2003 MSX Owner's Manual for Vehicle Maintenance and Safety
WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
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All information in this manual is based on the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements that may affect illustrations or explanations. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc. Polaris, Polaris The Way Out, and Workmobiles are registered trademarks of Polaris Industries Inc. Copyright 2002 Polaris Industries Inc.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.
TABLE OF CONTENTS WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TABLE OF CONTENTS . . . . . . . . . . . . . . . . . 4 YOUR RESPONSIBILITIES . . . . . . . . . . . . . 5 IDENTIFICATION NUMBERS . . . . . . . . . . . . 7 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FEATURES and CONTROLS . . . . . . . . . . . 24 EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 36 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 38 MAINTENANCE and LUBRICATION . .
YOUR RESPONSIBILITIES Do Your Part Riding your Polaris watercraft will be an enjoyable experience for you, your family and friends, but we must all do our part to ride safely and protect our environment so we can continue to enjoy this sport for many years. Please show respect for our waterways, our wildlife and other people. Know Your Vehicle As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment.
YOUR RESPONSIBILITIES Age Restrictions This vehicle is not a toy. Polaris recommends that all operators be 16 years of age or older. Contact local authorities to find out what the legal age requirements are in your area of operation. Maintenance Requirements Follow the recommended maintenance program outlined in your owner’s manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.
IDENTIFICATION NUMBERS Your watercraft’s hull and engine identification numbers are important for model identification when registering your watercraft, when obtaining insurance, and when ordering replacement parts. The hull identification number is located on the rear right-hand boarding platform (1). The engine identification number is located at the front of the engine near the stator cover (2).
SAFETY Signal Words and Symbols The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
SAFETY Safety Decals Important warning and instruction decals have been placed on the watercraft for your protection. Read and follow the instructions on each decal carefully. If any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needing replacement will be provided by Polaris at no charge. The warning decals summarize and highlight key safety and operational information.
SAFETY Safety Decals The general safety/warning decal is located on the rear of the watercraft, just below the seat.
SAFETY Safety Decals The collision warning decal is located on the dash of your watercraft. Collisions result in more INJURIES AND DEATHS than any other type of accident for personal watercraft (PWC). TO AVOID COLLISIONS: SCAN CONSTANTLY for people, objects and other watercraft. Be alert for conditions that limit your visibility or block your vision of others. OPERATE DEFENSIVELY at safe speeds and keep a safe distance away from people, objects, and other watercraft.
SAFETY Safety Decals The fuel warning decal is located near the fuel tank fill cap. The capsize warning decal is located at the rear of the watercraft, positioned upside down so the operator can read it when the boat is capsized. WARNING RIGHTING CAPSIZED BOAT S To prevent injury, do not place hands or objects into pump inlet, intake grate or nozzle.
SAFETY Informational Decals The Coast Guard exemption decal is located below the left-hand mirror. Located on the upper shroud near the front compartment door: FIRE EXTINGUISHER CONTAINER LOCATED INSIDE 7171396 Located on the engine water manifold: WARNING Do Not Remove Electrical Part When Starting Or During Operation. High Voltage Shock Hazard.
SAFETY Operator Safety WARNING Failure to follow the warnings and instructions contained throughout this manual and on your vehicle can result in severe injury or death. Read and understand your owner’s manual and all warning decals before operating a Polaris watercraft. Any operator of a Polaris watercraft must know and practice the following guidelines for personal safety and the safety of passengers.
SAFETY Operator Safety Your Polaris watercraft is capable of towing, but please be aware that towing can cause reduced steering control. Be extremely careful when towing other watercraft, skiers or objects behind this watercraft, as they have a significant impact on handling and steering. Observe local and state laws regarding water skiing and towing. Do not allow passengers to stand on the boarding platform while the watercraft is running or in motion. Passengers should always remain seated.
SAFETY Operator Safety WARNING Failure to wear protective clothing while operating a watercraft can result in serious injury. The jet pump emits a forceful stream of water that can injure body orifices. Falling off the watercraft while operating at higher speeds may also lead to injury. Always wear the recommended protective gear while riding on any watercraft. Safe Riding Gear Always wear protective clothing when operating or riding a personal watercraft.
SAFETY Operator Safety Overloading the Watercraft WARNING Overloading a watercraft will significantly reduce vehicle stability and control, which could result in an accident and lead to severe injury or death. Never allow more than the specified rider capacity on the watercraft. Polaris watercraft are designed to carry an operator and up to three passengers, depending on the model. Check the specifications section beginning on page 102 to determine your boat’s rider capacity.
SAFETY Operator Safety Weather and Darkness Protective Apparel Be aware of severe weather conditions. Observe weather forecasts and conditions before venturing out, and do not operate the watercraft when visibility is poor and when the water is rough. Operation of the watercraft in poor weather conditions can result in an accident and lead to severe injury, hypothermia or death. Never operate the watercraft after sunset, before sunrise or in any condition of darkness.
