Polaris 2003 MSX manual

Owner's Manual for V ehicle Maintenance and Safety Owner's Manual for V ehicle Maintenance and Safety 2003 MSX 2003 MSX[...]

W ARNING The engine exhaust from this product contains chemicals known to cause cancer , birth defects or other reproductive harm.[...]

1 We ’ ve created a web site, just for YOU! S T echnical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The W ay Out S Racing Information Check it out... www .polarisindustries.com/owner[...]

2 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 Ind[...]

3 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. W e proudly produce an exciting line of utility and recreational products. Polaris Recreational V ehicles S Snowmobiles S All-terrain vehicles (A TVs) S W atercraft S RANGER utility vehicles S V ictory motorcycles Polaris Professional Serie[...]

4 TABLE OF CONTENTS WELCOME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . T ABLE OF CONTENTS 4 . . . . . . . . . . . . . . . . . YOUR RESPONSIBILITIES 5 . . . . . . . . . . . . . IDENTIFICA TION NUMBERS 7 . . . . . . . . . . . . SAFETY 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEA TURES and CONTROLS 24 . . . . . . . [...]

5 YOUR RESPONSIBILITIES Do Y our 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 Y our V ehicle[...]

6 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 pr[...]

7 IDENTIFICATION NUMBERS Y our 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 loc[...]

8 SAFETY Signal W ords and Symbols The following signal words and symbols appear throughout this manual and on your vehicle. Y our 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 perso[...]

9 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 char ge.[...]

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

11 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). T O A VOID COLLISIONS: SCAN CONST ANTL Y for people, objects and other watercraft. Be alert for conditions that limit your visibility or block you[...]

12 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. RIGHTING CAPSIZED BOA T 7073865 S T o prevent injury , do not place hands or objects into pump inlet, intake grate or[...]

13 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: Located on the engine water manifold: 7171396 FIRE EXTINGUISHER CONT AINER LOCA TED INSIDE Do Not Remove Electrical Part When Starting Or During Operation. High V oltage Shock Hazard. 70[...]

14 SAFETY Operator Safety Any operator of a Polaris watercraft must know and practice the following guidelines for personal safety and the safety of passengers. Never permit a guest to operate this watercraft unless the guest has read and understands all warning decals and the owner ’ s manual. Operator Guidelines This watercraft is not a toy . I[...]

15 SAFETY Operator Safety Y our 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 [...]

16 SAFETY Operator Safety Safe Riding Gear Always wear protective clothing when operating or riding a personal watercraft. Consider attaching a whistle to your lanyard to summon help in emergency situations. 1 - Personal Floatation Device The operator and passenger must always wear an approved personal flotation device (PFD) at all times to prevent[...]

17 SAFETY Operator Safety Overloading the W atercraft 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 . When more than one person is riding, the watercraft handles differently , which means that[...]

18 SAFETY Operator Safety W eather and Darkness 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 , hypo[...]

19 SAFETY Operator Safety Obstacles and Shallow W ater 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 t[...]

20 SAFETY Operator Safety T urning and Accelerating T urning 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 water craft and to each side befor e accelerating and befor e making sudden turns. Always be aware of obstacles, swimmers and other[...]

21 SAFETY Operator Safety Jet Pump W ater Intake Safety 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.[...]

22 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 you ’ re an inexperienced operator . Do not exceed idle speed if any person is within 50 feet (15 m) of the rear[...]

23 SAFETY Operator Safety V ehicle Modifications 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 water craft or any of its components. Any modifications to the watercraft will void your warranty . Operator Fatigue and Dehydration Long hours [...]

24 FEATURES AND CONTROLS 1. Starter Button - Depress and hold the starter but- ton 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 at- tached to the engine stop switch to start the engine 2. Stop Switch/Lanyard - Push this switch down or disco[...]

25 FEATURES AND CONTROLS 1 5 2 4 6 15 16 14 3 8 7 9 10 12 13 11 11[...]

26 FEATURES AND CONTROLS 1. Fr ont Compartment Door - The door provides access to the fire extinguisher , oil tank, fuel fill, oil fill and main storage space. 2. Fir e 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 fi[...]

27 FEATURES AND CONTROLS 6 5 3 2 1 7 9 10 4 8[...]

28 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) 1 1. Spark arrestor/air filter 12. Engine coolin[...]

