1999 Polaris Genesis 1200 Service & Repair Manual

PQLRRI 5RLE5 inc. 1999 GENESIS, GENESIS FICHT®, X-45 PERSONAL WATERCRAFT SERVICE MANUAL Foreword This manual is designed primarily for use by Polaris personal watercraft service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. The technician should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary impor tance. This manual includes procedures for disassembly and reassembly, inspection, maintenance, component identifi cation and unit repair, along with service specifications for 1999 Genesis, Genesis FICHT®, and X-45 Polaris per sonal watercraft. A table of contents is placed at the beginning of each chapter to aid the user in locating specific areas of information. The alphabetic index at the end of the manual will help the user find specific information quickly. Care is taken to ensure that all information in this manual was technically correct at the time of publication. How ever, all materials and specifications are subject to change without notice. Comments or suggestions about this manual may be directed to: Engineering Services, Technical Writer, Polaris Sales Inc., 1225 Hwy 169 N, Minneapolis, MN 55441-5078. Technical Training Center Minneapolis, MN 55441 1999 Genesis, Genesis FICHT®, X-45 Personal Watercraft Service Manual (PN 9915673) Copyright 1999 Polaris Sales Inc., Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols: f\ The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! DANGER Failure to follow DANGER instructions will result in severe injury or death to the operator, passenger, bystander or person inspecting or servicing the watercraft. A WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator, passenger, bystand er or person inspecting or servicing the watercraft. CAUTION: A CAUTION indicates special precautions that must be taken to avoid minor personal injury, or watercraft or prop erty damage. NOTE: A NOTE provides key information to clarify instructions. Polaris acknowledges the following products mentioned in this manual: Loctite, Registered Trademark of the Loctite Corporation FLEXLOC, Registered Trademark of SPS Technologies MityVac, Registered Trademark of Neward Enterprises Torx, Trademark of Textron Teflon, Trademark of DuPont Vortex, Trademark of Ocean Pro Alemite, Trademark of Alemite Corporation

CHAPTER 1 GENERAL INFORMATION Publication Numbers 1.1 Paint Codes 1.1 Special Tools 1.1 -1.2 Service Bulletins 1.3 Model Identification Numbers 1.4 Model Specifications 1.5 Standard Torque Specifications 1.6 Decimal Equivalents 1.7 Conversion Table 1.8 Tap Drill Charts 1.9 Glossary of Terms 1.10-1.11 Service Tips 1.12

GENERAL INFORMATION Publication Numbers/Paint Codes Watercraft Publication Part Numbers Year 1999 Model Genesis Genesis FICHT® X-45 Model No. B995095 B995094 B994596 Parts Book 9915145 9915148 9915599 Micro- Fiche 9915146 9915149 9915602 Owner's Manual 9915132 9915132 9915132 Paint Codes Model Genesis Genesis FICHT® X-45 Color Bright White (P133) Agean Green Metallic (P285) Agean Green (P284) Seafoam Pearl (P287) Bright White (P133) Agean Green Metallic (P285) Agean Green (P284) Seafoam Pearl (P287) Black (P070) Dark Blue Cloissone (P204) Dealer orders can be placed through Midwest Industrial Coatings using the Polaris "P" number. Phone (612-942-1836). Mix as directed. Special Tools Part Numer 2872454 2872455 2872456 2872602 2872603 2872604 2872605 2872621 2872623 Tool FICHT® EMM Lap Top Communication Cord FICHT® Service Code Light FICHT® EMM Service Power Connector In-line schrader valve fitting used for testing fuel pressure. FICHT® diagnostic TPS Jumper Tool Engine Bumper Tool - For crankshaft indexing the FICHT® en gine. (See Engine section) FICHT® Fuel Injection Diagnostic Software Spanner, Fuel Pump Ring FICHT® PDS (Injector) Jumper Polaris Sales Inc. 1.1 5/99

GENERAL INFORMATION Publication NumbersIPaint Codes FICHTB Fuel Injection Special Tool Photos 5/99 1.2 Polaris Sales Inc.

