Polaris MSX 140 v2 Owner's Manual PDF

Pages 114
Year 2003
Language(s)
English en
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1 of 114

Summary of Content for Polaris MSX 140 v2 Owner's Manual PDF

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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...

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We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today... Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine weve ever produced... For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owners manual... Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician... Your Polaris dealer knows your vehicle best and is interested in your total satisfaction... Be sure to return to your dealership for all of your service needs during, and after, the warranty period... Refer to page 101 for the part numbers of Polaris products for your vehicle... We take great pride in our Pure Polaris Parts Apparel and Accessories (PAA), available at your Polaris dealership or through our online store at www... purepolaris... com... Have your Pure Polaris products delivered right to your door!

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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 74... ... ... ... ... ENGINE TROUBLESHOOTING 96... ... ... ... ... ... ... ... ... POLARIS PRODUCTS 101... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... SPECIFICATIONS 102... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... WARRANTY 104... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... CALIFORNIA EMISSIONS WARRANTY 107 INDEX 110... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

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Use Biodegradable Products Choose biodegradable products for cleaning your watercraft... Avoid environmentally harmful aerosol sprays, and dispose of used products and containers appropriately... Never place used oil and other chemicals (including soiled towels) in the trash, on the ground or down a drain... Contact your local or state office of public works to find out how to dispose of these wastes in your area...

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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 owners manual... This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals...

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IDENTIFICATION NUMBERS Your watercrafts 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)...

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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...

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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...

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SAFETY Safety Decals The general safety/warning decal is located on the rear of the watercraft, just below the seat...

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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

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To prevent major engine damage: Make sure engine is stopped by pulling lanyard from engine stop switch and turn boat to upright position in a clockwise direction...

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SAFETY Informational Decals The Coast Guard exemption decal is located below the left-hand mirror...

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Operator Guidelines This watercraft is not a toy... Its a high performance powerboat, and operating it requires learned and practiced skills... All operators and passengers should become familiar with proper operating techniques before attempting maneuvers... Always operate the watercraft at a speed appropriate for water conditions and for your level of experience...

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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...

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2 - Eye Protection Wear adequate eye protection to protect against water spray, sun, insects and other objects... To protect prescription eyewear and sunglasses against loss or damage, wear goggles that fit securely over them... 3 - Suit/Shoes/Gloves We recommend that all riders wear a wet/dry suit and watercraft shoes to protect against the force of the water, as well as exposure and unknown hazards in the water, such as debris and hidden objects... Riding gloves may also be considered... NOTE: A helmet may provide increased personal injury protection in some situations, such as impact with the watercraft or during a collision with other watercraft or an obstacle... However, a helmet may not provide adequate protection against all foreseeable impacts and may aggravate some injuries... For example, if a rider falls off a moving watercraft while wearing a helmet, the helmet could catch the water and cause choking, severe and permanent injuries or death... A helmet may also increase the possibility of an accident if it reduces your visibility or ability to hear or if its weight contributes to fatigue...

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Fire Safety Federal regulation requires that all watercraft carry an approved fire extinguisher... The operator is responsible for providing and maintaining the fully charged fire extinguisher in the watercraft... Do not operate the watercraft without a fire extinguisher on board...

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Protective Apparel Normal swimming attire may not provide adequate protection while riding a watercraft... At the rear of the watercraft, the jet pump emits a forceful stream of water that can injure body orifices, such as mouth, eyes, ears, rectum and vagina... In addition, falling off the watercraft while operating at higher speeds may lead to injury due to impact with the water... All riders must wear wet suit bottoms or clothing that provides equivalent protection...

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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... Ingesting sand into the cooling system will also cause the engine to overheat, which could lead to serious mechanical damage...

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Pre-Operation Check Always perform the pre-operation check (beginning on page 38) before starting and riding the watercraft... Make sure all critical components are operating correctly... Check fuel and oil levels and all controls, especially the throttle lever, handlebars, and steering nozzle... Failure of these critical components can result in an accident and lead to severe injury or death...

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Safe Riding Position Falling off a watercraft can result in serious injury... The operator and any passengers should always keep both feet firmly planted on the floorboards while the watercraft is in motion... The passenger should face forward and firmly hang on to the operators waist, except in towing situations, when the spotter faces the rear and uses the grab handle to hold on...

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SAFETY Operator Safety Operator Awareness 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 youre an inexperienced operator... Do not exceed idle speed if any person is within 50 feet (15 m) of the rear of the watercraft...