29 FEATURES AND CONTROLS Engine Components 3 7 8 6 12 10 9 4,1 1 5 2 1[...]

30 FEATURES AND CONTROLS New Generation Instrument (NGI) Primary Functions S Speedometer S Clock S T achometer S Engine Hourmeter S T rip Odometer S Oil Level S Fuel Level S Low Oil/Pressure/Fuel/ Battery V oltage W arnings S High Engine T emperature W arning S Check Engine W arning Accessible Functions S T achometer S Engine Hourmeter S T rip Odom[...]

31 FEATURES AND CONTROLS New Generation Instrument (NGI) Function Overview Speedometer The lar ge 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. T achometer The NGI has the ability to display between 0 and 9950 R[...]

32 FEATURES AND CONTROLS New Generation Instrument (NGI) Instrument Operation DISPLA Y MODE There are three dif ferent display modes the gauge uses to display information to the operator . The three modes are: MAIN MODE, SPEED/T ACHOMETER MODE and NA VIGA TION MODE. Press and release the MODE button on the left handlebar control to advance through [...]

33 FEATURES AND CONTROLS New Generation Instrument (NGI) Display W arnings 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 BA TTER Y VOL T AGE (Battery voltage is at or below 10.9 vDC) S HIGH TEMPERA TURE (T emperature is monitored by EMM) S CHECK[...]

34 FEATURES AND CONTROLS RPM Limiter Y our 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. If the high temperature indicator and warning displays, stop the engine immediately . Clean the jet [...]

35 FEATURES AND CONTROLS Standard Equipment S W atercraft Owner ’ s Safety and Maintenance Manual S W atercraft Safety V ideo PN 9916475 S Lanyard with wristband, lock plate and whistle S T ool Kit containing: wrench, flat screwdriver , Allen wrench, spark plug wrench with Phillips head screw- driver Contact an authorized Polaris dealer for repla[...]

36 EMISSIONS EP A 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 origi[...]

37 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. EP A ’ s 2006 standards for ma[...]

38 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. If a proper inspection is not performed before each use, severe injury or death could result. Always [...]

39 OPERATION Pre-Operation Inspection Item What T o 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 flus[...]

40 OPERATION Pre-Operation Inspection Fuel 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. S Always check for fumes prior to starting engine. S Always exercise extreme cau[...]

41 OPERATION Pre-Operation Inspection Fuel Y our 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. Refueling Carefully remove the fuel cap. NOTE: Keep the water[...]

42 OPERATION Pre-Operation Inspection Oil The oil fill cap (1) is located 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. Polaris synthetic 2-cycle oils are formulated to work [...]

43 OPERATION Pre-Operation Inspection Jet Pump Intake 1. Ride Plate 2. Impeller 3. Drive Shaft 4. Intake Grate 1. Remove the lanyard lock plate from the stop switch and disconnect the battery cables before inspecting the jet pump intake. Disconnect the negative (black) cable first. 2. Carefully check the jet pump intake and remove any weeds, shells[...]

44 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. Be sure the handlebars and handlebar grips fit snuggly . V isually inspect the control cable to ensure that it ’ s[...]

45 OPERATION Pre-Operation Inspection Loose Parts Inspect the watercraft for any loose nuts, bolts, fasteners and hoses. Be sure that all hose clamps are tight. Replace cracked or deteriorating hoses. Seat T o access the engine/storage compartment, disengage the rear seat latch (1). Always remove the seat and ventilate the engine compartment before[...]

46 OPERATION Pre-Operation Inspection Battery Confirm that the battery terminal connections are tight, and make sure the battery is securely fastened in its mounting position. Inspect the battery for leaks, and check the vent hose for kinks or blockage. Check the battery fluid level and add only distilled water if the level is low . T ap water cont[...]

47 OPERATION Pre-Operation Inspection Hull 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. Drain Plugs and Bilge T urn each bilge drain plug (1) counterclockwise and remove it. Clean the plug and plug hole of any sand and debris before reinstalli[...]

48 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[...]

49 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 th[...]

50 OPERATION Engine Break-in Procedure 1. Make sure the drain plugs are installed securely and launch the watercraft. 2. Push the rear of the watercraft up and down several times in the water . 3. Check the throttle for free operation. 4. Remove the seat and ventilate the engine compartment. 5. Secure the seat, board the craft and start the engine.[...]

