 20 Carburetor Adjustments 3 21 3 22 Carburetor Throttle Body Removal 3 23 3 25 Carburetor Throttle Body Disassembly 3 26 3 32 Carburetor Throttle Body Assembly 3 33 3 35 Carburetor Throttle Body Installation 3 36 3 37 Cable Adjustment 3 38 3 39 Mixture Screw Settings 3 40 3 41 Fuel Tank Vent...

Page 64: ...FUEL SYSTEM CARBURETION Carburetor Specifications and Initial Settings 2000 Virage TX Polaris Sales Inc 3 1 3 00 ...

Page 65: ...175 3050197 180 3050198 185 3050199 190 3050201 195 3050202 200 3050203 Gasoline Safety A WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or...

Page 66: ...2000 SLX PRO 1200 FUEL SYSTEM CARBURETION Vent Fuel Delivery Exploded View Fuel In Fuel Out Polaris Sales Inc 3 3 3 00 ...

Page 67: ...FUEL SYSTEM CARBURETION Vent Fuel Delivery Exploded View 2000 VIRAGE TX GENESIS 3100 3 4 Polaris Sales Inc ...

Page 68: ...2000 Genesis FFI1 FUEL SYSTEM CARBURETION Vent Fuel Delivery Exploded View Fuel Out Top Outlets Fuel In Bottom Inlets Polaris Sales Inc 3 5 3 00 ...

Page 69: ... View 2000 SLX Bolt Torque 18 24 ft l M Apply Loctite 242 Blue Clamp Torque 35 In lbs 4 Nm Tank Wountinig Bolt Torque Apply LoGtite 242 Blue Common Torque Guide Small Clamp Torque 22 in lbs 2 5Nm Large Clamp Torque 35 in lbs 4Nm 3100 3 6 Polaris Sales Inc ...

Page 70: ...View 2000 Pro 1200 Retainer Nut Torque 10 15 ft lbs 14 20 Nm Clamp Torque 35 In lbs 4 Nm Bolt Torque 18 24 ft lbs 2 3Nm Apply Loctite 242 Blue Common Torque Guide Small Clamp Torque 22 in lbs 2 5Nm Large Clamp Torque 35 in lbs 4Nm Polaris Sales Inc 3 7 3 00 ...

Page 71: ...FUEL SYSTEM CARBURETION Fuel Tank Fuel Pickup Exploded View 2000 Virage TX Nm Common Torque Guide Small Clamp Torque 22 in lbs 2 5Nm Large Clamp Torque 35 in lbs 4Nm 3 00 3 8 Polaris Sales Inc ...

Page 72: ...FUEL SYSTEM CARBURETION Fuel Tank Fuel Pickup Exploded View 2000 Genesis Genesis FFI1 Retainer Nut Torque Genesis FFI Only I Polaris Sales Inc 3 9 3 00 ...

Page 73: ...FUEL SYSTEM CARBURETION Air Intake Silencer 2000 SLX Virage TX Pro 1200 Genesis Genesis FFI Lock Washer Flat Washer Element 3100 3 10 Polaris Sales Inc ...

Page 74: ...BURETION Carburetor Assembly Exploded View Keihin Carburetor SLX Virage TX Pro 1200 Genesis Mid Jet Rjiot Jot Fuel Pump Gasket Mid Range Check Valve Synchronizing Screw Idle Mixture Screw 3 Polaris Sales Inc 3 11 3 00 ...

Page 75: ...FUEL SYSTEWl CARBURETION Throttle Body Exploded View Throttle Bodies Genesis FFI Screws Throttle Valve Throttle Shaft Screws 4 4 Bracket Screws TPS Lever 3 00 3 12 Polaris Sales Inc ...

Page 76: ...xploded View 2000 SLX Pro 1200 Common Torque Guide Small Clamp Torque 22 in lbs 2 5Nm Large Clamp Torque 35 in lbs 4Nm Clamp Torque 35 in lbs 4Nm Bolt Torque 35 46 in lbs 4 5 Nm Oil Tank Cradle Pro 1200 Only Polaris Sales Inc 3 13 3 00 ...

Page 77: ...ARBURETION Oil Tank Exploded View 2000 Virage TX Genesis Genesis FFI1 Oil Level Sender Oil Fill Hose Common Torque Guide Small Clamp Torque 22 in lbs 2 5Nm Large Clamp Torque 35 in lbs 4Nm 3100 3 14 Polaris Sales Inc ...

Page 78: ...tor fuel chamber and the engine Changes to pop off pressure are not recommended 3 Idle System At idle and low throttle settings fuel mixture is controlled by the idlejet and idle mixture screw At idle the throttle plate is open only far enough to uncover the idle port The idle mixture screw controls fuel delivery to the idle port on Keihin carbs When the throttle plate is closed fuel metered throu...

Page 79: ...ck Valves Throttle Plate Fuel Pump Diaphragm Mid range Port Transfer Bypass Holes Idle Port Impulse Fuel Inlet from Crankcase Fuel Delivery Effect Diagram Idle Mixture Screw Drain Main Jet Mid range Jet Fuel Inlet Seat Needle Valve Control Arm Atmospheric Vent Control Arm Spring Fuel Chamber Regulator Diaphragm Idle 1 4 1 2 3 4 WOT 3 00 3 16 Polaris Sales Inc ...

Page 80: ...FUEL SYSTEM CARBURETION System Operation Keihin Carburetor Mid Range High Speed Low Speed Polaris Sales Inc 3 17 3 00 ...

Page 81: ... death in a short time Shut off fuel valve if applicable whenever the watercraft is stored parked or transported For models without fuel valve disconnect battery ground terminal Fuel Filter A WARNING Set fuel valve to OFF Gasoline is extremely flammable and explosive under certain conditions Do not smoke or allow flames or sparks in the work area Be sure the work area is well ventilated See gasoli...

Page 82: ...level Empty trap if float appears to be off the bottom NOTE The maximum travel of the float is to the base of the filter or approximately one half the depth of the bowl Visually inspect the bowl for water collected at the bottom of the bowl See illustration If water is present it will ap pear as a clear liquid at the bottom of the bowl Turn off fuel valve Wrap a shop towel around the bowl and re m...

Page 83: ...Maintenance is required only if fuel tank fills up with water submerged or if you are experiencing running problems and suspect water in fuel tank A WARNING Gasoline is extremely flammable and explosive under certain conditions Do not smoke or allow flames or sparks in the work area Be sure the work area is well ventilated See gasoline handling warnings found on page 3 2 Failure to heed these warn...

Page 84: ...e carburetors to prevent debris from entering Do not force the needle into the needle seat If over tight ened needle damage will occur resulting in erratic carbu retor performance In the photo at right a needle shown with limiter cap removed is damaged and must be re placed Refer to carburetor specifications at the begin ning of this section Damaged Mixture Needle Bottom NOTE Water testing the cra...

Page 85: ... temperature and adjusting low speed screws in to lean or out to richen mixture until a smooth idle and good throttle response is obtained IMPORTANT Prior to performing any adjustments to car buretors check the following Verify that no water is present in the fuel system Check the water trap for presence of water Verify all fuel and vent lines are routed and secured properly Verify all seal and ga...

Page 86: ... any reference to certain carb features that do not apply to throttle bod ies e g choke cable Carburetor Throttle Body Removal 1 Turn fuel valve off On Genesis FFI disconnect negative terminal on battery 1 Remove bolts securing air intake silencer assembly 2 Inspect flange seal for damage or distortion 3 Loosen throttle and choke cable carb models only adjuster nuts and remove each cable from the ...

Page 87: ...ove fuel return line carb versions only 7 Remove oil lines from carburetors throttle bodies 8 Loosen clamp and remove fuel pump impulse line carb versions only 9 Remove carburetor throttle body mounting bolts and lift air intake silencer base with bolts 3 00 3 24 Polaris Sales Inc ...

Page 88: ...etor Throttle Body Removal 10 Inspect condition of intake silencer base plate gasket Replace upon reassembly Note the position of the intake base for reassembly 11 Remove carburetor throttle body assembly Polaris Sales Inc 3 25 3 00 ...

Page 89: ...g removal 13 Inspect passage sealing O ring and replace if worn or damaged The flat surface of the O ring faces the pump body away from cover 14 Remove accelerator pump components including spring diaphragm dust boot and O ring 15 Check guide bushing in pump body and replace front carburetor jet block assembly if worn The bushing is not replaceable 3 00 3 26 Polaris Sales Inc ...

Page 90: ...distortion or damage Replace accelerator pump assembly if damaged 18 Clean all passages See carburetor cleaning in this section NOTE Before removing metering diaphragm cover note position of water drain and low speed screw indi cators 19 Remove metering diaphragm cover and check to make sure the atmospheric vent is clear Polaris Sales Inc 3 27 3 00 ...

Page 91: ...tic button 2 should be 060 1 5 mm below casting surface 1 as per illustration at right Variances in control arm positioning will result in incorrect fuel supply If the control arm is too close to the diaphragm fuel levels will increase resulting in a rich operating condition If the control arm is too far below the casting parallel line a lean condition will re sult 22 Loosen screw and remove contr...

Page 92: ...jet block if seat is damaged Inspect control arm return spring Replace if corroded damaged or distorted 25 Remove screw and carefully lift jet block from carb body Carefully remove jet block from carb body 26 Inspect needle seat O rings for damage Replace O rings upon reassembly Clean screen of debris or replace if torn or damaged Good Condition Worn Deposits Polaris Sales Inc 3 29 3 00 ...

Page 93: ... of the jet Be sure jet is thoroughly cleaned or replace if corroded or questionable 28 Note position of limiter caps low speed mixture screws Carefully remove the caps pull off Turn each mixture screw in clockwise while counting the exact number of turns until lightly seated Record the number for future reference Carefully inspect the tip of each needle for wear or damage Replace if necessary Do ...

Page 94: ...s port cover 31 Remove mid range jet anti siphon valve cover plate and inspect the valve where applicable The valve must lay flat against the plate to seal properly Replace if distorted or bent Replace gasket if torn or damaged 32 Note location of idle discharge port Polaris Sales Inc 3 31 3 00 ...

Page 95: ...rep arable damage will occur Do not use agitator type car buretor cleaning equipment Rubber parts must be cleaned with mild detergent and hot water only 2 If the carburetor is extremely dirty or contaminated with fuel residue and varnish soak for short periods only in carburetor cleaner and rinse in hot water 3 Replace the jets if they are extremely dirty or have a buildup of fuel residue corrosio...

Page 96: ...tment Use Loctite 242 to prevent corrosion of car buretor mounting bolts and diaphragm cover Manually synchronize carburetors see pro cedure this section 1 Install O ring and anti siphon valves with plates FUEL SYSTEM CARBURETION Carburetor Assembly 2 Install bypass port cover 3 Install screen and new O rings on inlet needle seat Lubricate O rings with Polaris Premium 2 Cycle Lubricant Polaris Pre...

Page 97: ...e and verify throttle plates are just below first bypass hole not on or above Adjust accordingly with idle stop screw Bypass Ports Idle Port Correct Incorrect Bypass Ports Idle Port NOTE These are initial settings from which additional fine tuning may be necessary Do not force screw past lightly seated or screw and or seat will be damaged Operation of the craft with mixture screws improperly adjus...

Page 98: ...ly Loctite 242 Blue to screws and install diaphragm cover with drain hole facing downward toward throttle plate 12 Install diaphragm and dust boot Install O ring with flat side facing the pump body away from cover 13 Install spring and cover Tighten screws securely 14 Grease all exposed shafts and springs with Polaris Premium All Season Grease 15 Synchronize carburetors See page 3 34 Polaris Sales...

Page 99: ... carburetors throttle bodies in place 3 Install intake silencer base with new gaskets The silencer bolt flange must be positioned as shown towards the engine 4 Apply Loctite 242 Blue to mounting bolts Install bolts aligning all gaskets Torque to specifications Carb Mounting Bolt Torque Apply Loctite 242 Blue 108 in lbs 12 5 Nm 3 00 3 36 Polaris Sales Inc ...

