1999 Polaris PWC Genesis, Ficht, X-45 Service Manual
This is a complete Service Manual in English for the 1999 Polaris Personal Watercrafts.
This is the same manual that dealers and professional mechanics use to repair your vehicle.
Models covered in this manual:
Genesis
Genesis Ficht
X-45
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Full list of manual chapters:
1999 GENESIS, GENESIS FICHT, X-45 PERSONAL WATERCRAFT SERVICE MANUAL 9915673
SAFETY LABELS AND INSTRUCTIONS
Chapter 1 - General Information
Watercraft Publication Part Numbers
Paint Codes
Special Tools
FICHT Fuel Injection Special Tool Photos
2872454, 2872456, 2872604, 2872623, 2872621
Service Bulletin Index By Model
Identification Numbers
Model Specifications
Standard Torque Specifications
Glossary Of Terms
Service Tips
Chapter 2 - Maintenance / Tune Up
Maintenance Schedule
Periodic Maintenance Schedule
Engine Break-In
Lubrication
Recommended Lubricants/Maintenance Products
Throttle Cable And Choke Cable
Steering Cable
Steering Nozzle Pivot / Reverse Gate
Reverse Cable Lubrication - Genesis / X-45
Steering (Handlebar) Pivot Shaft
Seat Latch And Hooks
Throttle and Choke Shaft
Carburetor and Oil Injection Pump
Drive Shaft Lubrication
Bonded Rubber Coupler
Through-Hull Bearing Housing
Electrical
Electrical Connections
Terminal Board
Battery Safety
Battery Removal
Battery Connections
Battery Charging
Battery Installation
Battery Storage
Circuit Breaker
Engine
Engine Mounts
Compression Test
Spark Plugs
Cylinder Head Re-Torque
Cylinder Base Gasket Re-Torque
Exhaust Manifold Re-Torque
Exhaust Cooling Orifice/Screen Cleaning
Thermostat/Pop Off Valve Cleaning
Idle Speed - Genesis / X-45
Throttle Lever Freeplay
Oil Filter
Oil Pump Adjustment
Cable Adjustments
Throttle Cable Inspection/Adjustment
Choke Cable Inspection - X-45 / Genesis
Steering Cable Inspection
Reverse Cable Adjustment
Carb Air Intake - Single Element
Fuel/Water Separator - Genesis / X-45
Fuel Lines/Vent Lines
Fuel Filter - X-45 / Genesis
Water Separating Filter - Genesis FICHT
Carburetor Adjustments
Idle Speed
Cooling System Flushing and Salt Water Maintenance
Flushing Procedure
Off Season Storage Procedures
Engine Draining
Fuel System Storage
Engine Fogging Procedure - All Models
Cleaning
Fire Extinguisher
Bilge Siphon System
Bilge Drain Plug
MFD / MFI Gauges
MFD / MFI Fit Chart
Submerged Engine (Hydrolocked)
Pump/Impeller
Cooling Water Pickup Screen
Scoop/Ride Plate/Intake Grate
Impeller Clearance
Pump Housing Inspection
Sacrificial Anode
Handlebars/Hand Grips
Fasteners/Parts/Hoses
Seat Seal Inspection/Seat Adjustment
Storage Compartment Door Adjustment - X-45
Troubleshooting
Lean Condition
Poor Performance
Rich Fuel Mixture
Piston Damage
Engine Overheating/Misc.
