Polaris Freedom / Virage / Genesis / MSX service manual repair 2004 PWC

Chapter 1 General Information ............. Chapter 2 Maintenance ............. Chapter 3 Engine / Cooling Systems ............. Chapter 4 Fuel / Exhaust Systems ............. Chapter 5 Final Drive / Propulsion ............. Chapter 6 Hull / Control Systems ............. Chapter 7 Electrical Systems .............

1 2004 Polaris Personal Watercraft General Information 2004 PWC Identification Numbers 1.1 2004 PWC Publication Part Numbers 1.2 Required PWC Service Tools 1.3 2004 Freedom General Specifications 1.4 -- 1.5 2004 Virage General Specifications 1.6 -- 1.7 2004 Virage i General Specifications 1.8 -- 1.9 2004 Genesis i General Specifications 1.10 -- 1.11 2004 MSX 140 General Specifications 1.12 -- 1.13 General PWC Service / Safety Guidelines 1.14 Standard Torque Specifications 1.15 Decimal Equivalent Charts 1.16 Conversion Charts 1.17 Tap Drill Size Charts 1.18

P L E 1 2 3 4 5 6 7 8 9 10 11 12 Universal Manufacture I.D. Sequential Serial Numbers (Alphanumeric) Certification Month Certification Year Model Decade Model Year HIN (Boarding Platform) HIN (Inside Engine Compartment) HIN (Boarding Platform) HIN (Inside Engine Compartment) EMISSIONS CERTIFICATION LABEL ENGINE I.D. NUMBER FLYWHEEL COVER GENERAL INFORMATION 1.1 2004 Carbureted / DIt PWC Service Manual 2004 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: 4 = 2004

GENERAL INFORMATION 1.2 2004 Carbureted / DIt PWC Service Manual 2004 PWC Publication Part Numbers Model Model Number Owner’s Manual Parts Book Microfiche Freedom W045297DA Freedom International W045297IA 9919051 9919052 Virage W045197DA Virage International W045197IA 9918893 9919049 9919050 Virage i W045101CA 9918893 Virage i International W045101IA 9919047 9919048 Genesis i W045098CA Genesis i International W045098IA 9919045 9919046 MSX 140 W045303CA MSX 140 International W045303IA 9918971 9919053 9919054 S D = 49 State Domestic (No CARB Exemption). S C = 50 State Domestic (CARB Exemption). S A or B = Color Option. S I = International 2004 PWC Service Manual Part Numbers Book Part Number 2004 Carbureted / DIt Models (All) 9919061 2004 MSX 110 / 150 Models (All) 9919062 2004 OCTANE Update Packet 9919065 2004 PWC Flat Rate Manual 9919063 2004 Wallchart Packet TBA

GENERAL INFORMATION 1.3 2004 Carbureted / DIt PWC Service Manual Required Service Tools Tool Part Number (Must Order From Polaris Tool Vendor) 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 EMM Laptop Communication Cable 2872454 Deutsch--to--Packard Comm. Adapter PW--45776 Polaris DIt Diagnostic Software PW--46992 EMM Service Power Connector 2872456 TPS Jumper Tool 2872603 Bump Stop Tool 2872604 Fuel Injector Jumper 2872623 Impeller Removal Tool 2871036 Heavy Duty Flywheel Puller 2871043 Fuel Pump Ring Spanner Wrench 2872621 Driveshaft Removal / Installation Tool PW--46593 Driveshaft Alignment Coupler Tool PW--46592 Pump Alignment Tool 2871343 Crankshaft Truing Stand 2870569 Ducati Ignition Test Probes 2201209 Timing Light 2870630 Battery Hydrometer 2870836 Strap Wrench PU--45419 Fluke 77 Digital Multimeter PV--43568

2004 Freedom W045297DA or IA 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. (267 kg) . Category: Sport .. Riders: 1 to 3 ..... Fuel Capacity:17.8 US Gal. (67.4L) Oil Capacity: 6.0 US Qt. (5.68L) GENERAL INFORMATION 1.4 2004 Carbureted / DIt PWC Service Manual