Page 100: ...ARBURETION Carburetor Throttle Body Installation Fuel return line carb models only 6 Tighten clamps to specified torque Fuel Line Clamp Torque 10in lbs 1 4Nm 7 Install and adjust throttle cable choke cable carb models only and oil pump cable Polaris Sales Inc 3 37 3 00 ...

Page 101: ...2 17 See idle speed 2 Measure throttle lever freeplay between the lever block and lever as shown in III 1 3 To adjust loosen lock on cable Turn adjuster in clockwise to increase or out counterclockwise to decrease free play Tighten lock when adjustment is complete Choke Cable SLX PRO 1200 Choke cable adjustments are made by turning the cable lock nuts at the carburetor The choke knob should just t...

Page 102: ...fore performing oil pump adjustment 1 Inspect mark on oil pump lever and index mark on oil pump body The marks should align with throttle released idle speed 2 If marks are not aligned loosen cable adjuster nuts and adjust until marks are aligned 3 Tighten nuts securely and recheck adjustment Polaris Sales Inc 3 39 3 00 ...

Page 103: ...ow only slight adjustment of the screws in each direction to compensate for changes in altitude and temperature The base settings should not be changed If large adjustments are necessary for prop er mixture the carburetors fuel system and engine should be inspected to find the cause of a rich or lean condi tion See Lean Condition Troubleshooting in Maintenance section If the carburetor has been ta...

Page 104: ... 2 With craft in the water or test tank adjust idle speed to specifications see procedure this section 3 Start engine let it idle for one minute to normalize engine temperature Rev engine slightly for 10 20 seconds and return to idle 4 Turn each mixture screw to obtain highest idle RPM 5 Turn each screw out approximately 1 4 turn from this point Fine tune to achieve best throttle response Polaris ...

Page 105: ...ly pressure to the other end of the valve it should allow air to go through easily with no pressure build up Replace the check valve if found to be faulty Relief Valve Testing Apply air pressure with a Mity Vac to relief valve With air pressure applied in the direction of the ar row the valve should pop between 1 0 and 1 5 PSI In the opposite direction it should hold pres sure Fuel Tank Check Valv...

Page 106: ...check valve to close so fuel cannot return from the carburetor See III 1 When the piston is on its downstroke the pressure from the crankcase becomes positive causing the diaphragm to move in the opposite direction reversing the pressure in the pump chamber This causes the inlet check valve to close and the outlet valve to open delivering pressurized fuel to the carburetor fuel chambers see III 2 ...

Page 107: ...eparator or in the engine Impulse Diaphragm Inspection Loosen clamp and remove impulse line from pump fitting Apply 5 PSI pressure to impulse line fitting The dia phragm should hold pressure indefinitely Remove and inspect the pump diaphragms if the impulse chamber does not hold pressure Disassembly Inspection 1 Remove fuel pump body screws 4 and carefully lift assembly from carburetor 2 Remove ga...

Page 108: ...aks 5 Remove reed stuffers reed gaskets reed assembly and lower reed gaskets Reed Valve Inspection 1 Thoroughly inspect condition of reed valve stuffers reed valves and gaskets Replace if necessary 2 Reed valves are sometimes held open by carbon or other small particles Remove screws from reed stop Remove the reed making sure not to flip the reed if it is to be re used Reverse positioning of a ree...

Page 109: ...th 10 14 PSI The line should hold this pressure for five minutes If pressure will not hold check hose clamps and fuel shut off valve 2 To verify if the shut off valve is leaking bypass the valve If it maintains pressure the valve is faulty and should be repaired or replaced This test should be done on both main fuel line and reserve line switching the shut off valve accordingly 3 To check for air ...

Page 110: ...p outlet nozzle as the throttle is opened The pump reservoir must be full of fuel before performing this test After operating the accelerator pump two or three times the reservoir will be empty and fuel will no longer spray from the nozzle until the engine is started Some causes of improper pump operation are No fuel entering chamber Worn pump cam Diaphragm damaged or swollen Check valve in nozzle...

Page 111: ...nd Assembly Diagrams 4 5 4 12 Engine Removal 4 13 4 14 Engine Disassembly 4 15 4 24 Engine Assembly 4 25 4 40 Oil Pump Assembly 4 41 Engine Installation 4 42 Cylinder Honing 4 43 4 44 Cooling System Flow Charts 4 45 4 47 Thermostat Coolant Filter 4 48 4 49 Crankshaft Indexing 4 50 4 53 Crankshaft Truing 4 54 ...

Page 112: ...ENGINE Service Data Engine Specifications 2000 SLX Virage TX Pro 1200 Piston Identification 2241 Polaris Sales Inc 4 1 3 00 ...

Page 113: ...ing of grease Size 1 4 to 7 8 micro hose clamps torque to 22 in lbs Size 1 and larger hose clamps torque to 35 in lbs Do not install fasteners dry Always clean fasteners before reusing Cure time of locking agent is reduced when Loctite Primer N or Primer T is used to clean and prime fastener threads To convert in lbs to ft lbs divide by 12 To convert ft lbs to Nm multiply foot pounds by 1 356 To c...

Page 114: ...orque Patterns Polaris Domestic Engine Cylinder Head Cover SLX Virage TX Pro 1200 Genesis 22 ft lbs 30 Nm 0 0 Cylinder Head All 20 ft lbs 27 6 Nm 0 0 Intake Manifold 72 in lbs 8 3 Nm Polaris Sales Inc 4 3 3 00 ...

Page 115: ...kcase Bolts Bottom View 3 Cylinder 8mm 22 ft lbs 30 4 Nm 6 bolts 10mm 28 ft lbs 38 6 Nm 2 bolts PTO End PTO End Cylinder Base Nuts Top View 3 Cylinder 35 40 ft lbs 48 3 55 2 Nm Mag End Exhaust Manifold 3 Cylinder 26 ft lbs 35 96 Nm o 3 00 4 4 Polaris Sales Inc ...

Page 116: ...enesis FFI Ground must be clean and Apply Loctite 242 Blue Torque to 45 ft lbs 62 Nm Torque all to 50 ft lbs 69 Nm Apply Loctite 262 red Engine Mount To Hull 14 ft lbs 19 Nm Apply Loctite 242 Engine Alignment Shims Note number and location for reas sembly Always check engine to pump align ment after engine installation Polaris Sales Inc 4 5 3 00 ...

Page 117: ...Outlet Manifold 22 ft lbs 30 4 Nm 20 ft lbs 27 6 Nm Cylinder Head Cover Note alignment of head prior to disassembly and reassemble the same way it was removed Heads are one piece on Genesis FFI 35 40 ft lbs 48 55 Nm Cylinder Stuffer Reed Valve Assembly Gasket 108 in lbs 12 4 Nm 3 00 4 6 Polaris Sales Inc ...

Page 118: ...esis FFI1 ENGINE Crankshaft Piston Piston Rings f 1 Collar Piston Pin Circlip Connecting Rod Small End Bearing Connecting Rod Bearing Crank Pin Thrust Washer Snap Ring B Plated Spacer Snap Ring A Snap Ring A Spacer Polaris Sales Inc 4 7 3 00 ...

Page 119: ...enesis FFI1 Upper Crankcase Impulse Fitting Apply Loctite PST Thread Sealant Flywheel Cover Starter Housing 10mm 28 ft lbs 38 6 Nm Gasket Use only 3 Bond 1215 to seal crankcase and cover Lower Crankcase 8mm 22 ft lbs 30 4 Nm 3 00 4 8 Polaris Sales Inc ...

Page 120: ...200 Bolt Torque 14 ft lbs 19 Nm Bolt Torque 6 fl lbs 8 Nm Bolt Torque 8 ft lbs ENGINE Exhaust System Bolt Torque 44 ft lbs 60 Nm Bolt Torque 14 ft lbs 19 Nm Hoseclamp Torque 35 in lbs 4 Nm Polaris Sales Inc 4 9 3100 ...

Page 121: ...GINE Exhaust System 2000 Virage TX Bolt Torque 44 ft lbs 60 Nm Bolt Torque 14 ft lbs 19 Nm Bolt Torque 8 ft lbs 11 Nm Hoseclamp Torque 35 in lbs 4 Nm Bolt Torque 6 ft lbs 8 Nm 3100 4 10 Polaris Sales Inc ...

Page 122: ...FFI Spacer PN 5131945 Flat Washer PN 7555841 Lock Washer PN 7552608 Bolt PN 751691 Grommets PN 5411547 Exhaust Pipe Hoseclamp Torque 35 in lbs 4 Nm 18ft lbs 25Nm Clamp Torque 90 in lbs 10 Nm Bolt Torque 6 ft lbs 8 Nm Polaris Sales Inc 4 11 3 00 ...

Page 123: ...y Exploded View 1200 Marine Engines Oil Pump Cable EClip Lever Arm Note Replace O Ring every time oil pump is removed and it must be positioned properly to prevent water from entering flywheel area 3 00 4 12 Polaris Sales Inc ...

Page 124: ... remove temperature sender wire from terminal board Move electrical box out of the way to complete battery ground cable removal On Genesis FFI remove wires from EMM and electrical box 7 Disconnect battery ground cable from rear of engine crankcase 8 Loosen clamp and remove hose from water outlet manifold 9 Remove exhaust pipe and exhaust silencer 10 Remove exhaust manifold 11 Remove cable from sta...

Page 125: ...d coupler Use wrench on flats to remove coupler Use a wrench on the flats of the coupler to remove Do not use coupler removal tool PN 2871037 on the rubber damgfned coupler or misalignment may oc cur 19 Remove engine mount nuts 4 With the aid of a chain hoist lift engine upward and out of hull Engine alignment shim s may be in place on one or more of the engine rubber mount studs Note the number a...

Page 126: ...Remove reed blocks and stuffers Measure air gap between fiber reed and reed block as shown The air gap should not exceed 015 4 mm If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap Always replace them ifdamaged Check each fiber reed for white stress marks or missing material Replace if necessary Reed Air Gap Maximum 5 4mm Reed Pedal Clearance 015 38 mm max Exaggera...

Page 127: ...O ring condition and Remove flywheel cover bolts tap cover lightly with a soft faced hammer and remove cover and gasket Inspect starter drive bushing in cover for wear or damage Measure inside diameter and replace if worn beyond service limit Measure starter drive shaft O D calculate clearance and compare to specifications iStarter Drive Bushing Clearance Service Limit 1 0 10 w f 3 00 4 16 Polaris...

Page 128: ...lt Do not tighten the flywheel puller against the magnet holder screws or damage to the screws or magnet holder may result 10 Remove starter drive A thrust washer is located on each end Inspect gear teeth for wear cracks or damage Hold drive body and rotate drive gear to check operation of drive assembly The drive gear must slide smoothly outward without binding Inspect bushing in starter housing ...

Page 129: ...htly to break seal 14 Inspect condition of crankshaft seal in housing Always replace seal when rebuilding engine See Engine Assembly for seal replacement procedure 15 Remove water outlet manifold Clean and inspect gasket surfaces Note location of water outlet manifold and orientation of cylinder heads cylinder head covers 3 00 4 18 Polaris Sales Inc ...

Page 130: ...their respective cylinders 18 Remove cylinder heads cylinder head covers and inspect sealing surface Clean and inspect groove in cylinder for damage or debris Replace all O rings upon reassembly Mark cylinder heads so they can be re installed on their respective cylinders 19 Check each cylinder head for warping as shown Replace cylinder head if warp exceeds service limit Cylinder Head Warp Service...

Page 131: ...sure bore 1 2 down from top of cylinder in two directions in line with piston pin and 90p to the pin to determine if bore is out of round Repeat measurements at bottom of cylinder to determine taper or out of round at the bottom Record all measurements NOTE If cylinders are worn or damaged refer to page 4 43 4 44 for boring honing and port chamfer informa tion 22 Remove piston circlips carefully u...

