2000 Polaris Virage TX, SLX, Pro 1200, Genesis, Genesis FFI Personal Watercraft Service Manual, Page 33Get this manual
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MAINTENANCEITUNE UP Engine
ThermostatPop Off Valve Cleaning (FFI1M Watercraft)
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 cleanedInspect the thermostat pop off assembly if the watercraft has been stored for more than 30 days or has been used in salt water
Note the location of all parts when cleaning the thermostatpopoff valve assemblyBe sure all parts are positioned correctly during reassembly, or severe engine damage will result within very short period of operationDo not perform this maintenance while the watercraft is in the waterThe thermostat pop off assembly is under tension from an internal springWhen the screws are removed, the assembly will come apart quickly if not held together firmly1Using 316" (.5 cm) hexagonal wrench and flat screwdriver, remove screws while holding thermostat pop off assembly firmly togetherto Carefully take assembly apartBe careful lose any partsInspect thermostat pop off assembly for debris, such as sand or seaweed, and clean thoroughly with waterInspect pop off valve forwearSee III1Inspect condition of gaskets and rubber partsReplace any parts that appear cracked, damaged, or distortedInspect thermostat and housing for corrosionVisually inspect thermostat for damage or distortionIt should be closed at room temperatureApply Loctite 242 (Blue) to boltsCarefully assemble thermostat pop off assembly in the correct sequenceVerify proper alignment of all parts and gasketa-ring during assemblyThe arrow in the illustration indicates the direction of water flow (away from engine)See III2Internal Pop-off (Longer End Towards Engine) Valve SpringIII1 Thermostat Pop Off Valve