Polaris msx 110 Service Manual
  1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Boat
  5. msx 110
  6. Service manual

Polaris msx 110 Service Manual

Four stroke personal watercraft
Hide thumbs Also See for msx 110:
Table of Contents

Advertisement

Quick Links

Download this manual
msx 110
msx 150
Four Stroke Personal Watercraft Service Manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the msx 110 and is the answer not in the manual?

Questions and answers

Related Manuals for Polaris msx 110

Summary of Contents for Polaris msx 110

  • Page 1 110 msx 150 Four Stroke Personal Watercraft Service Manual...
  • Page 2 Table of Contents General Information Model Information / Safety Warnings / General Information Maintenance Periodic Maintenance Tables / Maintenance Procedures 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 Propulsion System...

  • Page 3: Table Of Contents

    MSX 110 / 150 Service Manual General Information PWC Identification Numbers 2004 PWC Publication Part Numbers Service Guidelines / Safety Warnings MSX 110 General Information 1.4 -- 1.5 MSX 150 General information 1.6 -- 1.7 Standard Torque Specifications Decimal Equivalent Chart Conversion Chart 1.10...

  • Page 4: General Information

    GENERAL INFORMATION 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.

  • Page 5: Pwc Publication Part Numbers

    GENERAL INFORMATION 2004 PWC Publication Part Numbers Owner’s Assembly Model Model Number Parts Book Microfiche Manual Instructions W045304CA MSX 110 (A) MSX 110 (A) W045304IA International W045304CB MSX 110 (B) 9919055 9919056 MSX 110 (B) W045304IB International W045304CC MSX 110 (C)
  • Page 6 Never re- -use Nyloktor Flex Lockt nuts when assembling components. Never re- -use Oetikert clamps when removed from fuel lines. Replace with small gear clamps. Always use Polaris- -authorized lubricants, greases, and locking agents when assembling components. Failure to do so may cause severe engine or vehicle damage.
  • Page 7 2004 MSX 110 Emission Certification The engines in all 2004 MSX 110 Personal Watercraft are certified as Two Star, Very Low Emission engines. The Two Star label identifies engines that meet the California Air Resources Board (CARB) 2004 exhaust emis- sion standards.
  • Page 8 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...
  • Page 9 GENERAL INFORMATION 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.
  • Page 10 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...

  • Page 11: Standard Torque Specifications

    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)

  • Page 12: Decimal Equivalent Chart

    GENERAL INFORMATION Decimal Equivalent Chart 1/64 ......0156 1/32 ..... .0312 .

  • Page 13: Conversion Chart

    GENERAL INFORMATION Conversion Chart Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m x .7376 = ft. lbs. kg-m x 7.233 = ft.
  • Page 14 GENERAL INFORMATION SAE Tap Drill Sizes Thread Size Drill Size Thread Size Drill Size #0-80 3/64 1/2-13 27/64 #1-64 1/2-20 29/64 #1-72 9/16-12 31/64 #2-56 9/16-18 33/64 #2-64 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 3/4-10 21/32 #4-40 3/4-16 11/16 #4-48 7/8-9 49/64...
  • Page 15 GENERAL INFORMATION Service Tools PW- - 46989 - - REQUIRED TOOL MAGNET ROTOR / GEAR REMOVER BOLT PW- - 46981 - - REQUIRED TOOL USED TO REMOVE MAGNET ROTOR AND BALANCE SHAFT GEAR WHEN CRANKSHAFT HAND CRANK (BARRING TOOL) USED WITH PW- -46982. USED TO ROTATE CRANKSHAFT PW- - 46991 - - REQUIRED TOOL VALVE COMPRESSOR TOOL...
  • Page 16 PW- - 43070 - - OPTIONAL TOOL ROLLING ENGINE STAND ACCEPTS PW- - 46984 ENGINE STAND ADAPTER PLATE PU- - 47102 - - REQUIRED TOOL MSX 110 / 150 COMM. CABLE ADAPTER CONNECTS LAPTOP CABLE TO ENGINE WIRING HARNESS. DIGITAL WRENCH DIAGNOSTIC SOFTWARE...
  • Page 17 MSX 110 / 150 Service Manual Maintenance Periodic Maintenance Table ........

  • Page 18: Periodic Maintenance Table

    MAINTENANCE 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. These procedures will be noted within the table. Operating a Personal Watercraft in saltwater or rough conditions requires additional service and maintenance attention.

  • Page 19: Safety Warnings

    MAINTENANCE Maintenance Notes / Safety Warnings Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 20: Flush Kit

    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.

  • Page 21: Service Products

    Glycol) (Used to boost cold weather protection freeze temperature in cold weather states.) Polaris Environmentally Safe Engine Coolant (50 / 50 Pre- -Mix) 2875041 - - 6 (1 Gallon) Case 2875042 - - 55 Gallon Drum Polaris Premium All Season Grease 2871312 (Grease Gun Kit) 2871322 (3 oz.
  • Page 22 MAINTENANCE Steering Cable / Steering Joints 1. Expose inner linkage and apply grease. Polaris Premium Grease PN 2871423 Steering Nozzle 1. Apply light film of grease to exposed steering linkage and pivot points. Polaris Premium Grease PN 2871423 Reverse System 1.

  • Page 23: Steering Post Removal / Assembly

    MAINTENANCE Steering Post Removal 1. Remove handlebar cover fasteners. The grab handle fasteners are located under the cover. If grab handle replacement is required, remove the two fasteners as well. ZERO, 1 OR 2 SHIMS INSTALLED TO AD- 2. Disconnect the throttle cable from the throttle flipper, JUST STRIKE PLATE CLEARANCE and the left--hand control wiring harness.

  • Page 24: Steering / Reverse Cable Adjustment

    MAINTENANCE Steering Cable Adjustment 1. Open front compartment door. Loosen and remove adjuster block. Align handlebars with centerline of Straight Edge watercraft. (Straight) Nozzle 2. Place a straight edge across horizontal center line of steering nozzle or trim nozzle. Hull Hull 3.

  • Page 25: E.s.p. Function Testing

    MAINTENANCE E.S.P. Function Testing 1. Watercraft must be on engine stand or on trailer to perform test. 2. Insert lanyard into stop switch. Start engine. NOTE: Severe engine damage may occur if engine is run more than 30 seconds without supplying water to the freshwater cooling circuit.
  • Page 26 MAINTENANCE Valve Clearance Adjustment Procedure - - Continued 9. Install the Valve Compression Tool, PN--46991 , under the rocker arm and over the top of the valve. Push the lever down, and extract the shim using a magnet. CAUTION: Do not compress the valve into the piston face. Do not damage or move the valve keepers.

  • Page 27: Engine Oil Level Check

    Never allow the oil level to exceed the OVERFILLED OIL LEVEL mark on the top of the dipstick. Severe engine damage may occur. ENGINE OIL SPECIFICATION POLARIS MARINE PS--4 SYNTHETIC 15W--50 PN: SEE PAGE 2.4 ROUTINE OIL CHANGE: 3.4 -- 3.7 US QUARTS 3.3 -- 3.5 LITERS...
  • Page 28 Torque gear clamp to 30 in.lbs. O--RING 11. Fill to oil tank with 3.4 -- 3.7 qts. (3.3 -- 3.5 L) of Polaris PS--4 Synthetic Marine engine oil. NOTE: Never add more than 3.7 qts. (3.5 L) 12.

  • Page 29: Engine Coolant Inspection / Change Procedure

    MIN and MAX marks on the side of the coolant expansion tank. (Never overfill the expansion tank.) AIR BLEED ENGINE COOLANT SPECIFICATION (Warm- -Weather States) POLARIS ENVIRONMENTALLY SAFE COOLANT 50/50 MIXTURE TO WATER PN: SEE PAGE 2.4 PUMP DRY CAPACITY:...
  • Page 30 MAINTENANCE Engine Cooling System Pressure Test 1. Test the system pressure capacity by removing the air bleed hose that connects the expansion tank to the coolant outlet manifold on the intake--side of the AIR BLEED engine. TO WATER PUMP 2. Insert a small bolt or plastic plug into the end of the bleed hose and secure with small gear clamp.

  • Page 31: Engine Compression Test

    MAINTENANCE Engine Compression Test A cylinder compression test is one of the most accurate methods in determining the condition of internal engine components. Always perform the compression test with a fully charged battery. Engine should rotate at least 300 RPM. 1.

  • Page 32: Battery Removal

    MAINTENANCE Battery Safety When removing and installing the battery, or when performing battery maintenance always heed the following warnings and cautions: WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with the skin, eyes or clothing. Antidote: EXTERNAL - Flush with water.

  • Page 33: Battery Connections

    MAINTENANCE Replenishing Battery Fluid The fluid level should be kept between the upper and low- er level marks. To refill use only distilled water. Tap water contains miner- Maintain als which are harmful to a battery. Between Battery Connections Upper and Lower Level Battery terminals and connections should be kept free of Marks...

  • Page 34: Battery Storage

    MAINTENANCE Battery Installation WARNING Always connect battery cables in the order specified. Red (positive) cable first, black (negative) cable last. 1. Install battery in its holder. 2. Install battery vent tube. It must be free from kinks, obstructions, or restrictions and securely installed. If not, battery gases could accumulate and cause an explosion.

