POLARIS MARINE 1200 Model #W000099D Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /00

Transcription

1 POLARIS MARINE 00 Model #W000099D 000 Polaris Sales Inc. PARTS MANUAL PN 9968 and MICROFICHE PN 9969 /00

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3 TABLE OF CONTENTS POLARIS MARINE 00 W000099D Parts Manual A AIR VENT A CARBURETOR B- COOLING SYSTEM A8 CRANKCASE A CRANKSHAFT and PISTON B CYLINDER and MANIFOLD B D DRIVE SYSTEM A ELECTRICAL BOX A9-0 ENGINE MOUNTING A E EXHAUST SYSTEM A7 C E MAGNETO B6 O OIL PUMP B OWNER S MANUAL PART NUMBER INDEX B8-0 PROPULSION A-6 STARTING MOTOR B7 W WATER INLET A WATER SIPHON A M P S The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

4 ENGINE MOUNTING POLARIS MARINE 00 W000099D 000 Polaris Sales Inc Ref. Part Qty. Description Ref. Part Qty. Description 087 Switch, Temperature Decal - Spark Plug 76 Ground, Spark Plug 79 Screw 800 Gasket, Exhaust Pipe 6 Decal - Warning (See Cylinder and Manifold Pg. B, Ref. ) Plate, Front Mount Washer, Lock Screw Plate, Rear Mount 00 Mount, Engine 77 AR Shim, Engine Mount Washer, Lock Screw 788 Washer, Flat 6 77 Nut, Nylok Washer, Lock Screw Kit - Short Block, Triple NOTE: The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston & crankshaft assembly Clip, Retainer 7660 Bolt /00 A

5 DRIVE SYSTEM POLARIS MARINE 00 W000099D Ref. Part Qty. Description Ref. Part Qty. Description 0609 Coupler, Drive 07 O-Ring 9 Shroud, Coupler Clamp, Hose 066 Bumper, Drive Shaft Shaft, Drive Fitting, Lubrication A Seal, Bearing 9 76 Bearing, DU 0 Asm., Bearing Housing (Incl. 7-9) 07 Hose, Bearing Housing 98 Nut, Bushing 7 O-Ring 98 Housing, Shaft, Thru-Hull /00

6 PROPULSION POLARIS MARINE 00 W000099D Reverse Gate NO TAG A

7 PROPULSION POLARIS MARINE 00 W000099D Ref. Part Qty. Description Ref. Part Qty. Description 600 Seal, Stator Bearing 008 Bearing 009 Spacer, Bearing 7 Stator 087 O-Ring O-Ring Shaft, Stub O-Ring Gate, Reverse, Directional 0 7 Nut, Nylok Rod End 70 Nut 7779 Screw 7866 Washer 0068 Collar Screw Washer, Flat 8 07 O-Ring 9 69 Pipe, Water, Engine 0 Extension, Pump 07 Seal, Water Pipe 06 Seal, Siphon Tube 990 Pipe, Water 7 Nut, Nylok 6 Bracket, Steering Cable 6 79 Washer, Seal Pump Stud 7 Stud, Pump Mounting Spacer, Impeller 9 0 Impeller Hose, Water Cable Tie 709 Screw 6098 Anode, Zinc 7 Housing, Pump 7966 Washer, Flat 6 06 O-Ring Seal, Tail Cone 8 9 Cone, Pump 9 Screen, Engine Inlet 0 8 Wedge, Pump 789 Bolt 78 Washer, Flat 760 Washer, Lock 0999 Nozzle, Steering 8 Bearing, Steering Nozzle Collar Screw Nozzle Screw /00 A6

8 EXHAUST SYSTEM POLARIS MARINE 00 W000099D Ref. Part Qty. Description Ref. Part Qty. Description Fitting, Inlet, Water Pipe, Exhaust Washer, Flat 76 6 Washer, Lock 7700 Screw Screw Screw Fitting, Screen, Exhaust Screw 0 Gasket, Exhaust Pipe (See Engine Mounting Pg. A, Ref. ) 7090 Fitting, Injector, Exhaust Clamp, Hose 7 Hose, Pipe/Silencer Clamp, Hose Silencer, Exhaust 6 0 Bumper, Rubber 7 7 Bracket, Silencer 8 69 Resonator, LH 9 60 Resonator, RH 0 77 Screw 788 Washer, Lock 786 Washer, Flat 8 Plate, External, Seal 7 Seal, External 8 Seal, Internal, Exhaust, Underwater Fitting, Exhaust, Underwater /00 A7