51 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 thes[...]

52 OPERATION Navigational Rules Rule 2 Ru le 2 i s “ The Genera l Prudential Rule ” of the Interna tional Rule. This rule states that all operators have the responsibility of taking action to avoid a collision. All vesse ls involved in a potentia l collision become give-w ay vessels. Encountering V essels There are three main situations in whic[...]

53 OPERATION Navigational Rules Overtaking V essels 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. Y ou 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 [...]

54 OPERATION Navigational Rules Non-Motorized Craft 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 ves- sels. S In a narrow channel,[...]

55 OPERATION Navigational Rules A void Collisions SCAN CONST ANTL Y for people, objects and other watercraft. Be alert for conditions that limit your visibility or block your vision of others. OPERA TE DEFENSIVEL Y at safe speeds, and keep a safe distance away from people, objects and other watercraft. S Do not follow directly behind PWCs or other [...]

56 OPERATION Launching the W atercraft 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 tr[...]

57 OPERATION Before Starting the Engine Before starting the engine: 1. V iew the watercraft safety video provided with the watercraft. 2. Read and understand this Owner ’ s Manual. 3. Be familiar with all controls and functions of the watercraft. 4. Perform the pre-operation check found on page 39. If you have any questions about the features or [...]

58 OPERATION Starting the Engine 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. Apply just enough throttle to keep the engine running. NOTE: If the engine was run out of fuel, it may take two[...]

59 OPERATION Boarding the W atercraft 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 W ater (Operator Only) Make sure the watercraft engine is turned of f when boarding in deep water . 1. Swim to[...]

60 OPERATION Boarding the W atercraft Boarding With a Passenger A watercraft behaves dif ferently 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[...]

61 OPERATION Reverse Operation 1. T o activate reverse, pull the reverse lever all the way up. The lever will remain in the full up position (1). 2. T urn the handlebars and apply throttle carefully to maintain steering control of the watercraft. NOTE: Engine RPM is limited during reverse operation. 3. T o return to forward operation, allow the eng[...]

62 OPERATION Stopping the W atercraft The operator of the watercraft should practice stopping to become familiar with the procedure. Stopping is af fected by gross weight (watercraft and rider), vehicle speed, wind direction and water surface conditions. The watercraft is not equipped with a brake system. When the throttle is released, the natural [...]

63 OPERATION Beaching the W atercraft 1. Slowly approach the beaching area and stop the engine in no less than two feet (60 cm) of water . Make sure there are no swimmers, boats or other obstacles close to the watercraft, as it will be impossible to turn the watercraft after stopping the engine. 2. Dismount the watercraft and guide it to the beach.[...]

64 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[...]

65 OPERATION T owing a Disabled W atercraft 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 -fitti[...]

66 OPERATION Righting a Capsized W atercraft 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. After righting the craft, follow the procedures for a submerged (waterlogged) engine on page 72 to prevent engine damage. 1. Be s[...]

67 OPERATION Operating W ith Passengers 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 . Never exceed the stated capacity for your vehicle. When more than one pe[...]

68 OPERATION Post Operation Maintenance Daily Care Remove the watercraft from the water every day to inhibit marine organism growth on the hull. 1. Remove the watercraft from the water . 2. Purge residual water from the exhaust system by starting the engine and revving it repeatedly at partial throttle for about ten seconds until water no longer co[...]

69 OPERATION Post Operation Maintenance Daily Care 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. 1 1. Inspect the area for damage. If damage is found, see your Polaris dealer for service. NOTE: Whenever possible, avoid operating the watercra[...]

70 OPERATION Post Operation Maintenance T emporary 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 p[...]

71 OPERATION Post Operation Maintenance T ransporting The W atercraft 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 des[...]

72 OPERATION Post Operation Maintenance Battery If the watercraft battery is run down, remove it and have it rechar ged. Refer to battery charging recommendations and service procedures beginning on page 86. Anti-Corrosion T reatment Spray all the metal components in the engine compartment with a lubricating type rust inhibitor . W e recommend T9 m[...]

73 OPERATION Post Operation Maintenance Engine W ater Removal Procedure Use the following procedure for removing water from a submer ged engine. Attempt this procedure only if you are mechanically experienced and have adequate assistance for lifting and supporting the watercraft. 1. Remove the watercraft from the water . Remove the lanyard cord fro[...]

