Polaris msx 110 User manual

Part Number 9919062
Printed in U.S.A
msx 110
msx 150
Personal Watercraft Service Manual
Four Stroke Personal Watercraft Service Manual
FOUR STROKE

Hull and Body Systems
Specifications / Components / Teardown and Rebuilding / Inspection
General Information
Model Information / Safety Warnings / General Information
Maintenance
Periodic Maintenance Tables / Maintenance Procedures
Propulsion System
Specifications / Components / Teardown and Rebuilding / Inspection
Engine Removal and Installation
Specifications / Removal and Installation
Engine Disassembly, Inspection and Re--Assembly
Specifications / Components / Testing / Troubleshooting / Teardown
Fuel / Ignition / Exhaust Systems
Specifications / Components / Testing / Troubleshooting
1
2
3
4
5
6
7
8
Electrical System
Specifications / NGI Gauge / System Interface Box / Starter Motor / Components
Table of Contents

1
MSX 110 / 150 Service Manual General Information
PWC Identification Numbers 1.1
2004 PWC Publication Part Numbers 1.2
Service Guidelines / Safety Warnings 1.3
MSX 110 General Information 1.4 -- 1.5
MSX 150 General information 1.6 -- 1.7
Standard Torque Specifications 1.8
Decimal Equivalent Chart 1.9
Conversion Chart 1.10
Tap Drill Sizes 1.11
Service Tools 1.12 -- 1.13

PLE
123456789101112
Universal
Manufacture
I.D.
Sequential Serial Numbers
(Alphanumeric)
Certification
Month
Certification
Year
Model
Decade
Model
Year
HIN (Boarding Platform)
HIN (Inside Engine Compartment)
HIN (Boarding Platform)
HIN (Inside Engine Compartment)
EMISSIONS DECAL
ENGINE SERIAL NUMBER DECAL
GENERAL INFORMATION
1.32004 Four Stroke PWC Service Manual
2004 PWC Identification Numbers
The engine I.D. number and hull I.D. number are used to register the watercraft. They are unique numbers that
distinguish each watercraft from others of the same model.
If the watercraft is ever stolen these numbers will help identify it. The owner should keep a record of these num-
bers in a place other than the watercraft.
Month Code: A = January; B = February; etc.
Year Of Manufacture: 4 = 2004

GENERAL INFORMATION
1.4 2004 Four Stroke PWC Service Manual
2004 PWC Publication Part Numbers
Model Model Number Owner’s
Manual Parts Book Microfiche Assembly Instructions
MSX 110 (A) W045304CA
MSX 110 (A)
International W045304IA
MSX 110 (B) W045304CB
MSX 110 (B)
International W045304IB 9919055 9919056
MSX 110 (C) W045304CC
MSX 110 (C)
International W045304IC
MSX 150 (A) W045305CA
MSX 150 (A)
International W045305IA 9918972 9919173
MSX 150 (B) W045305CB
MSX 150 (B)
International W045305IB
9
9
1
9
0
5
7
9
9
1
9
0
5
8
MSX 150 (C) W045305CC
9
9
1
9
0
5
7
9
9
1
9
0
5
8
MSX 150
International W045305IC
MSX 150 (D) W045305CD
MSX 150 (D)
International W045305ID
SC = 50 State Domestic (CARB Exemption).
SA / B / C / D = Color Option.
SI = International Model
2004 PWC Service Manual Part Numbers
Book Part Number
2004 Carbureted / DItModels (All) 9919061
2004 Four Stroke PWC Models (All) 9919062
2004 OCTANE Update Packet 9919065
2004 PWC Flat Rate Manual 9919063
2004 Wallchart Packet TBA