Page 132: ...nd inspect inner bore with a magnifying glass Look for any surface irregularities including pitting wear or dents 2 Run your fingernail around the inside of the rod and check for rough spots galling or wear 3 Oil and install needle bearing and pin in connecting rod Rotate pin slowly and check for rough spots or any resistance to movement Slide pin back and forth through bearing while rotating and ...

Page 133: ... clearance exceeds the service limit determine if piston or cylinder is worn and recondition or replace as necessary nder Clearance 4 Position each piston ring 1 2 1 3 cm from the top of the cylinder using the piston to push it squarely into place Measure installed gap with a feeler gauge at both the top and bottom of the cylinder NOTE A difference in end gap indicates cylinder taper The cylinder ...

Page 134: ...bolt has dielectric grease applied Note position of this bolt and orientation of mounts for reassembly Loosen and remove crankcase bolts following the order shown at right Tap crankcase on reinforced areas to separate top from bottom Remove bottom half of crankcase Remove crankshaft from bottom half of crankcase Remove seal collar and O ring Inspect sealing surface on collar and crankshaft Remove ...

Page 135: ...nce Standard 01 020 3 6 51mm Service Limit 022 56mm Connecting Rod Big End Radial Clearance 1 Rotate rod on crankshaft and check for rough spots Check radial end play in rod by securing crankshaft in a holding fixture Set up a dial indicator as shown in illustration at right Support connecting rod against one thrust washer and apply up and down pressure on connecting rod Read total movement of ind...

Page 136: ...if sealer dries causing premature engine wear Be sure to follow the Crankcase Assembly procedure below when assembling crankcases 1 Clean crankshaft and lubricate with Polaris Premium 2 Cycle Oil 2 If new outer main bearings are being installed heat new bearings on a hot plate Wear protective gloves to avoid burns when installing bearings 3 Install inner bearing on PTO end Install spacer and outer...

Page 137: ... 4 Install inner Mag end bearing spacer and outer bearing 5 Clean crankcase halves thoroughly rinse and dry completely Be sure all old sealer is removed from surface 6 Install crankshaft in upper crankcase 3 00 4 26 Polaris Sales Inc ...

Page 138: ... seal with lip and spring facing inward toward crankshaft 9 Apply a light film of grease and install O ring and seal collar being careful not to dislodge spring on seal during installation of collar i Slt r 10 Install seal retaining circlip with end gap facing upward The seal retainer circlip is plated to resist corrosion Polaris Sales Inc 4 27 3 00 ...

Page 139: ...se half on upper half aligning circlips and seals Press into place 14 Apply Loctite 242 blue to crankcase bolts install and tighten to specifications following torque pattern shown in illustration at right 15 Turn engine upright 16 Install front and rear engine mounts The two reinforcing ribs on each mount are positioned to the rear PTO end of engine Torque to specification Front Mag end has a rel...

Page 140: ...mium 2 Cycle engine oil and rotate crankshaft to distribute oil evenly 18 Install one C clip in piston with gap facing up or down Be sure clip is fully seated in groove 19 Lubricate and install piston rings on piston Letter marked on end of ring faces upward Polaris Sales Inc 4 29 3 00 ...

Page 141: ...t 21 Lubricate and install new connecting rod small end bearing in rod 22 Install piston with arrow facing exhaust ring locating pins should be facing intake 23 Install piston pin and remaining C clip with gap up or down Be sure both clips are fully seated on the groove 3100 4 30 Polaris Sales Inc ...

Page 142: ...entle front to rear rocking motion Install cylinder base nuts loosely Do not tighten them at this time Repeat Steps 18 26 for other cylinder s Do not twist or force cylinder during installation IMPORTANT To prevent possible water leaks at ex haust manifold the cylinders must be aligned be fore the base nuts are tightened 27 Temporarily install exhaust manifold to cylinders without gasket and tight...

Page 143: ...linder head O rings and install in groove Be sure O ring is properly positioned and groove is clean and free from debris 32 Install cylinder heads carefully Torque bolts evenly in three steps to specification NOTE Cylinder heads must be positioned correctly with the wide opening toward the intake and the small opening marked ex toward the exhaust On Genesis FFI en gine water manifold orientation i...

Page 144: ...enesis Be sure O rings are properly positioned and grooves in cover are clean and free from debris 35 Install covers with water manifold outlets on exhaust side SLX Pro 1200 Virage TX Genesis Do not tighten the bolts at this time 36 Temporarily install water outlet manifold and bolts to ensure proper alignment of covers SLX Pro 1200 Virage TX Genesis 37 Remove exhaust manifold apply Ultra Copper s...

Page 145: ...eps to specification Carb models ih Cylinder Head Cover Carb models 41 Install water outlet manifold with new gaskets and torque bolts evenly in a criss cross pattern to specification NOTE If flush plug was removed apply Loctite pipe sealant to threads and torque to 18 ft lbs 24 9 Nm Water Outlet Manifold Bolt Torque 108 in lbs 12 4Nm 3 00 4 34 Polaris Sales Inc ...

Page 146: ...e seal lip and spring face inward toward crankshaft 44 Apply grease to lip of seal and a light film on crankshaft 45 Before installing cover apply a thin film of 3 Bond 1215 to sealing surface and remove any hardened sealer from crankcase parting line 3 Bond 1215 PN2871S5 iiAie 46 Install starter housing cover Torque all bolts 4 to specification Starter Housing Cover Torque 22 ft lbs 30 4 Mm Polar...

Page 147: ...Screw Torque 60 in lbs 6 9 Nm Loctite 242 48 Push grommet into place in starter housing Remove housing bolt FFI and install grommet clamp install and torque bolts Be sure wire harness is positioned properly to clear the flywheel ring gear Grommet Clamp Bolt Torque 108in Ibs j2 JJfifj x Housing Bolt Torque 22 ft lbs 30 4 Nm 49 Install new washers on ends of starter drive 3 00 4 36 Polaris Sales Inc...

Page 148: ...s of the crankshaft 52 Install flywheel using puller bolts to hold flywheel Failure to do so may result in personal injury Install washer and nut Torque to specification NOTE Always check the condition and tightness of the two timing screws on the flywheel Carbu reted Models Flywheel Nut Torque 90 ft lbs 124 4 Nm Flywheel Holder Tool PN Carb models 229 53 Check for proper clearance between stator ...

Page 149: ...f specification replace 55 Install oil pump drive coupler 56 Grease and install spring and plastic bushing into flywheel cover 57 Install a new gasket on flywheel cover and water jacket cover Tighten bolts in a criss cross pattern 58 Grease O ring and install starter motor Torque mounting bolts to specification 3 00 4 38 Polaris Sales Inc ...

Page 150: ...e steps to specification following torque pattern found on page 4 3 108 hjbs 1X4 Nm 62 Install new carburetor throttle body flange gaskets on manifold Install carburetors throttle bodies gaskets and air intake mounting plate Wire choke plate closed or cover opening in manifold to prevent debris from entering Torque carburetor throttle body bolts to specification Polaris Sales Inc 4 39 3 00 ...

Page 151: ... the bolts and torque evenly to specifications Oil Pump Bolt Torque 60 in lbs 6 9 Nm 65 Install oil pump cable and connect oil lines to oil pump and carburetors throttle bodies Adjust as outlined on pages 2 18 2 22 66 Bleed oil pump and oil lines to ensure no air is trapped in pump or lines see page 4 41 67 Apply a light film of grease to crankshaft threads and install drive coupler Tighten hand t...

Page 152: ...r than 1 2 1 3 cm in length are present fill oil supply lines with oil using a small oil squirt can Troubleshooting NOTE See Maintenance section for adjustment in spection information 75 Remove lines from their fittings at the engine and pump Blow through them to ensure they are not plugged or restricted 76 Apply some pressure to the check valve fittings with the Mity Vac or similar tool These val...

Page 153: ... and wiring are routed and secured properly Adjust throttle cable and check throttle operation It must operate freely and return completely when released Verify proper operation of engine stop switch After engine installation pump alignment must be inspected Refer to the Final Drive section for inspection and alignment procedures Synchronize carburetors and be sure they are clean Adjust oil pump c...

Page 154: ...nnen Products Company of St Louis Missouri and Ammco Tools Inc of North Chicago Illinois De glazing If cylinder wear or damage is minimal hone the cylin der lightly with finish stones 1200 Engine Cylinder Honing On Polaris 1200 engines it is important to bolt exhaust manifold to cylinder to be honed and torqued to specifi cation before honing Honing To Oversize If cylinder wear or damage is excess...

Page 155: ...d file or a 3 sided de burring knife Hold the cylinder securely by installing bolts in the exhaust mounting holes and clamping in a soft jaw vise The corners top and bottom edges of ports should receive a standard chamfer 3 6mm with the widest portion at the center of the port window The sides of the ports require only de burring 05 3mm Refer to illustration below Chamfer Angle Port Standard Chamf...

Page 156: ...SLX VirageTX Pro 1200 ENGINE Cooling System Flow Chart Polaris Sales Inc 4 45 3100 ...

Page 157: ...ENGINE Cooling System Flow Chart Genesis 3100 4 46 Polaris Sales Inc ...

Page 158: ...Genesis FFI1 ENGINE Cooling System Flow Chart y OUT Polaris Sales Inc 4 47 3 00 ...

Page 159: ...from an internal spring When the screws are removed the assembly will come apart quickly if not held together firmly 1 Remove screws while holding thermostat pop off assembly firmly together Carefully take assembly apart Be careful not to lose any parts 2 Check thermostat pop off assembly for debris such as seaweed and clean it out 3 Check condition of rubber elements Also check thermostat and hou...

Page 160: ...ing Procedure 1 Loosen clamp and remove hose from fitting 2 Using a deep well 9 16 socket or flare nut wrench remove fitting from exhaust manifold 3 Inspect fitting for plugging Flush with water to clean 4 Reinstall fitting into exhaust manifold Tighten securely 5 Reinstall bleed hose and clamp Tighten securely Orifice Size Pro 1200 SLX Virage TX 070 1 8mm Fitting Exhaust Pipe Orifice Exhaust Pipe...

Page 161: ...nted concentrically with the crankshaft center line Cut a slot in a paper or cardboard degree wheel and slide it over the driveshaft if engine and pump shaft is installed in craft Again be sure to secure the degree wheel 2 Sharpen a coat hanger or section of welding rod and anchor it to a convenient spot Point the sharpened end at the outer perimeter of the flywheel or drive coupler mounted degree...

Page 162: ...piston hol ing Excessive vibration of engine backfiring etc Rough idle poor top speed Dial Caliper Crankshaft Indexing Be sure to keep the dial caliper vertical and in the center of the plug hole for greatest accuracy Disconnect battery ground cable and all spark plug high tension leads Ground high tension leads to engine Disconnect lanyard from engine stop switch before proceeding with the follow...

Page 163: ...d make sure it is mounted concentrically with the crankshaft center line Cut a slot in a paper or cardboard degree wheel and slide it over the driveshaft if engine and pump shaft is installed in craft Again be sure to secure the degree wheel 2 Sharpen a coat hanger or section of welding rod and anchor it to a convenient spot Point the sharpened end at the outer perimeter of the flywheel or drive c...

Page 164: ...ag end cylinder simply read the wheel and dial indicator 9 Install the bumpertool in cylinder 2 center Repeat steps 4 through 6 for cylinder 2 It should be 120 2 from cylinder 1 Proceed to PTO cylinder 3 Cylinder 3 should also be 120 2 from cylinder 1 Symptoms of an out of index crankshaft can include Difficulty calibrating carburetor repetitive plug fouling on one cylinder with no other cause Une...

Page 165: ...traighten the shaft 10 To correct a situation like the one shown in the illustration at right strike the shaft at point A with a brass hammer NOTE The rod pin position in relation to the dial indi cator position tells you what action is required to straighten the shaft 11 To correct a situation like the one shown in the illustration at right squeeze the crankshaft at point A Use tool from alignmen...