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Operator Fatigue and Dehydration Long hours of boating with exposure to noise, vibration, sun, glare and wind can result in operator fatigue and dehydration... These conditions can affect your balance, vision, judgment and reaction time... Fatigue and dehydration can increase your risk of an accident resulting in bodily injury or death... Combining alcohol consumption with this condition greatly increases your risk of causing an accident...

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4... Gauge Mode Button - This button operates the display change for the NGI... See page 30... 5... Throttle - Squeeze the throttle lever toward the handlebar to increase speed... Release the lever to slow the craft and return the engine to idle... NOTE: The throttle lever installed on your MSX is finger-operated, but Polaris also offers an accessory thumb-operated lever... See your Polaris dealer for more information... 6... Instrumentation - Instrumentation is New Gen- eration Instrument (NGI)... See page 30 for a detailed explanation of the NGI display... 7... Seat Latch - The seat latch secures the seat in posi- tion... When released, it provides access to the engine compartment...

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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 orienta- tion of the jet pump outlet nozzle, which in turn con- trols the direction of craft movement... 4... Console Storage 5... Seat/Engine Compartment - Removing the seat provides access to the engine, battery, electrical box, exhaust system, and other components...

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FEATURES AND CONTROLS Engine Components (under seat) 1... Battery 2... Engine Management Module (EMM) 3... Spark plugs 4... Air intake cover 5... Starter solenoid 6... Exhaust silencer 7... Exhaust pipe 8... Exhaust cooling water hose 9... Cooling water manifold 10... Thermostat assembly (under end of water manifold) 11... Spark arrestor/air filter 12... Engine cooling water outlet hose (under thermostat assembly)

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FEATURES AND CONTROLS New Generation Instrument (NGI) Primary Functions Speedometer Clock Tachometer Engine Hourmeter Trip Odometer Oil Level Fuel Level Low Oil/Pressure/Fuel/

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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...

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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...

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FEATURES AND CONTROLS New Generation Instrument (NGI) Display Warnings The NGI will alert the operator to the following conditions: LOW FUEL (Fuel level reaches 1/8 level... ) LOW OIL (Oil level reaches 1/7 level... ) LOW BATTERY VOLTAGE

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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...

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Contact an authorized Polaris dealer for replacement parts and equipment... Provide part numbers when possible... Accessories Polaris has a wide range of watercraft accessories, from wetsuits and life vests to accessory mirrors, touring and towing gear, and performance parts... Contact your Polaris dealer or visit www... polarisindustries... com to see our full line of available products...

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EMISSIONS EPA Emissions Regulations 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...

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The one-star label identifies engines that meet the Air Resources Boards 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... EPAs 2006 standards for marine engines...

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each use, severe injury or death could result... Always inspect the vehicle as outlined in the checklist before each use to ensure its in proper and safe operating condition... See page 75 for additional inspection information... Always remove the lanyard from the engine stop switch before performing the pre-operation inspection...

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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 wa- ter intake before starting...

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Never start the engine or let it run in an en- closed area... Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time...

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Your watercraft features an oil injection system, and its 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...

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Polaris synthetic 2-cycle oils are formulated to work with your watercraft engine... Theyve been thoroughly tested to provide the ultimate in performance and protection... Our biodegradable synthetic 2-cycle oil is also environmentally friendly... See page 101 for part numbers of Polaris products...

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CAUTION A clogged intake or the ingestion of sand into the cooling system will cause engine overheating and result in jet pump or engine damage... If any obstruction cannot be removed, have an authorized Polaris dealer service it immediately... Clear the pump of sand after operating in shallow water or after beaching the watercraft...

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OPERATION Pre-Operation Inspection Steering 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...

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Fire Extinguisher 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...

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Use a trickle charger to maintain the batterys charge during the off season... Doing so will ensure a good battery at the end of the storage period and a longer life for the battery... NOTE: The Polaris Battery Tender battery charger can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre-determined point... See your dealer or visit our online store at www... purepolaris... com...

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When the watercraft is out of the water, remove the drain plugs and carefully flush out the bilge with fresh water... Allow the bilge to drain completely... Wipe out the bilge with dry shop towels and reinstall the drain plugs... After launching the craft, remove the seat and check for leaks...

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3... If removing the lanyard lock plate successfully stopped the engine in the previous step, start the engine again and allow it to run for a few seconds... Depress the engine stop button... If the engine doesnt stop immediately, remove the lanyard lock plate to stop the engine... Do not ride the watercraft... See your Polaris dealer for service before operating the watercraft...