GENERAL INFORMATION
1.52004 Four Stroke PWC Service Manual
Service Guidelines -- Safety Warnings
SClean inside and outside of watercraft prior to servicing. Clean all parts before installing. Always use a service apron to
prevent damage to footwell and top--deck fiberglass.
SWatch for sharp edges which can cause personal injury. Protect hands and arms when working with sharp components.
SAlways use a soft--faced hammer and extreme care when removing difficult or stuck components.
SSome fasteners are installed with locking agents or lubricants. Use of impact drivers will aid in fastener removal.
SAlways follow torques specifications located throughout manual. Fasteners secured with either too little or too much torque
may fail and cause severe property damage, injury or death.
SAlways follow torque sequence patterns when found in this manual. Tighten each fastener evenly and to the specified torque
value, and with specified locking agent.
SAlways use new gaskets, o--rings and seals, clips, cir--clips, and snap rings when assembling components.
SNever re--use Nyloktor Flex Locktnuts when assembling components.
SNever re--use Oetikertclamps when removed from fuel lines. Replace with small gear clamps.
SAlways use Polaris--authorized lubricants, greases, and locking agents when assembling components. Failure to do so
may cause severe engine or vehicle damage.
SAlways disconnect the black (--) negative cable first from the battery when removing the battery. When installing the battery,
attach the red (+) positive cable first, then the black (--) negative cable.
SWear appropriate clothing, eye protection, and rubber gloves when working with batteries. Battery acid contains sulfuric
acid and is extremely poisonous. Serious burns can result when in contact with skin, clothing, eyes or internal body compo-
nents.
SIf battery acid is ingested, drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable
oil. Call a physician immediately.
SFlush eyes for15 minutes with water and seek prompt medical attention if acid comes in contact with eyes. Thoroughly wash
affected external body parts that come in contact with battery acid with water.
SKeep hands, arms, legs, feet and hair away from rotating parts, hot engine and exhaust components, drive pump and impel-
ler and engine induction when engine is running.
SNever attempt engine or driveline inspections and/or repairs without first removing lanyard and battery cables.
SGasoline is highly flammable and explosive under certain conditions. Always exercise extreme care when handling gaso-
line. Do not smoke or allow open flames in or near the area where refueling is performed or where gasoline is stored.
SAlways refuel the watercraft outdoors and in a well--ventilated area. Do not fill the tank to the fuel cap.
SIf you get gasoline or oil on your skin or clothing, wash it off immediately with soap and water and change clothing.
SThe engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
Only run engine outdoors or in a well--ventilated area.
SNever run the engine for more than 15 seconds without cooling water supply.

2004 MSX 110
W045304CA / CB / CC (W045304IA / IB / IC)
Length: 126 in. (320 cm)....
Width: 48.3 in. (122.6 cm).....
Height: 42.5 in. (108 cm)....
DryWeight: 650lbs. (295 kg)
Category: Midsize..
Riders: 1to3....
Fuel Capacity: 17.8 US Gal. (67.4L)
Emission Certification: Two Star -- Very Low Emission
MSX110 W045304CB Sarasota Yellow
GENERAL INFORMATION
1.6 2004 Four Stroke PWC Service Manual
2004 MSX 110 Emission Certification
The engines in all 2004 MSX 110 Personal Watercraft are certified as Two Star, Very Low Emission engines.
TheTwo Star label identifies engines that meet the California Air Resources Board (CARB) 2004 exhaust emis-
sion standards. Engines meeting these standards have 20% lower emissions than One--Star -- Low Emission
engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines.
Emission Control Information Decals
Theemission control information decal is located on the flywheel cover.
2004 MSX 110 Emission Decal
ENGINE FAMILY 3WEBMO.75H01
FAMILY EMISSION LIMIT 36.0 g/kW--hr
EMISSION CONTROL SYSTEM SFI(Sequential Fuel Injection)
FUEL Unleaded Gasoline 91 Octane R+M/2
SPARK PLUG Champion RC7PYCB
SPARK PLUG GAP .7 -- .8mm (.028 -- .032 in.)
ADVERTISED HORSEPOWER 82 kW (110HP)
ENGINE DISPLACEMENT 750cc