SAFETY Operator Safety Obstacles and Shallow Water Always be on the lookout for dangerous obstacles above and below the water surface, especially in shallow water. Use extra caution when riding in unfamiliar areas. Never ride in water that is less than two feet (60 cm) deep, and do not operate at more than an idle speed in water that is less than six feet deep. Colliding with an underwater object could result in severe injury or death.
SAFETY Operator Safety Turning and Accelerating Pre-Operation Check Turning and accelerating without checking for other boats and objects in your path can cause an accident and result in severe injury or death. Always look behind the watercraft and to each side before accelerating and before making sudden turns. Always be aware of obstacles, swimmers and other watercraft.
SAFETY Operator Safety Jet Pump Water Intake Safety Electrical Shock Hazard Contact with the jet pump or driveline components of the watercraft can result in severe injury, death or drowning. Do not allow hands, feet, ropes, straps, clothing or long hair to come in contact with the jet pump water intake (1) on the bottom of the watercraft while the engine is running.
SAFETY Operator Safety Operator Awareness Boating Under the Influence A collision can cause severe injury or death. Always be aware of other watercraft, swimmers and other obstacles while operating the watercraft. Always maintain a safe distance, especially if you’re an inexperienced operator. Do not exceed idle speed if any person is within 50 feet (15 m) of the rear of the watercraft.
SAFETY Operator Safety Vehicle Modifications Hypothermia Modifications to this machine could create safety hazards and reduce vehicle reliability as well as make it unsafe or illegal to operate. Do not modify this watercraft or any of its components. Any modifications to the watercraft will void your warranty. Your life may depend on a clear understanding of the effects of cold water on the human body. Many suspected drowning victims actually died from cold exposure (hypothermia) rather than drowning.
FEATURES AND CONTROLS 1. Starter Button - Depress and hold the starter button to start the engine. Release it as soon as the engine starts. Do not depress for more than ten seconds at a time. NOTE: The lanyard and lock plate must be attached to the engine stop switch to start the engine 2. Stop Switch/Lanyard - Push this switch down or disconnect the lanyard plate to stop the engine quickly. 3. Safety Lanyard Wrist Cord - The lock plate end is attached to the stop switch.
FEATURES AND CONTROLS 1 4 2 3 5 6 8 10 9 11 7 12 14 13 11 15 16 25
FEATURES AND CONTROLS 1. Front Compartment Door- The door provides access to the fire extinguisher, oil tank, fuel fill, oil fill and main storage space. 2. Fire Extinguisher Compartment - Located under the front compartment door and under the storage bucket in the left side flotation foam, this compartment provides secure storage for the fire extinguisher. 3. Handlebars - The handlebars control the orientation of the jet pump outlet nozzle, which in turn controls the direction of craft movement. 4.
FEATURES AND CONTROLS 3 6 4 2 7 5 1 10 8 9 27
FEATURES AND CONTROLS Engine Components (under seat) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
FEATURES AND CONTROLS Engine Components 4,11 5 2 1 3 12 6 10 9 8 7 29
FEATURES AND CONTROLS New Generation Instrument (NGI) Primary Functions S S S S S S S S Speedometer Clock Tachometer Engine Hourmeter Trip Odometer Oil Level Fuel Level Low Oil/Pressure/Fuel/ Battery Voltage Warnings S High Engine Temperature Warning S Check Engine Warning Accessible Functions S Tachometer S Engine Hourmeter S Trip Odometer 30
FEATURES AND CONTROLS New Generation Instrument (NGI) Function Overview Speedometer The large numeric speedometer displays vehicle speed. The NGI receives signals via a paddle wheel located on the ride plate. The gauge interprets these signals and computes actual vehicle speed. Tachometer The NGI has the ability to display between 0 and 9950 RPM. The gauge receives the tachometer signal from the EMM. Display tolerance is ± 100 RPM. Oil Level Oil level is displayed with a 7-bar LCD graphic.
FEATURES AND CONTROLS New Generation Instrument (NGI) Instrument Operation DISPLAY MODE There are three different display modes the gauge uses to display information to the operator. The three modes are: MAIN MODE, SPEED/TACHOMETER MODE and NAVIGATION MODE. Press and release the MODE button on the left handlebar control to advance through the three modes. MAIN MODE displays SPEED and CLOCK. SPEED/TACHOMETER MODE displays SPEED and TACHOMETER. NAVIGATION MODE displays SPEED, TRIP ODOMETER and ENGINE HOURS.
FEATURES AND CONTROLS New Generation Instrument (NGI) Display Warnings The NGI will alert the operator to the following conditions: S LOW FUEL (Fuel level reaches 1/8 level.) S LOW OIL (Oil level reaches 1/7 level.) S LOW BATTERY VOLTAGE (Battery voltage is at or below 10.9 vDC) S HIGH TEMPERATURE (Temperature is monitored by EMM) S CHECK ENGINE (Check engine warning is triggered by EMM) Regardless of warning, each warning will display a related ISO symbol on the screen and a blinking red LED warning.