9 COOLING SYSTEM POLARIS MARINE 00 W000099D Ref. Part Qty. Description Ref. Part Qty. Description Clamp, Hose Fitting, Thru-Hull 87 Gasket 87-0 Conduit, Flex Hose, Water Inlet 6 78 Fitting, Tee 7 79 Hose, Water In, Exhaust Pipe 8 Fitting, Inlet, Water (See Exhaust System Pg. A7, Ref. ) 9 Fitting, Exhaust Injector (See Exhaust System Pg. A7, Ref.) 0 Fitting, Exhaust Screen (See Exhaust System Pg. A7, Ref. 8) Clamp, Hose Hose, Stinger Cable Tie 0897 Hose, Stinger 98- Conduit, Flex Screw Screw Manifold, Exhaust Fitting, Drain, Exhaust Manifold Cover, Thermostat 0860 Seal, Thermostat Housing 0 Hose, Water Outlet 87- Conduit, Flex A8 /00

10 ELECTRICAL BOX POLARIS MARINE 00 W000099D A9

11 ELECTRICAL BOX POLARIS MARINE 00 W000099D Ref. Part Qty. Description Ref. Part Qty. Description 707 Screw 7706 Nut 76 Washer, Lock 787 Washer, Flat 7870 Washer, Rubber Dish 6 76 Plate, Bottom Cable Tie Fuse, Amp Fuse, / Amp Clip, Ignition Cable 0 Cap, Grommet 00 Regulator, Rectifier 0 Board, Terminal (Incl. 8,9) Controller, Ignition (See Magneto Pg. B6, Ref. ) 760 Plate, Top 6 0 Breaker, Circuit, Amp 7 0 Latch, Box 8 Pin, Latch 9 08 Strap, Rubber 0 7 D-Hook, SST Grommet Coil, Ignition (See Magneto Pg. B6, Ref. ) 8 Bracket, Coil/Solenoid 69 Seal, Electrical Box 7706 Nut, Nylok Boot, Threaded 7 9 O-Ring Decal - High Voltage Warning 9 66 Asm., Electrical Box (Incl. 7,8,) Decal - Reset Electrical System 7 Plate, Stator 786 Washer, Flat 7 Screw 87 Kit - Flush Kit Quick Connect 0 Asm., Pickup Sender Clamp, Hose /00 A0

12 WATER INLET POLARIS MARINE 00 W000099D Ref. Part Qty. Description Ref. Part Qty. Description Pitot Line, Formed End Cable Tie 7700 Nut, Nylon 787 Washer, Flat Gasket, Pitot 6 6 Fitting, Pitot, Molded A 7 60 Scoop, Inlet Plate, Ride 9 76 Screw Screw 7 Screw Grate, Inlet /00

13 AIR VENT POLARIS MARINE 00 W000099D 6 7 Ref. Part Qty. Description Ref. Part Qty. Description 767 Screw 760 Washer, Lock 78 Washer, Flat 7 Spacer 6-09 Silencer, Intake, Top Decal - 00 Intake Silencer Filter, Intake Silencer /99 A

14 WATER SIPHON POLARIS MARINE 00 W000099D 7 6 Ref. Part Qty. Description Ref. Part Qty. Description 86-. Conduit, Wire,. cm 09 Elbow, Siphon Hose Cable Tie Line, Fuel Line, Fuel Anchor, Cable Tie 7 06 Pickup, Siphon w/strainer /00 A

15 CRANKCASE POLARIS MARINE 00 W000099D Ref. Part Qty. Description Ref. Part Qty. Description 06 Kit - Crankcase, 00 (Incl. 6-0) 6980 Bushing 0 Plug, Timing Hole 7 Bushing 707 Spring Bushing 7 09 Cover, Flywheel Screw 9 9 O-Ring Screw 80 Gasket, Flywheel Cover 767 Screw Pin, Dowel 6 O-Ring 098 Asm., Flywheel Housing (Incl.,) Screw Plug Screw Stud, Cylinder Flange Pin, Dowel 70 Fitting /99 A