GENERAL INFORMATION
1.72004 Four Stroke PWC Service Manual
2004 MSX 110
Model Number W045304CA / CB / CC (W045304IA / IB / IC)
Engine
Platform Polaris LibertytMarine Intercooled Turbocharged Four Stroke
Engine Model Number ES075WLE--011
Engine Displacement 750cc
Number of Cylinders 2
Cylinder Lining Material Nicasil
Bore & Stroke (mm) 85 x 66
Compression Ratio (Effective) 9.0:1
Cylinder Compression @ Sea Level 140 ±14.5 psi (9.6 ±1 bar) -- Both spark plugs removed, engine turnover @ 300 RPM.
Cooling System Closed loop with engine coolant--to--freshwater heat exchanger.
Thermostat Opening Temperature 82_C
Overheat Warning Engine Overheat / Exhaust Manifold Overheat Switch -- RPM Limit / NGI Warning
Induction Type Intercooled Turbocharger
Lubrication Dry Sump
Oil Requirements Polaris Synthetic PWC Four Stroke Engine Oil (15W--50)
RPM Limiter 7800 to 8400 RPM -- Determined by ECU
Exhaust System Exhaust pipe w/water jacket and water injector.
Sound Reduction Turbo PLANETt
Engine Management System
Fuel Delivery Bosch Multi--Point Fuel Injection
Recommended Fuel Premium Unleaded Fuel (91 / 92 / 93 Octane)
Idle Speed (In Water) 1550 ±50 RPM
Ignition System EMS Bosch ME 7.4.4
Timing Degrees BTDC 22 Degrees BTDC
Spark Plug Champion RC7PYCB
Spark Plug Gap .6 -- .7mm (.025 -- .030 in.)
Electrical
Magneto Generator Output 25A / 350W @ 3000 RPM
Battery 12 Volts / 19A
Fuses 2A -- NGI Gauge / 15A -- Battery / 15A -- Ignition System / 15A -- Fuel Pump
30A -- Alternator / 15A x 3 -- Main Relay
Starting Electric Motor -- One Button Start / One Button Stop
Propulsion
Jet Pump Type Dominator 2 Single Stage Axial Flow w/Six Vane Stainless Steel Stator
Impeller Rotation Counter Clockwise (From Aft)
Coupling Type Three piece coupler
Minimum Depth For Operation 2 ft. (60cm.)
Impeller Type TBA
Impeller Diameter 5.8 in. (148mm)
Reverse System Manual w/3400 RPM Limit
Hull/Body
Hull Design Modified Full V
Hull Material FRC (Fiberglass Reinforced Composite)
Top Deck Material FRC (Fiberglass Reinforced Composite)

MSX 150 W045305CD Stealth Black
2004 MSX 150
W045305CA / CB / CC / CD (W045305IA / IB / IC / ID)
Length: 126 in. (320 cm)....
Width: 48.3 in. (122.6 cm).....
Height: 42.5 in. (108 cm)....
DryWeight: 660 lbs. (301 kg)
Category: Midsize..
Riders: 1to3....
Fuel Capacity: 17.8 US Gal. (67.4L)
Emission Certification: Two Star -- Very Low Emission
GENERAL INFORMATION
1.8 2004 Four Stroke PWC Service Manual
2004 MSX 150 Emission Certification
The engines in all 2004 MSX 150 Personal Watercraft are certified as Two Star, Very Low Emission engines.
TheTwo Star label identifies engines that meet the California Air Resources Board (CARB) 2004 exhaust emis-
sion standards. Engines meeting these standards have 20% lower emissions than One--Star -- Low Emission
engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines.
Emission Control Information Decals
Theemission control information decal is located on the flywheel cover.
2004 MSX 150 Emission Decal
ENGINE FAMILY 3WEBMO.75H01
FAMILY EMISSION LIMIT 36.0 g/kW--hr
EMISSION CONTROL SYSTEM SFI(Sequential Fuel Injection)
FUEL Unleaded Gasoline 91 Octane R+M/2
SPARK PLUG Champion RC7PYCB
SPARK PLUG GAP .7 -- .8mm (.028 -- .032 in.)
ADVERTISED HORSEPOWER 112kW(150HP)
ENGINE DISPLACEMENT 750cc