  • Page 35: Spark Plug

    Torque ignition coil fasteners to specification. Fuses MODEL FUSES COMPONENT LOCATION 2AMP NGI Gauge 10AMP Fuel Pump 15AMP Ignition System 15AMP Main Relay MSX 110 / 150 Harness Pod 15AMP Main Relay 15 AMP Main Relay 30AMP Alternator 2.18 2004 Four Stroke PWC Service Manual...

  • Page 36: Exhaust Cooling Injector Maintenance

    MAINTENANCE Exhaust Cooling Injector Maintenance The exhaust pipe rubber hoses and muffler are cooled by injecting a small amount of water injected through an orifice from the freshwater cooling system into the exhaust stream. The orifice should be inspected and cleaned periodically to ensure proper cooling of the exhaust muffler and connector hoses.

  • Page 37: Gasoline Safety / Fuel System Maintenance / Fuel Filter

    MAINTENANCE Gasoline Safety WARNING Gasoline is highly flammable and explosive under certain conditions. ♦ Always exercise extreme caution whenever handling gasoline. ♦ Always refuel with the engine stopped and outdoors or in a well ventilated area. ♦ Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 38: Bilge Drain Plugs

    MAINTENANCE Bilge Siphon System 1. Clean bilge siphon pickup screens whenever debris are present. View From Inside Hull Screen 2. Inspect the .040″ hole in fitting elbow. It must be clear to prevent siphoning of water into bilge. .040″ hole must 3.

  • Page 39: Impeller Clearance

    MAINTENANCE Cooling Water Pickup Screen Inspect the screen in the pump stationary nozzle for de- bris and clean if necessary. Screen Fasteners Inspect all fasteners in the pump area and make sure they are tight. These include the steering nozzle mount- ing bolts, steering cable bolt, trim nozzle mounting bolts (where applicable), and all reverse mechanism fasteners (where applicable).
  • Page 40 MAINTENANCE Pump Housing Inspection Inspect pump housing for excessive wear, cracks, or deep gouges. Replace if necessary. Sacrificial Anode The purpose of these anodes is to prevent corrosion of met- al parts due to electrolysis. The mounting surfaces must be clean and the mounting bolt tight to maintain a good con- nection between the pump and anode.
  • Page 41 MAINTENANCE Handlebar / Hand Grips 1. Pull and twist on hand grips to ensure they are not loose. Top Deck If loose or wore, the handlebar with grip assembly must be replaced. Grommet Plate 2. Reference chapter six for disassembly procedures. Handlebar Post Top Plate 1.

  • Page 42: Drain Plugs

    MAINTENANCE Drain Plugs A drain plug is located on the front of the intercooler and on the back of the intake manifold. 1. Intercooler drain plug. Apply marine grade silicone to threads when reinstalling. Hand tighten. 1. Intake manifold drain plug. Apply marine grade silicone to threads when reinstalling.

  • Page 43: Off--Season Storage

    4. Top off the fuel tank with fresh fuel. A full fuel tank will prevent the formation of moisture and mold inside the tank. 5. Add Polaris Premium Fuel Stabilizer, PN 2870652, to the fuel tank. Follow the mixing instruction outlined on the bottle’s label.
  • Page 44 MSX 110 / 150 Service Manual Engine Removal / Installation Engine Subassembly Removal ........

  • Page 45: Engine Removal And Installation

    ENGINE REMOVAL / INSTALLATION Engine Removal and Installation Several sub--systems must be removed before the engine can be extracted from the engine bay. These systems are: Intercooler and associated air intake hoses and components. Engine electrical harness. Oil storage tank assembly. Air intake and throttle body assembly.
  • Page 46 ENGINE REMOVAL / INSTALLATION Engine Removal and Installation - - Continued 4. Locate the fuel hose quick disconnect on top of the fuel PHOTO B rail. Wrap a shop towel around the disconnect and press the two tabs in while pulling up on the connector. 5.
  • Page 47 ENGINE REMOVAL / INSTALLATION Engine Removal and Installation - - Continued 12. Remove the hoses connected to the intercooler. (Photo D) 13. Remove the fasteners and slide the intercooler forward towards the fuel tank. NOTE: The intercooler cannot be removed until an engine hoist is connected to the engine and the en- gine assembly is moved rearward.
  • Page 48 ENGINE REMOVAL / INSTALLATION Engine Removal and Installation - - Continued 14. Locate the engine coolant recovery tank. Remove the tank and associated hoses. Identify each hose during removal. (Photo E) 15. Remove the freshwater and engine coolant hose from the heat exchanger.
  • Page 49 ENGINE REMOVAL / INSTALLATION Engine Removal and Installation - - Continued MANIFOLD FASTENERS x4 INTAKE MANIFOLD UPPER- -TO- -LOWER BRACKET FASTENERS x3 UPPER BRACKET LOWER BRACKET LOWER BRACKET FASTENERS x2 WATER- -TO- -WATER HEAT EXCHANGER 19. With the fasteners removed, carefully slide the intake manifold towards the rear of the engine compartment and out of the watercraft.
  • Page 50 ENGINE REMOVAL / INSTALLATION Engine Removal and Installation - - Continued STERN REAR ENGINE MOUNT LIFTING HOOKS FRONT ENGINE MOUNT 22. Locate and remove the four engine mounting nuts and washers.(Photo J) (Front Left Mount Shown) PHOTO J 2004 Four Stroke PWC Service Manual...
  • Page 51 ENGINE REMOVAL / INSTALLATION Engine Removal and Installation - - Continued 23. Attach hoist chains to the front and rear lifting hooks. Verify hoist will left engine up evenly.(Photo K) NOTE: The hoist chains must allow the engine to be moved in any direction and at any pitch.
  • Page 52 ENGINE REMOVAL / INSTALLATION Engine Removal and Installation - - Continued 28. Illustration of exhaust manifold--to--engine assembly. STERN MANIFOLD MOUNTING NUTS AND WASHERS x8 WASTEGATE MANIFOLD / TURBO UNIT 29. Reposition the core engine assembly into the center of the engine compartment. 30.
  • Page 53 ENGINE REMOVAL / INSTALLATION Engine Mounting Straps The front and rear engine mounting straps are an integral part of the core engine assembly. Both straps must be removed from the engine to proceed with any engine disassembly. ALIGNMENT DOWELS MOUNT FASTENERS x5 MOUNT FASTENERS x4 INTAKE- -SIDE OF ENGINE REAR ENGINE MOUNTING STRAP...

  • Page 54: Engine Installation

    ENGINE REMOVAL / INSTALLATION Engine Mounting Straps - - Continued 6. Loosen the rear engine mounting strap fasteners and remove the rear mounting strap. Remove the two alignment dowels from the engine case. 7. Attach the ENGINE STAND ADAPTER PLATE, PN PW--46984, to the engine case.
  • Page 55 MSX 110 / 150 Service Manual Engine Disassembly / Assembly Engine Specifications ..........

  • Page 56: Engine Specifications

    Premium Unleaded 91, 92, 93 Octane Minimum Fuel Requirement 87 Octane with reduced engine performance. Engine Oil Requirement Polaris Marine Synthetic Four Stroke Engine Oil Oil Grade Requirement 15W- -50 Synthetic SI Rated Engine Oil Capacity With Oil Filter Replacement 3.4 - - 3.7 US Quarts (3.3 - - 3.5 Liters)
  • Page 57 ENGINE DISASSEMBLY / ASSEMBLY Engine Specifications - - Continued Component Specification Valve Spring Free Length INTAKE 38.2mm (1.5″) EXHAUST 38.2mm (1.5″) Valve Spring Installed Length INTAKE 32mm (1.26″) EXHAUST 32mm (1.26″) Cylinder Head Warpage Limit .04mm (.001″) Cylinder Specifications BORE SIZE 85.00 - - 85.01mm (3.34″) TAPER LIMIT .008mm (.0003″)

  • Page 58: Engine Fastener Torque Specifications

    ENGINE DISASSEMBLY / ASSEMBLY Engine Fastener Torque Specifications Standard Torque Guide (mm) FT. LBS. 2.5 - - 3.6 3.4 - - 4.9 4.3 - - 5.7 5.9 - - 7.8 10 - - 14 14 - - 19 18 - - 25 25 - - 34 32 - - 45 44 - - 61...
  • Page 59 ENGINE DISASSEMBLY / ASSEMBLY Engine Specific Fastener Torque Specifications Component FT. LBS. Notes Fastener(s) Water Pump Cover M6 x 20 M6 x 30 Loctite 577 M6 x 35 Engine Coolant Outlet Manifold M6 x 20 Engine Coolant Outlet Manifold Plug Turbocharger Coolant Return Banjo Bolt Expansion Tank Fasteners...
  • Page 60 ENGINE DISASSEMBLY / ASSEMBLY Fuel Rail Specific Fastener Torque Specifications Component FT. LBS. Notes Fastener(s) Fuel Rail Fasteners Loctite 243 M6 x 20 Engine Management Components / Sensor Specific Fastener Torque Specifications Component FT. LBS. Notes Fastener(s) Electronic Throttle Body M6 x 45 Wastegate Solenoid Bracket Knock Sensor...
  • Page 61 ENGINE DISASSEMBLY / ASSEMBLY Oil Storage Tank / Oil Cooler Specific Fastener Torque Specifications Component FT. LBS. Notes Fastener(s) Oil Separator Fastener Hand Tighten K80 x30 Separator Oil Return Fitting Banjo Bolt Oil Cooler - - to - - Intercooler Bracket M6 x 20 Oil Storage Tank Rollover Valve Banjo Bolt...

