Polaris Freedom, Virage, Virage TX, Virage i,Virage TXi, Genesis, Genesis i PWC Service Manual 2002

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This workshop service repair manual PDF download for the 2002 Freedom, Virage, Virage TX, Virage i,Virage TXi, Genesis, 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 :

2002 Polaris – Freedom W025297D/I
2002 Polaris – Virage W025197D/I
2002 Polaris – Virage TX W025199D/I
2002 Polaris – Virage i W025101D/C/I
2002 Polaris – Virage TXi W025198D/C/I
2002 Polaris – Genesis W025099D/I
2002 Polaris – Genesis i W025098D/C/I

TABLE OF CONTENTS :

Chapter 1 – General Information
Chapter 2 – Maintenance
Chapter 3 – Engine / Cooling
Chapter 4 – Carburetion / Exhaust
Chapter 5 – Final Drive / Proplusion
Chapter 6 – Hull /Control Systems
Chapter 7 – Electrical Systems
Chapter 8 – Fuel Injection System
Wiring Diagrams

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9917370
Total Pages : 370

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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2002 Cover (PN 9917370)

Freedom, Virage, Virage TX, Virage i,Virage TXi, Genesis, Genesis i

Table of Contents

Chapter 1 – General Information

PWC Identification Numbers
PWC Publication Part Numbers
Personal Watercraft Service Tools
Specifications

2002 Freedom W025297D

2002 Virage W025197D
2002 Virage TX W025199D
2002 Virage i W025101D
2002 Virage TXi W025198D
2002 Genesis W025099D
2002 Genesis i W025098D
Standard Torque Specifications
Conversion Chart
Service Glossary
Service Guidelines
Chapter 2 – Maintenance

Recommended Maintenance Products
Periodic Maintenance Schedule
Fogging
PWC Specific Maintenance Products
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 Couple
Through-Hull
Bearing Housing
Electrical Components
Battery

Battery Safety
Battery Removal
Battery Connections
Battery Charging
Battery Installation
Battery Storage
Electrical Connections
Terminal Board
Circuit Breaker — Carbureted Models
Fuses — Carbureted Models
Circuit Breakers — DIt Models
Fuses — DIt Models
Spark Plugs
Engine
Engine Mounts
Compression Test
Engine Break-In
Cylinder Head Re-Torque
Cylinder Base Gasket Re-Torque
Exhaust Manifold
Water Injection Solenoid Maintenance — (Virage i Only)
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
Fuel Filter
DI Water Separating Filter

Carburetor Adjustments
Idle Speed
Carburetor Air Intake
External Engine Corrosion Prevention
Bilge Siphon System
Bilge Drain Plug
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
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
Steering Cable Inspection
Steering Cable Adjustment
Reverse Cable 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
700cc Engine Torque Specifications — Freedom / Virage
Polaris 800cc / 1200cc Engines — Carbureted / DI Torque Specifications

Virage TX / Virage i / Virage TXi / Genesis / Genesis i
700cc / 800cc Engine Torque Sequences — Freedom / Virage / Virage i
1200cc Engine — Carbureted / DI Torque Sequences — Virage TX / Virage TXi / Genesis / Genesis i
Flywheel cover – All Engines – Carbureted / DI Torque Sequences
700cc / 800cc Engine
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
1200cc Engine Mount Assembly
1200cc Crankcase Assembly — Carbureted Models
1200cc Crankcase Assembly — DI Models
1200cc Cylinder and Manifold Assembly — Carbureted Models
1200cc Manifold / Ignition Assembly — DI Models
1200cc Throttle Body Assembly — DI Models
1200cc Crankshaft and Piston Assembly
Oil Pump Assembly — All Engines
Engine Removal and Installation — All Models
Engine Removal
Engine Installation
Engine Disassembly — All Engines
Engine Assembly — All Engines
Engine Inspection — All Engines
Cylinder Honing
Port Chamfering
Crankshaft Truing
Crankshaft Indexing — 700cc Engines
Crankshaft Indexing — 1200cc Carbureted Engines
Crankshaft Indexing – DI Engines
Cooling System
Cooling System — Freedom / Virage
Cooling System — Virage TX
Cooling System — Virage i
Cooling System — Genesis
Cooling System — Virage TXi / Genesis i
Cooling System Overview
Thermostat Pop Off Assembly
Exhaust Cooling Orifice / Screen Cleaning
Chapter 4 – Carburetion / Exhaust