Page 166: ...rams 5 6 Pump Intake Diagrams 5 7 5 8 Reverse Systems 5 9 Intake Scoop Ride Plate Installation 5 10 Pump Removal 5 11 5 12 Pump Disassembly 5 13 5 16 Pump Assembly 5 17 Pump Installation 5 18 5 20 Pump Housing Removal 5 21 Pump Housing installation 5 22 Pump Drive Shaft Alignment 5 23 5 26 Pump Lubrication 5 27 5 28 Sacrificial Anode 5 29 Ventilation Cavitation Diagnostics 5 30 ...

Page 167: ...read locking agent red Note 271 is an acceptable substitute 242 indicates use of Loctite 242 thread locking agent blue Note 243 is an acceptable substitute AS indicates use of a light coating of grease or Anti Seize compound Do not install fasteners dry Always clean fasteners before installing Polaris Sales Inc 5 1 3 00 ...

Page 168: ...00 Pump Data Part number is located on impeller Impeller Torque All 100 ft lbs 138 3 Nm Apply grease to threads Use of impellers other than those listed above may result in engine failure Use only the impeller recommended 3 00 5 2 Polaris Sales Inc ...

Page 169: ...end play fwd rear should be 100 200 2 5 5 mm with new bumpers Install O Ring Lubricate every 25 hrs Virage TX Only One Clamp or monthly 15 hrs in salt water use Virage TX NOTE Drive shaft runout service limit 005 13mm Inspection information found on page 5 13 Install O ring on shaft grease and install into pump impeller Hose Clamp Torque 35in lbs 4 Nm Polaris Sales Inc 5 3 3 00 ...

Page 170: ...lin Surface For Wea Lubrication Fitting Grease Use only Polaris All Season Grease whenever grease is recommended Hose Clamp Torque 35in lbs 4 Nm NOTE Drive shaft runout service limit 005 13mm Inspection information found on page 5 13 NOTE Drive shaft end play fwd rear should be 100 200 2 5 5mm with new bumpers 3 00 5 4 Polaris Sales Inc ...

Page 171: ... O Ring Coupler Shroud Assembly Lubricate every 25 hrs or monthly 15 hrs in salt water use Install O ring on shaft grease and install into pump impeller Hose Clamp Torque 35in lbs 4 Nm NOTE Drive shaft runout service limit 005 13mm Inspection information found on page 5 13 NOTE Drive shaft end play fwd rear should be 100 200 2 5 5 mm with new bumpers Polaris Sales Inc 5 5 3 00 ...

Page 172: ...ly Anti seize Torque 30 ft lbs 41 5 Nm Install Seals With Lip Spring Toward Impeller 4 Pump Extension SLX VirageTX Pro 1200 Anode Pump must be flush against hull to prevent any possible leakage or cavitation Apply liberal amount of grease to the large mounting O ring Apply Marine Grade Silicone Sealant to pump housing and o ring PN 8560054 Note A Orifice size in water supply pipes are different de...

Page 173: ...lation IMPORTANT Apply continuous 1 2 1 3 cm bead of Marine Grade Silicone Sealant between hull scoop edges Clean excess silicone after installation NOTE If inlet scoop is damaged or bent during removal replace with a new scoop Ride Plate Torque to 8 ft lbs 11 Nm Apply Loctite 242 Blue IMPORTANT Apply continuous bead of Ma rine Grade Silicone Sealant to ride plate sealing area NOTE Cavitation may ...

Page 174: ...nstallation IMPORTANT Apply continuous 1 2 1 3 cm bead of Marine Grade Silicone Sealant between hull scoop edges Clean excess silicone after installation NOTE If inlet scoop is damaged or bent dur ing removal replace with a new scoop Torque to 8 ft lbs T1 Nm Apply Loctite 242 Blue IMPORTANT Apply continuous bead of Marine Grade Silicone Sealant to ride plate sealing area NOTE Ca vitation may resul...

Page 175: ...Pinion Cam Shaft Reverse Handle Reverse Plate Rear Bracket Reverse Lock Reverse Cable Reverse Arm Virage TX Genesis Genesis FFI Reverse Gate Assembly 14ft lbs 19 4Nm 14ft lbs 19 4Nm Polaris Electronic Reverse Control PERC Genesis Genesis FFI See chapter seven for PERC troubleshooting procedures Polaris Sales Inc 5 9 3 00 ...

Page 176: ...intake scoop has been removed clean a old sealant from hull mounting area Apply a 1 2 1 3 cm or larger continuous bead of marine grade silicone sealant to the area shown Be sure to apply sealant between hull and inlet scoop shown by arrows 2 Install intake scoop carefully push into place 3 Set ride plate in place and secure it with attaching screws Wipe off any excess sealant inside scoop area so ...

Page 177: ... and ride plate installed However if pump cavitation is suspected the intake grate ride plate and inlet scoop should be removed and re sealed Impeller Clearance 1 Remove lanyard cord and lock plate from engine stop switch Remove seat and battery hold down straps Move electrical box aside Disconnect battery ground cable Remove drive shaft coupler guard See III 1 and 2 Front of Watercraft Pro 1200 S...

Page 178: ...ge siphon hoses from extension housing NOTE On models equipped with an electric bilge pump the number of siphon hoses will vary 3 Loosen 4 5 16 mounting bolts Remove extension housing and wedge where applicable 4 Hold water inlet tube toward main pump body at the hull so as not to dislodge the O ring seal while removing extension housing 3 00 5 12 Polaris Sales Inc ...

Page 179: ...emove driveshaft from impeller by pulling straight outward NOTE If the pump housing intake scoop or ride plate must be removed refer to page 5 21 Drive Shaft Inspection 1 Clean driveshaft and support in V blocks as shown C Measure runout by rotating shaft and observing dial indicator at point B Replace if runout exceeds the service limit NOTE Excessive driveshaft runout can cause vibra tion bearin...

Page 180: ...nes are worn or damaged improper pump to hull or pump to engine alignment should be suspected Refer to Pump Drive shaft Alignment on page 5 24 for more informa tion Drive Shaft End Play 3 Inspect bolts and pivot bushings steering nozzle trim nozzle and reverse gate linkage for wear cracks or damage Replace worn parts Remove these components as necessary for further pump disassembly Reverse gates m...

Page 181: ...removal tool and turn counterclockwise to remove The tool can be identified by 3 knurled sections on shaft diameter is 852 Inspect impeller and stator vanes for cracks wear or damage and replace if necessary Impeller Removal Tool PN 2871036 Impeller Removal Tool has 3 knurled sections Impeller Tool Diameter 852 21 65mm Coupler Tool Has 2 Knurled Sections Coupler Tool Diameter 787 20 mm 8 Remove as...

Page 182: ...cone O ring before applying heat 10 Using a brass or aluminum drift tap bearing spacer to one side enough to expose inner bearing races Drive out tail cone end bearing and remove spacer Drive other bearing out removing seals with bearing See page 5 17 for bearing and seal installation procedure 11 Measure spacer length with a Vernier caliper Replace if worn beyond service limit If the spacer is to...

Page 183: ...er spacer and press remaining bearing into opposite end of housing Remove stub shaft 3 Apply marine grease to seal lips and also between the two seals Install two new oil seals as shown with both springs and lips up and visible toward impeller Press seals to bottom of chamfer on seal bore about 1 87 32 cm beyond end of bore NOTE Check pump alignment before installing stub shaft and impeller See pa...

Page 184: ...n driveshaft is past seals 2 Liberally grease a new driveshaft O ring and splines of shaft Install shaft in impeller 3 4 Install pump extension where applicable pump housing and impeller and driveshaft assembly while lining up splines in drive coupler If splines are not aligned turn stub shaft with a wrench slowly while pushing inward on pump Push assembly completely into place on pump housing whi...

Page 185: ...y Loctite 242 Blue to the four 5 16 mounting bolts and torque to specification NOTE Install wedge between stationary housing and stator housing where applicable Thick edge is posi tioned toward bottom and corner tabs must align Stator Section Mounting Bolt Torque Apply Loctite 242 Blue 18 ft lbs 24 9 Nm 7 Install bilge siphon lines and secure with new cable ties Tighten securely Polaris Sales Inc ...

Page 186: ...e Boll fmmlb 9 Install reverse mechanism if applicable Apply Loctite 242 Blue and torque to specifications Inspect reverse cable adjustment See Maintenance section Reverse gates may differ Reverse Gate Actuator Pivot Bolt TQrque Reverse Gate Pivot Bolt Torque 10 Thoroughly grease bearing housing and coupler 3 00 5 20 Polaris Sales Inc ...

Page 187: ...mp Cooling Water Supply Line View From Inside Hull Bilge Siphon Line 3 Remove pump housing nuts and washers 4 evenly in a criss cross pattern Pull the pump housing straight out to remove Intake Scoop Ride Plate Installation and Sealing IMPORTANT The area around the intake scoop and ride plate must be completely sealed in order to prevent ventilation of the pump area See Ventilation Cavitation page...

Page 188: ...alant to O rings on bilge siphon and cooling water supply fittings 2 Apply anti seize to threads of pump mounting studs 3 Install pump housing and hold inward against hull Apply Marine Grade Silicone Sealant PN 8560054 4 Torque pump housing nuts in three steps to 20 ft lbs 27 7 Nm using a criss cross pattern Do not use air tools Do not over tighten mounting nuts or hull damage may occur Marine Gra...

Page 189: ...e Pump Alignment Inspection Procedure 1 Disconnect lanyard cord lock plate from engine stop switch Remove battery negative cable 2 Remove driveshaft pump assembly See pump removal this section 3 Remove bearing housing from through hull fitting 4 Remove tail cone 5 Remove impeller and stub shaft from pump housing Inspect bearings for wear or damage and replace if necessary See Pump Disassembly Insp...

Page 190: ...ump mounting area such as loose mounting fasteners improperly installed pump mounting studs hull damage etc 2 To raise coupler Add shim s to the rear mounts or remove shim s from front To lower coupler Remove shim s from rear mounts or add shim s to front The number of shims installed in production is written next to each mount in permanent marker on late models Bearing Carrier Front of Watercraft...

Page 191: ...roblem is measuring the gap between the hull and pump housing with a feeler gauge The gap should not exceed 010 25mm Pump to hull misalignment can be caused by Improperly installed intake scoop check ride plate it should be flush with bottom of hull Hull damaged in pump mounting area Damage to hull may result if pump mounts are over tightened often due to the use of air tools or if studs are impro...

Page 192: ...e an assistant tightens stud mounting nuts inside hull Torque evenly in three steps to 28 ft lbs 38 7 Nm Apply Sealant Tighten 28 ft lbs 38 7 Nm 5 Torque pump mounting nuts outside of hull evenly in three steps to 28 ft lbs 38 7 Nm using a criss cross pattern 6 Check to be sure pump housing is tight against hull To inspect pump to hull fit measure the gap between the hull and pump housing with a f...

Page 193: ...instructions below in order to avoid personal injury Driveshaft Coupler Bearing Housing Lubrication 1 Remove lanyard cord and lock plate from the engine stop switch 2 Remove seat Remove battery ground cable 3 Loosen clamp holding plastic driveshaft shroud in place and rotate it 180 See III 1 4 Solid Couplers turn driveshaft coupler until grease fitting is accessible Bonded rubber couplers drive sh...

Page 194: ...clamps securing housing assembly to through hull fitting 2 Inspect bushings and seals in bearing housing assembly for wear or damage that may allow water to leak into hull The housing cannot be rebuilt Replace as an assembly if wear is evident 3 Check sealing and bearing surface on driveshaft for wear nicks or damage that may accelerate seal or bushing wear 3 00 5 28 Polaris Sales Inc ...

Page 195: ... electrolysis The mounting surfaces must be clean and the mounting bolt tight to maintain a good connection between the pump and anode 1 Periodically inspect anode for excessive wear 2 Check bolt to be sure it is tight If the bolt is loose remove anode and clean mounting surfaces on pump and anode 3 Apply dielectric grease to bolt threads and contact surfaces 4 Tighten bolt securely Polaris Sales ...

Page 196: ...ntake grate and set high speed screws back to original position 2 Ride plate The ride plate must be completely sealed in the area around the intake scoop and also in the area where the hull meets the pump cavity 3 Drive shaft bearing housing or through hull fitting If the drive shaft bearing carrier seals are worn or damaged air may be drawn into the pump from the engine compartment Also inspect t...