  • Page 62: Service Tools

    ENGINE DISASSEMBLY / ASSEMBLY Service Tools PW- - 46989 - - REQUIRED TOOL MAGNET ROTOR / GEAR REMOVER BOLT PW- - 46981 - - REQUIRED TOOL USED TO REMOVE MAGNET ROTOR AND BALANCE SHAFT GEAR WHEN CRANKSHAFT HAND CRANK (BARRING TOOL) USED WITH PW- -46982.

  • Page 63: Oil Filter Assembly

    ENGINE DISASSEMBLY / ASSEMBLY OIL FILTER ASSEMBLY FILTER CAP FILTER CARTRIDGE SEALING O- -RING EXHAUST- -SIDE OF ENGINE ASSEMBLY NOTES Filter Cap Torque 18 ft.lbs. (25 Nm) Apply a light film of engine oil to sealing o- -ring and filter cap threads during installation. OIL FILTER CHANGE INTERVAL: BREAK IN = 10 TO 12 HOURS / EVERY 25 HOURS THEREAFTER 2004 Four Stroke PWC Service Manual...

  • Page 64: Valve Cover Assembly

    ENGINE DISASSEMBLY / ASSEMBLY VALVE COVER ASSEMBLY VALVE COVER FASTENERS M6 X 45 CAM PHASE SENSOR PORT SPARK PLUG O- -RINGS VALVE COVER GASKET ASSEMBLY NOTES Valve Cover Fastener Torque 7 ft.lbs. (10 Nm) Cam Phase Sensor Fastener Torque 6.6 ft.lbs. (9 Nm) Always use new gaskets and o- -rings when removing or replacing parts.

  • Page 65: Valve Train Assembly

    ENGINE DISASSEMBLY / ASSEMBLY VALVE TRAIN ASSEMBLY AXLE CAPS BEARING AXLE CAMSHAFT SPROCKET VALVE SHIMS SPRINGS (SPRING BASE AND RETAIN- ING CAPS NOT SHOWN) VALVE STEM SEAL LONG ROCKER ARM SHORT ROCKER ARM SHORT ROCKER ARM LONG ROCKER ARM ROCKER ARM PINS CENTERING SLEEVES ASSEMBLY NOTES Camshaft Bearing Fastener Torque: 7 ft.lbs.

  • Page 66: Dry Sump Oil Pump Assembly

    ENGINE DISASSEMBLY / ASSEMBLY DRY SUMP OIL PUMP ASSEMBLY COMPONENT LAYOUT FILTER SCREEN DRIVE GEAR DRY SUMP OIL PUMP PLUG LOWER SUMP BEDPLATE OIL SUPPLY ELBOW (TO OIL COOLER) ASSEMBLY NOTES Screen Fastener Torque: 7 ft.lbs. (10 Nm) Apply Loctitet 243 to threads. Oil Pump Fastener Torque: 7 ft.lbs.

  • Page 67: Thermostat Housing

    ENGINE DISASSEMBLY / ASSEMBLY THERMOSTAT HOUSING ASSEMBLY O- -RING O- -RING INTAKE- -SIDE OF ENGINE BLEED HOSE FITTING WATER PIPE ELBOW PIPE THERMOSTAT O- -RING WATER PIPE FASTENERS M6 X 20 = COOLANT FLOW WHEN THERMOSTAT OPENS SNAP RING (CHAMFER FACES OUT) ASSEMBLY NOTES Water Pipe Fastener Torque: 7 ft.lbs.

  • Page 68: High Pressure Oil Pump Assembly

    ENGINE DISASSEMBLY / ASSEMBLY HIGH PRESSURE OIL PUMP ASSEMBLY BALANCE SHAFT TIMING KEY BALANCE SHAFT PTO- -END OF ENGINE INNER ROTOR TIMING ROTOR OUTER ROTOR RETAINING CAP O- -RINGS SNAP RING (CHAMFER FACES OUT) ASSEMBLY NOTES Use LIBERAL amounts of engine oil on timing rotor, inner and outer rotors, I.D. of retaining cap, and retaining cap o- -rings during oil pump assembly.
  • Page 69 ENGINE DISASSEMBLY / ASSEMBLY EXHAUST- - SIDE CHAIN GUIDE / TENSIONER ASSEMBLY COMPONENT LAYOUT TENSIONER M6 X 25 LOCTITEt 243 TENSIONER PLUG TIMING CHAIN (MUST USE CHAIN BREAKER TO DISASSEMBLE AND REASSEMBLE) M8 X 25 LOCTITEt 243 TENSIONER CHAIN GUIDE INSTALLED FROM BOTTOM OF UPPER CRANKCASE UPPER CHAIN GUIDE (INSTALLED FROM TOP OF CRANKCASE)

  • Page 70: Engine Case / Cylinder Head Assembly

    ENGINE DISASSEMBLY / ASSEMBLY ENGINE CASE / CYLINDER HEAD ASSEMBLY CYLINDER HEAD NUTS COMPONENT LAYOUT ROCKER ARM TOWER FASTENERS M6 X 20 ROCKER ARM TOWERS CENTERING SLEEVES CYLINDER HEAD HEAD GASKET UPPER CRANKCASE LOWER CRANKCASE PRESSURE RELIEF PISTON RELIEF SPRING WASHERS RELIEF VALVE COVER PLATE M8 X 70...
  • Page 71 ENGINE DISASSEMBLY / ASSEMBLY ENGINE CASE / CYLINDER HEAD ASSEMBLY - - CONTINUED ASSEMBLY NOTES CYLINDER HEAD - - TO - - CRANKCASE TORQUE SEQUENCE SPECIFICATIONS Apply engine oil to bolt threads. 1st STEP: Torque cylinder head nuts in sequence. 15 ft.lbs.

  • Page 72: Piston Assembly

    ENGINE DISASSEMBLY / ASSEMBLY PISTON ASSEMBLY COMPONENT LAYOUT UPPER RINGS OIL CONTROL RING PISTON PIN CONNECTING ROD BEARINGS CONNECTING ROD ROD CAP FASTENERS M10 X 1.32 ENGINE OIL ASSEMBLY NOTES AVAILABLE BEARINGS: 1. RED .0783 - - .0785IN. (1.990 - - 1.995mm) 2. YELLOW .0785 - - .0787IN. (1.995 - - 2.000mm) 3.
  • Page 73 ENGINE DISASSEMBLY / ASSEMBLY VALVE ASSEMBLIES COMPONENT LAYOUT VALVE SHIM VALVE KEEPER SPRING RETAINER SPRING SPRING BUCKET VALVE 4.18 2004 Four Stroke PWC Service Manual...

  • Page 74: Balance Plate / Pto Assembly

    ENGINE DISASSEMBLY / ASSEMBLY BALANCE PLATE / PTO ASSEMBLY COMPONENT LAYOUT CRANKSHAFT FLANGE SEAL FASTENERS M10 X 1 X 45 LOCTITEt 577 STUB SHAFT WASHERS BALANCE PLATE ASSEMBLY NOTES Balance Plate Fastener Torque: 51 ft.lbs. (70 Nm) Apply Loctitet 577 to threads. 4.19 2004 Four Stroke PWC Service Manual...
  • Page 75 ENGINE DISASSEMBLY / ASSEMBLY CRANKSHAFT / COUNTER BALANCER ASSEMBLIES COMPONENT LAYOUT CRANKSHAFT PLAIN BEARINGS BALANCE SHAFT GEAR TIMING KEY CRANKSHAFT BALANCE SHAFT BALANCE SHAFT PLAIN BEARINGS 4.20 2004 Four Stroke PWC Service Manual...
  • Page 76 ENGINE DISASSEMBLY / ASSEMBLY Engine Disassembly Process 1. Remove valve cover from engine. Discard PHOTO A gaskets.(Photo A) 2. Remove the coolant outlet manifold, oil filter cover, and PHOTO B electric starter motor from engine case. (Photo B) 3. Remove the two high pressure oil feed hose banjo bolts PHOTO C from the cylinder head exhaust--side rear mounting location.
  • Page 77 ENGINE DISASSEMBLY / ASSEMBLY Engine Disassembly Process 4. Remove stator cover from flywheel housing.(Photo D) NOTE: The stator is attached to the inside of the cover. Note the two alignment dowels as circled in photo. PHOTO D 5. Photo of stator inside of cover. (Photo E) PHOTO E 6.
  • Page 78 ENGINE DISASSEMBLY / ASSEMBLY Engine Disassembly Process 7. Remove the front engine gear cover. (Photo G) NOTE: Place drain pan underneath cover to catch oil. PHOTO G 8. Install two of the PTO coupler bolts into the PTO--end of the crankshaft. Have an assistant place a pry bar across these two bolts to prevent the crankshaft from rotating.
  • Page 79 ENGINE DISASSEMBLY / ASSEMBLY Engine Disassembly Process 11. Photo of front of engine. Remove the starter motor drive gear assembly (A) and oil pump drive gear (B). (Photo J) NOTE: The balance shaft gear (C) is removed by us- ing tool: PN PW- -46982 and PW- -46989. Gear remov- al is not required.
  • Page 80 ENGINE DISASSEMBLY / ASSEMBLY Engine Disassembly Process 15. Rotate the engine assembly 180_ so that the valve train PUSH WITH is up. Using the hand crank, crank the engine until the SCREWDRIVER PTO piston is at TDC on the compression stroke. HERE BOTH PTO ROCKER ARMS WILL BE LOOSE.
  • Page 81 ENGINE DISASSEMBLY / ASSEMBLY Engine Disassembly Process 24. Rotate the engine assembly 180_ so that the valve train is down, facing the floor. Using the hand crank, crank the timing chain out of the engine. PHOTO O 25. With the timing chain removed from the engine, the crankcase can be split in two.
  • Page 82 ENGINE DISASSEMBLY / ASSEMBLY Engine Disassembly Process 28. Rotate the engine assembly 180_ so that the valve train is up. Evenly loosen and remove the cylinder head nuts. (Photo R) 29. Carefully pull the cylinder head assembly up and off of the crankcase.
  • Page 83 ENGINE DISASSEMBLY / ASSEMBLY Engine Disassembly Process 33. Remove the balance shaft from the crankcase. Remove the PTO crankshaft case seal and discard. CRACKED MATING SURFACE Remove the piston lower rod cap bolts. (Photo R) 34. Carefully push each piston through and out of the crankcase.