GENERAL INFORMATION
1.92004 Four Stroke PWC Service Manual
2004 MSX 150
Model Number W045305CA / CB / CC / CD (W045305IA / IB / IC / ID)
Engine
Platform Polaris LibertytMarine Intercooled Turbocharged Four Stroke
Engine Model Number ES075WLE--011
Engine Displacement 750cc
Number of Cylinders 2
Cylinder Lining Material Nicasil
Bore & Stroke (mm) 85 x 66
Compression Ratio (Effective) 9.0:1
Cylinder Compression 140 ±14.5 psi (9.6 ±1 bar) -- Both spark plugs removed, engine turnover @ 300 RPM.
Cooling System Closed loop with engine coolant--to--freshwater heat exchanger.
Thermostat Opening Temperature 82_C
Overheat Warning Engine Overheat / Exhaust Manifold Overheat Switch -- RPM Limit / NGI Warning
Induction Type Intercooled Turbocharger
Lubrication Dry Sump
Oil Requirements Polaris Synthetic PWC Four Stroke Engine Oil (15W--50)
RPM Limiter 7800 to 8400 RPM -- Determined by ECU.
Exhaust System Exhaust pipe w/water jacket and water injector.
Sound Reduction Turbo PLANETt
Engine Management System
Fuel Delivery Bosch Multi--Point Fuel Injection
Recommended Fuel Premium Unleaded Fuel (91 / 92 / 93 Octane)
Idle Speed (In Water) 1550 ±50 RPM
Ignition System EMS Bosch ME 7.4.4
Timing Degrees BTDC 22 Degrees BTDC
Spark Plug Champion RC7PYCB
Spark Plug Gap .6 -- .7mm (.025 -- .030 in.)
Electrical
Magneto Generator Output 25A / 350W @ 3000 RPM
Battery 12 Volts / 19A
Fuses 2A -- NGI Gauge / 15A -- Battery / 15A -- Ignition System / 15A -- Fuel Pump
30A -- Alternator / 15A x 3 -- Main Relay
Starting Electric Motor -- One Button Start / One Button Stop
Propulsion
Jet Pump Type Dominator 2 Single Stage Axial Flow w/Six Vane Stainless Steel Stator
Impeller Rotation Counter Clockwise (From Aft)
Coupling Type Three piece coupler
Minimum Depth For Operation 2 ft. (60cm.)
Impeller Type 12 -- 18 3 Blade
Impeller Diameter 5.8 in. (148mm)
Reverse System Manual w/3400 RPM Limit
Hull/Body
Hull Design Modified Full V
Hull Material FRC (Fiberglass Reinforced Composite)
Top Deck Material FRC (Fiberglass Reinforced Composite)

GENERAL INFORMATION
1.10 2004 Four Stroke PWC Service Manual
Standard Torque Specifications
The following torque specifications are to be used as a general guideline. Use standard torque values for the
appropriate size fastener when torque values are not specified. Always consult the specific manual section
for torque values of fasteners and use of locking agent. When fastener replacement is required, use only
genuine Polaris fasteners.
RECOMMENDED TORQUE SPECIFICATION
STAINLESS STEEL FASTENERS (SAE)
Bolt Size Threads/Inch Torque
818 & 32 28 in. lbs.
10 24 & 32 40 in. lbs.
1/4 20 & 28 8 ft. lbs.
5/16 18 & 24 14 ft. lbs.
3/8 16 25 ft. lbs.
3/8 24 28 ft. lbs.
7/16 14 40 ft. lbs.
1/2 13 58 ft. lbs.
1/2 20 70 ft. lbs.
RECOMMENDED TORQUE SPECIFICATION
STAINLESS STEEL FASTENERS (METRIC)
Bolt Size Torque
5mm 45-52 in. lbs.
6mm 66-78 in. lbs.
8mm 13-16 ft. lbs.
10mm 26-30 ft. lbs.
12mm 40-44 ft. lbs.