Page 197: ... 4 Steering Assembly Diagrams 6 5 6 6 Deck Assembly Diagrams 6 7 6 9 Front Compartment Assembly Diagrams 6 10 6 11 Shroud Assembly Diagram 6 12 Decal Diagrams 6 13 6 16 Steering System 6 17 6 18 Cable Adjustment 6 19 6 21 Speedometer 6 22 Hull Repair 6 23 6 24 Sponsons 6 25 Foot Pad Replacement 6 25 ...

Page 198: ... STEERING AND CONTROLS Hull Body Specifications Hull Specifications Paint Codes Colors Paint Ordering Dealers can order Polaris paints through Midwest Industrial Coatings 612 942 1836 Polaris Sales Inc 6 1 3100 ...

Page 199: ... 11 17 Seat Strap Main Seat Seal Bolt Torque 14ft lbs 19 Nm Bolt Torque 8 12 ft lbs 11 17 Nm Underside Of Seat Seat Bumpers Seat Cover 1 Apply Loctite 242 Blue to threaded fasteners 2 Apply Polaris Premium Marine or All Season Grease to steering post bushings 3100 6 2 Polaris Sales Inc ...

Page 200: ...1200 Seat Cover Apply Polaris Premium Marine or All Season Grease Seat Seal Bolt Torque 8 12 ft lbs 11 17 Nm 1 Apply Loctite 242 Blue to threaded fasteners 2 Apply Polaris Premium Marine or All Season Grease to steering post bushings Polaris Sales Inc 6 3 3 00 ...

Page 201: ...Seat Strap w Clips Torque 8 12 ft lbs 11 17 Nm Latch Rear Seat Seal Rear Seat Trim Torque 8 12 ft lbs 11 17 Nm Seat Bumper Rear Seat Shiel Seat End Cap Torque 8 12 ft lbs 11 17 Nm Latch 1 Apply Loctite 242 Blue to threaded fasteners 2 Apply Polaris Premium Marine or All Season Grease to steering post bushings 3100 6 4 Polaris Sales Inc ...

Page 202: ... lbs 4 6 Nm Bolt Torque 14 ft lbs 19 3 Nm 52 in lbs 6Nm 40 in lbs 4 6 Nm Steering Post Steering Arm Steering Cable Adjuster Nuts 8 ft lbs 11 Nm DO NOT Over tighten Lever to block clearance 1 Apply Loctite 242 Blue to threaded fasteners 2 Apply Polaris Premium Marine or All Season Grease to steering post bushings 020 060 5 1 5mm Polaris Sales Inc 6 5 3 00 ...

Page 203: ...14 ft lbs 19 3 Nm Steering Support Genesis Genesis FFI Only Steering Post Steering Arm Steering Cable Adjuster Nuts 8 ft lbs 11 Nm DO NOT Over tighten Lever to block clearance 1 Apply Loctite 242 Blue to threaded fasteners 2 Apply Polaris Premium Marine or All Season Grease to steering post bushings 020 060 5 1 5mm 3 00 6 6 Polaris Sales Inc ...

Page 204: ...RING AND CONTROLS Deck Assembly 2000 Virage TX Bolt Torque 14 ft lbs 19 Nm Bolt Torque 14 ft lbs 19 Nm Bolt Torque 8 10in lbs 9 1 1 Nm 9 11 ft lbs 12 15 Nm Bow Strap Assembly 8 ft lbs 11 Nm Polaris Sales Inc 6 7 3 00 ...

Page 205: ...Pro 1200 Bolt Torque 14 ft lbs 19 Nm Torque 8 ft lbs 11 Nm Bolt Torque 8 10 In lbs 9 1 1 Nm NOTE Apply Loctite 242 Blue to threaded fasteners Bolt Torque 8 ft lbs 11 Nm Bolt Torque 9 11 ft lbs 12 15 Nm Bolt Torque 48 in lbs 5 5 Nm 3 00 6 8 Polaris Safes Inc ...

Page 206: ... Nm Important Use Loctite 242 Blue on stud whenever servicing Torque 14 ft lbs 19 Nm Torque 10 ft lbs 14 Nm Torque 48 in lbs 5 5 Nm Torque 40 in lbs 4 6 Nm Torque 14 ft lbs 19 Nm Torque 8 ft lbs 11 Nm Torque 8 ft lbs 11 Nm Seat Base Adjuster Periodic adjustment may be necessary to ensure a tight fit REAR PLUNGER 5 8 FRONT PLUNGER 1 1 8 fi r Polaris Sales Inc 6 9 3100 ...

Page 207: ...m Bolt Torque 4 ft lbs 5 Nm SLX Pro 1200 Bolt Torque 6 8 ft lbs 8 11 Nm 25 In lbs 3Nm Bolt Torque 10 ft lbs 13 Nm Bolt Torque 35 In lbs 4 Nm Bolt Torque 14 ft lbs 19 Nm NOTE Apply Loctite 242 Blue To Threaded Fasteners Virage TX Bolt Torque 40 In lbs 4Nm Bolt Torque 6 8 ft lbs 8 11 Nm 3100 6 10 Polaris Sales Inc ...

Page 208: ...s Genesis FFI1 NOTE Apply Loctite 242 Blue To Threaded Fasteners Torque 35 in lbs 4Nm Access Panel Asm Rubber Strai 3 Latch Compartment Door Torque 40 in lbs 4 6 Nm Torque 6 8 ft lbs 3 11 Nm Hinge Asm Gas Spring Boot Fire Extinguisher Container Polaris Sales Inc 6 11 3 00 ...

Page 209: ...lue To Threaded Fasteners Torque 6 8 ft lbs 8 3 11 Nm Console Latch Torque 35 in lbs 4Nm Console Lid Seal Console Pad Receiver Latch Plate Steering Shroud Tool Kit Strap Tool Kit Console Hook Mirror Gasket Torque 60 in lbs 6 9 Nm Shroud Support Bracket Torque 10 in lbs 1 1 Nm Mirror Grommet Wire Shroud Cover 3 00 6 12 Polaris Sales Inc ...

Page 210: ...un Heat the decal area first then peel back the decal while intermittently applying some heat to the decal 2 Wash the area where the new decal is to be placed with mild soap and warm water While the area is still wet apply the new decal Smooth out any trapped air bubbles with a soft flexible plastic squeegee Polaris Sales Inc 6 13 3 00 ...

Page 211: ...at the decal area first then peel back the decal while intermittently applying some heat to the decal 2 Wash the area where the new decal is to be placed with mild soap and warm water While the area is still wet apply the new decal Smooth out any trapped air bubbles with a soft flexible plastic squeegee 3 00 6 14 Polaris Sales Inc ...

Page 212: ... Heat the decal area first then peel back the decal while intermittently applying some heat to the decal 2 Wash the area where the new decal is to be placed with mild soap and warm water While the area is still wet apply the new decal Smooth out any trapped air bubbles with a soft flexible plastic squeegee Polaris Sales Inc 6 15 3 00 ...

Page 213: ...air gun Heat the decal area first then peel back the decal while intermittently applying some heat to the decal 2 Wash the area where the new decal is to be placed with mild soap and warm water While the area is still wet apply the new decal Smooth out any trapped air bubbles with a soft flexible plastic squeegee 3100 6 16 Polaris Sales Inc ...

Page 214: ... cable from throttle block by loosening jam nut and unscrewing adjuster 4 Remove the 3 stop switch screws separate the switch and set it aside 5 Remove 4 bolts on handlebar clamp and remove handlebar 6 Remove steering cable from steering arm 7 Remove 4 bolts on steering housing 8 Slide steering column up and out of the support hub Reverse procedure for reassembly Grease column 9 Re install cover R...

Page 215: ...er passing cable through threadedfitting Seal the cable nuts and washers with Marine Grade silicone sealant Tighten nuts to proper torque 4 Perform steering cable adjustment following procedures on pages 6 19 6 21 Make sure area where cable passes through hull is properly sealed A A warning Be certain to check for free and correct operation of the steering system when reassembly is complete Remove...

Page 216: ...steering in center position 3 4 Place a straight edge across horizontal center line of steering nozzle or trim nozzle NOTE The trim nozzle mounting bolts can be used as a reference for the center line on models with Quick Trim See III 2 Measure distance from straight edge to hull on left and right side Be sure to measure at right angles to the straight edge and at equal distances from the nozzle T...

Page 217: ...ring or trim nozzle to station ary nozzle Distance should be equal 1 1 Minor adjustments can be made using the steering cable rod end s Loosen jam nut on rod end s Remove end from top of steering nozzle Turn rod end in or out to adjust Reinstall rod end apply Loctite 242 Blue and tighten bolt to specifications See III 2 The cable must be threaded into the rod end a minimum of 3 8 1 Omm Do not atte...

Page 218: ...le near steering pod Open front compartment and remove storage tray for access to bottom nut The cable is not adjustable at the through hull end See III 3 5 Using two 11 16 open end wrenches hold one nut and loosen the other Lengthen or shorten cable to adjust nozzle centering Tighten cable nuts securely after adjustment is complete 6 Turn handlebars to left and right through entire steering range...

Page 219: ...ting and to back of speedometer The fitting must be aligned with the pump intake grate to read accurately 2 Occasionally foreign debris such as grass or weeds will lodge in the fitting or line To clear hose and fitting disconnect hose from speedometer and apply low pressure air to hose 3 To test speedometer unit connect a Mity Vac to the fitting on the speedometer Apply pressure and compare the re...

Page 220: ... marine quality paint Do not use power sanding equipment on the repair area or bond strength may be affected Hand sand only NOTE For bonding use 3M 08101 structural adhesive or equivalent Example shown is through hull fitting installation Basic preparation procedure is the same for repairing damaged hull deck components 1 Remove all original adhesive and sand the area to be repaired with 80 grit p...

Page 221: ...orm a mold 4 Mix enough polyester resin and catalyst to complete the repair following instructions for resin being used 5 Apply resin to inside of patch area using a disposable paint brush 6 Lay in small pieces of shredded fiberglass mat Use the paint brush to force air bubbles out Add more resin and move mat around NOTE Pieces of mat between 1 to 2 2 5 to 5 cm square work best 7 Keep adding mat a...

Page 222: ...soft plastic material 3 Remove Goo Gone residue with mild detergent soap 4 Wipe surface with acetone Allow acetone to completely dry 5 Remove backing from new foot well pad and immediately apply to the deck 6 Work the pad with your fingertips until the entire pad is pressed onto the deck surface Constant pressure activates the adhesive and works any air bubbles out from under the pad 7 Allow for 2...

Page 223: ...Troubleshooting 7 18 Warning Sensor Testing 7 19 Fuel Sender FFI Fuel Pump Testing 7 20 FFI Fuel Pump Diagram 7 21 FFI Fuel Pump Water Filter Removal 7 22 7 23 FFI Fuel Pump Testing 7 23 7 24 RPM Limiter Circuit Overview Testing 7 25 Oil Level Sensor Overview Testing 7 26 PVL Ignition Testing Troubleshooting 7 27 7 30 Ignition Coil Identification 7 31 Trigger Coil Testing 7 32 7 33 Ignition Timing...

Page 224: ...more information and stator resistance specifica tions lgnition timing specification for high RPM Check at specified RPM 5000 6250 not operating RPM Ignition Timing on Genesis FFI is set at the factory and is controlled by the EMM Timing cannot be changed or altered in any way on Genesis FFI personal watercraft When replacing a CDI box on a Virage TX SLX Pro 1200 or Genesis it is very important to...

Page 225: ...C 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Inches MM 026 63 032 81 038 96 044 1 12 051 1 30 059 1 49 067 1 70 075 1 91 084 2 14 094 2 38 104 2 64 114 2 90 125 3 18 137 3 47 148 3 77 161 4 08 174 4 41 187 4 74 200 5 09 215 5 45 229 5 82 244 6 20 259 6 59 275 6 99 291 7 40 308 7 82 3100 7 2 Polaris Sales Inc ...