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Turning the handlebar pivots the jet pump nozzle (water outlet) which controls the watercrafts direction... The throttle must be applied in order to turn the watercraft... Engine Break-in Procedure The break-in period for your new Polaris watercraft is defined as the time it takes to use the first full tank of gasoline... No single action on your part is as important as following the procedures for a proper break-in... Careful treatment of a new engine will result in more efficient performance and longer life for the engine... Perform the following procedures carefully...

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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...

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OPERATION Navigational Rules This watercraft must be operated in accordance with all navigational rules and regulations governing it and the waterway on which its 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...

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Meeting 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... Keep the other vessel to your port (left) side and take evasive action to the starboard (right) side (1)... This rule does not apply if youll be clear of the other vessel by maintaining your course and speed (2)...

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Crossing Paths When two power vessels are crossing each others path close enough to run the risk of collision, the vessel having the other on the starboard (right) side must give way... For example, if the other vessel (4) is on your vessels (3) starboard (right) side, you must give way... If the other vessel is on your port (left) side, your vessel is the stand-on vessel and should maintain its course and direction... The other vessel must give way... However, always drive defensively in case the give-way vessel fails to give your vessel the proper right-of-way... Always be prepared to stop quickly or take evasive action...

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Fishing Vessel Right-of-Way All vessels that are fishing with nets, lines or trawls are considered fishing vessels under International Rules... Vessels with trolling lines are not considered fishing vessels... Fishing vessels have the right-of-way, regardless of position... However, they must not interfere with the passage of other vessels in narrow channels...

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Reading Buoys and Markers United States waters are marked for safe navigation through the use of buoys and markers with various shapes, colors, numbers and lights to guide boaters... The same is true for waters in particular states... Marking may vary by geographic location... Consult local authorities before riding your watercraft in unfamiliar waters...

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1... Release the throttle lever... When the engine has slowed to an idle and the craft has stopped moving, push in the stop button... The engine should stop immediately... You may also stop the engine by pulling the lanyard lock plate off the engine stop switch...

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CAUTION If the engine is run 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...

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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...

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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...

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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...

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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...

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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...

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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...

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OPERATION Operating in Rough Conditions If riding in rough conditions, its 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...

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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...

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CAUTION Failure to right a capsized craft promptly and correctly may result in severe engine damage if the engine is operated with air or water in the lines... A capsized watercraft must be uprighted in a clockwise direction as viewed from the rear... If the watercraft has remained in a 180 (capsized) position for more than two minutes, all fuel and oil lines must be inspected for water and/or air...

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When more than one person is riding, the watercraft handles differently, which means that the operator must have enough prior riding experience to handle the watercraft with one or more passengers aboard... The operator should be skilled in operation and maneuvers before carrying any passenger...

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starting the engine and revving it repeatedly at partial throttle for about ten seconds until water no longer comes out... NOTE: If the craft is towed up or down a steep hill after removing it from the water, this procedure may be repeated...

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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...

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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...

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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...

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NOTE: Only mechanically experienced individuals should attempt to remove water from a waterlogged engine... Use the procedure on page 73... All others should take the watercraft to an authorized Polaris dealer for service... If this is not possible, call your Polaris dealer for further instructions...

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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...

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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... Do not use petroleum based protectants or lubricants in the engine compartment, as most are flammable and may also deteriorate rubber components...

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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...

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ENGINE Engine corrosion protection/fogging(daily-if used in salt water) L** L L Cooling system flushing (daily after use in salt water) I** I Exhaust cooling hose screen I/C I/C Exhaust hose condition I I Engine mounts (replace if removed for engine service) I I Thermostat/popoff valve assembly/spring I/C I/C* R Water inlet and outlet hoses and clamps I I I R Spark plugs/Compression test I I Spark Plugs (replace every 100 hours) R I R Engine fastener re-torque (cyl head/cyl base, exhaust) I I Oil pump adjustment I I ELECTRICAL Battery condition, fluid level I I Battery vent hose condition/routing (must be clear) I I Battery and starter cables(clean connections / tight) I I I Ground cables-condition, corrosion, fastener torque I I I Engine overheat warning/tone/electrical connections I I Lanyard cord/engine stop switch I I

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Drive shaft/spider coupler/bearing carrier (seals, bearings) I I I I Drive shaft shroud condition I I Siphon system pick-up screens and hoses I/C I/C Cooling water inlet screen/hoses, clamps I/C I/C Jet pump intake grate fasteners and condition I I Impeller condition and impeller clearance I I Pump Sacrificial Anode I I Reverse mechanism I/A I/A

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Seat and compartment seals (condition of seal) I/A I/A Fire extinguisher I I Inspect and tighten all fasteners, including throttle body mounts, en- gine mounts, exhaust system, all hose clamps; inspect muffler, bat- tery, oil and fuel tank fastening devices, pump, steering fasteners... Aggressive riding requires more frequent service...

