2002 POLARIS VIRAGE I Factory Service & Work Shop Manual

Freedom Virage Virage Virage TX Virage TX Virage i Virage i Virage TXi Genesis Genesis i 2002 Personal Watercraft Service Manual 2002 Personal Watercraft Service Manual Part Number 9917370 Part Number 9917370

2002 Freedom, Virage, Virage TX, Virage i, Virage TXi, Genesis, Genesis i 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 identification and unit repair, along with service specifications for the 2002 Freedom, Virage, Virage TX, Virage i, Virage TXi, Genesis, and Genesis i 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. 2002 Personal Watercraft Service Manual (PN 9917370 ) Copyright 2001 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: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow DANGER instructions will result in severe injury or death to the operator, passenger, bystander or person inspecting or servicing the watercraft. Failure to follow WARNING instructions could result in severe injury or death to the operator, passenger, bystander 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 ............. Chapter 2 Maintenance ............. Chapter 3 Engine / Cooling ............. Chapter 4 Carburetion / Exhaust ............. Chapter 5 Final Drive / Propulsion ............. Chapter 6 Hull / Control Systems ............. Chapter 7 Electrical Systems ............. Chapter 8 Fuel Injection System / ............. Software

2002 PWC Identification Numbers 1.1 .................................. 2002 PWC Publication Part Numbers 1.2 ............................... Service Tools 1.3 .................................................... Freedom Specifications 1.4 -- 1.5 ........................................... Virage Specifications 1.6 -- 1.7 ............................................. Virage TX Specifications 1.8 -- 1.9 .......................................... Virage i Specifications 1.10 -- 1.11 ............................................ Virage TXi Specifications 1.12 -- 1.13 .......................................... Genesis Specifications 1.14 -- 1.15 ............................................ Genesis i Specifications 1.16 -- 1.17 ........................................... Standard Torque Specifications 1.18 .................................... Decimal Equivalent Charts 1.19 ........................................ Conversion Chart 1.20 ................................................ Tap Drill Size Charts 1.21 .............................................. Service Glossary 1.22 -- 1.23 ................................................. Service Guidelines 1.24 ...............................................

PLE 00000 A 0 02 Manufacturers I.D. Serial Number Month of Manufacture Year of Manufacture Model Year of Craft Hull Number Identification US Country of Manufacture HULL I.D. NUMBER Engine I.D. Number (Polaris Domestic Engine) Starter Cover General Information 1.1 2002 PWC 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. Month Code: A = January; B = February; etc. Year Of Manufacture: 1 = 2001; 2 = 2002; etc.

General Information 1.2 2002 PWC Publication Part Numbers Model Model Number Owner’s Manual Parts Book Microfiche Freedom W025297D/I 9917547 9917548 Virage W025197D/I 9917129 9917130 Virage TX W025199D/I 9917132 9917133 Virage i W025101D/C/I 9917128 9917138 9917139 Virage TXi W025198D/C/I 9917135 9917136 Genesis W025099D/I 9917141 9917142 Genesis i W025098D/C/I 9917144 9917145 D = US/Canada C = California I = International Watercraft Service Manual Part Numbers Book Part Number 2002 All Models 9917370 2002 PWC Wallcharts 9917372 2002 PWC Flat Rate Manual 9917371 2001 SLH / Virage 9917163 2001 1200s (SLX, Virage TX, Genesis, PRO 1200, Virage TXi, Genesis i) 9917164 2001 PWC Wallcharts 9917166 2000 700 / 785 9916289 2000 1200 9916290 FFIt Diagnostic Guide 9916771 1999 1200 9915673 1999 PWC Volume II 9915085 1995 Supplement 9913365 1992 -- 1996 PWC Volume I 9912201 Watercraft Service Video Part Numbers Video Part Number Introduction to FICHT Fuel Injection 9915680 FICHT Diagnostics 9915891 PWC Jet Pump Service 9915819 Generation III Ignition Troubleshooting 9917441