FEATURES AND CONTROLS RPM Limiter CAUTION A clogged intake and/or impeller can cause engine overheating and/or damage to the jet pump and impeller parts. Always keep the intake and/or impeller free of debris and weeds. Your Polaris watercraft is equipped with a device that will limit engine revolutions per minute (RPM) if the engine overheats. This feature is designed to help prevent engine damage caused by engine overheating.
FEATURES AND CONTROLS Standard Equipment Optional Equipment S S S S See page 101 for a list of Polaris products for servicing your watercraft. S U.S.
EMISSIONS EPA Emissions Regulations California Star Labels All direct injection equipped engines manufactured by Polaris Industries are certified to the United States Environmental Protection Agency regulations for the control of air pollution. For this reason, factory procedures for servicing must be strictly followed, and wherever practicable, returned to the original intent of the design.
EMISSIONS California Star Labels One Star - Low Emission The one-star label identifies engines that meet the Air Resources Board’s 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines. Three Stars - Ultra Low Emission The three-star label identifies engines that meet the Air Resources Board’s 2008 exhaust emission standards.
OPERATION Pre-Operation Inspection Use the Pre-Operation checklist beginning on page 39 to verify that your vehicle is in proper operating condition before each use. Procedures are outlined in further detail on the pages following the checklist. WARNING If a proper inspection is not performed before each use, severe injury or death could result. Always inspect the vehicle as outlined in the checklist before each use to ensure it’s in proper and safe operating condition.
OPERATION Pre-Operation Inspection Item What To Do Bilge Drain water from the bilge before putting the craft in the water. Fuel/oil tank levels Check fuel/oil; add as necessary; inspect for presence of water. Jet pump water intake Inspect and remove any debris; ensure intake grate is secure; push rear of craft up and down in the water to flush sand out of water intake before starting. Throttle Check for proper operation. Steering Check for proper operation; inspect control cable.
OPERATION Pre-Operation Inspection WARNING Fuel WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas. Gasoline is highly flammable and explosive under certain conditions. Always heed the following warnings pertaining to gasoline and fumes. S Always remove the seat an ventilate the engine compartment before starting the engine.
OPERATION Pre-Operation Inspection Fuel Refueling CAUTION Using a non-recommended fuel may cause serious engine damage. Polaris recommends the use of 87 octane (or higher) non-oxygenated or 89 octane (or higher) oxygenated fuel only. Your watercraft features an oil injection system, and it’s not necessary to pre-mix the gasoline and oil. Refer to the specifications section beginning on page 102 for the proper fuel octane and oil requirements for your Polaris watercraft. Carefully remove the fuel cap.
OPERATION Pre-Operation Inspection Oil CAUTION Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris synthetic 2-cycle oils. Never mix oil brands. The oil fill cap (1) is located 1 under the front compartment door. Check the oil level before each use of the vehicle and add oil as necessary. Make sure the engine is off and the safety lanyard is removed from the engine stop switch before adding oil.
OPERATION Pre-Operation Inspection Jet Pump Intake 1. Ride Plate 2. Impeller 3. Drive Shaft 4. Intake Grate 1 2 WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When disconnecting cables, always disconnect the negative (black) cable first. When reconnecting, always connect the negative (black) cable last. 4 3 1.
OPERATION Pre-Operation Inspection Steering Engine and Storage Compartments Check the handlebars for free movement throughout their full range. Make sure the jet pump outlet nozzle changes direction as the handlebars are turned from left to right and vice versa. Be sure the handlebars and handlebar grips fit snuggly. Visually inspect the control cable to ensure that it’s in working condition.
OPERATION Pre-Operation Inspection Loose Parts Fire Extinguisher Inspect the watercraft for any loose nuts, bolts, fasteners and hoses. Be sure that all hose clamps are tight. Replace cracked or deteriorating hoses. The operator of the watercraft is required by law to carry a fire extinguisher on board. Always keep a fully charged and working fire extinguisher inside the fire extinguisher holder, which is located inside the storage area under the front compartment door.
OPERATION Pre-Operation Inspection Battery WARNING Causing sparks while servicing the battery or servicing the battery when gas fumes are present can result in an explosion, causing serious injury or death. Never create a spark while servicing the battery. If you smell fuel in the craft, do not service the battery. Take the watercraft to your dealer immediately for inspection. Confirm that the battery terminal connections are tight, and make sure the battery is securely fastened in its mounting position.
OPERATION Pre-Operation Inspection Hull Riding Gear Use a non-abrasive cleaner to remove any marine growth and inspect the hull for cracks or damage. Do not operate the watercraft if the hull is damaged. Be sure all operators and passengers have the appropriate riding gear, including a PFD (see page 16). Make sure all trailing objects are securely tied back or stowed. Drain Plugs and Bilge Turn each bilge drain plug (1) counterclockwise and remove it.