Electrical
Vibration / Jet Pump
Porpoising / Hull
Hydrolock
Chapter 3 - Fuel System / Carburetion
Carburetor Specifications and Initial Settings
Carburetor Jet Part Numbers
High Elevation Recommendations
FUEL SYSTEM / CARBURETION
Vent/Fuel Delivery Exploded View - X-45
Vent/Fuel Delivery Exploded View - Genesis Ficht
Vent/Fuel Delivery Exploded View - Genesis
Fuel Tank/Fuel Pickup Exploded View
1999X-45
1999 Genesis / Genesis FICHT
Air Intake Silencer
1999 X-45, Genesis, Genesis FICHT
Carburetor Assembly Exploded View
Keihin Carburetor - Genesis
Bing Carburetor - X-45
Throttle Bodies - Genesis FICHT
Oil Tank Exploded View
1999 X-45
1999 Genesis / Genesis FICHT
System Operation - Keihin and Bing Carburetor
System Operation - Keihin Carburetor
System Operation - Bing Carburetor
Fuel Shut Off Valve Disassembly and Inspection
Fuel Filter
Fuel/Water Separator
Water Separating Filter - Genesis FICHT
Carburetor Adjustment and Service
Carburetor Mixture Screw Adjustment - Keihin
Low Speed Mixture Screw Adjustment - Keihin
Mixture Screw Adjustment - Bing
Carburetor / Throttle Body Removal
Carburetor Disassembly/Inspection
Cleaning
Carburetor Assembly
Carburetor/Throttle Body Synchronization - Bing
Carburetor / Throttle Body Installation
Mixture Screw Settings - Keihin
Mixture Screw Adjustment - Base Setting - Keihin
Mixture Screw Adjustment - Tuning - Keihin
Throttle Cable Adjustment
Choke Cable - X-45 and Genesis
Oil Pump Cable
Fuel Tank Vent System
Relief Valve Testing
Fuel Tank Check Valve Testing
Fuel Pump Operation
Fuel Pump Maintenance
Disassembly/Inspection
Reed Valve Removal
Reed Valve Inspection
Fuel Line Air Leak Testing
Oil Check Valve Testing
Accelerator Pump Testing
Chapter 4 - Engine
Engine Specifications
Torque Chart - Engine Fasteners
Torque Patterns - Polaris Domestic Engine
Engine and Mount Assembly
Cylinder and Manifold
Crankshaft/Piston
Crankcase
Exhaust System
Oil Pump Assembly Exploded View
Engine Removal - Polaris Engines
Disassembly / Inspection - Polaris Engines
Piston Pin / Needle Bearing Inspection
Connecting Rod Small End Inspection
Piston Inspection/Measurement
Crankshaft Main Bearing Inspection
Connecting Rod (Big End) Radial Clearance
Assembly - Polaris Engines
Cylinder Installation
Oil Pump Bleeding
Troubleshooting
Engine Installation
Cylinder Honing
Port Chamfering
Cooling System Flow Chart
Genesis / X-45
Genesis FICHT
Thermostat Pop Off Assembly
Exhaust Coolant Filter - Polaris Engines
Cleaning Procedure
Crankshaft Indexing - X-45 and Genesis
Crankshaft Indexing - Genesis FICHT
Crankshaft Truing
Chapter 5 - Final Drive / Jet Pump / Bilge System
Final Drive Jet Pump Torque Values
1999 Jet Pump Data
Impeller Part Numbers
High Elevation Recommendations
Driveshaft/Coupler
Jet Pump
Jet Pump Assembly
Jet Pump Intake
X-45
Genesis / Genesis FICHT
Intake Scoop/ Ride Plate Installation and Sealing, All Models
Impeller Clearance
Jet Pump Removal
Drive Shaft Inspection
Stub Drive Shaft Inspection
Jet Pump Assembly
Jet Pump Installation
Jet Pump Housing Removal
Intake Scoop / Ride Plate Installation and Sealing
Jet Pump Housing Installation
Jet Pump Drive Shaft Alignment
Engine Alignment Inspection
Pump-To-Hull Alignment Inspection
Driveshaft Lubrication (All Models)
Driveshaft Coupler / Bearing Housing Lubrication
Through-Hull Bearing Housing Removal/Inspection
Sacrificial Anode
Jet Pump Ventilation/Cavitation Diagnostics
Chapter 6 - Hull / Deck, Steering, Controls
Seat Assembly
X-45
Genesis / Genesis FICHT
Steering Assembly
X-45
Genesis/ Genesis FICHT
Deck Assembly
X-45
Genesis / Genesis FICHT
Front Compartment Assembly
X-45
Genesis / Genesis FICHT
Shroud
Genesis / Genesis FICHT
Decals
X-45
Genesis / Genesis FICHT
Steering Cover/Steering Post
Steering Cover/Steering Post (Handlebar) Removal
