Thermostat / Pop-off Valve Cleaning
1992-1998 Polaris Personal 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 cleaned. Inspect the thermostat pop off assembly if the watercraft has been stored for more than 30 days or has been used in salt water.
CAUTION
Note the location of all parts when cleaning the thermostat/popoff valve assembly. Be sure all parts are positioned correctly during reassembly, or severe engine damage will result within a very short period of operation: Do not perform this maintenance while the watercraft is in the water. The thermostat pop off assembly is under tension from an internal spring. When the screws are removed, the assembly will come apart quickly if not held together firmly.
- Using a 3/16" (0.5 cm) hexagonal wrench and a flat screwdriver, remove screws while holding thermostat pop off assembly firmly together. Carefully take assembly apart. Be careful not to lose any parts.
- Inspect thermostat pop off assembly for debris, such as sand or seaweed, and clean thoroughly with water. Inspect pop off valve for wear.
- Inspect condition of gaskets and rubber parts. Replace any parts that appear cracked, damaged, or distorted.
- Inspect thermostat and housing for corrosion. Visually inspect thermostat for damage or distortion. It should be closed at room temperature.
- Apply Loctite 242 (Blue) to bolts . Carefully assemble thermostat pop off assembly in the correct sequence. Verify proper alignment of all parts and gasket/a-ring during assembly. The arrow in the illustration indicates the direction of water flow (away from engine). See illustrations below.
Updated on: Saturday, December 26, 2020