  • Page 84: Engine Inspection

    ENGINE DISASSEMBLY / ASSEMBLY Engine Inspection Procedures Valve Inspection NOTE: Valves cannot be replaced. If valve face is burned or excessively worn, replace valve. Measure diameter of valve. Out of specification: Replace Measure valve face width. Out of specification: Replace valve Measure valve seat contact width.
  • Page 85 ENGINE DISASSEMBLY / ASSEMBLY Engine Inspection Procedures Valve Inspection Measure valve margin thickness. Out of specification: Replace valve Measure valve stem diameter. Out of specification: Replace valve Measure valve guide inside diameter. Out of specification: Replace valve guide 4.30 2004 Four Stroke PWC Service Manual...
  • Page 86 ENGINE DISASSEMBLY / ASSEMBLY Engine Inspection Procedures Valve Inspection Measure valve stem runout. Out of specification: Replace valve Measure valve spring free and installed length. Out of specification: Replace spring Cylinder Head Inspection Measure cylinder head warpage. Out of specification: Replace cylinder head 4.31 2004 Four Stroke PWC Service Manual...
  • Page 87 ENGINE DISASSEMBLY / ASSEMBLY Engine Inspection Procedures Cylinder Block Inspection Measure cylinder bore size. Out of specification: Replace cylinder block NOTE: Cylinders are plated with NiCaSil. Measure cylinder for taper and out--of--round limits. 1. BORE = Maximum diameter of Da -- Df. 2.
  • Page 88 ENGINE DISASSEMBLY / ASSEMBLY Engine Inspection Procedures Camshaft Inspection Measure cam lobe height. Out of specification: Replace camshaft Measure camshaft runout. Out of specification: Replace camshaft Measure camshaft bearing hole inside diameter. Out of specification: Replace camshaft NOTE: Bearings must be removed to measure I.D. 4.33 2004 Four Stroke PWC Service Manual...
  • Page 89 ENGINE DISASSEMBLY / ASSEMBLY Engine Inspection Procedures Camshaft Inspection Measure camshaft axle outside diameter. Out of specification: Replace axle Measure camshaft axle clamp inside diameter. Out of specification: Replace cylinder head Rocker Arm Inspection Measure rocker arm axial play. Out of specification: Replace rocker arm 4.34 2004 Four Stroke PWC Service Manual...
  • Page 90 ENGINE DISASSEMBLY / ASSEMBLY Engine Inspection Procedures Rocker Arm Inspection Measure rocker arm shaft outside diameter. Out of specification: Replace rocker arm shaft Measure rocker arm post bore inside diameter. Out of specification: Replace rocker arm post Crankshaft Inspection Measure crankshaft deflection. Out of specification: Replace crankshaft 4.35 2004 Four Stroke PWC Service Manual...
  • Page 91 ENGINE DISASSEMBLY / ASSEMBLY Engine Inspection Procedures Crankshaft Inspection NOTE: Do not move crankshaft until measurement process is completed. Do not place on oil holes. Measure crankshaft main bearing clearance. 1. Place upper journal bearings into upper casehalve. 2. Install crankshaft. Place a piece of Plastigauge...
  • Page 92 ENGINE DISASSEMBLY / ASSEMBLY Connecting Rod Inspection Measure big end oil clearance. NOTE: Do not move crankshaft or connect- ing rods until measurement process is com- pleted. 1. Remove lower connecting rod caps. 2. Place a piece of Plastigauge across the journal surface.
  • Page 93 ENGINE DISASSEMBLY / ASSEMBLY Engine Inspection Procedures Balance Shaft Inspection Measure balance shaft runout at several locations. Out of specification: Replace balance shaft Measure bearing diameter. Out of specification: Replace balance shaft Piston Inspection Measure piston diameter. Out of specification: Replace piston 15mm 4.38 2004 Four Stroke PWC Service Manual...
  • Page 94 ENGINE DISASSEMBLY / ASSEMBLY Engine Inspection Procedures Piston Inspection Measure piston pin boss inside diameter. Out of specification: Replace piston Measure piston pin outside diameter. Out of specification: Replace piston pin Confirm piston--to--cylinder clearance specification. Out of specification: Replace piston pin Measure installed ring end gap.
  • Page 95 ENGINE DISASSEMBLY / ASSEMBLY Engine Inspection Procedures Piston Inspection Measure piston ring grove clearance. Out of specification: Replace piston ring Piston or piston Ring Feeler Gauge High Pressure Oil Pump Inspection Measure relief spring free length and piston dimensions. Out of specification: Replace spring and piston 4.40 2004 Four Stroke PWC Service Manual...

  • Page 96: Chain Tensioner

    ENGINE DISASSEMBLY / ASSEMBLY Engine Inspection Procedures Chain Tensioner Verify chain tensioner function. FULLY EXTENDED 1. Push tensioner into housing until flush with threaded housing. Tensioner should lock into place. (6 audible clicks should be heard when tensioner is pushed in from fully extended position.) 2.
  • Page 97 ENGINE DISASSEMBLY / ASSEMBLY Engine Inspection Procedures Timing Chain Inspect timing chain. Replace timing chain if any damage, obvious wear and tear, or broken / mis-- shaped plates are found. Valve Removal 1. Install rocker arm shafts. Install valve spring compression tool, PN--PW--46991.

  • Page 98: Engine Assembly

    ENGINE DISASSEMBLY / ASSEMBLY Engine Assembly 1. Remove any remaining gasket material from the upper and lower crankcase mating surfaces. 2. Remove gasket material from bedplate mating surface. 3. Clean the following parts with engine cleaning solvent: Upper / Lower Crankcase Cylinder Head Bedplate Lower Sump...
  • Page 99 ENGINE DISASSEMBLY / ASSEMBLY Engine Assembly 9. Carefully install each piston assembly into the cylinders. Take care in not scratching the cylinder bore. RING COMPRESSOR 10. Install the intake--side chain guide. Tighten fastener to specification. 11. Carefully rotate engine 180_. Do not allow the pistons to fall out of cylinders.
  • Page 100 ENGINE DISASSEMBLY / ASSEMBLY Engine Assembly 18. Push pistons so the connecting rods engage the crankshaft. Obtain the two con--rod caps with bearings installed. Apply engine oil to connecting rod bearings. 19. Match each unique cap mating surface with the appropriate connecting rod.
  • Page 101 ENGINE DISASSEMBLY / ASSEMBLY Engine Assembly 24. Verify the crankcase stud oil jackets are installed on the four studs as outlined in the photo. STUD JACKETS NOTE: Verify stud jackets are installed in the middle of each stud. STUD JACKETS 25.
  • Page 102 ENGINE DISASSEMBLY / ASSEMBLY Engine Assembly 27. Apply a light film of grease to the crankshaft seal. Install the seal around the flange. Evenly press seal into crankcase. CAUTION!: Use extreme care when installing seal. Do not fold seal lips over when pressing around flange.
  • Page 103 ENGINE DISASSEMBLY / ASSEMBLY Engine Assembly 32. Rotate the engine 180_. (Cylinder Head Down) 33. Install the oil pump relief valve piston and spring. Place cover over spring and insert fastener. Hand--tighten fastener. 34. Install the remaining lower crankcase fastener. 35.
  • Page 104 ENGINE DISASSEMBLY / ASSEMBLY Timing Chain Installation / TDC Procedure A special procedure is required for installing the timing chain into the engine. Four service tools are required when installing the timing chain and setting the engine timing. They are: Timing Chain Installation Guide PN--PW--47079 Timing Chain Hook / Stuffer PN--PW--47108 Crankshaft Turning Hand Crank PN--PW--46981...
  • Page 105 ENGINE DISASSEMBLY / ASSEMBLY Timing Chain Installation 5. Slowly insert the chain into chain gallery. Wiggle the chain slightly until it falls down through the engine and protrudes from the bottom of the cylinder head. CAUTION!: Do not drop the chain into the engine. 6.
  • Page 106 ENGINE DISASSEMBLY / ASSEMBLY Timing Chain Installation 8. Wrap the chain around the camshaft sprocket. 9. While firmly holding the chain against the camshaft sprocket, remove the stuffer, and wrap the chain around the balance shaft sprocket and under the crankcase support member. NOTE: The hooked- -end of the Timing Chain Hook / Stuffer Tool will simplify pulling the chain around the sprocket.
  • Page 107 ENGINE DISASSEMBLY / ASSEMBLY Timing Chain Installation 11. Rotate the camshaft until one of the holes in the PTO--end points to the floor. 12. Install Camshaft Alignment Tool, PN--PW--47077, into the hole, press against the rocker arm towers. NOTE: The Camshaft Alignment Tool will lock the camshaft into the correct timing position in relation to the crankshaft and balance shaft.
  • Page 108 ENGINE DISASSEMBLY / ASSEMBLY Engine Assembly 1. Reassemble the timing chain with a new plate. Crimp the new chain pins and plates together using the Chain Breaker Tool, PN--PW--46985. ROUNDED PIN FITTING WITHOUT HOLE THE ROUNDED PIN PRESSES AGAINST THE SIDE IN WHICH THE NEW PLATE IS ATTACHED.
  • Page 109 ENGINE DISASSEMBLY / ASSEMBLY Engine Assembly 5. Verify the blade of the screwdriver contacts the face of the tensioner. 6. Push the blade of the screwdriver against the tensioner SCREWDRIVER face and twist. Do this until the tensioner goes in past flush and activates.
  • Page 110 ENGINE DISASSEMBLY / ASSEMBLY Engine Assembly 14. If the starter motor was removed, reinstall and tighten fasteners to specification. 15. Attach the starter motor battery cable to the motor at this time. 16. Press the water pump shaft into the mechanical seal. 17.
  • Page 111 ENGINE DISASSEMBLY / ASSEMBLY Engine Assembly 21. Apply a generous amount of engine oil to the crankshaft end and roller bearings. 22. Install the roller bearing, starting gear, and flywheel key ROLLER BEARINGS into end of crankshaft. 23. Install the flywheel on to the crankshaft. Verify flywheel ONE- -WAY CLUTCH fits over key.
  • Page 112 ENGINE DISASSEMBLY / ASSEMBLY Engine Assembly 27. Apply a thin bead of Three Bond 1215t sealant to stator cover mating surface. 28. Install stator cover with stator mounted inside of cover. Route harness as not to pinch or cut wires. 29.

