2003 Polaris Freedom/Virage/Genesis Watercraft OEM Service & Repair Manual

Freedom Virage Virage i Genesis i 200

2003 Freedom, Virage, Virage i, 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 2003 Freedom, Virage, Virage i, 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. 2003 Personal Watercraft Service Manual (PN 9918112) Copyright 2002 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! 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. WARNING 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 property 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 FICHT, Registered trademark of BMC Inc. NOTE: All attempts were made to provide the most current information available at the time of printing. Polaris reserves the right to change specifications at any time without incurring obligations. The information contained within this service manual is protected by U.S. and international copyright laws, and is the property of Polaris Industries Inc.

Chapter 1 General Information ............. Chapter 2 Maintenance ............. Chapter 3 Engine / Cooling ............. Chapter 4 Fuel / Exhaust ............. Chapter 5 Final Drive / Propulsion ............. Chapter 6 Hull / Control Systems ............. Chapter 7 Electrical Systems ............. Chapter 8 Fuel Injection System / ............. Diagnostic Software

1 2003 PWC Identification Numbers 1.1 .................................. 2003 Publication / Service Material Part Numbers 1.2 ................... Personal Watercraft Service Tools 1.3 .................................. 2003 Freedom Specifications 1.4 -- 1.5 ...................................... 2003 Virage Specifications 1.6 -- 1.7 ........................................ 2003 Virage i Specifications 1.8 -- 1.9 ....................................... 2003 Genesis i Specifications 1.10 -- 1.11 ...................................... PWC Emission Certification / Model Emission Decals 1.12 -- 1.13 ................. Service Guidelines 1.14 ............................................... Standard Torque Specifications 1.15 .................................... Decimal Equivalent Chart 1.16 ......................................... Conversion Chart 1.17 ................................................ Tap Drill Sizes 1.18 ...................................................

HULL I.D. NUMBER Engine I.D. Number (Polaris Domestic Engine) Starter Cover 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 General Information 1.1 2003 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: 2 = 2002; 3 = 2003; etc.

General Information 1.2 2003 PWC Publication Part Numbers Model Model Number Owner’s Manual Parts Book Microfiche Freedom W035297DA 9918097 9918098 Virage W035197DA 9918123 9918099 9918101 Virage i W035101CA 9918123 9918104 9918105 Genesis i W035098CA 9918102 9918103 S D = 49 State Domestic (No CARB Exemption). S C = 50 State Domestic (CARB Exemption). S A or B = Color Option. S I = International Watercraft Service Manual Part Numbers Book Part Number 2003 Freedom, Virage, Virage i, Genesis 9918112 2003 MSX 140 9918121 2003 MSX Four Strokes 9918569 2003 PWC Wallcharts 9918115 2003 PWC Flat Rate Manual 9918114 2003 Octane Service Manual 9918113 2002 All Models 9917370 2002 PWC Wallcharts 9917372 2002 PWC Flat Rate Manual 9917371 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 PW--45776 Polaris FICHT Diagnostic Software All years and all DIt models. 2874492 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

2003 Polaris Freedom/Virage/Genesis Watercraft OEM Service & Repair Manual

You're Reading a Preview

Recently Viewed