Polaris Freedom, Virage, Virage i, Genesis i PWC Repair Service Manual 2003

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This workshop service repair manual PDF download for the 2003 Freedom, Virage, Virage i, Genesis i Polaris Personal Watercraft has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

2003 Polaris Freedom – W035297DA
2003 Polaris Virage – W035197DA
2003 Polaris Virage i – W035101CA
2003 Polaris Genesis i – W035098CA

TABLE OF CONTENTS :

Chapter 1 General Information
Chapter 2 Maintenance
Chapter 3 Engine / Cooling
Chapter 4 Fuel / Exhaust
Chapter 5 Final Drive / Propulsion
Chapter 6 Hull / Control Systems
Chapter 7 Electrical Systems
Chapter 8 Fuel Injection System
Index A-W

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9918112
Total Pages : 294

This polaris watercraft manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.

This polaris service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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Polaris 2003 Freedom, Virage, Virage i, Genesis i Service Manual PN 9918112
Index
Chapter 1 General Information
PWC Identification Numbers
PWC Publication Part Numbers
Watercraft Service Manual Part Numbers
Personal Watercraft Service Tools
2003 Freedom W035297DA
2003 Virage W035197DA
2003 Virage i W035101CA
2003 Genesis i W035098CA
Polaris PWC Emission Certification
PWC Service Guidelines
Standard Torque Specifications
Chapter 2 Maintenance
Recommended Maintenance Products
Periodic Maintenance Schedule
General Lubrication
Throttle / Choke Cable
Steering Cable / Steering Joints
Steering Nozzle
Reverse System
Seat Latch / Hooks
Steering Pivot Shaft
Throttle / Choke Shafts
Oil Injection Pump
Drive Shaft Lubrication
Bonded Rubber Coupler
Bearing Housing
Electrical Components
Battery Connections
Battery Charging
Battery Installation
Battery Storage
Connections / Circuit Breakers / Fuses
Terminal Board
Circuit Breakers
Spark Plugs
DI Model Spark Plug Replacement
Engine
Engine Mounts
Engine Break-In
Cylinder Head Re-Torque
Cylinder Base Gasket Re-Torque
Exhaust Manifold
Water Injection Solenoid Maintenance — Virage i
Exhaust Cooling Orifice/Screen Cleaning
Thermostat/Pop Off Valve Cleaning
Oil Filter
Oil Pump Adjustment
Throttle / Choke Cable Inspection
Throttle Cable Adjustment
Choke Cable Adjustment
Fuel / Water Separator
Fuel Lines / Vent Lines
DI Water Separating Filter
Carburetor Adjustments
Idle Speed — Carbureted Models
Carburetor Air Intake
Cooling System
Cooling System Flushing and Salt Water Maintenance
Flushing Procedure
Storage / Exterior Care
Off Season Storage Procedures
Engine Draining
Fuel System Storage
Engine Fogging Procedure
Cleaning
Fire Extinguisher
Bilge Siphon System
Bilge Drain Plug
Final Drive / Propulsion
Cooling Water Pickup Screen
Scoop / Ride Plate / Intake Grate
Impeller Clearance
Pump Housing Inspection
Sacrificial Anode
Hull / Control Systems
Handlebars/Hand Grips
Seat Adjustment
General Troubleshooting
Lean Condition
Poor Performance
Rich Fuel Mixture
Piston Damage
Engine Overheating / Misc.
Electrical
Vibration / Pump
Porpoising / Hull
Hydrolock
Chapter 3 Engine / Cooling
Engine specifications

