Polaris Genesis 1200 Manual
Service Manual Application: 2000 Polaris Virage TX, SLX, Pro 1200, Genesis, Genesis FFI WaterCraft (Water craft) PWC. Models covered in this manual: 2000 Polaris Virage TX, 2000 Polaris SLX, 2000 Polaris Pro 1200, 2000 Polaris Genesis, 2000 Polaris Genesis FFI.
INTRODUCTION These manuals contains an introductory description on and procedures for the inspection, service and overhaul of its main components. General knowledge information is not included. Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning your personal watercraft PWC in the manual. Read and refer to the other sections in this manual for information regarding proper inspection and service procedures. These manuals have been prepared using the latest information available at the time of publication. If a modification has been made since then, differences may exist between the content of these manuals and the actual PWC personal water craft.
Illustrations in these manuals are used to show the basic principles of operation and work procedures of the actual personal watercraft and components in exact detail. These manuals are intended for use by technicians who already possess the basic knowledge and skills to service a personal watercraft motors and components. Persons without such knowledge and skills should attempt with caution to service any component or engine by relying on this manual only.
Never attempt to perform any work with out the assistance of a service manual. Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may or may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the engine unsafe for the watercraft operator and passengers. POLARIS WATERCRAFT SERVICE MANUALS AVAILABLE: 1992 1998 Polaris PWC WaterCraft Service Manual (Water Craft) Service Manual Application: Polaris 1992, 1993, 1994, 1995, 1996, 1997 & 1998 WaterCraft (Water craft) PWC. Models covered in this manual: 1992: SL650 (SL-650) - 1993: SL650 (SL-650), SL750, SLT - 1994: SL650, SL750 (SL-750), SLT - 1995: SL650 (SL650 International), SL650 STD (SL650 STD International), SL750 (SL750 International).
SYSTEM COMPONENTS SERVICE INFORMATION TROUBLESHOOTING ALTERNATOR STATOR IGNITION PULSE GENERATOR FLYWHEEL REMOVAL STARTER CLUTCH FLYWHEEL INSTALLATION SERVICE INFORMATION GENERAL. This section covers service of the alternator stator, flywheel and starter clutch. The service procedures in this section must be performed with the engine removed.
Refer to page 16-8 for alternator stator inspection. Refer to page 18-6 for starter motor servicing.
SPECIFICATIONS Unit: mm (in) TORQUE VALUES TOOLS TROUBLESHOOTING Engine does not turn. Faulty starter clutch.
1999 Polaris Genesis 1200 Manual
Damaged reduction gear/shaft ITEM STANDARD SERVICE LIMIT Starter driven gear boss O.D. 51.699 – 51.718 (2.0354 – 2.0361) 51.684 (2.0348) Alternator stator torx bolt 12 Nm (1.2 kgfm, 9 lbfft) Alternator wire clamp socket bolt 9.8 Nm (1.0 kgfm, 7 lbfft) Starter clutch outer socket bolt 16 Nm (1.6 kgfm, 12 lbfft) Apply locking agent to the threads. Flywheel bolt.
ALTERNATOR STATOR REMOVAL Remove the front crankcase cover (page 6-9). Remove the socket bolt and wire clamp. Remove the alternator stator wire grommet from the crankcase cover.
Remove the four socket bolts and alternator stator from the crankcase cover. INSTALLATION Install the alternator stator onto the crankcase cover and tighten the four socket bolts. Apply silicone sealant to the wire grommet seating surface and install the grommet into the crankcase cover groove. Install the wire clamp, aligning the groove with the boss of the crankcase cover, and tighten the socket bolt. Install the front crankcase cover (page 6-14). IGNITION PULSE GENERATOR REMOVAL/INSTALLATION Remove the front crankcase cover (page 6-9). Remove the pulse generator wire grommet from the crankcase cover.
Remove the two bolts and ignition pulse generator from the crankcase cover. Install the ignition pulse generator onto the crankcase cover and tighten the two bolts. Apply silicone sealant to the wire grommet seating surface and install the grommet into the crankcase cover groove. Install the front crankcase cover (page 6-14). ALTERNATOR/STARTER CLUTCH 11-10 Apply locking agent to the driven gear bolt threads and install the bolt with the washer.
Install the idle gear and shaft. Install the gear holder between the balancer idle and driven gears, and tighten the right balancer driven gear bolt.
Make sure the balancer timing marks are aligned properly as shown when the “T” mark on the drive coupler is aligned with the index mark. Install the coupler cover A (page 3-14).
ELECTRIC STARTER 18-4 TROUBLESHOOTING Starter motor does not turn 1. Fuse Inspection Check for blown main fuse (30 A) or sub-fuse E (5 A). Is the fuse blown?
YES – Replace the fuse. NO – GO TO STEP 2. Battery Inspection Check that the battery is fully charged and in good condition. Is the battery in good condition?
YES – Charge the battery (page 16-6). NO – GO TO STEP 3. Starter Relay Switch Operation Inspection Check the operation of the starter relay switch (page 18-12). Does the starter relay switch click? YES – GO TO STEP 4. NO – GO TO STEP 5. Starter Motor Inspection Remove the safety lanyard switch from the engine stop switch.
Apply battery voltage to the starter motor directly. Does the starter motor turn? YES –. Poorly connected starter motor cable. Faulty starter relay switch NO – Faulty starter motor (page 18-6) 5. Relay Coil Ground Line Inspection Remove the safety lanyard switch from the engine stop switch. Check the ground line of the starter relay switch (page 18-12).
Is the ground line normal? YES – GO TO STEP 6. NO – Open circuit in the Green wire 6. Relay Coil Power Input Line Inspection Check the power input line of the starter relay switch (page 18-13). Is the power input line normal? YES – GO TO STEP 7. NO –.
Faulty engine stop switch (page 19-18). Faulty starter switch (page 19-18). Blown sub-fuse B (5 A). Faulty main relay or its circuits (page 19-19). Loose or poor contact of the related connector.
Polaris Genesis I 1200 Manual
Open circuit in the wire harness 7. Starter Relay Switch Inspection Check the function of the starter relay switch (page 18-13). Does the starter relay switch function properly?