74 MAINTENANCE AND LUBRICATION General Maintenance Replace the pop-of f valve, spring and 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 sp[...]

75 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule NOTE: Maintenance intervals are based upon average operating conditions. W atercraft 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 fo[...]

76 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule DESCRIPTION Pre-ride Pre- season Monthly or 25 hrs. 3 mos. or 50 hrs. 6 mo s. o r 100 hrs. T une up item 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 ?[...]

77 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule DESCRIPTION Pre-ride Pre- season Monthly or 25 hrs. 3 mos. or 50 hrs. 6 mo s. o r 100 hrs. T une up item FUEL SYSTEM Fuel filter and oil filter R I • Throttle cable I I/L/A L • Fuel cap/oil cap gaskets IIII R Fuel lines, oil lines, related hose clamps, check valves and hose inspection[...]

78 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule DESCRIPTION Pre-ride Pre- season Monthly or 25 hrs. 3 mos. or 50 hrs. 6 mo s. o r 100 hrs. T une up item HULL / DECK / STEERING / CONTROLS Steering support hub bushings/fasteners/handgrips I/L I/L • Steering cable I/L/A I/L • Steering Nozzle Bushings I R Reverse cable inspection, lubr[...]

79 MAINTENANCE AND LUBRICATION Lubrication Proper lubrication and corrosion protection are necessary to maintain optimum performance and ensure years of service from your watercraft. W e 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 depres[...]

80 MAINTENANCE AND LUBRICATION Lubrication Seat Latch And Hooks Grease the locking mechanism of the seat latch at the rear of the seat opening. 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 . Electrical Connections Apply dielectric grease to batte[...]

81 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[...]

82 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[...]

83 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. W e recommend the use of the Polaris products listed on page 101. See your Polaris dealer for additional information about the care of your water[...]

84 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 o[...]

85 MAINTENANCE AND LUBRICATION Steering Cable Inspection 1. The handlebars and steering nozzle should operate smoothly . If movement is stif f, see your authorized Polaris dealer for service. 2. T urn 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 th[...]

86 MAINTENANCE AND LUBRICATION Battery Battery Maintenance and Charging Keep the battery terminals and connections free of corrosion. If cleaning is necessary , remove the corrosion with a stiff wire brush. W ash 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 [...]

87 MAINTENANCE AND LUBRICATION Battery 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 not to tip it sideways and[...]

88 MAINTENANCE AND LUBRICATION Battery Battery Charging Make sure the battery char ger is turned off and unplugged before connecting the cables to the battery . This prevents the possibility of sparks at the terminals, which could ignite the battery gases. 1. Remove the caps from the cells (1). Add distilled water , if necessary , to bring the elec[...]

89 MAINTENANCE AND LUBRICATION Battery Battery Installation 1. Set the battery in the battery holder . 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. A void skin[...]

90 MAINTENANCE AND LUBRICATION Salt W ater and Unclean W ater 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 af fected areas of the watercraft. Flush the cooling sy[...]

91 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[...]

92 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 t[...]

93 MAINTENANCE AND LUBRICATION Extended Storage W atercraft 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 th[...]

94 MAINTENANCE AND LUBRICATION Extended Storage 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 . Rinse and drain thoroughly . W ipe up remaining water with clean, dry shop cloths. Do not use abrasive cleaners. NOTE: Store the watercraft with the drai[...]

95 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. Lubrica[...]

96 ENGINE TROUBLESHOOTING Engine Doesn ’ t T urn Over Possible Cause Solution Blown fuse Replace the fuse Low battery voltage Rechar ge battery to 12.5 VDC Loose battery connections or ground Check all connections and tighten as needed Hydrolock (water in engine) See your Polaris dealer Loose starter relay (solenoid) connections Check all connect[...]

97 ENGINE TROUBLESHOOTING Engine Runs Irregularly , Stalls or Misfires Possible W eak Spark Cause Solution Fouled or defective spark plugs Inspect, clean and/or replace spark plugs W orn 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 a[...]

98 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 Clog[...]

99 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 W eak spark Replace spark plugs and/or wires Incorrect fuel or [...]

100 ENGINE TROUBLESHOOTING Engine RPM is T oo 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 W eeds or debris lodged in impeller Clean the impeller Damaged driveshaft See your P[...]