OPERATION Pre-Operation Inspection Switches/Buttons Perform these checks while the watercraft is in the water: 1. Check the inside of the engine compartment for fuel or water leaks. Do not operate the watercraft until any leaks have been repaired and the engine compartment has been ventilated. 2. Start the engine and let it run for a few seconds. Remove the lanyard lock 2 plate (1) from the engine stop 1 switch (2) to test operation. The engine should stop immediately.
OPERATION Principles of Operation The engine is directly coupled to a driveshaft. When running, the driveshaft rotates the impeller. The impeller is positioned so that water is drawn up from beneath the watercraft. The water travels through the impeller and is accelerated, producing thrust to move the watercraft forward. Pulling or squeezing the throttle lever increases engine speed (watercraft speed). Turning the handlebar pivots the jet pump nozzle (water outlet) which controls the watercraft’s direction.
OPERATION Engine Break-in Procedure CAUTION If the engine is operated while the watercraft is in very shallow water, sand, weeds and debris may be sucked into the jet intake and could cause damage to the impeller or injury to bystanders. Ingesting sand into the cooling system will cause the engine to overheat, which could lead to engine damage. Whenever starting the engine, always be sure the watercraft is in water at least two feet (60 cm) deep. 50 1.
OPERATION Navigational Rules This watercraft must be operated in accordance with all navigational rules and regulations governing it and the waterway on which it’s operated. These rules are used and enforced internationally, as well as by the U.S. Coast Guard and local law enforcement. Any operator of this watercraft should be aware of these rules and should obey them when encountering other vessels. The following rules are condensed and are provided only for your convenience. Consult a U.S.
OPERATION Navigational Rules Rule 2 Meeting Vessels Rule 2 is “The General Prudential Rule” of the International Rule. This rule states that all operators have the responsibility of taking action to avoid a collision. All vessels involved in a potential collision become give-way vessels. When meeting another power vessel head-on and a collision appears likely, neither vessel has the right-of-way. Both vessels are obligated to alter course to avoid an accident.
OPERATION Navigational Rules Overtaking Vessels Crossing Paths If your watercraft is passing another vessel, your craft is the give-way vessel. The other vessel is expected to maintain its course and speed. You must not interfere with its course of travel. If your craft is the stand-on vessel, maintain your course and speed until the other vessel has passed you.
OPERATION Navigational Rules Non-Motorized Craft Fishing Vessel Right-of-Way Non-motorized craft (sailboats, canoes, etc.) are normally given the right-of-way, with the following exceptions: S When a non-motorized craft is overtaking a power vessel, the power vessel has the right-of-way. S Non-motorized craft should stay clear of fishing vessels. S In a narrow channel, a non-motorized craft should not interfere with the safe passage of a power vessel.
OPERATION Navigational Rules Avoid Collisions Reading Buoys and Markers SCAN CONSTANTLY for people, objects and other watercraft. Be alert for conditions that limit your visibility or block your vision of others. OPERATE DEFENSIVELY at safe speeds, and keep a safe distance away from people, objects and other watercraft. S Do not follow directly behind PWCs or other boats. S Do not go near others to spray or splash water.
OPERATION Launching the Watercraft Stopping the Engine 1. Inspect the drain plugs to ensure they’re securely installed. 2. Launch the watercraft in an area free of weeds and debris. Make sure the craft is in at least two feet of water before starting the engine. 3. Push the rear of the watercraft up and down several times to flush out any sand that could be trapped in the pump. 4. Remove the seat to ventilate the engine compartment. Reinstall the seat and latch securely. 5.
OPERATION Before Starting the Engine Starting the Engine Before starting the engine: 1. Attach the lanyard wrist band (1) to your left wrist or PFD. 2. Fasten the lanyard lock plate to the engine stop switch on the handlebars by pushing the lock plate around the barrel of the switch. Be sure the lanyard is not tangled around the handlebars or controls. NOTE: The engine will not start if the lanyard lock plate is removed from the engine stop switch. 1.
OPERATION Starting the Engine WARNING Starting the engine immediately generates a forward thrust, which could cause an unprepared operator to fall from the machine, causing serious injury or death. Always be seated and alert when starting the watercraft. Never hold the throttle open while starting. 3. Push the starter switch with your left hand while feathering the throttle (very slight open and close motion) with your right hand. As soon as the engine starts, release the starter switch and throttle.
OPERATION Boarding the Watercraft Practice boarding the watercraft in shallow water before riding in deep water. Any passengers should also practice boarding in the event they must reboard in deep water. Boarding and Starting in Deep Water (Operator Only) Make sure the watercraft engine is turned off when boarding in deep water. 1. Swim to the rear of the watercraft. Grip the boarding handle near the rear of the seat. 2. Pull yourself up onto the boarding platform. 3. Move up to the seat and straddle it.
OPERATION Boarding the Watercraft Boarding With a Passenger A watercraft behaves differently with a passenger on board, requiring more operator skill. Practice operating skills alone, before taking a passenger on board. Make sure the watercraft engine is turned off when boarding with a passenger. 1. The operator should board first as outlined on page 59. Attach the lanyard lock plate to the engine stop switch and fasten the lanyard wrist band to the left wrist or PFD. Do not start the engine yet.