GENERAL INFORMATION
1.112004 Four Stroke PWC Service Manual
Decimal Equivalent Chart
1/64 .0156..........................
1/32 .0312 1 mm = .0394″..................... ..................
3/64 .0469..........................
1/16 .0625...............
5/64 .0781 2 mm = .0787″.......................... ..................
3/32 .0938.....................
7/64 .1094 3 mm = .1181″......................... ..................
1/8 . .1250.. ........
9/64 .1406..........................
5/32 .1563 4 mm = .1575″..................... ..................
11/64 .1719.........................
3/16 .1875 5 mm = .1969″............... ..................
13/64 .2031.........................
7/32 .2188.....................
15/64 .2344 6 mm = .2362″......................... ..................
1/4 .25...........
17/64 .2656 7 mm = .2756″......................... ..................
9/32 .2813.....................
19/64 .2969.........................
5/16 .3125 8 mm = .3150″............... ..................
21/64 .3281.........................
11/32 .3438 9 mm = .3543″.................... ..................
23/64 .3594.........................
3/8 .375...........
25/64 .3906 10 mm = .3937″......................... ..................
13/32 .4063....................
27/64 .4219 11 mm = .4331″......................... ..................
7/16 .4375...............
29/64 .4531.........................
15/32 .4688 12 mm = .4724″.................... ..................
31/64 .4844.........................
1/2 .5 13 mm = .5118........... .....................
33/64 .5156.........................
17/32 .5313....................
35/64 .5469 14 mm = .5512″......................... ..................
9/16 .5625...............
37/64 .5781 15 mm = .5906″......................... ..................
19/32 .5938....................
39/64 .6094.........................
5/8 .625 16 mm = .6299″........... ...................
41/64 .6406.........................
21/32 .6563 17 mm = .6693″.................... ..................
43/64 .6719.........................
11/16 .6875..............
45/64 .7031 18 mm = .7087″......................... ..................
23/32 .7188....................
47/64 .7344 19 mm = .7480″......................... ..................
3/4 .75...........
49/64 .7656.........................
25/32 .7813 20 mm = .7874″.................... ..................
51/64 .7969.........................
13/16 .8125 21 mm = .8268″.............. ..................
53/64 .8281.........................
27/32 .8438....................
55/64 .8594 22 mm = .8661″......................... ..................
7/8 .875...........
57/64 .8906 23 mm = .9055″......................... ..................
29/32 .9063....................
59/64 .9219.........................
15/16 .9375 24 mm = .9449″.............. ..................
61/64 .9531.........................
31/32 .9688 25 mm = .9843.................... ..................
63/64 .9844.........................
11.0............

GENERAL INFORMATION
1.12 2004 Four Stroke PWC Service Manual
Conversion Chart
Unit of Measure Multiplied by Converts to
ft. lbs. x12 =in.lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 =Nm
in. lbs. x .0115 =kg-m
Nm x .7376 = ft. lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 =in.lbs.
kg-m x10 =Nm
in. x 25.4 =mm
mm x .03937 =in.
in. x2.54 =cm
mile (mi.) x1.6 =km
km x .6214 = mile (mi.)
Ounces (oz.) x 28.35 = Grams (g)
Grams (g) x 0.035 = Ounces (oz.)
lb. x .454 =kg
kg x 2.2046 =lb.
Cubic inches (cu in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu in)
Imperial pints (Imp pt) x 0.568 = Liters (l)
Liters (l) x1.76 = Imperial pints (Imp pt)
Imperial quarts (Imp qt.) x 1.137 = Liters (l)
Liters (l) x0.88 = Imperial quarts (Imp qt.)
Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.)
US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.)
US quarts (US qt.) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt.)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)
°Cto°F: 9 (°C + 40) ÷5--40=°F
°Fto°C: 5 (°F + 40) ÷9--40=°C