Page 226: ...e appropriate wiring diagram Refer to the wiring diagram for the model you are working on If resistance specifications are not listed on the wiring diagram use specifications listed be low Refer to test procedures in this section All electrical resistance readings should be done at room temperature Reading may vary 10 Disconnect component to be tested Always subtract meter lead resistance when mea...

Page 227: ...I Module Ignition Coil Assembly Refer to Wiring diagram for resistance specifications When replacing a CDI box on a Virage TX SLX Pro 1200 or Genesis it is very important to check timing A new CDI box may be pro grammed slightly different than the one being replaced causing igni tion timing to be advanced or retarded too far 3 00 7 4 Polaris Sales Inc ...

Page 228: ... Regulator LR 505 CDI Controller Q When replacing a CDI box on a Virage TX SLX Pro 1200 or Genesis it is very impor tant to check timing A new CDI box may be programmed slightly different than the one being replaced causing ignition tim ing to be advanced or retarded too far Stator Harness Ignition Coil Bottom View Polaris Sales Inc 7 5 3 00 ...

Page 229: ...ICAL 2000 SLX Electrical Box Terminal Board V 9 2 4 6 8 10 Ground Harness Circuit Breaker 15 AMP Trim Harness Battery Cable hi I Ignition Coil Stator Harness Starter Solenoid Cable 3 00 7 6 Polaris Sales Inc ...

Page 230: ...ELECTRICAL 2000 Genesis FFI 2 4 6 8 10 13 5 7 9 Starter Solenoid Cable Terminal Board Battery Solenoid Cable Accessories Harness 0 0 Engine Harness Polaris Sales Inc 7 7 3 00 ...

Page 231: ...ndition of rectifier diodes cannot be used for testing except when the diodes are out of circuit A Amps AC not used A Amps DC used to check battery charge rate system draws etc NOTE When using the Amp settings the red test lead must be moved to the 10A unfused socket on the front of the instrument Charging System Testing Unregulated Voltage 1 Remove electrical box cover for component access 2 Turn...

Page 232: ...art Stop Switch Testing 1 Set multitester to ohms Q position 2 Unplug MFD MFI connector 3 Connect one of the test leads to the red purple pin and the other lead to the yellow red pin Depress start button The reading should be 3 ohms or less A high resistance or open reading indicates a faulty switch 4 Release start button An open reading OL should be indicated If low resistance is measured replace...

Page 233: ...marks on case Set battery aside and allow it to cool and stabilize for 1 2 hour Add electrolyte to bring level back to upper level mark on case NOTE This is the last time that electrolyte should be added If the level becomes low after this point add only distilled water Charge battery at 1 3 of its amp hr rating for up to 2 hrs NOTE This charge rate is to be used only on new batteries during the f...

Page 234: ...ity reading at 40 F Battery Hydrometer PN 2870836 Load Test A battery may indicate a full charge condition in the OCV test and the specific gravity test but still not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encountered NOTE This test cannot be performed...

Page 235: ...is at proper level Add distilled water if necessary Charge at a rate no greater than 1 10 of the battery s amp hr capacity until the electro lyte s specific gravity reaches 1 270 or greater Store battery either in machine with cables disconnected or store in a cool dry place NOTE Stored batteries lose their charge at the rate of 1 per day They should be recharged to a full charge every 60 to 90 da...

Page 236: ... 2 Remove housing through bolts ELECTRICAL Starter Motor 3 Remove brush end bushing dust cover and armature thrust washers Keep washers in orderfor reassembly 4 Remove drive end cover and armature Remove thrust washer phenolic washer and shim washers Keep washers in order for reassembly Polaris Sales Inc 7 13 3 00 ...

Page 237: ...air or replace as necessary 7 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Slide brush end frame off end of starter NOTE The electrical input post must stay with the field coil housing 8 Measure resistance between ground brush and brush plate Resistance should be 3 ohms or less Brush Inspection 1 Measure length of each carbon brush Replace brush ...

Page 238: ...of the segments of the commutator The reading should indicate 3 ohms or less 2 Measure resistance between commutator and armature shaft Reading should be infinite OL Inspect surface of commutator wear or discoloration Replace if excessively worn or damaged 3 Place armature in a growler With growler on position a hacksaw blade lengthwise 1 8 3 cm above armature coil laminates Rotate armature 360 If...

Page 239: ... and terminal nut 3 While holding brush springs away from brushes push brushes back and hold in place 4 Slide armature into field magnet housing Release brushes 5 Lightly grease drive end bushing and reinstall drive end frame on armature Inspect seal for wear or damage Replace drive end cap if necessary Lip of seal faces needle bearing Do not reuse Replace with new parts 3 00 7 16 Polaris Sales In...

Page 240: ...ate and install cover and screws 9 Reinstall bolts and tighten evenly and securely 10 Lightly grease pinion shaft and install pinion spring stopper and snap ring Starter Solenoid Bench Test To measure the resistance of the pull in coil connect one meter lead to the Yellow Red wire and the other to ground The resistance should be 2 8 3 6 ohms Refer to Electric Starter System Testing in this section...

Page 241: ...econnect the solenoid Connect the tester black lead to the battery positive terminal and the red tester lead to the solenoid end of the battery to solenoid cable Push the start button The reading must be less than 1v DC Is it No Yes Clean the battery to solenoid cable ends or replace the cable Connect the black tester lead to the solenoid end of the battery to solenoid cable and the red tester lea...

Page 242: ...On Polaris engines the sensor is located on the exhaust manifold Ground the sensor wire from MFD MFI with engine running to see if temp light activates Refer to MFD MFI function test ing in this section Temperature Sensor Test The temperature warning switch is normally open Us ing a digital VOM set in the Ohms position and with the wires disconnected contact one test probe to the switch terminal a...

Page 243: ... a complete unit They should not be disassembled in any way If one of the components tests bad the whole unit must be replaced Gasoline Safety A WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or spa...

Page 244: ...Fuel Pump Module ELECTRICAL Genesis FFI Fuel Pump Module Brown Red Black Electric Fuel Pump Secondary Filter Inside Housing Float Valve Asm Primary Fuel Filter Bleed Tube Float Lever Asm Polaris Sales Inc 7 21 3 00 ...

Page 245: ...Separating Filter Removal 1 Loosen fuel pump module ring by using fuel pump ring spanner wrench PN 2872621 Remove module nut from fuel tank Slide module out Fuel Pump Spanner Ring 2 Remove primary filter and float and valve assembly 3 00 7 22 Polaris Sales Inc ...

Page 246: ...mp Module Genesis FFI Water Separating Filter Removal cont Secondary Filter inside housing Genesis FFI Fuel Sender Testing 1 Test fuel sender as shown below Empty Float Down 240 ohms Full Float Up 35 ohms Polaris Sales Inc 7 23 3 00 ...

Page 247: ... amps maximum If pump shows different replace fuel pump module Fuel pump flow should be 18 gph minimum Genesis FFI Fuel Pump Module Installation 1 Install fuel pump module into fuel tank Torque fuel pump module nut to 36 44 ft lbs 49 8 60 8 Nm using fuel pump ring spanner tool PN 2872621 Torque Nut to 36 44 ft lbs 49 8 60 8 Nm 3 00 7 24 Polaris Sales Inc ...

Page 248: ... 4500 RPM A circuit within the CDI senses the ground path connection and activates the limiting function See diagram below Low Fuel No low fuel limiters are present on these models Important Note When the engine overheat circuit has caused the system to limit it will continueto limit until both of the following conditions are met 1 The problem that caused the initial limiting must be corrected coo...

Page 249: ...fications Consult the appropriate wiring diagram for specifications and wire colors 4 Inspect all electrical connections including the pins in the harness connector on the back of the MFD Connections must be clean and tight Refer to MFD troubleshooting tips at the end of this chapter for more information Oil Level Sending Unit Resistance Full Float up 35 Ohms Empty Float down 240 Ohms All readings...

Page 250: ...pm Verify the firing order If the plug leads are all the same length trim them so they can only be installed on the correct cylinder Read through the entire procedure before proceeding Some steps are repeated The correct sequence depends on the readings obtained in step one 1 1 Check continuity from inside spark plug caps to engine stud If reading is OK proceed to Step 2 II 1 ohms To Coil Engine G...

Page 251: ...ections or physical damage A Verify the correct installation of the Yellow stator wire and Yellow Purple jumper wire if so equipped a Disconnect the stator from the electrical box at the stator connector b Connect the negative test lead of the ohm meter to the black wire coming from the stator and leave it connected for the duration of test 2 c Connect the positive test lead to an engine ground Ig...

Page 252: ... ing wires one at a time SPECIFICATIONS III 6 RED PURPLE OPEN GRAY OPEN Open readings are correct for Tektronix DMM 155 meter Other meters may show a very high Meg ohm reading f Connect the negative test lead of the ohm meter to the gray wire coming from the stator and repeat step e Stator Purple Wire Stator Black Wire II 5 Red Purple and Gray wre one at a time Brown Red Green andBlue one at a tim...

Page 253: ...esis PVL Ignition Troubleshooting Cont g Check the primary side resistance of the ignition coils h Check the secondary side resistance of the ignition coils III 8 BLACK coil wire to each secondary lead III 8 To Coil Black Coil Wire Amp 3 00 7 30 Polaris Sales Inc ...

Page 254: ... Effect sensor in the stator On models with sequential firing the high tension leads spark plug wires must be installed on their respective cylinders or the engine will not run properly t Front Air Box 1 3 2 Bulkhead Mounted Electrical Box 1550Q Coil Pack Wire Sequence When replacing a CDI box on a Virage TX SLX Pro 1200 or Genesis it is veryimportant to check timing A new CDI box may be programme...

Page 255: ...ssion With RFI suppression II 2 Start End Time Electrical current wave with without RFI suppression RFI is caused by the tendency of plug voltage to rise and fall rapidly once the spark plug is fired These alternating currents are suppressed by the use of resistor spark plugs and resistor spark plug wires The creation of RFI can distrupt the the micro processors within the CDI box and cause igniti...

Page 256: ...dication The ohmmeter should indicate an open circuit oo until the magnet in the magnet holder passes by the sensor At this point the reading should switch to low resistance under 25 ohms It should go back to infinite as flywheel rotation continues 3 Repeat the test for the other trigger coils STATOR EXCITERS To Green Red or Blue wire NOTE Actual resistance readings may vary with different meters ...

Page 257: ...ndicator As the piston touches the indicator plunger the dial will begin to rotate Find the exact point where the pointer stops rotating and reverses direction This will be Top Dead Center TDC 4 While holding crankshaft with piston at TDC zero indicator by rotating bezel until O on dial and pointer align 5 Rotate crankshaft oppositethe direction of rotation about 200 BTDC 2 pointer revolutions 6 R...

Page 258: ... timing Move the magnet holder in the opposite direction approximately the same amount as the mark must move Tighten screws securely 4 Verify proper ignition timing with the timing light Static Ignition Timing Adjustment Static Timing Light tool PN 2871745 can used to verify that the hall effect sensors are working 1 To check the sensors simply connect the white test wire to the Blue Cen or Green ...

Page 259: ...l box 3 Remove negative cable from battery terminal 4 Carefully open the electrical box Remove the LR module and the CDI 5 With the CDI box accessible attach the harness of the Ignition Point Adjustment Unit PN 2872290 to the serial port on the CDI 6 Reassemble the electrical box completely Reconnect the battery and exhaust hoses 7 Remove the timing cover plug 3 00 7 36 Polaris Sales Inc ...

Page 260: ...Press the POS or NEG button to advance or retard timing until timing is at specification Pressing the POS or NEG buttons will advance or retard the timing in one degree increments up tp two degrees each way 10 After correct timing has been established remove the timing light and install the timing cover plug 11 Remove exhaust and battery cable Open electrical box and disconnect the Ignition Point ...