GENERAL INFORMATION 1.5 2004 Carbureted / DIt PWC Service Manual 2004 Freedom Model Number W045297DA or IA Engine Platform Polaris Libertyt Marine 700LE Engine Model Number W70--SCSP--06B Engine Displacement 701cc Number of Cylinders 2 Cylinder Lining Material Iron Bore & Stroke (mm) 81 x 68 Compression Ratio (Effective) 7.0:1 Cooling System Water Cooled / Thermostat Pop--Off, self--draining, Direct From Propulsion. Thermostat Opening Temperature 143°F (62°C) Overheat Warning Warning Light with 3500 RPM Limit Induction Type Case Reed Lubrication Oil Injected Oil Requirements Polaris Nature Oil TC--W3 RPM Limiter 7200 RPM Exhaust System Water Cooled and Injected 700H Sound Reduction PLANETt Fuel Management System Fuel Delivery Single 40mm Keihin LE Carburetor Fuel Requirement 87 Non--Oxygenated / 89 Oxygenated Idle Speed (In Water) 1300 ± 100 RPM Electrical Ignition System Digital CDI Magneto Generator Output 5A / 60Watts @ 4500 RPM Spark Plug NGK BPR8ES Spark Plug Gap .024 -- .028(.6 -- .7mm) Timing Degrees BTDC 20° @ 3000 RPM Battery 12 Volts / 19 Amps Circuit Breaker / Fuses 15A Battery Circuit Breaker / 2A Gauge Fuse / 3A Bilge Pump Starting Electric Motor -- One Button Start / One Button Stop Propulsion Jet Pump Type Extended Big Mouth Reverse, Single Stage Axial Flow with 5 Vane Aluminum Stator Impeller Rotation Counter Clockwise (From Aft) Coupling Type Bonded Rubber Coupler Minimum Depth For Operation 2 ft. (60cm.) Impeller Type .585° Overlap Impeller Diameter 5.8 in. (148mm) Reverse System N/A Hull / Body Hull Design Full-- V Hull Material SMC (Sheet Molded Compound) Top Deck Material FRC (Fiberglass Reinforced Composite)

2004 Virage W045197DA or IA 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: 600 lbs. (270 kg) . Category: Sport .. Riders: 1 to 3 ..... Fuel Capacity:17.8 US Gal. (67.4L) Oil Capacity: 6.0 US Qt. (5.68L) GENERAL INFORMATION 1.6 2004 Carbureted / DIt PWC Service Manual

GENERAL INFORMATION 1.7 2004 Carbureted / DIt PWC Service Manual 2004 Virage Model Number W045197DA or IA Engine Platform Polaris Libertyt Marine 700LE Engine Model Number W70--SCSP--06B Engine Displacement 701cc Number of Cylinders 2 Cylinder Lining Material Iron Bore & Stroke (mm) 81 x 68 Compression Ratio (Effective) 7.0:1 Cooling System Water Cooled / Thermostat Pop--Off, self--draining, Direct From Propulsion. Thermostat Opening Temperature 143°F (62°C) Overheat Warning Warning Light with 3500 RPM Limit Induction Type Case Reed Lubrication Oil Injected Oil Requirements Polaris Nature Oil TC--W3 RPM Limiter 7200 RPM Exhaust System Water Cooled and Injected 700H Sound Reduction PLANETt Fuel Management System Fuel Delivery Single 40mm Keihin LE Carburetor Fuel Requirement 87 Non--Oxygenated / 89 Oxygenated Idle Speed (In Water) 1300 ± 100 RPM Electrical Ignition System Digital CDI Magneto Generator Output 5A / 60Watts @ 4500 RPM Spark Plug NGK BPR8ES Spark Plug Gap .024 -- .028(.6 -- .7mm) Timing Degrees BTDC 20° @ 3000 RPM Battery 12 Volts / 19 Amps Circuit Breaker / Fuses 15A Battery Circuit Breaker / 1/4A MFI Fuse / 3A Bilge Pump fuse Starting Electric Motor -- One Button Start / One Button Stop Propulsion Jet Pump Type Extended Big Mouth Reverse, Single Stage Axial Flow with 5 Vane Aluminum Stator Impeller Rotation Counter Clockwise (From Aft) Coupling Type Bonded Rubber Coupler Minimum Depth For Operation 2 ft. (60cm.) Impeller Type .585° Overlap Impeller Diameter 5.8 in. (148mm) Reverse System Manual with 3500 RPM Limit Hull / Body Hull Design Full-- V Hull Material SMC (Sheet Molded Compound) Top Deck Material FRC (Fiberglass Reinforced Composite)

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Polaris Freedom / Virage / Genesis / MSX service manual repair 2004 PWC

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