OPERATION Reverse Operation WARNING Activating reverse while the craft is moving forward could cause loss of control and result in damage to the watercraft or severe personal injury to the operator or passenger(s). Do not attempt to activate reverse while moving forward above planing speed. 1. To activate reverse, pull the reverse lever all the way up. The lever will remain in the full up 1 position (1). 2. Turn the handlebars and apply throttle carefully to maintain steering control of the watercraft.
OPERATION Stopping the Watercraft WARNING Colliding with an object in the water can result in serious injury to the operator or passengers. All riders must keep feet, arms and hands inside the watercraft at all times, and especially while approaching a dock, vessel or other object. Do not turn off the engine while approaching an object. Engine power is required for steering. The operator of the watercraft should practice stopping to become familiar with the procedure.
OPERATION Beaching the Watercraft CAUTION Sand, pebbles, weeds and debris can enter the jet pump and cause severe damage to components. Ingestion of sand into the cooling system may cause the engine to overheat and could result in severe engine damage. Never beach the watercraft while the engine is running. Shut off the engine when entering water less than two feet (60 cm) deep. 1. Slowly approach the beaching area and stop the engine in no less than two feet (60 cm) of water.
OPERATION Operating in Rough Conditions If riding in rough conditions, it’s possible for the operator to hit his/her chest or face on the watercraft or handlebars and be injured. If the operator is ejected from the craft, injuries may make it difficult to reboard. Operating the craft in rough water conditions is not recommended, and it’s illegal in some states to operate the watercraft in or near the surf line.
OPERATION Towing a Disabled Watercraft If the watercraft becomes inoperable in the water, it can be towed by another watercraft. Before towing, use a vice grip pliers to close off the cooling water inlet hose (1) located at the bottom of the watercraft hull (the hose from the pump box to the exhaust pipe). Clamp it off as near to the T-fitting as possible.
OPERATION Righting a Capsized Watercraft Capsizing a watercraft is not recommended by Polaris and should be avoided. Overturning a watercraft is not considered the normal operation for which your vehicle is intended. WARNING This watercraft does not right itself if it has been capsized. If the operator is unable to right a capsized watercraft, operator and passengers may be stranded, which could lead to serious injury or death.
OPERATION Operating With Passengers WARNING Overloading a watercraft will significantly reduce vehicle stability and control, which could result in an accident and lead to severe injury or death. Never exceed the load capacity for the watercraft. Polaris watercraft are designed to carry an operator and up to three passengers, depending on the model. Refer to the capacity decal on your craft and the specifications beginning on page 102 to determine your boat’s rider capacity.
OPERATION Post Operation Maintenance Daily Care Remove the watercraft from the water every day to inhibit marine organism growth on the hull. 3. Wash the hull, jet pump intake and outlet with fresh water. 4. Remove the drain plugs to drain any water in the bilge. 5. Remove the seat and rinse the engine compartment with a generous amount of fresh water. After the water has drained, wipe the engine compartment (bilge) dry with clean towels. 1. Remove the watercraft from the water. 2.
OPERATION Post Operation Maintenance Daily Care WARNING Serious injury and damage to the watercraft will result if the jet pump and impeller are cleaned while the engine is running. Always stop the engine, remove the lanyard lock plate and disconnect the battery before servicing the jet pump and impeller. 10. Stop the engine and disable all starting mechanisms. Clean the jet pump and impeller of any weeds and debris that may have collected during operation. 11. Inspect the area for damage.
OPERATION Post Operation Maintenance Temporary Storage If the watercraft will be stored temporarily (less than 30 days), perform the daily maintenance procedures beginning on page 68 and also perform the following temporary storage procedures. 1. Block the seat (engine compartment) open about 1/2″ (1.3 cm) to provide air circulation and to prevent condensation from forming. 2. If the seat is saturated with water, stand it on end and allow it to dry out.
OPERATION Post Operation Maintenance Transporting The Watercraft Do not route ropes or tie downs over the seat as they could cause permanent damage to the seat. Protect the watercraft body by placing padding or similar material between the ropes or cables and the watercraft body. Be sure the trailer matches the watercraft’s weight and design and that it meets trailer laws and regulations in your area.
OPERATION Post Operation Maintenance Battery Submerged (Waterlogged) Engine If the watercraft battery is run down, remove it and have it recharged. Refer to battery charging recommendations and service procedures beginning on page 86. If the engine becomes water-flooded, tow the craft to shore and immediately perform the following procedures. WARNING A weak battery may not be able to start the engine and could leave you stranded, which could result in severe injury or death.
OPERATION Post Operation Maintenance Engine Water Removal Procedure Use the following procedure for removing water from a submerged engine. Attempt this procedure only if you are mechanically experienced and have adequate assistance for lifting and supporting the watercraft. WARNING Accidental starting during the water removal procedure could cause severe personal injury. Before removing water from a submerged engine, make sure the lanyard cord and lock plate are removed from the engine stop switch. 1.