Engine Torque Specifications
700cc / 800cc Engine Torque Sequences
1200cc Engine Torque Sequences
Flywheel Housing Cover Torque Sequences
700cc / 800cc Engine Mount Assembly
700cc Crankcase Assembly
700cc Cylinder and Manifold Assembly
700cc Crankshaft and Piston Assembly
800cc Engine Crankcase Assembly
800cc Flywheel and Magneto Housing
800cc Engine Cylinder / Manifold / Ignition Assembly
800cc Engine Throttle Body Assembly
800cc Engine Crankshaft Assembly
1200cc Engine Mount Assembly
1200cc Magneto / Flywheel Cover Housing
1200cc Crankcase Assembly
1200cc Manifold / Ignition Assembly
1200cc Throttle Body Assembly
1200cc Crankshaft and Piston Assembly
Oil Pump Assembly — All Engines
Engine Removal and Installation — All Models
Engine Disassembly — All Engines
Engine Assembly — All Engines
Engine Inspection — All Engines
Cylinder Honing
De-glazing
Honing To Oversize
Port Chamfering
Cleaning the Cylinder After Honing
Crankshaft Truing
Crankshaft Indexing — 700cc Engines
Crankshaft Indexing — 1200cc Carbureted Engines
Crankshaft Indexing – DI Engines
Cooling System — Freedom / Virage
Cooling System — Virage i
Cooling System — Genesis i
Cooling System Overview
Thermostat Pop Off Assembly
Exhaust Cooling Orifice / Screen Cleaning
Chapter 4 Fuel / Exhaust
Freedom / Virage Carburetor Specifications
Keihin Carburetor Jet Part Numbers
Keihin Carburetor System Overview
Keihin 40mm LE Carburetor w/Accelerator Pump — Freedom / Virage
Keihin Carburetor System
Air Intake Cover Assemblies
Vent / Fuel Line Delivery Exploded View — Freedom / Virage
Vent / Fuel Delivery Exploded View — All DI Models
Oil Tank — All Models
Fuel Tank — All Models
Carburetor Pop–Off Valve Testing
Testing Needle and Seat Pop Off Pressure
Fuel / Water Seaparator
Fuel/Water Separator – (Carbureted Models)
Fuel / Water Separator — DI Models
Mixture Screw Inspection and Adjustment
Carburetor Disassembly / Inspection
Carburetor Cleaning
Carburetor Assembly
Carburetor Installation
Cable Adjustment
Throttle / Choke Cable Inspection
Throttle Cable Adjustment
Choke Cable Adjustment
Oil Pump Cable
Idle Speed Adjustment
Mixture Screw Adjustment – Base Setting – Keihin
Mixture Screw Adjustment and Tuning
Fuel Tank Vent Operation
Fuel Tank Check Valve Testing
Fuel Pump Operation
Fuel Pump Maintenance
Disassembly/Inspection
Accelerator Pump Testing
Reed Valve Removal
Reed Valve Inspection
Fuel Line Air Leak Testing
Exhaust System Exploded View — Freedom / Virage / Virage i
Exhaust System Exploded View — Genesis i
Exhaust System — Inspection
Exhaust System Troubleshooting
Chapter 5 Final Drive / Propulsion
Jet
Pump Specifications
Final Drive / Propulsion Service Quick Reference Guide
Ventilation / Cavitation Diagnostics
Ventilation
Cavitation
Driveshaft / Coupler Exploded View
Jet Pump Assembly — Exploded View — Freedom / Virage Models
Jet Pump Assembly — Exploded View — Genesis i
Jet Pump Induction — Freedom / Virage Models
Jet Pump Induction — Genesis i
Reverse System — Virage Models
Reverse System — Genesis i
Jet Pump Removal
Jet Pump Assembly / Installation
Impeller Clearance
Drive Shaft Inspection
Jet Pump Stator Disassembly
Jet Pump Stator Assembly
Jet Pump Alignment
Troubleshooting
Engine Alignment Inspection (Vertical)
Pump Alignment — Continued
Driveshaft Lubrication
Driveshaft Coupler / Bearing Housing Lubrication
Through-hull Bearing Housing Removal / Inspection
Sacrificial Anode
Intake Scoop / Ride Plate Removal and Installation
Chapter 6 Hull / Control Systems
Hull Specifications
Paint Codes / Colors
Freedom / Virage Series Hull Assembly
Genesis i Hull Assembly
Freedom / Virage Series — Front Compartment Door Assembly
Genesis i — Front Compartment Door Assembly
Steering Control Assembly
Steering Assembly
Shroud Assembly
Freedom / Virage Series — Seat Assembly
Genesis i Seat Assembly
Handlebar Cover / Steering Post Removal
Steering Cable Removal / Installation — All Models
Steering Cable Installation
Steering Cable Adjustment
Reverse Cable Adjustment
Speedometer Operation
Top Deck / Hull Repair
Footpad Removal
Footpad Application
Sponson Removal / Installation
Chapter 7 Electrical Systems
