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  1. #1
    bobkyle2's Avatar
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    2002 Virage 800 di ... Water in ski

    I'm working on a freinds Ski (Never worked on ski's before .. but lost of 2 stroke work and outboard engines) ...

    He just bought the ski..And its getting water inside the ski... Found a hose on the right side of the ski.. That has a blackish/gray square plastic fitting looking thing...lol.... looks like its threaded to go on something on one side and has 2 smaller holes on the other like like it mounted somewhere.

    Didn't have time to look at it very long. Will be looking at it again. But wanted to see if you guys new what i was talking about.. Will try to get a picture of the part if i cannot find where it goes. And how to fix it.


    Thanks guys!!

    BTW .... ITs a 2002 Polaris Virage 800 di ...


  2. #2
    Possibly sounds like the cooling line that runs to the stator and then through the EMM (computer). Post pics.

  3. #3
    bobkyle2's Avatar
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    Got the water leak fixed... It was that line that went to the computer.

    Now its got a fuel leak, Its the Injector. I heard that the new injector or used injector will have to be programmed to the computer? ....Anyone have any idea if that is correct.. And what it normally cost.

    Searching some thread right now looking for answers Thanks fellers!

  4. #4
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    might just be a simple o ring

  5. #5
    Click avatar for tech links/info, donation request K447's Avatar
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    That black block shaped item was probably the water injection solenoid. It is essentially an emissions device and can be deleted.

    See my signature links below for tips on how to properly delete it. There is a fitting on the exhaust pipe that should be capped and the water hose tee needs to be removed or capped.

    The same water lines also provide cooling water flow for the EMM and that flow must remain unimpeded.

    Fuel leaks are a big deal since fumes inside the enclosed hull create an explosion hazard.

    Inspect the fuel hoses where they rub against the injector brackets. Polaris issued a service bulletin regarding adding protective sheathing to prevent the fuel lines from abrading and leaking.

    Also inspect all the plastic hose fittings at the injectors. Look for any signs of cracks or loose hose crimps. Fuel pressure is over 20PSI.

    Each plastic fuel line connection to the injectors has two small o-rings. If you need to remove the hose connections you first remove the injector bolts and wiggle the injector bracket off the injector. Then the hose connection can be wiggle out of the injector.

    Mark each injector with the cylinder it came from and be sure to put them back on the same cylinders. When reinstalling injectors it is important to not over torque the bolts and make very sure the injector is not canted in the cylinder head opening.

  6. #6
    bobkyle2's Avatar
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    What seals the injector to the head? Is there a Oring somewhere or a gasket?

  7. #7
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by bobkyle2 View Post
    What seals the injector to the head? Is there a Oring somewhere or a gasket?
    The injector uses a high precision metal to metal mating between the seat in the cylinder head and the injector tip. That is why it is important to keep the injector aligned and properly bolt torqued.

    There IS a fat o-ring on top of the injector but that is used as a compression spring under the bracket dome to clamp the injector tip against the head.

  8. #8
    bobkyle2's Avatar
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    That is were it's leaking... We have tried every which way to get it to stop leaking... But will not stop.... He has two other injector but i have read you cannot swap them out without having them coded or something?

  9. #9
    Click avatar for tech links/info, donation request K447's Avatar
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    Where exactly is the fuel leaking from?

    Is the fat o-ring in place on top of the injector, underneath the bracket dome?

    The injectors must all be fully seated and torqued properly before pressing the Start button.

  10. #10
    bobkyle2's Avatar
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    Its leaking around out of the head/injector... Like its not mating against the cylinder correctly.

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