GENERAL INFORMATION
1.132004 Four Stroke PWC Service Manual
SAE Tap Drill Sizes
Thread Size Drill Size Thread Size Drill Size
#0-80 3/64
#1-64 53
#1-72 53
#2-56 51
#2-64 50
#3-48 5/64
#3-56 45
#4-40 43
#4-48 42
#5-40 38
#5-44 37
#6-32 36
#6-40 33
#8-32 29
#8-36 29
#10-24 24
#10-32 21
#12-24 17
#12-28 4.6mm
1/4-20 7
1/4-28 3
5/16-18 F
5/16-24 I
3/8-16 O
3/8-24 Q
7/16-14 U
7/16-20 25/64
1/2-13 27/64
1/2-20 29/64
9/16-12 31/64
9/16-18 33/64
5/8-11 17/32
5/8-18 37/64
3/4-10 21/32
3/4-16 11/16
7/8-9 49/64
7/8-14 13/16
1-8 7/8
1-12 59/64
1 1/8-7 63/64
1 1/8-12 1 3/64
11/4-7 17/64
1 1/4-12 1 11/64
11/2-6 111/32
1 1/2-12 1 27/64
13/4-5 19/16
1 3/4-12 1 43/64
2-4 1/2 1 25/32
2-12 1 59/64
2 1/4-4 1/2 2 1/32
21/2-4 21/4
23/4-4 21/2
3-4 2 3/4
Metric Tap Drill Sizes
Tap Size Drill Size Decimal Equivalent Nearest Fraction
3x.50
3x.60
4x.70
4x.75
5x.80
5x.90
6 x 1.00
7 x 1.00
8 x 1.00
8 x 1.25
9 x 1.00
9 x 1.25
10 x 1.25
10 x 1.50
11 x 1.50
12 x 1.50
12 x 1.75
#39
3/32
#30
1/8
#19
#20
#9
16/64
J
17/64
5/16
5/16
11/32
R
3/8
13/32
13/32
0.0995
0.0937
0.1285
0.125
0.166
0.161
0.196
0.234
0.277
0.265
0.3125
0.3125
0.3437
0.339
0.375
0.406
0.406
3/32
3/32
1/8
1/8
11/64
5/32
13/64
15/64
9/32
17/64
5/16
5/16
11/32
11/32
3/8
13/32
13/32

GENERAL INFORMATION
1.14 2004 Four Stroke PWC Service Manual
Service Tools
PW--46981 -- REQUIRED TOOL
CRANKSHAFT HAND CRANK (BARRING TOOL)
USED TO ROTATE CRANKSHAFT
PW--46982 -- REQUIRED TOOL
GEAR REMOVAL TOOL
USED TO REMOVE BALANCE SHAFT GEAR WHEN USED WITH
PW--46989 GEAR REMOVER BOLT.
PW--46983 -- REQUIRED TOOL
PISTON RING COMPRESSOR
USED TO INSTALL PISTONS INTO ENGINE BLOCK
PW--46984 -- REQUIRED TOOL
ENGINE STAND ADAPTER PLATE
PW--47054
ENGINE STAND ADAPTER SLEEVE
ATTACHES TO REAR OF ENGINE BLOCK. ALLOWS TECHNI-
CIAN TO ROTATE ENGINE DURING DISASSEMBLY AND RE--
ASSEMBLY.
ADAPTER SLEEVE EXPANDS MOUNTING OPTIONS WHEN
USING DIFFERENT ENGINE STANDS.
PW--46989 -- REQUIRED TOOL
MAGNET ROTOR / GEAR REMOVER BOLT
USED TO REMOVE MAGNET ROTOR AND BALANCE SHAFT GEAR WHEN
USED WITH PW--46982.
PW--46991 -- REQUIRED TOOL
VALVE COMPRESSOR TOOL
USED TO COMPRESS VALVE SPRINGS WITH ENGINE EITHER
INSTALLED OR REMOVED FROM WATERCRAFT HULL.
PW--47077 -- REQUIRED TOOL
CAMSHAFT ALIGNMENT TOOL
INSTALLS INTO CAMSHAFT TO LOCK INTO BDC POSITION.
PW--47079 -- REQUIRED TOOL
TIMING CHAIN INSTALLATION TOOL
ROUTES TIMING CHAIN THROUGH ENGINE CRANKCASE DUR-
ING INSTALLATION.
PW--47108 -- REQUIRED TOOL
TIMING CHAIN WEDGE AND HOOK TOOL
USED DURING TIMING CHAIN INSTALLATION

