2001 Polaris SLH / Virage Personal Watercraft Factory Service Manual (P/N 9917163)

This 2001 Polaris factory service manual, P/N 9917163, covers the SLH and Virage with the W70-SCSP-04A engine. Virage TX and TXi models use a separate service publication.

• Engine repair: Engine removal and installation, crankcase disassembly, piston and cylinder inspection, crankshaft truing and indexing, and reassembly procedures.

• Fuel and carburetion: Keihin LE carburetor overhaul, needle-and-seat pop-off testing, fuel-pump inspection, accelerator-pump testing, reed-valve checks, and fuel-line air-leak tests.

• Cooling and exhaust: Thermostat/pop-off assembly service, exhaust coolant-filter cleaning, cooling-system flushing, and exhaust removal, inspection, and installation.

• Jet pump and driveline: Pump and stator disassembly, bearing, seal, and O-ring replacement, driveshaft inspection, engine-to-pump alignment, and ventilation/cavitation diagnosis.

• Hull and controls: Steering-cable replacement and adjustment, Virage reverse-cable adjustment, SMC and FRC repair, and sponson removal and installation.

• Electrical troubleshooting: Generation III PVL ignition tests, starter-motor overhaul, MFD/MFI diagnosis, warning-circuit checks, and separate SLH and Virage wiring diagrams.

Written primarily for Polaris personal watercraft service technicians in a properly equipped shop, this manual assumes a sound knowledge of mechanical theory, tool use, and shop procedures.

Engine Inspection and Reassembly

Internal engine coverage includes connecting-rod small- and big-end inspection, crankshaft main-bearing and runout checks, cylinder taper and out-of-round measurement, honing, and port chamfering. Component torque tables and tightening-sequence diagrams accompany the assembly procedures.

Crankshaft indexing checks address damage associated with hydrolock, impeller impacts, or piston failure. Polaris specifies trained technicians and specialized equipment for crankshaft repair and straightening.

Keihin Carburetion and Fuel Delivery

The Fuel Delivery Effect Diagram explains how the carburetor circuits overlap through the throttle range. Fuel-system diagnosis extends to tank check and relief valves, impulse-pump diaphragms, water-separator restriction, and intake air leaks.

Separate SLH and Virage fuel/vent-line and Oil Tank Exploded Views distinguish the two installations. The separator's colored float indicates collected water; a rising float calls attention to contamination that can restrict fuel delivery.

Cooling, Exhaust, and Storage

Cooling coverage identifies the water-inlet and outlet routing, thermostat/pop-off assembly, and exhaust cooling orifice and screen. Incorrect thermostat/pop-off reassembly can quickly cause severe engine damage.

Exhaust inspection addresses leaks, melted hose linings, and the Virage's PLANET acoustic resonators. Saltwater and off-season sections cover corrosion protection, engine fogging, draining, and battery storage, with a Bilge Siphon System layout for the water-removal circuit.

Pump Alignment and Bearing Service

Ventilation/cavitation diagnosis distinguishes air leaks around the intake tract from impeller or housing damage. The Cutaway View of Pump identifies the related sealing areas, helping narrow down high engine speed with weak thrust before pump parts are replaced.

The procedures identify impeller removal tool PN 2871036 and engine/pump alignment tool PN 2871343. Allowing the impeller spacer to displace the seal lips during stator assembly can admit water to the bearing housing.

The through-hull bearing housing is inspected and replaced as an assembly; it is not rebuilt.

Steering, Hull Repair, and Electrical Diagnosis

Control-system coverage distinguishes SLH electric Quick Trim from Virage manual reverse. Hull repair separates SMC structural-adhesive work from FRC fiberglass repair, alongside seat, compartment-door, decal, and footpad service.

Electrical sections cover the SLH Multi-Function Display and Virage Multi-Function Instrument, electrical-box connections, Hall-effect sensor testing, and starter voltage-drop diagnosis. Model-specific wiring diagrams provide connector pin assignments and wire-color codes.

Ignition coverage limit: Printed page 7.26 is missing from the PVL ignition troubleshooting section; the surrounding diagnostic pages are included.

Follow the manual's fuel-vapor and electrical-isolation precautions when servicing the fuel system, starter, or exposed driveline.

A Sample of Engine Fit and Operating Data

These examples are a small selection of the manual's inspection and operating data.

For the SLH/Virage engine, standard piston-to-cylinder clearance is .0055–.0065 in. (.14–.16 mm), with a .010-in. (.25-mm) service limit. The inspection section distinguishes the normal fit from the wear limit.

The thermostat opening temperature is 143°F (62°C). Electrical specifications list magneto output as 5A/60W at 4,500 RPM.

Text Search, Diagram Detail, and PDF Contents

Search and schematic detail: Most sections support text search, with OCR recognition errors. Engine assembly page 3.37 and the Virage wiring diagram lack searchable text; SLH diagram search is limited. Bookmarks cover chapters and many subsections, though starter disassembly opens one page early. Small wiring labels require zooming.

Supplied as one printable, English-language 258-page PDF. That total already includes both covers, one Notes page, and one duplicate Virage Deck Assembly page, printed 6.4.