MAINTENANCE AND LUBRICATION General Maintenance Replace the pop-off valve, spring and 1 seals every 100 hours. Replace inlet and outlet hoses and clamps every 100 hours. After washing the engine compartment of the watercraft, protect the metal components with a T9 Metal Protectant or another non-flammable metal protectant. Do not use flammable sprays or protectants in the engine compartment.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule NOTE: Maintenance intervals are based upon average operating conditions. Watercraft operated in saltwater require daily corrosion protection and engine flushing, and more frequent maintenance and lubrication. Fogging kits should be added to all Polaris watercraft. The engine should be fogged if the watercraft will not be used for more than 48 hours. Maintenance Schedule Key * Perform every 15 hours or monthly when operated in salt water.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule DESCRIPTION ENGINE Engine corrosion protection/fogging(daily-if used in salt water) Cooling system flushing (daily after use in salt water) Exhaust cooling hose screen Exhaust hose condition Engine mounts (replace if removed for engine service) Thermostat/popoff valve assembly/spring Water inlet and outlet hoses and clamps Spark plugs/Compression test Spark Plugs (replace every 100 hours) Engine fastener re-torque (cyl head/cyl base, exhaust) Oil pum
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Pre-ride Preseason Monthly or 25 hrs. R I Throttle cable I I/L/A Fuel cap/oil cap gaskets I I DESCRIPTION 3 mos. or 50 hrs. 6 mos. or 100 hrs.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Pre-ride DESCRIPTION Preseason Monthly or 25 hrs. 3 mos. or 50 hrs. 6 mos. or 100 hrs.
MAINTENANCE AND LUBRICATION Lubrication Proper lubrication and corrosion protection are necessary to maintain optimum performance and ensure years of service from your watercraft. We recommend the use of Polaris All Season Premium Grease. See page 101 for part numbers of Polaris products. Throttle Cable 1. Lubricate the throttle cable by depressing the throttle lever and squirting grease onto the cable. 2. Push and release the throttle several times to work the grease down the cable.
MAINTENANCE AND LUBRICATION Lubrication Seat Latch And Hooks Steering Nozzle Pivot Shaft Grease the locking mechanism of the seat latch at the rear of the seat opening. Lubricate the steering nozzle shaft pivot connections (1). Throttle Body And Oil Injection Pump Steering Handle Pivot Shaft Grease springs, exposed portions of cable and shafts at the throttle bodies. Grease often if used in salt water. Lubricate the handle pivot shaft and bushing (2). Tighten the steering shaft if it’s loose.
MAINTENANCE AND LUBRICATION Spark Plugs Always use the recommended spark plugs for your Polaris watercraft and make sure the spark plug gap is within specification. Measure gap (1) with a wire thickness gauge. S Use NGK PZFR6H spark plugs. S Proper electrode gap is .028″ +/- .002″ (.71 mm +/- .05 mm). S Spark plug torque is 18 ft. lbs. (24 Nm). 1 CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use the spark plugs recommended for your Polaris watercraft.
MAINTENANCE AND LUBRICATION Spark Plugs A spark plug with cracked porcelain or damaged threads should be changed immediately. If the electrodes are badly worn or burned the plug should also be replaced. If the spark plug is in good condition, clean it with a clean shop cloth and/or wire brush. Adjust the gap to the recommended dimension using a wire thickness gauge. WARNING Removing a spark plug while the engine or exhaust system is hot could result in serious burns.
MAINTENANCE AND LUBRICATION Hull and Deck Care The use of non-recommended cleaning or polishing products could seriously damage the appearance and/or integrity of your watercraft’s gelcoat surface. We recommend the use of the Polaris products listed on page 101. See your Polaris dealer for additional information about the care of your watercraft.
MAINTENANCE AND LUBRICATION Oil Polaris synthetic 2-cycle oils are formulated specifically to work with your Polaris Liberty marine engine. They’ve been thoroughly tested and provide the ultimate in performance and protection for your engine. In addition, our biodegradable oil is environmentally friendly. See page 101 for the part numbers of Polaris products. CAUTION Mixing brands or using a non-recommended oil may cause serious engine damage. Always use a recommended oil. Never mix oil brands.
MAINTENANCE AND LUBRICATION Steering Cable Inspection Fuses 1. The handlebars and steering nozzle should operate smoothly. If movement is stiff, see your authorized Polaris dealer for service. 2. Turn the handlebars from lock to lock and check to be sure that the clearances between the steering nozzle and the rear hull are even on both sides. If the alignment is not even, see your authorized Polaris dealer for service. The NGI is protected by a 2 amp fuse.
MAINTENANCE AND LUBRICATION Battery Battery Maintenance and Charging WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases.
MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. 1 Battery Removal 1. 2. 3. 4. 5. Release the battery by loosening the straps (1). Remove the battery vent tube from the battery. Disconnect the black (negative) battery cable first.