  • Page 113: Engine Cooling System

    ENGINE DISASSEMBLY / ASSEMBLY Engine Cooling System The MSX 110 and 150 engine packages feature two independent cooling circuits. The first is the FRESHWATER circuit. The freshwater cooling circuit is responsible for cooling the intercooler, water--to--water heat exchanger, oil storage tank, exhaust manifold / turbine housing, and exhaust system.
  • Page 114 ENGINE DISASSEMBLY / ASSEMBLY Thermostat Removal / Installation NOTE: Coolant will flow out of the cylinder head into the bilge when the outlet rail elbow is re- moved. Tilt the bow down to prevent coolant from escaping outlet rail. 1. Remove the snap ring using a snap ring pliers. 2.
  • Page 115 ENGINE DISASSEMBLY / ASSEMBLY Freshwater Circuit Cooling Hose Routings FRESHWATER INJECTOR HOSE EXHAUST PIPE FRESHWATER OUTLET HOSE FRESHWATER OUTLET HOSE FRESHWATER OUTLET HOSE (FROM INTERCOOLER TO HEAT EXCHANGER) (FROM HEAT EXCHANGER TO OIL STORAGE TANK) WATER- -TO- -WATER HEAT EXCHANGER FRESHWATER INLET HOSE (TO INTERCOOLER) FRESHWATER INLET HOSE...
  • Page 116 ENGINE DISASSEMBLY / ASSEMBLY Freshwater Circuit Cooling Hose Routings FRESHWATER OUTLET HOSE (FROM INTERCOOLER TO HEAT EXCHANGER) FRESHWATER OUTLET HOSE (FROM HEAT EXCHANGER TO OIL STORAGE TANK) TEE FITTING (TO EXHAUST COOLING WATER INJECTOR) FRESHWATER OUTLET HOSE (FROM OIL STORAGE TANK TO EXHAUST MANIFOLD / WATER INJECTOR) 4.61...
  • Page 117 ENGINE DISASSEMBLY / ASSEMBLY Internal Engine Coolant Hose Routing - - Top View ENGINE COOLANT HOSE (FROM EXPANSION TANK TO WATER PUMP HOUSING) ENGINE COOLANT HOSE (FROM WATER OUTLET RAIL TO HEAT EXCHANGER - - THERMOSTAT OPEN) ENGINE COOLANT HOSE (FROM TURBO TO WATER PUMP) ENGINE COOLANT HOSE (FROM WA-...
  • Page 118 ENGINE DISASSEMBLY / ASSEMBLY Internal Engine Coolant Hose Routing - - Front View ENGINE COOLANT HOSE (FROM WATER OUTLET RAIL TO EXPANSION TANK) ENGINE COOLANT HOSE (FROM WATER PUMP TO TURBO) ENGINE COOLANT HOSE (FROM TURBO TO WATER PUMP) ENGINE COOLANT HOSE (FROM WATER PUMP TO CYLINDER HEAD) 4.63 2004 Four Stroke PWC Service Manual...
  • Page 119 ENGINE DISASSEMBLY / ASSEMBLY Internal Engine Coolant Hose Routing - - Right View ENGINE COOLANT HOSE (FROM WATER OUTLET RAIL TO OIL TANK - - THERMOSTAT CLOSED) ENGINE COOLANT HOSE (FROM EXPANSION TANK TO WATER PUMP) ENGINE COOLANT HOSE (FROM THERMOSTAT HOUSING TO HEAT EXCHANGER - - THER- MOSTAT OPEN) ENGINE COOLANT HOSE...

  • Page 120: Oil Lubrication System

    ENGINE DISASSEMBLY / ASSEMBLY Oil Lubrication System The lubrication system features two oil pumps. The first pump is the low pressure pump that pumps oil to the oil cooler, and then on to the oil storage tank. The second pump, high pressure, is located on the PTO end of the engine crankcase.
  • Page 121 ENGINE DISASSEMBLY / ASSEMBLY Crankcase Ventilation Engine blow--by is recovered via the oil separator or cyclone. The oil separator is located on the oil storage tank. Engine oil and fuel vapors are collected in the top housing of the oil storage tank. These vapors are routed to the separator.
  • Page 122 ENGINE DISASSEMBLY / ASSEMBLY Oil Lubrication System Hose Routings SUPPLY HOSE - - BLOW BY OIL - - TANK - -TO - - OIL SEPARATOR RIGHT SIDE STERN OIL SEPARATOR SUPPLY HOSE - - BLOW BY SUPPLY HOSE - - OIL OIL SEPARATOR - - TO - - AIR INTAKE OIL TANK - - TO - - OIL PRESSURE PUMP...
  • Page 123 ENGINE DISASSEMBLY / ASSEMBLY High Pressure Oil Supply HIGH PRESSURE HOSE TO ANTI SIPHON VALVE HIGH PRESSURE HOSE TO TURBOCHARGER 4.68 2004 Four Stroke PWC Service Manual...
  • Page 124 ENGINE DISASSEMBLY / ASSEMBLY High Pressure Oil Supply GREEN = LOW PRESSURE / PRE FILTRATION BLUE = HIGH PRESSURE / PRE FILTRATION RED = HIGH PRESSURE / POST FILTRATION 4.69 2004 Four Stroke PWC Service Manual...
  • Page 125 MSX 110 / 150 Service Manual Fuel Injection / Ignition / Exhaust Systems Bosch Engine Management System Overview ......
  • Page 126 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Bosch ME - - Motronic 7.4.4 Engine Management System The Bosch engine management system implements the engine’s operational status in--line with the operator’s demands. The microprocessor responds to this demand by translating the throttle flipper travel into a specified engine output.
  • Page 127 TURBOCHARGER Type 3K Warner Intercooler Type Freshwater Cooled Charge Air Cooler Maximum Boost Pressure MSX 110 [.75 BAR (10.8 PSI) GAUGE] / 1750 MB ABSOLUTE MSX 150 [1.1 BAR (16 PSI) GAUGE] / 2100 MB ABSOLUTE OVERBOOST CONDITION MSX 110 [.8 - - .9 BAR (11.6 - - 13 psi for more than 400ms.) GAUGE]...
  • Page 128 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Air Inlet Hose Routings ASSEMBLY NOTES Each air intake hose must be positioned as outlined in illustration. 2004 Four Stroke PWC Service Manual...

  • Page 129: Fuel Hose Routings

    FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Fuel Hose Routing FUEL FILTER FUEL SUPPLY FUEL RETURN STEERING CABLE ASSEMBLY NOTES Fuel supply hose is connected to “S” nozzle on fuel pump. Fuel return hose is connected to “R” nozzle on fuel pump. Fuel filter is connected to supply hose.