Freedom / Virage Carburetor Specifications
Virage TX Carburetor Specifications
Genesis Carburetor Specifications
Keihin
Carburetor
Keihin Carburetor Jet Part Numbers
Keihin Carburetor System Overview
Pop Off Pressure
Needle Valve / Diaphragm Operation
Keihin 40mm LE Carburetor w/Accelerator Pump — Freedom / Virage
Keihin 40mm CDK Carburetor w/Accelerator Pump — Virage TX / Genesis
Keihin Carburetor Diagram

Air Intake Cover Assembly Exploded View — 700 Engines
Air Intake Cover Assembly — Exploded View — 800 / 1200 Engines
Vent / Fuel Line Delivery Exploded View — Freedom / Virage
Vent / Fuel Delivery Exploded View — All 1200cc Carbureted Engines
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 Filter
Fuel / Water Separator
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
Inspection
Relief Valve Testing
Fuel Tank Check Valve Testing
Fuel Pump Operation
Fuel Pump Maintenance
Fuel Pump Disassembly/Inspection
Accelerator Pump Testing
Reed Valve Removal
Reed Valve Inspection
Fuel Line Air Leak Testing
Exhaust System
2002 Exhaust System Exploded View — Freedom / Virage / Virage i
2002 Exhaust System Exploded View — Virage TX
2002 Exhaust System Exploded View — Virage TXi
2002 Exhaust System Exploded View — Genesis / Genesis i
Exhaust System — Inspection
Exhaust System Troubleshooting
Chapter 5 – Final Drive / Proplusion
Jet Pump Specifications
Final Drive / Propulsion Quick Reference Guide
Jet Pump Ventilation / Cavitation Diagnostics
Ventilation
Cavitation
Driveshaft / Coupler Exploded View — Freedom / Virage Series
Driveshaft / Coupler Exploded View — Genesis Series
Jet Pump Assembly — Exploded View — Freedom / Virage Series
Jet Pump Assembly — Exploded View — Genesis Series
Jet Pump Induction — Freedom / Virage Series
Jet Pump Induction — Genesis Series
Reverse System — Virage / Virage TX / Virage i / Virage TXi
Reverse System — Genesis Series
Jet Pump Removal
Jet Pump Assembly / Installation
Jet Pump Impeller Clearance
Drive Shaft Inspection
Jet Pump Stator Disassembly
Jet Pump Stator Assembly
Jet Pump Alignment
Troubleshooting
Engine Alignment Inspection
Driveshaft Lubrication
Driveshaft Coupler / Through-Hull Bearing Housing Lubrication
Sacrificial Anode
Intake Scoop / Ride Plate Removal and Installation
Chapter 6 – Hull /Control Systems
Hull Specifications
Paint Codes / Colors
Freedom / Virage Series Hull Assembly
Freedom / Virage Series — Front Compartment Door Assembly
Genesis / Genesis i Hull Assembly
Genesis / Genesis i — Front Compartment Door Assembly
Steering Control Assembly
Steering Assembly
Shroud Assembly
Freedom / Virage Series — Seat Assembly
Genesis / 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 / Adjustment
SMC Hull Repair
FRC Fiberglass Repair
Decal Removal / Application
Footpad Removal / Application
Sponson Removal / Installation
Chapter 7 – Electrical Systems
Spark Plug Specifications
Alternator Specifications
Ignition Timing / CDI 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
RPM Limiter System Troubleshooting
Carb. Models (Except Freedom) — Overheat
Carb. Models (Except Freedom) — Reverse RPM Limit
DI Models — Overheat and Reverse Limit
Warning System Troubleshooting — Freedom
2002 Freedom Warning System
RPM Limiter System
2002 RPM Limiter System Diagram — Virage / Virage TX
2002 RPM Limiter System Diagram — Virage i / Virage TXi
2002 RPM Limiter System Diagram — Genesis
2002 RPM Limiter System Diagram — Genesis i
Start / Stop Regulator
Start / Stop Regulator (LR–505)
Start / Stop Regulator (LR–503–1)
LR–503–1 Wire Designations
LR–85 (Freedom Lamp Driver) Wire Designations
Start / Stop Regulator (LR 505 Module) Troubleshooting
Start / Stop Regulator (LR 503–1 Module) Troubleshooting
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
700cc Domestic Ignition System Overview — Carbureted Models
1200cc Domestic Ignition System Overview — Carbureted Models
Electrical Testing
Charging System Testing — Unregulated Voltage — Carbureted Models
Charging System Testing — Regulated Voltage — Carbureted Models
Start / Stop Switch Testing — All Models
Tether Switch Testing — All Models
Battery
Battery Testing
Off-season Storage
Charging Procedure
Multi–Function Instrument (MFI)
MFI Troubleshooting
MFI Compass Calibration
Ignition Timing
Dynamic Ignition Timing Adjustment — All Domestic Carbureted Models
Ignition Timing Adjustment
Static Ignition Timing Adjustment
Ignition Timing Adjustment — Ignition Point Adjustment Unit
Trigger Coil Testing — Generation III PVL Ignition Systems
Alternate Method Of Testing Hall Effect Sensors
PVL Ignition Troubleshooting — 700cc Carbureted Domestic Engine
700cc Carbureted Domestic Engine Ignition Coils
To Determine Wire Sequence
PVL Ignition Troubleshooting — 1200cc Carbureted Domestic Engine
1200cc Carbureted Ignition Coils
Wire Sequence
Starter Motor
Disassembly
Inspection
Brush Replacement
Cleaning
Armature Testing
Assembly
Starter Solenoid Bench Test
Troubleshooting
Coolant Temperature Warning Circuit Operation — Carbureted Models
Temperature Warning Circuit Test
Temperature Sensor Test
Coolant Temperature Sensor Wiring Diagram — Carbureted Models
Coolant Temperature Warning Circuit Operation — DFI Models
Coolant Temperature Sensor Wiring Diagram — DFI Models
Fuel Level Sensor — Carbureted Models
Fuel Level Sensor Wiring Diagram — Carbureted Models
Fuel Level Sensor — DFI Models
Fuel Level Sensor Wiring Diagram — DFI Models
Oil Level Sensor
Oil Level Sensor Wiring Diagram
Polaris Electronic Reverse Control (PERCt) — Genesis / Genesis i
REVERSE MOTOR ASSEMBLY TEST
Chapter 8 – Fuel Injection System
Ficht Fuel Injection System – Components
Internal EMM Sensors
External EMM Sensors
S.L.O.W. Warning System (Speed Limiting Overheat Warning)
S.L.O.W. Service Codes
DI Service Specifications
DI Individual Service Tests
Fuel System Pressure Test
Fuel Injector Resistance
Ignition Coil Primary Resistance
Ignition Coil Secondary Resistance
Crankshaft Position Sensor (CPS)
Throttle Position Sensor (TPS) — 2002 Models
Water Injection Solenoid (Virage i)
Water Temperature Sensor
Stator Resistance
Stator — Short Circuit Test
Stator — Cranking Vac Test
DI System Overview
System Overview
System Overview Diagram
EMM Connectors
EMM 8 Pin Connector
EMM 12 Pin Connector
EMM 40 Pin Connector
Service Codes
“Hard” Service Codes