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Drive Line The drive line consists of a drive shaft spider coupler and a bearing carrier with a sealed bearing inside... It does not require routine greasing... However, grease is required during reassembly of the system when its been disassembled for service... Grease must be applied to the drive shaft before its installed through the bearing carrier... NOTE: We recommend that all drive line service be performed by your Polaris dealer...

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Throttle Body And Oil Injection Pump Grease springs, exposed portions of cable and shafts at the throttle bodies... Grease often if used in salt water...

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Spark plug condition is indicative of engine operation... The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds... Immediately check the spark plug for correct color... A slightly brownish tip is considered normal... The

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Wipe any water from the spark plug and the inside of the cap... Install the spark plug and torque to 18 ft... lbs... (24 Nm)... If a torque wrench is not available, 1/4 to 1/2 turn beyond finger-tight is close to the correct torque... Push the cap down on the plug until it clicks... NOTE: Apply dielectric grease to the inside of the spark plug cap to prevent corrosion... Before installing a used plug, wipe off the threads and apply dielectric grease... Also clean the gasket surface...

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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 watercrafts 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...

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MAINTENANCE AND LUBRICATION Oil Polaris synthetic 2-cycle oils are formulated specifically to work with your Polaris Liberty marine engine... Theyve 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...

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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...

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corrosion... If cleaning is necessary, remove the corrosion with a stiff wire brush... Wash with a solution of one tablespoon baking soda and one cup water... Rinse well with tap water and dry off with clean shop towels... Coat the terminals with dielectric grease or petroleum jelly... Be careful not to allow cleaning solution or tap water into the battery...

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Battery Removal 1... Release the battery by loosening the straps (1)... 2... Remove the battery vent tube from the battery... 3... Disconnect the black (negative) battery cable first... 4... Disconnect the red (positive) battery cable next... 5... Lift the battery out of the watercraft, being careful

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4... Check the results of charging... The specific gravity of each cell must be 1... 26 at room temperature... The voltage should be 14... 5-15... 5 V during charging and 12... 2-12... 8 V after charging...

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2... Install the battery vent tube... NOTE: It must be free of obstructions and securely installed... If 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...

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MAINTENANCE AND LUBRICATION Salt Water and Unclean Water Care 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...

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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...

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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...

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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)... The fogging oil coats all internal parts for prevention of rust and corrosion, which in turn will extend the life of the engine... See page 101 for part numbers of Polaris products...

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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...

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2... Inspect the spark plugs and apply dielectric grease to the threads... Install new plugs if necessary...

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Loose battery connections or ground Check all connections and tighten as needed

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Fouled or defective spark plugs Inspect, clean and/or replace spark plugs

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Weak spark from spark plugs Inspect, clean and/or replace spark plugs

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Clogged exhaust and/or cooling system Clean exhaust, flush cooling system

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ENGINE TROUBLESHOOTING Engine RPM is Too High With Limited Speed

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Fuel System Maintenance Products Carbon Clean Plus 2871326

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ELECTRICAL Alternator Output 12 amp/ 160watt @ 4500 rpm

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Impeller, Stainless Steel 3 Blade, Progressive Pitch, Radial Blade

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REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days... Upon receipt of this registration, Polaris will record the registration for warranty... No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement... If you have not signed the original registration and received the customer copy, please contact your dealer immediately... NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR PERSONAL WATERCRAFT IS REGISTERED WITH POLARIS AND YOU HAVE CONFIRMED THAT YOU HAVE WATCHED THE SAFE- TY AND OPERATION VIDEO AND REVIEWED THE SUMMA- RY TRAINING POINTS...

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Warranty Policy This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling... This warranty also does not cover any per- sonal watercraft that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unautho- rized parts... In addition, this warranty does not cover physical damage to paint or finish, gel coat stress cracks, tearing or puncturing of uphol- stery material, corrosion, or defects in parts, components or personal watercraft due to fire, explosions or any other cause beyond Polaris control...