Page 261: ...olon begins to flash PEAK SPEED RPM While in TACH mode pressing the SET key will display both the peak speed and maximum sustained RPM since the last reset or auto off occurred While displayed holding the SET key for 4 seconds will reset the peak memories KEY FUNCTIONS AND DISPLAY MODE KEY Toggles multi LCD display modes as pressed Annunciators scroll from left to right to indicate selec tion SET ...

Page 262: ...can be reset by pressing the SET key for 4 seconds while in DIST mode VOLT Red wire purple tracer 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 ENGLISH METRIC While in the VOLT mode pressing and holding SET will toggle the instrument between MPH and KPH The distance funct...

Page 263: ...n is pressed or alternately by press ing and holding any button for 1 second AUTO OFF The MFI will return to sleep mode after 5 minutes of inactivity While in sleep mode the clock contin ues to show time and the fuel level oil level and the compass rose are displayed If the SECURITY LOCK is active the display will also show LOCKED TACHOMETER The analog tachometer visually displays the revolutions ...

Page 264: ...pointer on the gauge moves in synchronization with the reverse gate as it is lowered over the jet nozzle when actuated by the electric thumb switch The indicator is useful in establishing a neutral position beween forward and re verse The LED will flash when the reverse gate is not fully forward Pressing any key will disable the LED for five minutes SECURITY LOCK Briefly pressing and releasing the...

Page 265: ... while in DIGITAL DIS PLAY mode toggles the display back to the standard VOLT DISTANCE HOURS display ENGLISH METRIC To change units between English and metric press and hold the 1 6 button and the 2 7 but ton simultaneously for several seconds When in metric mode km appears in the distance meter and the MTRS icon will illuminate in the depth gauge where applicable if activated WARNING INDICATIONS ...

Page 266: ... are located correctly in the connector clip by comparing wire color to the key on the schematic wiring diagram Intermittent malfunctions Be sure to get an accurate description of the problem from the customer if a malfunction is intermittent Intermit tent malfunctions are usually traced to a loose connection on the sender or signal wire power supply or ground path If the display is completely dea...

Page 267: ...es significantly or if the battery is disconnected NOTE It is important that the watercraft is floating and away from any large metal objects or magnetic sources at the time of calibration 1 Press the MODE button until ENGINE HOUR is displayed 2 Press SET for approximately 4 seconds until CC SET 1 is displayed 3 Carefully align and hold the watercraft in any direction 4 Press the SET key The displ...

Page 268: ...or and control switches inside the hull 3 Reverse gate at the jet pump nozzle 4 Graphic display in the MFI depicting reverse gate position 1 Forward Reverse switches on the handlebar control the up and down movement of the reverse gate Think of these switches as polarity switches for the reverse motor 2 The reverse motor is a DC motor that can run either direction depending upon the polarity of th...

Page 269: ...or Connector GRN WHT NO3 Forward Switch NC2 GRN WHT BLK BLU WHT NO3 Reverse Switch NC2 BLU WUT BLK BLK BLK NO3 Reverse Sync Switch NC2 GRY OR Not used Gear Reduction Box Reverse Switch Input Switch Output to MFI Reverse Switch Input Switch Output to MFI Ground Engine Limit Switch Output to MFI and EMM 3 00 7 46 Polaris Sales Inc ...

Page 270: ...HT 1BLK 2 BLU WHT 3 GRN WHT Motor Resistance In Forward or Reverse 0 8Q In Neutral 2 6Q CONTINUITY TO PIN 1 GROUND CONTINUITY TO PIN 4 FORWARD REVERSE SWITCH CONTACT CONTINUITY TO PIN 6 FORWARD REVERSE SWITCH CONTACT SWITCH POSITION Italicized text indicates reverse gate position The motor windings resistance is approximately 8Q Polaris Sales Inc 7 47 3 00 ...

Page 271: ...does not run replace bilge pump If pump runs with alternate power and ground start engine and check for battery voltage on Orange wire terminal If no power replace LR module or repair connection If power is present on Orange terminal inspect pump ground circuit If pump continues to run after engine is off replace LR module Inspect inlet area regularly for debris 3 00 7 48 Polaris Sales Inc ...

Page 272: ...000 Virage TX Wiring Diagram Polaris Sales Inc 7 49 3100 Per Polaris Service Bulletin PWC 00 05 Move Red Purple CDI power wire male end to Orange terminal LR switched power Corrects for engine no restart condition ...

Page 273: ...L 2000 SLX Wiring Diagram 3100 7 50 Polaris Sales Inc Per Polaris Service Bulletin PWC 00 05 Move Red Purple CDI power wire male end to Orange terminal LR switched power Corrects for engine no restart condition ...

Page 274: ...ICi O LjJ QC C lxj o uj o_ se s s ii irgsoe z cljjo z o_j as3ci uj J ICC QC LxJLxJ3I C Ceo cqcdoq Oq co ccz I C L4J I II I II II OS J _ Q_LU Polaris Sales Inc 7 51 3 00 Per Polaris Service Bulletin PWC 00 05 Move Red Purple CDI power wire male end to Orange terminal LR switched power Corrects for engine no restart condition ...

Page 275: ...I813313 Nl SlN3H0dHOD S 5 J Q 2E ie II a 3E 1 LlJ _J UJ Q_ 2E ie jice c uj O Q Ij OI ce 3s X3 3 00 7 52 Polaris Sales Inc Per Polaris Service Bulletin PWC 00 05 Move Red Purple CDI power wire male end to Orange terminal LR switched power Corrects for engine no restart condition ...

Page 276: ...ELECTRICAL 2000 Genesis FFI Wiring Diagram ILHHlil ii TSQli J IS 1353S 1VRN v si uaxvatie Polaris Sales Inc 7 53 3 00 ...

Page 277: ...R 8 FICHT FUEL INJECTION FFI Theory System Overview 8 1 8 5 EMM Service Code Chart 8 6 Preliminary Tests 8 6 8 7 FFI Diagnostic Guide 8 8 8 13 FFI Action Steps 8 14 8 18 FFI Specifications Specific Tests 8 19 ...

Page 278: ...tors are in a 38 45 volt system and there is one injector per cylinder The injectors are secured to the cylinder head by a flange and two bolts Each injector has two ports one for fuel inlet large port on bottom the other an outlet smaller port on top both on the same side of the injector body The inlets and outlets are different sizes to prevent fuel line mis installation The EMM controls injecto...

Page 279: ... functions Provides a ring gear for starter motor engagement Has cast in timing encoder ribs on the outer diameter that work in conjunction with the magnetic crankshaft position sensor to control ignition timing and fuel injector operation Houses magnets that work in conjunction with the stator to provide power to operate the ignition injectors EMM MFI multi function instrumentation gauge and acce...

Page 280: ... the EMM to compensate for pressure changes caused by altitude so it can adjust fuel flow accordingly If sensed values are out of limits or the sensor or circuit fails the EMM will turn on the MFI check engine light and store a service code EMM Temperature Sensor Monitors fuel injector driver circuit temperature to prevent it from exceeding design limits One or more fuel injectors could malfunctio...

Page 281: ...relative to the position of the throttle As the throttle opens voltage increases As the throttle closes voltage decreases A third wire completes the ground circuit back to the EMM If sensed values are out of limits or the sensor or its circuit fails the EMM will turn on the check engine light and store a service code If the TPS becomes open during engine operation engine RPM will drop to idle spee...

Page 282: ...r operation It begins a gradual five second drop in engine RPM to a threshold limit of approximately 3500 RPM This is accom plished by cutting out one cylinder at a time The EMM turns on the MFI check engine light As long as S L O W is activated the engine will run normally below 3500 RPM Above 3500 RPM the engine will run poorly Recovery The engine will operate as described as long as the conditi...

Page 283: ...ay service code Preliminary Tests A WARNING The FFI ignition system presents a serious shock hazard The primary circuit operates at 300 volts the secondary circuit operates in excess of 35 000 volts Use caution to avoid injury from shock or injury from your reaction to shock Do not handle primary or secondary ignition components while the engine is cranking or running 3 00 8 6 Polaris Sales Inc ...

Page 284: ...rk on all fault is in fuel or electrical system Go to Step 6 No spark test battery for full charge No spark Inspect starter Check for too much voltage drop See Electrical Section No spark on some or all note problem cylinders Go to appropriate symptom in Diag nostic Guide Step 6 If engine will run perform the following tests while problem is occurring if possible NOTE Polaris Diagnostic Software i...

Page 285: ...FFI FUEL INJECTION Diagnostic Guide DIAGNOSTIC GUIDE ENGINE WONT CRANK 3 00 8 8 Polaris Sales Inc ...

Page 286: ...FFI FUEL INJECTION Diagnostic Guide ENGINE CRANKS BUT WONT START Polaris Sales Inc 8 9 3 00 ...

Page 287: ...FFI FUEL INJECTION Diagnostic Guide ENGINE STARTS AND DIES 3 00 8 10 Polaris Sales Inc ...

Page 288: ...FFI FUEL INJECTION Diagnostic Guide ENGINE SURGES RUNS ROUGH Polaris Sales Inc 8 11 3 00 ...

Page 289: ...FFI FUEL INJECTION Diagnostic Guide LOW MAXIMUM RPM ENGINE WONT SHUT OFF 3100 8 12 Polaris Sales Inc ...

Page 290: ...FFI FUEL INJECTION Diagnostic Guide EXCESSIVE SMOKING FALSE WARNING LIGHT Polaris Sales Inc 8 13 3 00 ...

Page 291: ...re there is fuel in tank no water B Inspect all fuel hoses and connections Step 1 Verify Fuel Delivery to Injectors A WARNING Fuel system may be under pressure and could spray fuel when schrader valve is installed gauge is at tached in fuel line or when fuel line is removed from an injector A Install in line schrader valve fitting PN 2872602 in fuel out line If applicable B Connect a 100 psi 690 k...

Page 292: ...tests See Step 5 All injectors react correctly and consistently Test finished Some injectors do not operate Monitor EMM signal lead at injector using an inductive timing light Be sure to clip onto only one wire per injector NOTE Some timing lights may not flash consistently during cranking Timing light pickup orientation can also affect results and should be tried both ways Any flashes in either c...

Page 293: ...unning Cranking approximately 20 volts Check White Red wire and ground Engine running more than 24 volts and steady at idle More than 40 volts and steady above 3500 RPM Results As specified check supply voltkge at injector Go to Step D Any less than specified test charging system E Check injector supply voltage at the leads of each injector connector using PDS injector jumper tool PN 2872623 Volta...

Page 294: ...ons clean and tight A Verify tether cord is connected to stop switch NOTE Perform the following tests while problem is occurring B Verify fused B battery positive is present at Red Purple wire terminals 1 and 8 of the PCM see Chapter 9 page 27 Check should show either 9 5 or more volts while cranking or 12 or more volts while running OK go to Step C Low voltage while cranking Verify battery capaci...

Page 295: ...Voltages fluctuate and engine misfires suspect a loose battery connection or damaged capacitor Step 7 Capacitor Verification capacitor is mounted above EMM A Connect tether cord to stop switch B Monitor voltage at capacitor while disconnecting tether cord Voltage quickly bleeds to near zero 0 volts capacitor is OK Voltage drops to zero 0 immediately replace capacitor Voltage does not drop verify s...

Page 296: ...eter lead to green wire pin and move sensor arm smoothly meter reading should change evenly with arm movement Retain meter lead on green wire pin and alternate the other lead to the other sensor pin Repeat procedure any erratic meter reading change indicates a sensor problem Air Temperature Sensor Resistance Test Water Temperature Sensor Resistance Test Measure resistance of sensor Stator Resistan...

Page 297: ...re Requirements 9 1 Setting Up The EMM 9 2 Running The Boot Program 9 2 9 3 Installing And Running The FFI Program 9 3 9 5 Error Messages 9 6 9 7 EMM Communication Problems 9 8 Program Select Menu 9 9 FFI Diagnostics 9 10 9 18 Service Utilities Menu 9 19 9 25 EMM Connectors 9 26 9 27 ...

Page 298: ...ery powered laptop computer To minimize electric shock hazard DO NOT connect A C powered computers to the watercraft The Polaris Diagnostic Software will operate on a wide range of laptop computers It has been tested on laptops using 286 386 486 Celeron and Pentium class processors including AMD At least 400 kilo bytes K of DOS memory must be available for the program to run The screen fonts and c...