101 POLARIS PRODUCTS Oil and Lubricants Premium Gold Synthetic 2-Cycle Oil Quart 2871721 Gallon 2871722 VES II Synthetic 2-Cycle Oil Quart 2874438 Gallon 2874439 2.5 Gallon 2874443 Nature Oil Biodegradable 2-Cycle Oil Gallon 2872607 Fuel System Maintenance Products Carbon Clean Plus 2871326 Isopropyl Fuel De-Icer 2870505 Premium Fuel Stabilizer 287[...]

102 SPECIFICATIONS CAP ACITIES / DIMENSIONS Fuel T ank 17.8 gal. (67.4 l) Oil Reservoir 6.0 gal. (5.68 l) Rider Capacity 1-3 people Rider W eight Limit (total) 500 lbs. (227 kg) T otal W eight Capacity 565 lbs. (256 kg) Length 126 in. (320 cm) W idth 48.3 in. (122.6 cm) Height 42.5 in. (108 cm) Dry W eight 685 lbs. (311 kg) Hull Material Fiber glas[...]

103 SPECIFICATIONS PROPULSION Impeller , Stainless Steel 3 Blade, Progressive Pitch, Radial Blade Propulsion Jet Drive Jet Pump T ype Dominator , Single Stage Axial Flow , Six V ane Stainless Steel Stator Transmission Direct Drive Reverse System Standard Impeller Diameter 5.83 in. (148 mm) FEA TURES Instrumentation New Generation Instrument (NGI) S[...]

104 WARRANTY Obtaining Service and W arranty Assistance Read carefully and understand the service data and the Polaris W arranty contained in this manual. Contact your Polaris dealer in matters pertain- in g to replacement parts, service, or warranty . Y o ur dealer is constantly kept up-to-date on changes, modifications, and tips on personal water[...]

105 WARRANTY W ARRANTY COVERAGE AND EXCLUSIONS: Limitations of W arranties and Remedies This Polaris limited warranty covers all parts and components except fo r 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 b[...]

106 WARRANTY HOW TO OBT AIN W ARRANTY 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 W arranty Registration form to the dealer . (The cost of transportation to an d from the dealer[...]

107 CALIFORNIA EMISSION CONTROL SYSTEM LIMITED WARRANTY POLARIS W A TERCRAFT ENGINES YOUR W ARRANTY RIGHTS AND OBLIGA TIONS Th e California Air Resources Board and Polaris Industries, Inc. (Polar- is) are pleased to explain the California emission control system limited warranty on your Model Y ear 2002 or later Polaris watercraft engine. In Califo[...]

108 CALIFORNIA EMISSION CONTROL SYSTEM LIMITED WARRANTY OWNER ’ S W ARRANTY RESPONSIBILITIES: As the watercraft engine owner, you are responsible for performance of the required maintenance listed in your owner ’ s manual. Polaris rec- ommends that you retain all receipts covering maintenance on your wa- tercraft engine, but Polaris cannot deny[...]

109 CALIFORNIA EMISSION CONTROL SYSTEM LIMITED WARRANTY W ARRANTED P AR TS: 1.Fuel Metering System – Fuel injection system – Cold start enrichment system – Intake valves 2.Air Induction System – Intake manifold – Air filter 3.Ignition System – Spark plugs – Magneto or electronic ignition system – Spark advance / retard system – Ig[...]

11 0 INDEX A Accessories 35 . . . . . . . . . . . . . . . . . . . . . Age Restrictions 6 . . . . . . . . . . . . . . . . . . Anti-corrosion T reatment 72 . . . . . . . . . . A void Collisions 55 . . . . . . . . . . . . . . . . . B Battery 46, 72, 86-89 . . . . . . . . . . . . . . . . Battery Char ging 88 . . . . . . . . . . . . . . . . . Battery Fl[...]

111 INDEX N Navigational Rules 51-55 . . . . . . . . . . . . . New Generation Instrument 30-33 . . . . . . Non-motorized Craft 54 . . . . . . . . . . . . . . O Obstacles and Shallow W ater 19 . . . . . . . Oil 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating in Rough Conditions 64 . . . . . Operating With Passengers 67 . . . . .[...]

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 W A TERCRAF T , I[...]