General Information 1.3 Personal Watercraft Service Tools Tool Part Number (Must Order From Polaris Tool Vendor) Piston Pin Puller 2870386 Piston Pin Puller Adapter (Works with 2870386) 2871445 Piston Support Block 2870390 C--Clip Installation Tool 2870773 Piston Pin Puller (800 / 1200cc Engines) PU--45255 Piston Pin Puller Adapter (800 / 1200cc Engines) PU--45248 Timing Adjustment Tool 2872290 EMM Laptop Communication Cable 2872454 Deutsch--to--Packard Comm. Adapter 2874061 1999 to Current DIt Diagnostic Software 2874118 Service Code Light 2872455 EMM Service Power Connector 2872456 TPS Jumper Tool 2872603 Bump Stop Tool 2872604 Fuel Injector Jumper 2872623 Impeller Removal Tool (Rubber Coupler Remover) 2871036 Steel Coupler Removal Tool 2871037 Pump Alignment Tool 2871343 Through--Hull Fitting Tool 2871425 Static Timing Tool 2871745 Heavy Duty Flywheel Puller 2871043 2002 TPS Test Tool 2201519 2002 TPS Test Tool Adapter (Allows connection of tool to both snowmo bile and PWC TPS sensors.) TBD Use Diagnostic Software

2002 Freedom W025297D Length: 120.3 in. (305.6 cm.) .... Width: 49.3 in. (125.2 cm.) ..... Height: 39 in. (99.1 cm.) ..... Draft: 9 in. (22.9 cm.) ...... Dry Weight: 590 lbs. . Category: Sport .. Riders: 1 to 3 ..... Fuel Capacity:17 US Gallons (64.4 L) Oil Capacity: 6 US Quarts (5.8 L) General Information 1.4

General Information 1.5 2002 Freedom Model Number W025297D Engine Platform Polaris Marine 700 LE Engine Model Number W70--SCSP--05A Engine Displacement 701cc Number of Cylinders 2 Bore & Stroke (mm) 81x68 Compression Ratio (Full Stroke) 7.0:1 Horsepower 95 Maximum Torque 69.2 Cooling System Water Cooled / Thermostat Pop--Off, self--draining, Direct From Propulsion. Thermostat Opening Temperature 143F (62C) Overheat Warning Low oil and Overheat / RPM Limit at 3500 RPM Induction Type Case Reed Lubrication Oil Injected Oil Requirements Polaris TC--W3 RPM Limiter 7200 RPM Exhaust System Water Cooled / Injected 700H Sound Reduction New Silencer / PLANETt Carburetion Fuel Delivery (1) 40mm Keihin LE Carburetor Fuel Requirement 87 Non--Oxygenated / 89 Oxygenated Idle Speed (In Water) 1350100 Electrical Ignition System Digital CDI / Flywheel Magneto Magneto Generator Output 5A / 60W @ 4500 RPM Spark Plug NGK BPR8ES Spark Plug Gap .024 -- .028(.6 -- .7mm) Timing Degrees BTDC 20 @ 3000 RPM Battery 12V / 19A Circuit Breaker / (Fuses) 15A Circuit Breaker (3A Bilge Located within electrical box) Starting Electric (One button start and stop) Propulsion Jet Pump Type Extended Big Mouth Reverse, Single Stage Axial Flow w/ Five Vane Aluminum Stator Impeller Rotation Counter Clockwise (From AFT) Coupling Type Rubber Coupler Minimum Depth For Operation 2 ft. (60cm.) Pivoting Angle 30 Impeller Type .585 Overlap Impeller Diameter 5.8 in. Reverse System N/A Hull / Body Hull Design Full V Hull Material SMC (Sheet Molded Compound) Top Deck Material FRC (Fiberglass Reinforced Composite)

2002 POLARIS VIRAGE I Factory Service & Work Shop Manual

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