GENERAL INFORMATION
1.152004 Four Stroke PWC Service Manual
Service Tools
PW--47053 -- OPTIONAL TOOL
ADAPTER PLATE TABLE MOUNT
USED TO MOUNT ENGINE STAND ADAPTER PLATE TO WORK-
BENCH.
PW--46985 -- REQUIRED TOOL
TIMING CHAIN LINK REMOVAL / INSTALLATION TOOL
USED IN REMOVING AND RE--INSTALLING TIMING CHAIN.
PU--46219 -- OPTIONAL TOOL
MANUAL OIL PUMP / CONTAINER
USED TO REMOVE OIL FROM OIL TANK
PW--43070 -- OPTIONAL TOOL
ROLLING ENGINE STAND
ACCEPTS PW--46984 ENGINE STAND ADAPTER PLATE
DIGITAL WRENCH DIAGNOSTIC SOFTWARE
REQUIRED TOOLS
COMPLETE KIT: PU--47063
UPDATE SOFTWARE ONLY: PU--47052
PU--47102 -- REQUIRED TOOL
MSX 110 / 150 COMM. CABLE ADAPTER
CONNECTS LAPTOP CABLE TO ENGINE WIRING
HARNESS.

2
MSX 110 / 150 Service Manual Maintenance
Periodic Maintenance Table 2.1.......................................
Safety Warnings 2.2.................................................
Maintenance Tools / Torque Guide 2.3.................................
Flush Kit 2.3........................................................
Service Products 2.4.................................................
Steering / Reverse System Lubrication 2.5..............................
Steering Post Removal / Assembly 2.6.................................
Steering / Reverse Cable Adjustment 2.7...............................
E.S.P. Function Testing 2.8...........................................
Valve Clearance Adjustment Procedure 2.8 -- 2.9.............................
Engine Oil Level Check 2.10...........................................
Oil Change Procedure 2.10 -- 2.11............................................
Engine Coolant Inspection / Change Procedure 2.12......................
Cooling System Pressure Test 2.13.....................................
Engine Compression / Fuel System Pressure Tests 2.14...................
Battery Safety and Maintenance 2.15 -- 2.17...................................
Spark Plug 2.18......................................................
Fuses 2.18...........................................................
Exhaust Cooling Injector Maintenance 2.19..............................
Throttle Cable Adjustment 2.19.........................................
Gasoline Safety / Fuel System Maintenance / Fuel Filter 2.20..............
Bilge System / Siphons 2.21...........................................
Propulsion System Maintenance 2.22 -- 2.23...................................
Handlebar Maintenance / Intake Manifold Re--Torque Procedure 2.24.......
Drain Plugs 2.25......................................................
Off--Season Storage 2.26..............................................

MAINTENANCE
2.12004 Four Stroke PWC Service Manual
Periodic Maintenance Table
The periodic maintenance table must be followed in order to ensure maximum watercraft performance and long--
term durability. Certain procedures require advanced mechanical and/or electrical knowledge. Theseprocedures
will be noted within the table.
Operating a Personal Watercraft in saltwater or rough conditions requires additional service and maintenance
attention. When checked (n) the procedure must be completed after watercraft operation.
n= Requires basic mechanical and/or electrical knowledge.
J= Requires advanced mechanical and/or electrical knowledge.
R = REPLACE
* = Every 4 years
ITEM PROCEDURE
BREAK IN PERIOD
(Hours) REGULAR INTERVAL (Hours) PRE
R
I
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SALT
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END
OF
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M
P
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C
E
D
U
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10 -- 12 25 50 100
R
I
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E
W
A
T
E
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O
F
YEAR
Spark Plugs Adjust Gap / Clean n n Rn
Flame Arrestor Inspect n n
Engine Oil Inspect Level n n n nR
Engine Oil / Filter Replace nRnRnR
Engine Coolant Inspect n n n n
Engine Coolant Replace J*
Compression Inspect J J
Valve Clearance Inspect / Adjust J J
Cooling / Oil / Air
Hoses Inspect n n n n
Engine Mounts Inspect J J
Engine Fasteners Inspect J J
Intake Manifold Adjust Torque n n
Chassis Fasteners Inspect J J
Freshwater Loop Flush n n n n
Exhaust System Inspect n n n
Throttle Cable Inspect / Adjust / Lubricate n n n n
Reverse Cable Inspect / Adjust / Lubricate n n n n
Steering Cable Inspect / Adjust / Lubricate n n n
Handlebars Inspect / Adjust n n n
ESP Function Inspect n n
Impeller / Pump Inspect / Flush n n n
Sacrificial Anode Inspect n n n n
Drive Couplers Inspect n n
BilgeArea/Drains Inspect / Clean / Flush n n n n n
Battery / Vent Inspect n n n
Electrical Connec-
tions Inspect n n
Fuel System Inspect J J n
Fuel / Vent Hoses Inspect n n n
Fuel Tank Inspect J n
Fuel Filter Replace J
Fire Extinguisher Inspect n n
Start / Stop Switch Inspect n n