MAINTENANCE AND LUBRICATION Battery Battery Charging WARNING Batteries produce explosive gases. Any sparks in the area could result in an explosion and cause serious injury or death. Keep sparks, flame, cigarettes, etc. away. Never charge a battery while it’s in the watercraft. Always remove the battery and charge in a safe area. Make sure the battery charger is turned off and unplugged before connecting the cables to a battery. Ventilate when charging or using in an enclosed space.
MAINTENANCE AND LUBRICATION Battery Battery Installation 1. Set the battery in the battery holder. 1 2. Install the battery vent tube. NOTE: It must be free of obstructions and securely installed. If Black (-) Red (+) not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion. Avoid skin contact with electrolyte, which can cause severe burns. 3. Connect and tighten the red (positive) cable first. 4.
MAINTENANCE AND LUBRICATION Salt Water and Unclean Water Care Jet Pump Water Inlet Screen When the watercraft is operated in salt water or water with impurities like silt, sand and other particulates, additional cleaning and maintenance is mandatory after each use. Clean the jet pump water inlet screen and all other affected areas of the watercraft. Flush the cooling system. The water inlet screen (1) is located inside the stationary nozzle of the jet pump.
MAINTENANCE AND LUBRICATION Cooling System Flushing The watercraft uses water for propulsion and for cooling. Flushing the cooling system with fresh water (never anti-freeze) will neutralize the corroding effects of salt water or water with impurities like silt, sand, alkali and other particles. Flushing will also clean out other residue left in the water passages of the watercraft cooling system.
MAINTENANCE AND LUBRICATION Extended Storage When the watercraft will not be used for a month or more, preventative maintenance is required to keep components from deteriorating. An authorized Polaris dealer can do the required preventative maintenance or you can do it yourself with a minimum of tools. Perform all of the procedures outlined in this section of your owner’s manual before storing the watercraft. Refer to page 101 for part numbers of Polaris products.
MAINTENANCE AND LUBRICATION Extended Storage CAUTION Failure to fog the engine can result in serious engine corrosion during off season or extended storage. Always fog the engine as outlined before storing the watercraft for extended periods. Watercraft Engine Fogging Procedure Polaris recommends the use of fogging oil to prevent rust and corrosion on internal engine parts (i.e. crankshaft, bearings, pistons, rings, cylinder walls).
MAINTENANCE AND LUBRICATION Extended Storage CAUTION Never clean the watercraft with strong detergents, abrasives, degreasers, paint thinner, acetone, window cleaners, ammonia or products containing alcohol. They can damage finishes, decals, vinyl and plastics and accelerate UV breakdown, which could cause color change and premature deterioration of parts. Cleaning 1. Remove the drain plugs and clean the bilge and engine area with hot water and mild detergent (such as dish soap) or with bilge cleaner.
MAINTENANCE AND LUBRICATION Extended Storage Lubrication 1. Remove the spark plugs and pour about one tablespoon of a recommended 2-cycle oil into each cylinder. 2. Inspect the spark plugs and apply dielectric grease to the threads. Install new plugs if necessary. 3. Lubricate the throttle and steering cables as outlined on page 79. 4. Lubricate all areas recommended in the maintenance section beginning on page 79. 5. Remove and store the battery as outlined beginning on page 86.
ENGINE TROUBLESHOOTING Engine Doesn’t Turn Over Possible Cause Solution Blown fuse Replace the fuse Low battery voltage Recharge battery to 12.
ENGINE TROUBLESHOOTING Engine Runs Irregularly, Stalls or Misfires Possible Weak Spark Cause Solution Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose spark plug connections Check all connections and tighten Water present in fuel Replace with new fuel Clogged exhaust pipe screen fitting Clean screen fitting Water in exhaust pipe Dra
ENGINE TROUBLESHOOTING Engine Overheats Possible Cause Solution Clogged jet pump intake Clean intake Use of non-recommended fuel or oil Replace with recommended fluids Sand or debris in cooling system Flush the cooling system Plugged thermostat assembly Disassemble and clean thermostat Plugged cooling system Inspect and clean cooling system Clogged exhaust pipe screen fitting Clean screen fitting Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or repl
ENGINE TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap Set gap to specs or replace plugs Engine Loses Power Possible Cause Solution Weak spark Replace spark plugs and/or wires Incorrect fuel or fuel mixture Replace with recommended fuel Water present in fuel or oil tank Replace with recommended fluids Clogged fuel filter See your Polaris dea
ENGINE TROUBLESHOOTING Engine RPM is Too High With Limited Speed Possible Cause Solution Clogged jet pump intake Clean intake Cavitation, impeller damaged or worn See your Polaris dealer Unusual Noise or Vibration From Propulsion System Possible Cause Solution Weeds or debris lodged in impeller Clean the impeller Damaged driveshaft See your Polaris dealer Damaged pump bearings See your Polaris dealer 100
POLARIS PRODUCTS Oil and Lubricants Premium Gold Synthetic 2-Cycle Oil Quart Gallon VES II Synthetic 2-Cycle Oil Quart Gallon 2.5 Gallon Nature Oil Biodegradable 2-Cycle Oil Gallon General Maintenance Products 2871721 2871722 2874438 2874439 2874443 2872607 Fuel System Maintenance Products Carbon Clean Plus Isopropyl Fuel De-Icer Premium Fuel Stabilizer 2871326 2870505 2870652 All Season Premium Grease 3 oz. / 4 pack 14 oz.