  • Page 130: Vent Hose Routing

    FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Vent Hose Routing ASSEMBLY NOTES Vent hose is connected to “V” nozzle on fuel pump. Hose routed between reverse assembly and top deck. 2004 Four Stroke PWC Service Manual...
  • Page 131 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Fuel Tank Assembly FUEL CAP CAP RETAINER FUEL PUMP LOCKING NUT FUEL CAP LOCKNUT FUEL PUMP O RING HOLD- -DOWN STRAPS FUEL TANK PROTECTIVE PAD ASSEMBLY NOTES Fuel Pump Nut Torque: 36 - - 44 ft.lbs. (50 - - 61 Nm) Fuel Filler Nut Torque: 10 - - 15 ft.lbs.
  • Page 132 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Fuel Supply / Vent Hoses QUICK CONNECT FITTING VACUUM RELIEF VALVE CHECK VALVE FUEL RETURN HOSE FUEL PUMP FUEL SUPPLY HOSE FUEL FILTER ASSEMBLY NOTES Small Worm Gear Clamp Torque: 22 in.lbs. (2.5 Nm) Fuel filter located on supply hose.
  • Page 133 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Fuel Rail / Fuel injectors REGULATOR CIRCLIP FUEL RETURN FUEL PRESSURE REGULATOR FUEL SUPPLY INJECTOR RETAINING CLIPS FUEL INJECTORS ASSEMBLY NOTES Fuel Rail Fastener Torque: 7 ft.lbs. (10 Nm) DO NOT OVERTIGHTEN! Use extreme care when removing fuel injectors from fuel rail. Store removed fuel injectors in clean, dry place.
  • Page 134 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Electronic Throttle Body / Intake Manifold AIR INTAKE PIPE BOOST / AIR TEMP. SENSOR PURGE VALVE HOSE ELECTRONIC THROTTLE BODY (ETB) HIGH PRESSURE AIR HOSE INTAKE MANIFOLD MANIFOLD PRESSURE SENSOR HIGH PRESSURE AIR BANJO FITTING HEAT EXCHANGER MOUNTING PADS LOWER BRACKET ASSEMBLY NOTES...
  • Page 135 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Spark Plugs / Ignition Coils IGNITION COIL SPARK PLUG VALVE COVER ASSEMBLY NOTES Spark Plug Torque: 20 ft.lbs. (27 Nm) 7 ft.lbs. (10 Nm) Ignition Coil Fastener Torque: 7 ft.lbs. (10 Nm) Apply Nyogelt to inside of spark plug cap during installation. 5.10 2004 Four Stroke PWC Service Manual...

  • Page 136: Ecu Mounting Illustration

    FUEL INJECTION / IGNITION / EXHAUST SYSTEMS ECU Mounting ASSEMBLY NOTES ECU Mounting Bracket Fastener Torque: 10 ft.lbs. (13Nm) ECU- -To- -Rubber Insulators: 24 in.lbs. (3 Nm) ECU w/insulators- -To- -Mounting Bracket: 6 ft.lbs. (8Nm) Starter Solenoid / Relay Fastener Torque: 6 ft.lbs. (8 Nm) DO NOT APPLY NYOGELt TO THE STARTER SOLENOID CONNECTOR OR INSIDE OF CONNECTOR HOUSING.
  • Page 137 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS ECU C100 Harness Connector (Grey Color Code) ECU C100 Harness Connector Interface Description (As viewed from terminal side.) WIRE COLOR PIN FUNCTION SENSOR / SENSOR PIN # BLACK Electronic Ground Splice 8 BLUE/WHT Manifold Pressure Signal Manifold Pressure Sensor / 4 BLUE/WHT...
  • Page 138 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS ECU C200 Harness Connector (Brown Color Code) ECU C200 Harness Connector Interface Description (As viewed from terminal side.) WIRE COLOR PIN FUNCTION SENSOR / SENSOR PIN # BLU/WHT Ignition Switch Input System Interface Box / C GRN/RED Check Engine MIL Lamp Engine -- Chassis Connector / G...
  • Page 139 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS ECU C300 Harness Connector (Black Color Code) ECU C300 Harness Connector Interface Description (As viewed from terminal side.) WIRE COLOR PIN FUNCTION SENSOR / SENSOR PIN # BLU/GRN Throttle Position 2 Electronic Throttle Body / 5 BLU/RED Temp.
  • Page 140 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Electronic Throttle Body Circuit ECU 300 (Black) TPS Supply Voltage Ground Reference Throttle Valve Negative Terminal Throttle Valve Positive Terminal Throttle Position Sensor 2 Throttle Position Sensor 1 ECU 100 (Grey) Circuit Trouble Codes P - - Code Description Summary...
  • Page 141 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Pedal Position (PPU) Circuit ECU 300 (Black) Pedal Position Sensor 1 PPU Voltage Supply Pedal Position Sensor 2 Splice 10 Splice 11 Pedal PPU Ground Reference Position Unit PPU Voltage Supply ECU 100 (Grey) Circuit Trouble Codes P - - Code Description...
  • Page 142 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Fuel Injection Circuit ECU 300 (Black) To Main Relay Terminal 4 Splice 1 Injector (PTO) Injector 1 (PTO) Control Injector 2 (MAG) Control Injector (MAG) ECU 100 (Grey) Circuit Trouble Codes P - - Code Description Summary P0261...
  • Page 143 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Ignition Coil Circuit ECU 300 (Black) Splice 6 Ignition Ignition Ground Coil 2 Ignition Coil 2 (MAG) (MAG) Control Splice 2 Ignition Coil 1 (PTO) Control Ignition Ignition Power Coil 1 To Main Relay (PTO) Terminal 5 ECU 100 (Grey)
  • Page 144 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Lambda Sensor Circuit ECU 300 (Black) O2 Heating Control O2 Heating Power Relay To Main Terminal 13 O2 Signal O2 Ground Exhaust ECU 100 (Grey) Circuit Trouble Codes P - - Code Description Summary P0030 Heated Oxygen Sensor Circuit: Open Load...
  • Page 145 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Boost / Air Temperature Circuit ECU 300 (Black) Boost Pressure Signal Air Temperature Signal Splice 5 Reference 5- -Volt Boost/Air Temp Sensor Splice 4 Ground Reference ECU 100 (Grey) Circuit Trouble Codes P - - Code Description Summary P0112...
  • Page 146 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Manifold Pressure Circuit ECU 300 (Black) Manifold Pressure Sensor Splice 5 Reference 5- -Volt Splice 4 Ground Reference Manifold Pressure Sensor ECU 100 (Grey) Circuit Trouble Codes P - - Code Description Summary P0105 Intake Manifold Pressure: Plausibility Error The measured intake manifold pressure is outside an acceptable...
  • Page 147 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Engine Coolant Temperature Sensor Circuit ECU 300 (Black) Engine Temperature Signal Engine Temperature Ground Coolant Temperature Sensor ECU 100 (Grey) Circuit Trouble Codes P - - Code Description Summary P0116 Engine Temperature: Signal Error Indicates the engine temp.
  • Page 148 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Engine Crankshaft Position (Engine Speed) Sensor Circuit ECU 300 (Black) Crank Signal A Crankshaft Crank Signal B Sensor Ground Reference ECU 100 (Grey) Circuit Trouble Codes P - - Code Description Summary P0335 Loss of Synchronization The number of pulses, or teeth on the timing rotor are not cor- rect.
  • Page 149 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Camshaft Position Circuit ECU 300 (Black) Ground Reference Camshaft Camshaft Signal Sensor 5- - Volt Supply Splice 5 ECU 100 (Grey) Circuit Trouble Codes P - - Code Description Summary P0340 Camshaft Sensor Circuit: Plausibility Error The camshaft sensor signal level is outside an acceptable range.

  • Page 150: Knock Sensor

    FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Knock Sensor Circuit ECU 300 (Black) Knock Signal Ground Reference Knock Sensor ECU 100 (Grey) Circuit Trouble Codes P - - Code Description Summary P0324 Knock Control Signal Failure Indicates a failure with the knock control sensor. P0327 Knock Sensor Signal Low The knock sensor signal is too low.

  • Page 151: Wastegate Solenoid

    FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Wastegate Solenoid Circuit ECU 300 (Black) Wastegate Solenoid Control Wastegate Solenoid Wastegate Power Splice 1 To Main Relay Terminal 4 ECU 100 (Grey) Circuit Trouble Codes P - - Code Description Summary P0243 Wastegate Solenoid: Open Circuit Indicates an open circuit within the control circuit.
  • Page 152 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Fuel Pump / Main Relay Circuit ECU 300 (Black) Main Relay Fuel Pump Relay Driver ECU 100 (Grey) Circuit Trouble Codes P - - Code Description Summary P0230 Fuel Pump: Open Load Indicates the fuel pump relay circuit is open. Can be caused by a faulty relay, damaged wiring, damaged fuel pump, or ECU failure.
  • Page 153 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS ECU / ECU Connections The wiring harness connections at the ECU are a latching type. Extreme care must be taken when handling the connectors. 1. Remove connectors from front to back. Re--install from back to front. FRONT REAR 2.

  • Page 154: Etb Learning Procedure

    FUEL INJECTION / IGNITION / EXHAUST SYSTEMS General Engine Management Trouble Codes P - - Code Description Summary P0171 Fuel System: Maximum Adaption Limit Reached Indicates the air/fuel mixture is too lean and the ECU has reached the maximum amount of fuel it can possibly deliver. Can be caused by a faulty O2 sensor, air leak, faulty injector or any other failure that would cause a lean- -running condition.
  • Page 155 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Electronic Throttle Body (ETB) / Pedal Position Unit (PPU) - - Troubleshooting The ETB and PPU components are integral to the engine management system. To perform any troubleshooting procedures, the ECU must be connected to the Digital Wrench diagnostic software.