GENERAL INFORMATION Service Bulletin Index By Model 1999 PWC Bulletin Index By Model Always consult latest service information. Bulletins published after 5-6-99 are not listed in the following index. Model Bulletin # Type Notes All 1999 Models 1999 X-45 1999 Genesis PWC-99-04 Service | Battery Cable Re-routing 1999 Genesis FICHT® 1998 PWC Bulletin Index By Model Model All 1998 Models 1998 SLTX 1998SLXH 1998 SLH 1998 SLTH 1998SLXPro785 Bulletin # PWC-98-02 PWC-98-02 PWC-98-03 PWC-98-03 S-98-01 Type Service Service Safety Safety Service Notes Hard Starting and/or Lean Condition at Part Throttle Hard Starting and/or Lean Condition at Part Throttle Handlebar Clamp Bolts Handlebar Clamp Bolts Cooling Water Outlet Hose Restrictor Service Bulletins -1998 PWC-98-01 1998 SLX Pro 785 Cooling Water Outlet Hose Restrictor PWC-98-02 1998 SLTX; SLXH Hard Starting and/or Lean Condition at Part Throttle PWC-98-03 Safety Alert 1998 SLH; SLXH Handlebar Clamp Bolts Polaris Sales Inc. 1.3 5/99

GENERAL INFORMATION Model Identification Identification Numbers The engine I.D. number and hull I.D. number are used to register the watercraft. They are unique numbers that distinguish each watercraft from others of the same model. If the watercraft is ever stolen these numbers will help identify it. The owner should keep a record of these numbers in a place other than the watercraft. US PLE Hull Number Identification 00000 99 Country of Manufacturers I.D. Serial Month of Year of Model Year Manufacture Number Manufacture Manufacture of Craft Month Code: A = January; B = February; etc. Year Of Manufacture: 8 = 1998; 9 = 1999; etc. Starter Cover Engine I.D. Number (Polaris Domestic Engine) 5/99 1.4 Polaris Sales Inc.