“Intermittent” Service Codes
Ficht Fuel Injection System – Troubleshooting
Ficht Fuel Injection System – Action Steps
Fuel System / Fuel Injectors
Ignition System
Diagnostic Software
Laptop (Computer Hardware) Requirements
Installing the Polaris Diagnostic Software (PODIAG)
Connecting the laptop to the EMM
Laptop–To–EMM Connections
Understanding the EMM communication cable.
Service Power Connector
Using the Polaris Diagnostic Software: PODIAG
Option 1 – FFI Diagnostics
Service Code Review Screen
Retest
Session Completion / Code Clearing
FFI Diagnostics — Static Tests
Testing Fuel Injectors
Testing Ignition System
Testing Electric Fuel Pump
FFIt Diagnostics – CYLINDER DROP TEST
To Diagnose a Misfire
To Diagnose Low Performance or Rough Running
Timing Verification Procedure
EMM INFORMATION SCREEN
RPM PROFILE
Option 2 – Service Utilities

Service Reports
View Current EMM Report
Save Current EMM Report
Print
View Saved Report
Print Saved Report
Injector Information
Replacing Injectors / 2000 and later DI Models
Option 3 – Service (Replace) EMM
Engine Monitoring
SENSORS
SWITCHES
RESULTS
SWITCHES
VOLTAGE
Diagnostic Software ‘Map’
Communication Problems

Wiring Diagrams

Freedom
Virage
Virage TX
Virage i
Virage TXi
Genesis
Genesis i
Back Cover PN 9917370

 

Download Ebook

Polaris Freedom, Virage, Virage TX, Virage i,Virage TXi, Genesis, Genesis i PWC Service Manual 2002.pdf

Source : Sitelux.com

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