  • Page 156: Exhaust System Illustration

    FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Exhaust System OUTLET PIPE EXHAUST PIPE PLANETt RESONATOR EXHAUST SILENCER TORQUE SEQUENCE ASSEMBLY NOTES Outlet Pipe Fastener Torque 6 ft.lbs. (8 Nm) Apply marine grade silicone to threads, and outlet pipe mating surfaces. Exhaust Pipe Fastener Torque 22 ft.lbs.
  • Page 157 The turbocharger uses the energy of expanding exhaust gases to power a compressor. Intake air is drawn into the compressor impeller and pre--compressed before entering the combustion chamber. Components of the turbocharger employed on the MSX 110 and 150 watercraft are: Turbine...
  • Page 158 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Turbocharger EXHAUST MANIFOLD TURBINE COMPRESSOR WASTEGATE SOLENOID = FRESH AIR WASTEGATE = COMPRESSED AIR = EXHAUST GASES = COMPRESSED AIR TO WASTEGATE = EXHAUST GASES BLED THROUGH WASTEGATE DOOR 5.33 2004 Four Stroke PWC Service Manual...
  • Page 159 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Charge Air Cooler (Intercooler) Whenever air is compressed, the air molecules within the air are packed tightly together and create friction be- tween each other. The increased friction between the air molecules generates heat. A charge air cooler removes most of the heat by transferring it to the freshwater cooling circuit.

  • Page 160: Rpm Limiting Modes

    FUEL INJECTION / IGNITION / EXHAUST SYSTEMS RPM Limiting Modes The engine management software will limit engine RPM in several different scenarios. Engine RPM is limited to protect either the operator or engine from injury of damage. RPM will be limited when the following occurs: Limit Mode Approximate Trigger...

  • Page 161: Troubleshooting: Engine Will Not Turnover

    FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Troubleshooting - - Engine Will Not Turnover System / Component Inspection Procedure Suspected Problem Battery Condition of Battery Static battery voltage must be at least 12 Vdc. Voltage drop cannot drop below 10.5 Vdc while pushing START button.

  • Page 162: Troubleshooting: Engine Turns Over; Will Not Start

    FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Troubleshooting - - Engine Turns- - Over; Will Not Start System / Component Inspection Procedure Suspected Problem Battery Condition of Battery Static battery voltage must be at least 12 Vdc. Voltage drop cannot drop below 10.5 Vdc while pushing START button.

  • Page 163: Troubleshooting: Engine Stalls; Will Re--Start

    FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Troubleshooting - - Engine Stalls; Will Re- -Start System / Component Inspection Procedure Suspected Problem Battery Condition of Battery Static battery voltage must be at least 12 Vdc. Voltage drop cannot drop below 10.5 Vdc while pushing START button.

  • Page 164: Troubleshooting: Engine Stalls: Will Not Re--Start

    FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Troubleshooting - - Engine Stalls; Will Not Re- - Start System / Component Inspection Procedure Suspected Problem Battery Condition of Battery Static battery voltage must be at least 12 Vdc. Voltage drop cannot drop below 10.5 Vdc while pushing START button.

  • Page 165: Troubleshooting: Engine Lacks Performance, Rpm Limits

    FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Troubleshooting - - Engine Lacks Performance, RPM Limits Indicated Problem Suspected Problem Solution Engine RPM will not rise with throttle flipper No reaction to throttle input. PPU not work- Check ETB and PPU wiring harness con- movement.
  • Page 166 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Troubleshooting - - Engine Lacks Performance / RPM Limits - - Continued Indicated Problem Suspected Problem Solution Engine RPM limited to 4700 ± 200 and the ECU has detected an overboost condition. Stop engine, pull lanyard and then re- -insert CHECK ENGINE MIL LIGHT is on.
  • Page 167 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Troubleshooting - - Engine Lacks Performance / RPM Limits - - Continued Indicated Problem Inspection Procedure Suspected Problem Air Intake System Inspect condition of hoses and clamps. Inspect condition of intake screen. Inspect the intake system purge valve. Alternator / Charging System Verify at least 14 vDC present at battery ter- minals at idle speed.

  • Page 168: Troubleshooting

    FUEL INJECTION / IGNITION / EXHAUST SYSTEMS Troubleshooting Indicated Problem Inspection Procedure Suspected Problem Idle Speed Too High Adjust throttle flipper freeplay to zero. (0) Check for air leaks around ETB assembly. Re- -Torque ETB fasteners. Verify correct ESP system operation. (ESP circuit grounded.) Inconsistent Performance Inspect:...
  • Page 169 MSX 110 / 150 Service Manual Propulsion Pump Specifications / Quick Reference Guide ..... . . Fastener Guide ..........
  • Page 170 5410663 5410663 Driveshaft Bumper (Between Impeller and Shaft) (Between Impeller and Shaft) *Impeller torque for ALL Polaris impellers: 100ft.lbs. (138Nm) Apply Loctitet 242 to threads. Final Drive / Propulsion Quick Reference Guide Topic Service Recommendations Drive Couplers Inspect at preseason and at year end.

  • Page 171: Pump Assembly

    PROPULSION Fastener Guide - - Final Drive / Propulsion Torque Component(s) Component(s) Remarks Remarks FT.LBS. Driveshaft / Bearing Carrier Bearing Carrier - - To - - Hull Tighten in criss- -cross pattern. Coupler Guard 35 (In. Lbs.) Apply Loctitet 242 Pump Assembly Zinc Anode 25 (In.

  • Page 172: Ventilation Troubleshooting

    PROPULSION Ventilation Troubleshooting Ventilation results when air enters the pump inlet tract and is compressed by the impeller, causing a reduction in thrust and an increase in engine RPM. Small leaks are often difficult to diagnose. Some possible sources of air are: 1.
  • Page 173 PROPULSION Pump Assembly PUMP STATOR WATER PIPE BEARING SPACER STEERING NOZZLE PUMP HOUSING IMPELLER EXTENSION WEDGE ANODE 28 ft.lbs. (38 Nm) TAIL CONE 40 in.lbs. (4.5 Nm) THRU- -HULL LOCK PLATE STUB SHAFT ASSEMBLY NOTES Pump Housing - - To- - Hull Fasteners Torque: 28 ft.lbs. (38 Nm) Follow sequence listed on page 5.2. Anode Fastener Torque: 25 in.lbs.
  • Page 174 PROPULSION Stator Assembly STUBSHAFT O- -RINGS BEARING BEARING SPACER SEALS (LIPS FACE IMPELLER) STATOR HOUSING BEARING IMPELLER SPACER IMPELLER 100 ft.lbs. (138 Nm) ASSEMBLY NOTES Impeller Torque: 100 ft.lbs. (138 Nm) Apply Loctite 242 to threads. Bearing Spacer Length: 1.730 in. 43.94mm (Service Limit) Apply light film of Premium grease to seal lips, o- -rings, and stubshaft during installation.
  • Page 175 PROPULSION Driveshaft / Bearing Carrier Assembly COUPLER GUARD SHIM WASHERS TAPERED SPACER COUPLER ASSEMBLY DRIVESHAFT BUMPER BEARING CARRIER 14 ft.lbs. (19 Nm) ASSEMBLY NOTES Bearing Carrier Fastener Torque: 14 ft.lbs. (19 Nm) Tighten in criss- -cross pattern. Driveshaft Run Out Service Limit: .005″ (.13mm) Fit tapered end of spacer over driveshaft taper.
  • Page 176 PROPULSION Pump Induction Assembly 30 in.lbs. (3 Nm) PADDLE WHEEL Install paddle wheel with harness- -end to front of boat. Route harness along ride plate. RIDE PLATE 8 ft.lbs. (11 Nm) INLET SCOOP INTAKE GRATE 8 ft.lbs. (11 Nm) ASSEMBLY NOTES Paddle Wheel Fastener Torque: 30 in.lbs.
  • Page 177 Stator assembly w/impeller. Extension housing. Pump Assembly Pump assembly is the reversal of disassembly. Polaris recommends applying dielectric grease to all nozzle--to-- nozzle mating surfaces to prevent corrosion. Follow torque specifications listed on page 6.2. NOTE: Always install new Nylock nuts and cotter pins.

  • Page 178: Bearing Carrier Removal

    PROPULSION Bearing Carrier Removal The bearing carrier uses sealed bearings. Bearing maintenance or lubrication is not required. 1. From inside the engine compartment, remove the drive coupler guard. 2. Remove the pump assembly as outlined in the Pump Removal section. 3.

  • Page 179: Driveshaft Shim Procedure

    PROPULSION Driveshaft Shim Procedure The driveshaft must be shimmed to prevent driveline damage. NOTE: The NOMINAL number of shims = 2. 1. Install tapered spacer over driveshaft end. Verify beveled edge is flush with driveshaft bevel. 2. Install two shims, then hand thread coupler on to driveshaft.
  • Page 180 PROPULSION WARNING Before working on the drive system, be sure the lanyard cord and lock plate are removed from the engine stop switch to kill the ignition or severe injury could result. Impeller Clearance 1. Remove lanyard cord and lock plate from engine stop switch.