SPECIFICATIONS CAPACITIES / DIMENSIONS Fuel Tank Oil Reservoir Rider Capacity Rider Weight Limit (total) Total Weight Capacity Length Width Height Dry Weight Hull Material 17.8 gal. (67.4 l) 6.0 gal. (5.68 l) 1-3 people 500 lbs. (227 kg) 565 lbs. (256 kg) 126 in. (320 cm) 48.3 in. (122.6 cm) 42.5 in. (108 cm) 685 lbs. (311 kg) Fiberglass Reinforced Composite ELECTRICAL Alternator Output Spark Plug Type Spark Plug Gap Starting System Battery 12 amp/ 160watt @ 4500 rpm NGK PZFR6H .028″ +/- .002″ (.
SPECIFICATIONS PROPULSION Impeller, Stainless Steel Propulsion Jet Pump Type Transmission Reverse System Impeller Diameter 3 Blade, Progressive Pitch, Radial Blade Jet Drive Dominator, Single Stage Axial Flow, Six Vane Stainless Steel Stator Direct Drive Standard 5.83 in.
WARRANTY Obtaining Service and Warranty Assistance LIMITED WARRANTY Read carefully and understand the service data and the Polaris Warranty contained in this manual. Contact your Polaris dealer in matters pertaining to replacement parts, service, or warranty. Your dealer is constantly kept up-to-date on changes, modifications, and tips on personal watercraft maintenance that may supersede information contained in this manual.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: Limitations of Warranties and Remedies This Polaris limited warranty covers all parts and components except for impeller damage caused by ingestion of rocks, sand, or gravel or any other damage caused by operation in shallow water. The warranty also excludes any other failures that are not caused by a defect in material or workmanship. Warranty Policy This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling.
WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your personal watercraft requires warranty service, it must be taken to a Polaris dealer authorized to repair Polaris personal watercraft. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (The cost of transportation to and from the dealer is your responsibility.) Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service.
CALIFORNIA EMISSION CONTROL SYSTEM LIMITED WARRANTY POLARIS WATERCRAFT ENGINES YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Polaris Industries, Inc. (Polaris) are pleased to explain the California emission control system limited warranty on your Model Year 2002 or later Polaris watercraft engine. In California, new watercraft engines must be designed, built and equipped to meet the State’s stringent anti–smog standards.
CALIFORNIA EMISSION CONTROL SYSTEM LIMITED WARRANTY OWNER’S WARRANTY RESPONSIBILITIES: As the watercraft engine owner, you are responsible for performance of the required maintenance listed in your owner’s manual. Polaris recommends that you retain all receipts covering maintenance on your watercraft engine, but Polaris cannot deny warranty coverage solely for lack of receipts or your failure to ensure the performance of all scheduled maintenance.
CALIFORNIA EMISSION CONTROL SYSTEM LIMITED WARRANTY WARRANTED PARTS: 1.Fuel Metering System –Fuel injection system –Cold start enrichment system –Intake valves 2.Air Induction System –Intake manifold –Air filter 3.
INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . Age Restrictions . . . . . . . . . . . . . . . . . . Anti-corrosion Treatment . . . . . . . . . . Avoid Collisions . . . . . . . . . . . . . . . . . 35 6 72 55 B Battery . . . . . . . . . . . . . . . . 46, 72, 86-89 Battery Charging . . . . . . . . . . . . . . . . . 88 Battery Fluid . . . . . . . . . . . . . . . . . . . . 86 Battery Installation . . . . . . . . . . . . . . . 89 Battery Maintenance . . . . . . . . . . . . . .
INDEX N Navigational Rules . . . . . . . . . . . . . 51-55 New Generation Instrument . . . . . . 30-33 Non-motorized Craft . . . . . . . . . . . . . . 54 O Obstacles and Shallow Water . . . . . . . 19 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Operating in Rough Conditions . . . . . 64 Operating With Passengers . . . . . . . . . 67 OPERATION . . . . . . . . . . . . . . . . . 38-73 Operator Awareness . . . . . . . . . . . . . . 22 Operator Fatigue and Dehydration . . .
Pantone 307 Read and understand all warning labels and Owner's Manual before operation. Severe injury or death can result from ignoring warnings or from improper use. Never permit a guest to operate this watercraft unless the guest has read and understands all warning labels and the Owner's Manual. THIS MANUAL SHOULD REMAIN WITH THE WATERCRAFT, IN ITS STORAGE BAG, AT ALL TIMES. For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy.