X-45
Genesis / Genesis FICHT
Steering Cable Replacement
Steering Cable Adjustment
Adjustment Procedure
Wire Clip Replacement
Speedometer
Speedometer Operation and Inspection
SMC Hull Repair
RTM Surface Repair Process
FRC Fiberglass Repair
Sponson Removal/Installation
Chapter 7 - Electrical
Spark Plugs / Alternator / CDI Specifications
Ignition Timing Chart - Stroke Degrees to Piston Position
Warning Systems Operating Characteristics
Stator Plate Assembly And Ignition System Test Specifications
Ignition System - Genesis and X-45
Electrical Box
X-45
Genesis
Charging System - Genesis / X-45
Electrical Testing
Charging System Testing (Unregulated Voltage)
Charging System Testing (Regulated Voltage)
Start/Stop Switch Testing
Tether Switch Testing
Battery
Battery Testing
Battery Testing
Off-season Storage
Charging Procedure
Starter Motor
Starter Motor Disassembly
Brush Replacement
Cleaning
Armature Testing
Starter Assembly
Starter Solenoid Bench Test
Electric Starter System Testing
Temperature Warning Genesis / X-45
Coolant Temperature Warning Circuit Operation
Temperature Warning Circuit Test
Temperature Sensor Test
Fuel Sender Operation and Sender Testing
Genesis FICHT Fuel Pump Module Testing
Genesis FICHT Fuel Pump Module diagram
Genesis FICHT Water Separating Filter Removal
Genesis FICHT Fuel Sender Testing
Genesis FICHT Fuel Pump Testing
Genesis FICHT Fuel Pump Module Installation
RPM Limiter Circuits
RPM Limiter Function
RPM Limiter System Troubleshooting
Oil Level Sensor Troubleshooting
Ignition System Testing - PVL - Genesis / X-45
PVL Ignition Troubleshooting (1200 Carbureted Engines)
Ignition Coil Identification - Genesis / X-45
Wire Sequence
PVL Ignition Troubleshooting Genesis / X-45
Trigger Coil Testing - Genesis / X-45
Ignition Timing Adjustment - Genesis / X-45
Dynamic (Running) Ignition Timing
Ignition Timing Adjustment
Static Ignition Timing Adjustment
Multi-Function Display
OPERATION AND MODES
KEY FUNCTIONS AND DISPLAY
Multi-Function Instrument
DISPLAY SUMMARY
PRIMARY FUNCTIONS
WARNING INDICATIONS:
MFD / MFI Troubleshooting
Bilge Pump
Wiring Diagrams
1999 X-45 (B994596) Wiring Diagram
1999 Genesis (B995095) Wiring Diagram
1999 Genesis Ficht (B995094) Wiring Diagram
Chapter 8 - Ficht Fuel Injection
Theory
Overview
Fuel Injectors
FFI Combustion Process
Flywheel
Stator
Capacitor
ENGINE MANAGEMENT MODULE (EMM)
Internal EMM Sensors
External EMM Sensors
S.L.O.W. WARNING SYSTEM
EMM Service Code Chart
Preliminary Tests
Diagnostic Guide
ENGINE WONT CRANK
ENGINE CRANKS BUT WON'T START
ENGINE STARTS AND DIES
ENGINE SURGES / RUNS ROUGH
LOW MAXIMUM RPM
ENGINE WON'T SHUT OFF
EXCESSIVE SMOKING
FALSE WARNING LIGHT
Action Steps - Fuel System
Delivery System
Fuel Injection System
Action Steps - Ignition System
Service Code Retrieval
Using Service Code Light
To Enter Diagnostic Mode
To Manually Erase Service Codes
To Leave Diagnostic Mode
Using Polaris Diagnostic Software
Specifications / Tests
Chapter 9 - PODIAG Diagnostic Software
Introduction
Computer Hardware Requirements
Installing Polaris Diagnostic Software (PN 2872605)
Setting Up The Program
Running The Program
Error Messages
Communication Problems
Main Menu Selections
Menu Option 1 - Diagnostic Session
Service Code Review Screen
Service Code Screens
Retest Option
Session Completion / Code Clearing
Menu Option 2 - Static Tests
Testing Fuel Injectors
Testing Ignition System
Testing Electric Fuel Pump
Menu Option 3 - Cylinder Drop Test
To Diagnose a Misfire
To Diagnose Low Performance or Rough Running
Menu Option 4 - Engine Monitoring
Sensors
Results
Switches
Voltage
Menu Option 5 - EMM Information
Menup Option 6 - Engine RPM Profile History
EMM Connectors
EMM 40 Pin Connector
EMM 12 Pin Connector
EMM 8 Pin Connector
Index A - W
Back Cover PN 9915673