GENERAL INFORMATION Model Specifications Polaris reserves the right to change specifications at any 1 999 X-45 1999 GeneSJS 1 999 Genesis FICHT® time without incurring obligations. Model Number B984596 B995095 B995094 Dimensions/Materials/Capacities Length 120.3" (305.56 cm) 131.1" (330.5 cm) 131.1" (330.5 cm) Width 49.3" (125.22 cm) 49.3" (125.22 cm) 49.3" (125.2 cm) Height 39" (99.06 cm) 40.4" (102.6 cm) 40.4" (102.6 cm) Dry Weight 615 (279 kg) 650 (295 kg) 650 (295 kg) Rider Capacity 3 person/500 lbs. (227 kg) 4 person/600 lbs. (272 4 person/600 lbs. (272 kg) kg) Rated Fuel Capacity including reserve .... 15 U.S. Gal (56.8L) 17 U.S. Gal (64.4L) 17 U.S. Gal (64.4L) Fuel Reserve N/A N/A N/A Oil Reservoir Capacity - U.S. quarts 5.5 (5.20L) 6.0 (5.68L) 6.0 (5.68L) Hull Material Sheet Molded Compound Fiberglass Reinforced Fiberglass Reinforced (SMC) Composite (FRC) Composite (FRC) Top Deck Material Sheet Molded Compound Fiberglass Reinforced Fiberglass Reinforced (SMC) Composite (FRC) Composite (FRC) Full Throttle Cruising Range (Approx.) 55 miles (88.5 km) 55 miles (88.5 km) 61 miles (85 km) Engine/Cooling Engine Model No W120-99TCSP-01A3 W120-99TCSP-01A3 W120-99DFI-01 Engine Displacement 1165cc 1165cc 1165cc Engine Type (# Of Cylinders) Polaris Marine 1200 (3) Polaris Marine 1200 (3) Polaris Marine 1200 FICHT® (3) Bore & Stroke 84mm x 70mm 84mm x 70mm 84mm x 70mm Compression Ratio (Full Stroke) 9.8:1 9.8:1 12.1:1 Horsepower 135 HP @ 6700 RPM 135 HP @ 6700 RPM 135 HP @ 6700 RPM Cooling System Water cooled Water cooled Water cooled Thermostat Open 140°F (60°C) 140°F (60°C) 140°F (60°C) Overheat Warning 3500 Rev Limit @ 237°F 3500 Rev Limit @ 237°F S.L.O.W. "/Warning Light (114°C) (114°C) Induction Type Case Reed Case Reed Case Reed Lubrication Oil Injected Oil Injected Oil Injected Oil Type Polaris TC-W3 or Premium Polaris TC-W3 or Polaris TC-W3 or Premium Gold Synthetic Premium Gold Synthetic Gold Synthetic RPM Limiter Operation 7200 RPM ±100 7200 RPM ±100 7200 RPM ±100 Carburetion Carburetors 3-40mm, Bing 3-40mm, CDK 3-FICHT® Fuel Injectors Fuel Type Regular Unleaded Gasoline Regular Unleaded Regular Unleaded Gasoline (87 Octane or 89 if Gasoline (87 Octane or (87 Octane or 89 if oxygenated) 89 if oxygenated) oxygenated) Idle Speed (In Water) 1350±50 1350±50 1150±50 Electrical Magneto Generator Output 8.5A/60Wat 4500 RPM 8.5A / 60W at 4500 RPM 8.5A/60W at 4500 RPM Ignition System Digital CDI Digital CDI FICHT® Spark Plug Type NGK BR9ES NGK BPR8ES Champion QC10PEP Spark Plug Gap (inches) 028" (0.7mm) .028" (0.7mm) .030" (0.76mm) Timing Degrees BTDC 18°±2 @3000 18°±2 @3000 N/A 13°±2 @6250 13°±2@6250 Battery 12V 19A YB16CL-B 12V 19A YB16CL-B 12V 19A YB16CL-B Starting System Electric Electric Electric Fuse 15A resettable circuit breaker 15A resettable circuit 15A resettable circuit breaker breaker Propulsion Jet Pump Type Single Stage Axial Flow Single Stage Axial Flow Single Stage Axial Flow Impeller Rotation Counterclockwise Counterclockwise Counterclockwise Coupling type Rubber Rubber Rubber Bilge Pump Type Electric Electric Electric Minimum Water Level For Jet Pump 2 Feet (60cm) 2 Feet (60cm) 2 Feet (60cm) Pivoting Angle 30° 30° 30° Impeller Type Slim Hub Stainless Slim Hub Stainless Slim Hub Stainless 3 Blade 3 Blade 3 Blade Impeller Diameter 5.83" (14.8cm) 5.83" (14.8cm) 5.83" (14.8cm) Reverse System Std Std Std *MFD / MFI includes: Speedometer, Peak Speed, Peak RPM, Tachometer, Clock, Hour Meter, Oil Level, Trip Meter, Low Oil Warning, Fuel Level, Volts, Low Fuel Warning, Hot Engine Warning, Compass. Polaris Sales Inc. 1.5 5/99

GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used as a general guideline. Use standard torque values for the appropriate size fastener when torque values are not specified. Always consult the specific manual section for torque values of fasteners and use of locking agent. RECOMMENDED TORQUE SPECIFICATION STAINLESS STEEL FASTENERS (SAE) Bolt Size 8 10 1/4 5/16 3/8 3/8 7/16 1/2 1/2 Threads/Inch 18&32 24&32 20&28 18&24 16 24 14 13 20 Torque 28 in. lbs. 40 in. lbs. 8 ft. lbs. 14 ft. lbs. 25 ft. lbs. 28 ft. lbs. 40 ft. lbs. 58 ft. lbs. 70 ft. lbs. RECOMMENDED TORQUE SPECIFICATION STAINLESS STEEL FASTENERS (METRIC) Bolt Size 5mm 6mm 8mm 10mm 12mm Torque 45-52 in. lbs. 66-78 in. lbs. 13-16 ft. lbs. 26-30 ft. lbs. 40-44 ft. lbs. To convert in. lbs. to ft. lbs. divide by 12 To convert ft. lbs. to kg-m multiply foot pounds by .138. To convert kg-m to Nm move the decimal to the right one position. 5/99 1.6 Polaris Sales Inc.

1999 Polaris Genesis 1200 Service & Repair Manual

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