Spark Plug Specifications
Alternator Output Specifications
Ignition Timing / CDI Specifications
PWC Battery Specifications
700 Domestic Engine Degrees–to–Piston Position Conversion Chart
800 / 1200 Domestic Engine Degrees–to–Piston Position Conversion Chart
RPM Limiter Systems
RPM Limiter Function
Reverse RPM Limiters
Overheat RPM Limiter Troubleshooting — Freedom / Virage
Reverse RPM Limiter Troubleshooting — Virage
RPM Limiter System Troubleshooting — DI Models — Overheat and Reverse Limit
Warning System Troubleshooting — Freedom
Freedom Warning System / RPM Limiter
RPM Limiter System Diagram — Virage
RPM Limiter System Diagram — Virage I
RPM Limiter System Diagram — Genesis i
Start / Stop Regulator (LR–505)
LR–505 Wire Designations
Start / Stop Regulator (LR–503–1)
LR–503–1 Wire Designations
LR–85 (Freedom Lamp Driver) Wire Designations
Start / Stop Regulator (LR 505 Module) Schematic — Freedom / Virage
Start / Stop Regulator (LR 503–1 Module) Schematic — Virage i / Genesis i
Start / Stop Regulator Troubleshooting — Theory Of Operation
Step–By–Step Starting Process
Step–By–Step Engine Kill Process
Step–By–Step Pump Switch Process
Switched DC Circuit Override
Bilge Pump
Electrical Testing
Charging System Testing — Unregulated Voltage — Freedom / Virage
Charging System Testing — Regulated Voltage — Freedom Virage
Start / Stop Switch Testing — Freedom / Virage / Virage i / Genesis i
Tether Switch Testing — Freedom / Virage / Virage i / Genesis i
Battery
Battery Testing
Preparing A New Battery For Service
OCV – Open Circuit Voltage Test
Load Test
Off-season Storage
Charging Procedure
Multi–Function Instrument (MFI)
DISPLAY SUMMARY
PRIMARY FUNCTIONS
MFI Troubleshooting
Blowing Fuses
Speedometer Reading
MFI Compass Calibration
Dynamic Ignition Timing Adjustment — Carbureted Models
Ignition Timing Adjustment
Ignition Timing Adjustment — Ignition Point Adjustment Unit
Hall Effect Sensor Testing
Alternate Method Of Testing Hall Effect Sensors
Generation III PVL Ignition System Troubleshooting — Freedom / Virage
To Determine Wire Sequence
Starter Motor — Disassembly
Starter Motor — Inspection
Starter Motor — Assembly
Starter Motor — Troubleshooting
Polaris Electronic Reverse Control (PERCt) — Genesis i
REVERSE MOTOR ASSEMBLY TEST
Chapter 8 Fuel Injection System
Fuel Injection System — Components
S.L.O.W. Warning System (Speed Limiting Overheat Warning)
DI Service Specifications
EMM Information Specifications
EMM / Fuel Injector Part Numbers
Fuel Injection Wiring Diagram
EMM Connectors
EMM 8 Pin Connector
EMM 12 Pin Connector
EMM 40 Pin Connector
EMM Service Codes
Ficht Fuel Injection System — Diagnostic Software PODIAG
Laptop Requirements
Laptop–To–EMM Connections
Connecting the Laptop to the EMM
Understanding the EMM communication cable
Service Power Connector
Using the Polaris Diagnostic Software: PODIAG
MAIN MENU – OPTION 1 -FFI DIAGNOSTICS
Service Code Review Screen
Service Code Screens
Retest Option
Session Completion / Code Clearing
FFI Diagnostics — Static Tests
Testing Fuel Injectors
Testing Ignition System
Testing Electric Fuel Pump
FFI Diagnostics – CYLINDER DROP TEST
Diagnose a Misfire
Diagnose Low Performance or Rough Running
Timing Verification Procedure
EMM INFORMATION SCREEN
RPM PROFILE
EXIT PROGRAM
MAIN MENU OPTION 2 -SERVICE UTILITIES MENU
Service Reports
View Current EMM Report
Save Current EMM Report
Print
View Saved Report
Print Saved Report
Injector Information
Replacing Fuel Injectors
Service and Utilities Menu -Option 3 – Service (Replace) EMM
Service EMM
Engine Monitoring
Polaris FFI Diagnostic Software “Site Map”
Communication Problems — Error Screen
Communication Problems — Diagnostic Cable
FICHT
Troubleshooting
ENGINE WILL NOT TURN OVER
ENGINE TURNS–OVER, BUT WILL NOT START
ENGINE DIES / LOSES POWER / NO TOP END
PODIAG COMMUNICATION ERRORS
WIRING DIAGRAMS
Freedom
Virage
Virage i (1 of 2)
Virage i (2 of 2)
Genesis i (1 of 2)
Genesis i (2 of 2)
Index A-W

 

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Polaris Freedom, Virage, Virage i, Genesis i PWC Repair Service Manual 2003.pdf

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