MAINTENANCE
2.2 2004 Four Stroke PWC Service Manual
Maintenance Notes / Safety Warnings
Gasoline is extremely flammable and explosive under certain conditions.
SAlways stop the engine and refuel outdoors or in a well ventilated area.
SDo not smoke or allow open flames or sparks in or near the area where refueling is
performed or where gasoline is stored.
SDo not overfill the tank. Do not fill the tank neck above the fuel tank insert. Leave air space
to allow for fuel expansion.
SIf you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.
Never try to syphon gasoline using mouth suction.
SIf you spill gasoline on your skin or clothing, immediately wash it off with soap and water
and change clothing.
SNever start the engine or let it run in an enclosed area. Engine exhaust fumes are
poisonous and can cause loss of consciousness or death in a short time.
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
Improper repairs or service can create
unsafe conditions that may cause
severe personal injury or death.
The engine and exhaust components
on this product become very hot during
operation and remain so for a period of
time after the engine is stopped.

MAINTENANCE
2.32004 Four Stroke PWC Service Manual
Maintenance -- Specific Tools
TOOL PART NUMBER
Compression Gauge PV--33223
Fuel Pressure Gauge PV--43506
Oil Pressure Gauge PV--43531
Feeler Gauge Commercially Available
Spark Plug Gap Gauge / Feeler Gauge Commercially Available
Fluke 77 Digital Multimeter PV--43568
Fluke Compatible Peak Voltage Tester PV--39991
PWC Four Stroke Flush Kit 2874833
Oil Pump and Containment System PW--46219
Valve Adjustment Tool PW--46991
Maintenance Procedures Fastener Torque Guide
F
A
S
T
E
N
E
R
SPECIFIED TORQUE
F
A
S
T
E
N
E
R
FOOT POUNDS NEWTON METERS SPECIAL
SPARK PLUG 20 27 AS
IGNITION COILS 710
OIL FILTER CAP 17 24
VALVE COVER 710
ENGINE MOUNT--TO--HULL 14 Loctitet262
ENGINE STRAP--TO--ENGINE MOUNT 50 Loctitet262
STEERING CABLE JAM NUTS 40 in.lbs. 4.5Nm
STEERING CABLE ADJUSTER CLAMP 811 Loctitet242
REVERSE CABLE JAM NUTS 40 in.lbs. 4.5Nm
STEERING CLAMP 811 Loctitet242
SACRIFICIAL ANODE 25 in. lbs. 2.8Nm
PTO DRIVE COUPLER HAND TIGHTEN
Flush Kit
A flush kit will allow the operator to clean the freshwater cooling circuit after riding in saltwater or for performing
routing maintenance procedures. The addition of a flush kit is highly recommended for performing maintenance
procedures such has changing the engine oil.
Polaris PWC Four Stroke Flush Kit PN: 2874833
1. Follow the instructions included within the kit and
install the flush kit in the FRESHWATER cooling
hose located between the water--to--water heat
exchanger and oil storage tank.
NOTE: Only allow the flow of water to the flush
kit after the engine has started, and always turn
off the flow of water before stopping the engine.