16 CYLINDER and MANIFOLD POLARIS MARINE 00 W000099D Ref. Part Qty. Description Ref. Part Qty. Description Screw 7078 Decal - Warning Manifold, Water 8006 Gasket, Water, Manifold 0706 Spark Plug, NGK BR9ES Cover, Head, Big Bore, Red O-Ring 8 9 Ring, Head 9 0 Head, Cylinder 0 Kit - Asm., Triple Crankcase (See Crankcase Pg. A, Ref.) 09 Asm., Triple Reed Block 6 Stuffer, Reed Block 608 Adaptor, Carburetor, Cylinder Screw Screw Retainer Gasket, Carburetor 8 80 Gasket, Cylinder Base Cylinder, 8mm Nut, Acorn, Flange 09 O-Ring 7 O-Ring 77 8 Screw 767 Screw /00 B

17 CRANKSHAFT and PISTON POLARIS MARINE 00 W000099D Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Crankshaft, 00 Triple (Incl. 6,8,-8) 079 Circlip, Piston 000 Pin, Piston Kit - Piston (Std.)(Incl.,,) Kit - Piston (.mm O/S)(Incl.,,) Kit - Piston (.0mm O/S)(Incl.,,) Kit - Piston Rings (Standard) Kit - Piston Rings (.mm O/S) Kit - Piston Rings (.0mm O/S) 0 Kit - Connecting Rod Asm. 6 Bearing Key, Woodruff Bushing 9 76 Coupler, Pump Drive 0 Nut (See Magneto Pg. B6, Ref. 0) Washer (See Magneto Pg. B6, Ref. 9) 600 Seal 770 Ring, Retaining 80 8 Bearing, Ball, Deep Groove 7 Crankweb, MAG, Big Bore 6 7 Crankweb, Center, Big Bore Labyrinth 8 76 Crankweb, PTO, Big Bore 9 Seal Ring, Retaining, Internal 06 O-Ring 9 Collar, Crankshaft 0/99 B

18 CARBURETOR POLARIS MARINE 00 W000099D B

19 CARBURETOR POLARIS MARINE 00 W000099D Ref. Part Qty. Description Ref. Part Qty. Description Asm., Carburetor, Keihin 0090 Kit - Carb Rebuild (Incl. 9,7,,0) Screw, Fuel Pump Kit - Fuel Pump Body Kit - Gasket, Fuel Pump 00 Nozzle, PTO 00 Hose, Fuel Cable Tie Screw Base, Intake Silencer Gasket, Carb, Upper Block, Jet 007 Kit - Synchronizing Screw 006 Joint, Connecting 007 Tube, Rubber 0068 Kit - Check Valve, Mid Range ( Per Carb) 00 Screen, Fuel Strainer Kit - Accelerator Pump ( Per Carb) Kit - Needle Valve ( Per Carb) Jet, Main (Per Carb) Mag Jet, Main (Per Carb) Center Jet, Main (Per Carb) PTO Jet, Pilot ( Per Carb) Jet, Pilot ( Per Carb) 00 Screw, Jet Block Cover 009 Cover, Jet Block 0070 Kit - Diaphragm, Jet Block ( Per Carb) 007 Screw, Jet Block ( Per Carb) 009 Block, Jet O-Ring, Jet Block Kit - Idler Mixture Screw ( Per Carb) Cap, Limiter Collar O-Ring, Valve Seat Kit - Check Valve, Main ( Per Carb) 007 Kit - Idle Stop Screw 00 Nozzle, Magneto, Keihin 006 Tube, Rubber 00 Hose, Fuel, Accelerator Pump 6 00 T-Fitting Plate, Connecting Screw, Connecting Plate 9 00 Nozzle, Center, Keihin Gasket, Carb /00 B

20 OIL PUMP POLARIS MARINE 00 W000099D Ref. Part Qty. Description Ref. Part Qty. Description Cable, Oil Pump Line, Oil Clamp 9 O-Ring B 7707 E-Ring, Retaining 6 79 Washer, Nylon Screw Asm., Oil Pump (Incl. ) /99