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Polaris warrants to the ultimate purchaser and each subsequent pur- chaser that this engine is designed, built, and equipped to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act... Polaris warrants that this engine is free from defects in materi- als and workmanship that would cause the engine to fail to conform with applicable regulations for the U... S... EPA emission warranty period, which is one (1) year from the date of purchase for the emission-related components in this engine...

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Select emission control parts from model year 2002 and later watercraft engines are warranted for 4 years, or for 250 hours of use, or for the peri- od prior to the first scheduled replacement of the warranted part as re- quired by the maintenance schedule in the owners manual or other written instructions provided by Polaris, whichever occurs first... How- ever, warranty coverage based on the hourly period is only permitted for watercraft engines equipped with appropriate hour meters or their equivalent... The electronic engine management module in your water- craft engine contains a very accurate clock (i... e... , hour meter) that accu- mulates engine run time... This clock will be used by Polaris to limit warranty coverage to 250 hours of use, within the first 4 years... Warran- ty coverage expires after 4 years, regardless of the hours of use... If any emissionrelated part is defective under warranty, the part will be re- paired or replaced by Polaris...

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CALIFORNIA EMISSION CONTROL SYSTEM LIMITED WARRANTY OWNERS WARRANTY RESPONSIBILITIES: As the watercraft engine owner, you are responsible for performance of the required maintenance listed in your owners manual... Polaris rec- ommends that you retain all receipts covering maintenance on your wa- tercraft engine, but Polaris cannot deny warranty coverage solely for lack of receipts or your failure to ensure the performance of all sched- uled maintenance... As the watercraft engine owner, you should however be aware that Polaris may deny you warranty coverage if your water- craft engine or a part has failed due to abuse, neglect, improper mainte- nance, or unapproved modifications... Receipts and records pertaining to regular scheduled maintenance may be relevant in the event ques- tions arise concerning maintenance... The receipts should be transferred to each subsequent owner of this watercraft...

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This limited warranty is void if the direct cause of the need to repair or replace a warranted part is due to owner/operator abuse, neglect, im- proper maintenance, tampering, modification, misuse, alteration, or improper adjustment... Use of parts that are not equivalent to Polaris parts, improper service, or lack of required maintenance which causes the warranted part(s) to fail may constitute abuse and/or improper ser- vice, thereby invalidating warranty liability hereunder... In addition, the use of addon or modified parts will be grounds for disallowing a war- ranty claim...

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Battery 46, 72, 86-89... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Charging 88... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Fluid 86... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Installation 89... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Maintenance 86... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Removal 87... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Storage 89... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Beaching the Watercraft 63... ... ... ... ... ... ... ... ... ... ... Before Starting the Engine 57... ... ... ... ... ... ... ... ... Boarding in Deep Water 59... ... ... ... ... ... ... ... ... ... ... Boarding the Watercraft 59-60... ... ... ... ... ... ... ... ... Boarding With a Passenger 60... ... ... ... ... ... ... ... ... Boating Under the Influence 22... ... ... ... ... ... ... ... Break-In Procedure 49-50... ... ... ... ... ... ... ... ... ... ... ... ... Buoys And Markers 55... ... ... ... ... ... ... ... ... ... ... ... ... ...

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Safe Riding Gear 16... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Safe Riding Position 21... ... ... ... ... ... ... ... ... ... ... ... ... ... SAFETY 8-23... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Safety Decals 9-12... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Safety Training 5... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Salt Water and Unclean Water Care 90... ... ... Seat 45... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Service and Maintenance 20... ... ... ... ... ... ... ... ... ... Signal Words and Symbols 8... ... ... ... ... ... ... ... ... ... Signal words and symbols 8... ... ... ... ... ... ... ... ... ... Spark Plugs 81-82... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... SPECIFICATIONS 102-103... ... ... ... ... ... ... ... ... ... ... Stand-on Vessel 51... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Starting In Deep Water 59... ... ... ... ... ... ... ... ... ... ... ... Starting the Engine 57-58... ... ... ... ... ... ... ... ... ... ... ... ... Steering Cable 79... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Steering Cable Inspection 85... ... ... ... ... ... ... ... ... ... Steering Inspection 44... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Stopping the Watercraft 62... ... ... ... ... ... ... ... ... ... ... ...

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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...

Manualsnet FAQs

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