Page 299: ...ort Diagnostic Cable Cap Front of Boat EMM Service Power Connector PN 2872456 Diagnostic Software Overview The FFI Diagnostic software program can either be run from your computer s A drive or C drive Instal ling the software on your computer s C drive will allow the program to run much faster as well as retain pre vious consumer FFI information on your hard drive For 2000 the FFI diagnostic softw...

Page 300: ...ARE Installing Software Installing and Starting the FFI Program NOTE The following outlines the proper proce dures for installing and running the FFI diagnos tic program from your computer If you experience problems running the FFI diagnostic program or with the software not communicating with the EMM please refer to the previous section Installing the FFI Diagnostic Program 1 If your laptop is po...

Page 301: ...l allow you to explore the various files and folders on your laptop 6 Within the Open text box type A lnstall bat and click OK Executing this function will automatically download the FFI program into your laptop Running the FFI Diagnostic Program 1 If powered off turn on your laptop 2 On the Windows desktop click on the Start button 3 Click Run Once the Run window opens type A PODIAG in the text b...

Page 302: ... the port you have plugged the diagnostic communication cable into Set the diagnostic pro gram to use the same port To change the default com port press the F3 key from the Title screen or the Main Menu This will cause the Com Port screen to display The Select Com Port screen displays a numbered list of com ports Type the com port number you desire When you exit the Com Port screen a message in fo...

Page 303: ...ame of the port you have plugged the diagnostic communication cable into Make sure the diagnostic program is set up to use the same port See the section titled Changing a Com Port in this booklet Some computers have the ability to enable and disable the com ports Consult the documentation that came with your computer Make sure the com port is enabled Something is already using the com port This is...

Page 304: ... program size must be more than 400k 400 000 If not reconfi gure the computerto make more memory avail able Attempting to start the program out side of the PODIAG directory Change to the PODIAG directory before start ing the program C PODIAG podiag 40 DATABASE ERROR RESTART PROGRAM IF ERROR OCCURS AGAIN REINSTALL PRO GRAM FROM THE DISKETTE Damaged or erased program file Reinstall the program See t...

Page 305: ... battery voltage is at least 12 volts electrical connections are clean and tight circuit breaker is not tripped communication cable is attached to the laptop and to the diagnostic connector of the engine wiring harness com port number you entered when starting or configuring the program is connected to the communication cable This screen will also be displayed if the laptop mo mentarily loses comm...

Page 306: ...te any fuel injector Fire any ignition coil Test the Fuel Pump Timing Verification EMM Information Screen RPM Profile Option 2 Service Utilities Reports Injectors EMM Allows you to retrieve information on the EMM and injectors replace injectors or the EMM and real time engine monitoring For testing purposes allows you to View current and past service reports View injector information and replace i...

Page 307: ...Service Codes stored in the EMM Three types of Service Codes are displayed Within each catego ry the codes are displayed in the orderthey should be diagnosed Hard Codes are displayed first A Hard Code means the problem that created the code ex ists now Intermittent Codes are displayed second An Intermittent Code means the problem that created the code is not occurring at this time Repaired Codes a...

Page 308: ...or value that is higher than expected This can be caused by mechanical damage to the sensor or linkage that increases the sensor travel toward the WOT posi tion Damage to the sensor could also cause this Ser vice Code See Diagnostic Manual PRESS ANY KEY FOR NEXT CODE Indicates the number of operating hours on the engine when this code was last present This field will update during a run during a s...

Page 309: ...ntarily im proves contact the computer will beep when the connection is good The computer will then display a message that the code appears to be repaired If the connection breaks the computer will beep again and display the Retest screen When you exit the Retest feature you will automatically re turn to the Code screen The Class field will reflect the status of the Service Code either Hard or Re ...

Page 310: ... then page through the Code screens again 3 You can end the session and return to the Main Menu without clearing the Service Codes by typing ESC Illustration 3 shows the Static Test screen You get to this screen by pressing 2 at the Main Menu It allows you to select and test one of three engine functions NOTE Before selecting a static test make sure the engine is not running SESSION COMPLETION Ple...

Page 311: ...or 5 seconds The screen counts down the amount of time to the end of the test If you press any key the injector will stop firing immedi ately The screen changes back to the previous screen when the injector stops firing The FFI fuel injector will make an audible click ing sound each time it s activated This sound indi cates the injector is being activated by the EMM and that the injector armature ...

Page 312: ...ead Do not look directly at timing light or eye damage may occur The computer will next display a screen that allows you to enter the number of the cylinder you want to fire Type the number of the ignition you want to fire The next screen not shown tells you which cylin der is firing and how long it will continue to fire The ignition will fire approximately once a second for 5 seconds Use the spar...

Page 313: ...ntarily shut off fuel to any one cylinder while the engine is running To use the Cylinder Drop Test you must run the en gine with the laptop attached Remove the spark checker and install all spark plug leads Run wa tercraft on trailer in water or in test tank To start the Cylinder Drop Test type 3 at the Main Menu The computer will display the Cylinder Drop Test information screen Read and underst...

Page 314: ...an focus on that cylinder To Diagnose Low Performance or Rough Running Run the engine under a load in the water at 2000 2500 RPM and drop each cylinder Watch the RPM on the screen or on the tachometer The RPM drop will be substantially less on a cylinder that is weak If you drop a cylinder and the engine RPM does not change at all that cylinder has a problem When you are finished with the Cylinder...

Page 315: ...Model Number Engine Serial Number EMM Serial Number Software Version Number Map Version Number Engine Hours To return to the FFI Main Menu press any key on the laptop MENU OPTION 5 RPM PROFILE To enter the RPM Profile screen press 5 The RPM profile screen will display the total hours spent in each RPM range by percentages Press ESC to return to the FFI Main Menu MENU OPTION 6 EXIT PROGRAM Press 6 ...

Page 316: ...ine monitoring Service Utilities Menu Option 1 Service Reports The Service Reports option allows the user to view save and print past and current EMM reports Functions of the Service Reports option include 1 View Current EMM Report 2 Save Current EMM Report 3 Print Current EMM Report 4 View Save Report 5 Print Saved Report 6 Return to the Program Select Menu 1 View Current EMM Report Type 1 from t...

Page 317: ...DIAGNOSTIC SOFTWARE Service Reports EMM Report Page 1 EMM Report Page 2 Values Given in Charts are for Demonstration Only Polaris Sales Inc 9 20 3 00 ...

Page 318: ...y to return to the Service Re port Menu 4 View Saved Report Type 4 on the Service Report Menu to a view a previously saved report You will be asked to enter a file name or select a file name from a list Use the Arrow keys to move through the list of files This option will allow you to view files about an engine that is not currently connected to your laptop Press the ESC to return to the Service R...

Page 319: ...ve a YELLOW warning label that informs you about acceptable service practic es See Page 9 23 NOTE You must use the 2000 FFI diagnostic software PN 2873377 when you perform either of the follow ing service procedures on an engine that has the above capability Replacing the EMM Replacing a Fuel Injector The Injector Information option allows the user to view the serial numbers given to each injector...

Page 320: ...ng Yellow Label 4 Remove the lanyard and install the new EMM 5 With the new EMM installed re attach the lanyard 6 Connect the laptop to the new EMM 7 Press any key on the laptop to upload the copied information to the new EMM Press ESC to cancel the entire operation 8 When the program is finished loading the replacement EMM the screen will display REPLACEMENT EMM HAS BEEN SUCCESSFULLY INITIALIZED ...

Page 321: ...tage values for the sensors reflect the voltage at the analog to digital con verter inside the EMM Voltages measured at the sensor will be substantially different Water Displays engine water temperature in volts degrees F and degrees C Unplug sensor to see this value go to maximum high Jump sensor leads together to see the value go to maximum low When operating correctly voltage and temperature in...

Page 322: ...njector measured in milliseconds Barometric Pressure Indicated in Inches of Hg This data allows EMM altitude compensation SWITCHES In S L O W YES or NO YES means engine is in S L O W mode The water tempera ture sensor reading can verify this condition Ground the water temperature switch lead and watch this value change when engine goes into S L O W VOLTAGE Use these readings to verify regulator an...

Page 323: ...DIAGNOSTIC SOFTWARE EMM Connectors EMM 40 Pin Connector ...

Page 324: ...ors EMM 12 Pin Connector EMM 8 Pin Connector COLOR CODE BLU Blue BLK Black GRN Green PUR Purple OR Orange PK Pink R Red Y Yellow W White T Tan GRY Gray NOTE Two color wires are shown with main trace colors 3 00 9 27 Polaris Sales Inc ...

Page 325: ...27 3 28 3 29 3 30 3 31 3 32 Carburetor Jet Part Numbers 3 2 Carburetor Low Speed Mixture Adjustment 3 22 Carburetor Mixture Adjustment 3 21 Carburetor Operation 3 15 Carburetor Operation Keihin 3 16 3 17 Carburetor Service 3 26 3 27 3 28 3 29 3 30 3 31 3 32 3 33 3 34 3 35 Carburetor Synchronization Manual 2 29 Carburetor Exploded View 3 11 Carburetor Throttle Body Installation 3 36 3 37 Carburetor...

Page 326: ...7 Diagnostic Software FFI Diagnostics 9 10 Diagnostic Software Hardware Requirements 9 1 Diagnostic Software Installing and Starting The FFI Program 9 3 Diagnostic Software Introduction 9 1 Diagnostic Software Overview 9 2 Diagnostic Software Setting Up The EMM 9 2 Diagnostic Software Starting From The Boot Disk 9 2 Dial Caliper Crankshaft Indexing 4 51 Drive Shaft Inspection 5 13 5 14 5 15 5 16 D...

Page 327: ...tor Theory 8 2 FFI Theory 8 1 8 2 8 3 8 4 8 5 FFI Throttle Position Sensor 8 4 FFI Throttle Position Sensor Resistance Test 8 19 FFI Water Temperature Sensor 8 4 FFI Water Temperature Sensor Resistance Test 8 19 Fire Extinguisher 2 33 Flushing Procedure 2 30 Foot Pad Replacement 6 25 Freeplay Throttle Lever 2 17 Front Compartment Exploded View 6 10 6 11 Fuel Filter 3 18 Fuel Filter Maintenance Non...

Page 328: ...2 5 2 6 2 7 Lubrication Bearing Housing 2 7 Lubrication Carburetor 2 6 Lubrication Choke Cable 2 4 Lubrication Drive Shaft 2 7 5 27 Lubrication Drive Shaft Bearing Housing 5 27 Lubrication Driveshaft Coupler 5 27 5 28 Lubrication Electrical Connections 2 8 Lubrication Oil Injection Pump 2 6 Lubrication Reverse Cable 2 5 Lubrication Seat Latch and Hooks 2 6 Lubrication Steering Cable 2 5 Lubricatio...

Page 329: ...6 Pump Exploded View 5 6 Reed Valve Inspection 3 45 Reed Valve Removal 3 45 Relief Valve Testing 3 42 Reverse Cable Adjustment 2 25 Reverse Exploded View 5 9 Reverse Polaris Electronic Reverse Control PERC 7 45 7 46 Ride Plate 2 37 Ride Plate Installation 5 10 Ride Plate Installation and Sealing 5 21 RPM Limiter Function 7 25 RPM Limiter System Troubleshooting 7 25 S L O W Initiation 8 5 S L O W R...

Page 330: ...26 Troubleshooting Oil Pump 4 41 Troubleshooting PERC 7 47 Troubleshooting Piston Damage 2 42 Troubleshooting Poor Performance 2 40 Troubleshooting Porpoising 2 44 Troubleshooting Rich Fuel Mixture 2 41 Troubleshooting RPM Limiter 7 25 Troubleshooting Vibration 2 44 Temperature Sensor Test Fuji Engines 7 19 Temperature Warning Circuit Operation 7 19 Temperature Warning Circuit Test 7 19 Terminal B...

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