Maintenance
2.17
Engine -- Continued
Thermostat/Pop Off Valve Cleaning
If low end performance of the watercraft begins to deteriorate, and the jet pump intake area is free of debris and
weeds; or if the overheat alarm sounds, the thermostat pop off assembly should be checked for debris and
cleaned. Inspect the thermostat pop off assembly if the watercraft has been stored for more than 30 days or has
been used in salt water.
CAUTION:
Note the location of all parts when cleaning the thermostat/pop--off valve assembly. Be sure all parts are posi-
tioned correctly during reassembly, or severe engine damage will result within a very short period of operation.
Do not perform this maintenance while the watercraft is in the water. The thermostat pop off assembly is under
tension from an internal spring. When the screws are removed, the assembly will come apart quickly if not held
together firmly.
1. Using a 3/16² (.5 cm) hexagonal wrench and a flat
screwdriver, remove screws while holding
thermostat pop off assembly firmly together.
Carefully take assembly apart. Be careful not to
lose any parts.
2. Inspect thermostat pop off assembly for debris,
such as sand or seaweed, and clean thoroughly
with water. Inspect pop off valve for wear . See Ill. 1.
3. Inspect condition of gaskets and rubber parts.
Replace any parts that appear cracked, damaged,
or distorted.
4. Inspect thermostat and housing for corrosion.
Visually inspect thermostat for damage or
distortion. It should be closed at room temperature.
5. Apply Loctite 242 (Blue) to bolts. Carefully
assemble thermostat pop off assembly in the
correct sequence. It is recommended to hold the
assembly in one hand and hand tighten screws.
Verify proper alignment of all parts and
gasket/O-ring during assembly. The arrow in the
illustration indicates the direction of water flow
(away from engine). See Ill. 2.
W ARNING: If pop--off spring or thermostat are mis--
aligned during assembly, severe engine damage may
occur.
Ill. 1
New
Replace
Thermostat Pop Off Valve
Ill. 2
Pop Off Valve
Thermostat
Reversed Housing
*The Virage TX, and Genesis feature a re-
versed housing assembly.
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