21 MAGNETO POLARIS MARINE 00 W000099D Ref. Part Qty. Description Ref. Part Qty. Description 006 Stator, Ignition 777 Screw 77 Screw Clamp, Stator Wire 0 O-Ring 6 8 Holder, Magnet Asm., Flywheel (Incl.,6,8) 8 08 Kit - Timing Screws Washer Nut 608 Harness, 9 Wire Stator 0079 Controller 00 Coil, Ignition, Triple 008 Solenoid, Starter Wire, Spark Plug, 7 cm Wire, Spark Plug, 6 cm Wire, Spark Plug, cm B6 /00

22 STARTING MOTOR POLARIS MARINE 00 W000099D Ref. Part Qty. Description Ref. Part Qty. Description 0608 Starter, Big Bore (Incl.,-) 0 Bolt, Through Screw 0 Brush (Incl. -8) 06 Nut 07 Washer, Spring 6 09 Washer O-Ring 8 0 Spring, Brush Ring, Rubber Asm., Rear Bracket 08 AR Washer, Thrust B7 0 Washer, Thrust 00 Asm., Armature 006 Asm., Front Bracket 0 O-Ring Washer, Thrust 7 06 Ring, Snap 8 0 Stopper 9 0 Cover Spring 7 Bushing, Flange 00 Asm., Gear (Incl. 6-) 0609 Asm., Bendix (Incl. 6-) /99

23 Part Ref. Grid A B A A B B A A A A A B B B B B B B B B B B B B B B B B A A B B B A A A A B B A A B A B B B B B B B B B B B Part PART NUMBER INDEX POLARIS MARINE 00 W Ref. B8 Grid B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B A B A A A... B A B A A B B B B B B6 Part Ref. Grid A B B B A B B A A A A A A A A A A B A B A A A A B B B A A A A A A A B A B A A A A A A B A A A 8... A A A A A A A B

24 Part Ref. Grid B A A A A A A A A A... B A B A A B A B A A A A A A A A A A A A A B A B A A A A A A B A A A A A A A A B A B B A Part PART NUMBER INDEX POLARIS MARINE 00 W Ref. B9 Grid A A A A A A A A A A B 0... B A B B B A A 0... B A A A A A A A B A A A A6... A8.. A 6... B A A A A A A A A0.. A A B B A B A7 6.. A A A A A Part Ref. Grid A A A A A A B B A A8.. A A A... B B... B B B A A A A A A A A B B A A A A B A A A A A A B A B A A A A... A6.. A A A A A A7.. A A0

25 Part Ref. Grid A A A A A A A B B6 Part PART NUMBER INDEX POLARIS MARINE 00 W Ref. Grid B A B A A A A B Part Ref. Grid B B B A A A B A B0

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27 In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication. or FAX your report to: POLARIS PUBLICATIONS REPORT Publication Machine Publ. Date Page Report of Error Suggestion Name Company Address City, State, Zip Phone ( ) Date Thank you for your help! Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge. /9 Rev

28 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. ROSEAU, MINNESOTA POSTAGE WILL BE PAID BE ADDRESSEE ATTN: TECHNICAL PUBLICATIONS POLARIS SALES INC. 0 TH AVE. S.W. ROSEAU, MN 67

29 In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication. or FAX your report to: POLARIS PUBLICATIONS REPORT Publication Machine Publ. Date Page Report of Error Suggestion Name Company Address City, State, Zip Phone ( ) Date Thank you for your help! Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge. /9 Rev

30 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. ROSEAU, MINNESOTA POSTAGE WILL BE PAID BE ADDRESSEE ATTN: TECHNICAL PUBLICATIONS POLARIS SALES INC. 0 TH AVE. S.W. ROSEAU, MN 67

31 In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication. or FAX your report to: POLARIS PUBLICATIONS REPORT Publication Machine Publ. Date Page Report of Error Suggestion Name Company Address City, State, Zip Phone ( ) Date Thank you for your help! Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge. /9 Rev

32 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. ROSEAU, MINNESOTA POSTAGE WILL BE PAID BE ADDRESSEE ATTN: TECHNICAL PUBLICATIONS POLARIS SALES INC. 0 TH AVE. S.W. ROSEAU, MN 67

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34 PRINTED IN THE USA PARTS MANUAL PN 9968 and MICROFICHE PN 9969 /00