2000 Polaris VIRAGE PRO 1200 Genesis Watercraft Service Manual

The Way Out. 2000 Virage TX, SLX, Pro 1200, Genesis FFI ™ 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 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 taken to ensure that all information in this manual was technically correct at the time of publication. How ever, all materials and specifications are subject to change without notice. Comments or suggestions about this manual may be directed to: Engineering Services, Technical Writer, Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340. Technical Training Center Minneapolis, MN 55447 2000 Virage TX, SLX, Pro 1200, Genesis, Genesis FFI Personal Watercraft Service Manual (PN 9916290) Copyright2000 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: j\ 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 Alemite, Trademark of Alemite Corporation

CHAPTER 1 GENERAL INFORMATION Publication Numbers 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

GENERAL INFORMATION Publication 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

GENERAL INFORMATION Publication 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.

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. 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 3/00

GENERAL INFORMATION Model Specifications Polaris reserves the right to change specifications at 2000 Wage TX 2000 GeneSJS 2000 GeneSJS FF1™ any time without incurring obligations. * Model Number W005199D W005099D W005098D Dimensions/Materials/Capacities Length 120.3" (305.56cm) 131.1" (330.5cm) 131.1" (330.5cm) Width 49.3" (125.22cm) 49.3" (125.22cm) 49.3" (125.2cm) Height 39" (99.06cm) 40.4" (102.6cm) 40.4" (102.6cm) Dry Weight 620 (280 kg) 625 (282 kg) 625 (282 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 .... 17 U.S. Gal (64.4L) 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 6.0 (5.68L) 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 Fiberglass Reinforced Fiberglass Reinforced Fiberglass Reinforced Composite (FRC) Composite (FRC) Composite (FRC) Engine/Cooling Engine Model No W120-TCSP-02B1 W120-TCSP-02B2 W120-DFI-02B Engine Displacement 1165cc 1165cc 1165cc Engine Type (# Of Cylinders) Polaris Marine 1200 (3) Polaris Marine 1200 (3) Polaris Marine 1200 FFI® (3) Bore & Stroke 84mm x 70mm 84mm x 70mm 84mm x 70mm Compression Ratio (Full Stroke) 6.8:1 6.8:1 6.8:1 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, Premium 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 (87 Octane or 89 if oxygenated) 89 if oxygenated) oxygenated) Idle Speed (In Water) 1350±100 1350± 100 1150±50 Electrical Magneto Generator Output 8.5A / 60W at 4500 RPM 8.5A / 60W at 4500 RPM 12A /160W at 4500 RPM Ignition System Digital CDI Digital CDI FICHT® Spark Plug Type NGK BR9ES NGK BR9ES NGK PZFR6H Spark Plug Gap (inches) 028" (0.7mm) .028" (0.7mm) .032" (0.8mm) Timing Degrees BTDC 23°±1 @3000 23°±1 @3000 N/A 15°±1 @6500 15°±1 @6500 Battery 12V19AYB16CL-B 12V19AYB16CL-B 12V19AYB16CL-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 Dominator Style Dominator Style Dominator Style ImpellerRotation Counterclockwise Counterclockwise Counterclockwise Couplingtype 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° ImpellerType Progressive Pitch Slim Hub Progressive Pitch Radial Progressive Pitch Radial 3 Stainless 3 Blade NuJet 7.0 3 Blade Skat Trak Blade Skat Trak ImpellerDiameter 5.8" (14.73cm) 5.8" (14.73cm) 5.8" (14.73cm) 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. 300 1.4 Polaris Sales Inc.

GENERAL INFORMATION Model Specifications Polaris reserves the right to change specifications at any time without incurring obligations. 2000 SLX 9000 Pro 1900 ModelNumber W004699D W004999D Dimensions/Materials/Capacities Len9th 108.5" (276cm) 108.5" (276cm) Width 47.5" (120.7 cm) 47.5" (120.7cm) Height 39.5" (100.3cm) 39.5" (100.3cm) Dry Weight 565(256kg) 625(282kg) RiderCapacity 2 person/370 lbs. (168 kg) 2 person/370 lbs. (168 kg) Rated Fuel Capacity including reserve 12.5 U.S. Gal (47.3L) 9.8 U.S. Gal (37.1 L) Fuel Reserve N/A N/A Oil Reservoir Capacity - U.S. quarts 5.0 (4.73L) 3.5 (3.31 L) Hull Material Sheet Molded Compound Fiberglass Reinforced (SMC) Composite (FRC) Top Deck Material Fiberglass Reinforced Fiberglass Reinforced Composite (FRC) Composite (FRC) Engine/Cooling EngineModeINo W120-TCSP-02B1 W120-TCSP-02B1 Engine Displacement 1165cc 1165cc Engine Type (# Of Cylinders) Polaris Marine 1200 (3) Polaris Marine 1200 (3) Bore&Stroke 84mmx70mm 84mmx70mm Compression Ratio (Full Stroke) 6.8:1 6.8:1 Horsepower 135 HP @ 6700 RPM 135 HP @ 6700 RPM CoolingSystem Watercooled Watercooled Thermostat Open 140°F(60°C) 140°F(60°C) Overheat Warning 3500 Rev Limit @ 237°F 3500 Rev Limit @ 237°F (114°C) (114°Q Induction Type Case Reed Case Reed Lubrication Oil Injected Oil Injected Oil Type Polaris TC-W3, Premium 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 at 4500 RPM 8.5A / 60W at 4500 RPM Ignition System DigitalCDI DigitalCDI SparkPlugType NGKBR9ES NGKBR9ES Spark Plug Gap (inches) , 028" (0.7mm) .028" (0.7mm) TimingDegrees BTDC 23°±1 @3000 23°±1 @3000 15°±1 @6500 15°±1 @6500 Battery 12V19A YB16CL-B 12V19A YB16CL-B Starting System Electric Electric Fuse 15A resettable circuit breaker 15A resettable circuit breaker Propulsion Jet Pump Type Single Stage Axial Flow Single Stage Axial Flow Dominator Style Dominator Style ImpellerRotation Counterclockwise Counterclockwise Couplingtype Rubber Rubber Bilge Pump Type Electric Electric Minimum Water Level For Jet Pump 2 Feet (60cm) 2 Feet (60cm) PivotingAngle 30° 30° Impeller Type Progressive Pitch Slim Hub Progressive Pitch Radial Stainless 3 Blade NuJet 7.0 3 Blade NuJet 7.0 ImpellerDiameter 5.8" (14.73cm) 5.8" (14.73cm) Reverse System N/A N/A *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. (Some models do not have all features.) Polaris Sales Inc. 1.5 3/00

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. 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.

2000 Polaris VIRAGE PRO 1200 Genesis Watercraft Service Manual

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