Engine / Cooling
3.27
Engine Removal and Installation -- All Models
Engine Removal
S Disconnect the negative (--), then positive (+) battery cables from the battery.
S On DIt models, the injectors can be simply removed from the cylinder heads as a complete set.
Unless an injector is being replaced, there is no need to disconnect the fuel lines. Simply relieve
any fuel pressure as outlined in chapter four , wrap the injectors in a plastic bag, and set bag in
footwell.
S If the injectors are disconnected from the fuel lines, mark each injector with the cylinder number
from which it was installed.
S Always turn fuel valve off on carbureted models.
S Remove the water inlet and outlet hoses from the engine and exhaust pipe(s).
S Disconnect the throttle and choke cable (carbureted models) from the throttle bodies.
S Disconnect the engine ground straps, and starter motor leads.
S Disconnect the wiring harness from the engine sensors and components. Label connections for
reassembly.
S Disconnect the oil feed hose from the oil pump. Plug end with bolt and gear clamp. Always se-
cure the oil feed hose so that the open end is higher than the oil tank outlet nipple. This will pre-
vent oil from leaking into the hull when the engine is removed.
S Remove the pump and driveshaft from the watercraft as outlined in chapter five.
S On some models the exhaust system will have to be removed. This includes the manifold, pipe,
silencer, and the connecting hoses.
S Depending on the model, it may be necessary to remove the throttle bodies, carburetors prior
to engine removal. If the carburetors/throttle bodies are removed, tape of the intake manifold
openings.
S Always use the help of an assistant or an engine hoist when removing the engine from the engine
bay.
Engine Installa tion
Engine installation is done in reverse order of the removal instructions. A few important tips are listed below to
ensure long and trouble free service.
S Verify prior to installing engine that the cooling hoses and ground wires are properly routed
through the hull. Do not allow any wires or hoses to get pinched between the hull and engine
mount straps.
S Reference the appropriate chapter in routing the steering cables and throttle cables.
S The first tank of fuel for carbureted models should be pre--mixed with Polaris 2 cycle engine oil
at a 40:1 ratio.
W ARNING
Do not install the battery ground (--) cable until all other fuel and electrical connections are done. Electrolyte or fuel
vapors may be present in the engine compartment and a spark could ignite them, resulting in personal injury.
CAUTION:
Shims used for engine and driveshaft alignment must be reinstalled in their original locations. Do not
allow them to be mixed up. Always verify proper engine to pump alignment after engine installation as
outlined in the Jet Pump, Final Drive, Bilge section. In most cases, the number of shims used in
production is marked in permanent marker next to each engine mount. The same number must be
installed as a starting point, and in most cases adjustment will not be necessary. Always verify proper
engine alignment before installing pump.
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