  • Page 181: Stator Disassembly

    PROPULSION Stator Disassembly 1. Remove tail cone screws (3) and tail cone. Inspect O--ring seal located behind tail cone. Replace seal if damage is evident. NOTE: When removing tail cone, hold stator with cone pointed down. Twist cone off. This will allow any water from enter- ing the impeller assembly.
  • Page 182 PROPULSION Stator Disassembly - - Continued 4. Remove stator assembly from vise. Using a soft--faced hammer, tap stub shaft out of housing. 5. Inspect shaft and collar for wear, scratches, or damage. Install new o--rings upon reassembly. 6. Using a brass hammer or aluminum drift, tap bearing spacer to one side of the stator housing.
  • Page 183 PROPULSION Stator Assembly NOTE: Seals, bearings, and o-rings should be replaced if removed. Heat the impeller housing evenly with a heat gun to ease removal of bearings in next step. Remove tail cone O-ring before applying heat To ease installation, wrap bearings in wax paper and chill in a freezer for 30 minutes or longer.
  • Page 184 PROPULSION Driveshaft Alignment 1. Disconnect the NEGATIVE (--) first, then POSITIVE (Illustration 1) (+) battery cables from the battery. DO NOT PROCEED WITHOUT PERFORMING STEP 1! 2. Remove coupler guard. 3. Remove the reverse cable and steering cable linkage from the pump. (Photo A) Discard all Nylokt nuts. Remove the four pump mounting bolts that mount the pump sections to the pump housing.
  • Page 185 Discard the gasket and o--ring. NOTE: Steps 11, 12, and 13 are only required if you do not have an “extra” Polaris pump stator already setup with bearings available. If you already have a stator setup to perform align- ment checks, proceed with STEP 15.
  • Page 186 PROPULSION Driveshaft Alignment - - All Models 13. Carefully insert the tapered--end of the PUMP ALIGNMENT TOOL, PN 2871343, through the pump PUMP STATOR HOUSING stator. Securely mount the pump stator to the pump housing. (Photo D) DRIVESHAFT ALIGNMENT TOOL 2871343 (Photo D ) 14.
  • Page 187 PROPULSION Driveshaft Alignment Procedure 1. Reference the illustrations below. Loosen one engine mounting nut at a time, add or subtract shims, and re--check alignment. 2. Obtain new alignment shims, PN 5246894 NOTE: Always remember to torque mounting nuts to APPROXIMATELY 10 ft.lbs. to obtain an accurate alignment.
  • Page 188 PROPULSION REASSEMBLY PROCEDURE 1. Apply Loctitet 262 to engine mount bolt threads. Torque engine mount nuts to 50 ft.lbs. (68 Nm) 2. Remove Driveshaft Alignment Tool and Driveshaft Alignment Coupler Tool. 3. Obtain the engine--side drive coupler. Apply a thin film of Premium Grease, PN 2871322, to the inner threads.
  • Page 189 PROPULSION Sacrificial Anode A zinc sacrificial anode is in place on all models on the pump housing. The purpose of the anode is to prevent corrosion of metal parts due to electrolysis. The mounting surfaces must be clean and the mounting bolt tight to maintain a good connection between the pump and anode.
  • Page 190 PROPULSION Intake Scoop / Ride Plate Removal and Installation Removal 1. Remove pump assembly as outlined on pages 5.10 to 5.12. 1. Remove the inlet grate and ride plate mounting Inlet Grate Mounting Bolt bolts. 2. Insert a length of 2x4 wood through the water inlet housing from the rear of the watercraft.
  • Page 191 PROPULSION Intake Scoop / Ride Plate Removal and Installation - - Continued 1. Insert inlet scoop into pump cavity. Apply marine grade silicone to scoop / ride plate mating surface. Apply Silicone Marine Grade Silicone PN 8560054 2. Apply marine grade silicone to pump mount assembly, and inlet scoop to pump mount mating surface.
  • Page 192 MSX 110 / 150 Service Manual Hull and Body Hull Specifications / Paint Codes ........
  • Page 193 P207 Hull P070 Footwell Pads P318 * Polaris paints can only be ordered through the an authorized Polaris dealership. P070 ... . . BLACK P207 ... . .
  • Page 194 HULL AND BODY Fastener Guide - - Hull / Control Systems HULL / BODY Torque Where Used Where Used Remarks Remarks FT.LBS LH & RH / Upper Console Shrouds Console Shroud Assembly - - To - - Top Deck Mesh Screens 10 (In.Lbs.) Windscreen 22 (In.Lbs.)
  • Page 195 HULL AND BODY Steering Cable Routing CABLE PROTECTION COVER Reverse Cable Routing CABLE PROTECTION COVER 2004 Four Stroke PWC Service Manual...

  • Page 196: Siphon Hose Routing

    HULL AND BODY Siphon Hose Routings SECURE WITH ZIP TIES 2004 Four Stroke PWC Service Manual...

  • Page 197: Hull Assembly

    HULL AND BODY Hull Assembly INSERT RUB RAIL SEAT POST AND TOW HOOK MAY BE ONE- -PIECE DESIGN SEAT POST FOOTWELL PADS TOW HOOK GRAB HANDLE SPONSON HULL ASSEMBLY NOTES Rub Rail Fastener Torque: 25 in.lbs. (2.8 Nm) Rub Rail Insert Fastener Torque: 25 in.lbs. (2.8 Nm) Bumper Fastener Torque: 25 in.lbs.
  • Page 198 HULL AND BODY Hull Assembly - - Continued 1.02″ - - 1.09″ BILGE PLUGS Ref.A FIRE EXTINGUISHER SEAT U BOLT (Ref. A) TIE DOWN LOOPS BOW LOOP AIR INLET DUCTS (2QTY.) HULL ASSEMBLY NOTES Bilge Plug Fastener Torque: 8 - - 10 in.lbs. (1 Nm) Tie Down Loop Torque: 8 ft.lbs.

  • Page 199: Compartment Door Assembly

    HULL AND BODY Compartment Door Assembly MIRROR ASSEMBLY WINDSCREEN NGI GAUGE COMPARTMENT DOOR PLUNGER LATCH DOOR POST HINGE ASSEMBLY COMPARTMENT DOOR ASSEMBLY NOTES Mirror Nut Torque: 22 in.lbs. (2.5 Nm) Windscreen Bolt Torque: 22 in.lbs. (2.5 Nm) NGI Gauge Bolt Torque: 14 in.lbs. (1.5 Nm) Plunger Latch Fastener Torque: 8 ft.lbs.

  • Page 200: Shroud And Storage Assemblies

    HULL AND BODY Shroud and Storage Assemblies SIDE SHROUDS MESH SCREENS (x2) GLOVE BOX UPPER SHROUD SPLASH GUARD SHROUD AND STORAGE ASSEMBLY NOTES Splash Guard Fastener Torque: 40 in.lbs. (4.5 Nm) Side Shrouds - - To - - Upper Shroud Fasteners: 23 ft.lbs. (31 Nm) Mesh Screen Fastener Torque: 10 in.lbs.

  • Page 201: Seat Assembly

    HULL AND BODY Seat Assembly PLUNGER LATCH 41 - - 57 IN.LBS. (4.6 - - 6.4Nm) SEAT ASSEMBLY SEAT SEAL SEAT ASSEMBLY NOTES Plunger Latch Fasteners 41 - - 57 in.lbs. (4.6 - - 6.4Nm) Seat Post Nut Torque: 18 ft.lbs. (24Nm) Apply Loctitet 262 to nut threads. Seat post height is fixed.

  • Page 202: Steering Control Assembly

    HULL AND BODY Steering Control Assembly GRAB HANDLE START / STOP SWITCH DECK PLATES HANDLEBAR COVER STEERING HOUSING STEERING POST THROTTLE BLOCK SHIMS ROD END ADJUSTER / CLAMP STEERING CABLE ROD END STEERING NOZZLE STEERING CLAMP STEERING CONTROL ASSEMBLY NOTES Handlebar Cover Fasteners: 20 in.lbs.

  • Page 203: Esp Switch Assembly

    HULL AND BODY ESP Switch Assembly REED SWITCH REED SWITCH BRACKET 8 ft.lbs. (11 Nm) MAGNET BRACKET MAGNETS 35 in.lbs. (4 Nm) APPLY LOCTITEt 262 ASSEMBLY NOTES Magnet Bracket Fastener Torque: 35 in.lbs. (4 Nm) Apply Loctitet 262 to threads. Reed Switch Bracket Nut Torque: 8 ft.lbs.

  • Page 204: Ppu Assembly

    HULL AND BODY PPU Assembly 22 in.lbs. (2.5 Nm) PPU Assembly ASSEMBLY NOTES PPU - - To - - Top Deck Fastener Torque: 22 in.lbs. (2.5 Nm) 7.12 2004 Four Stroke PWC Service Manual...

  • Page 205: Reverse System Assembly

    HULL AND BODY Reverse System Assembly 40 in.lbs. (4.5 Nm) APPLY LOCTITEt 242 REVERSE GATE THRU- -HULL NUTS / WASHERS 16 ft.lbs. (21 Nm) APPLY LOCTITEt 242 HANDLE 14 ft.lbs. (19 Nm) GASKET REVERSE TRACK DRIVER 22 in.lbs. (2.5 Nm) 6 ft.lbs.
  • Page 206 HULL AND BODY Handlebar Cover / Steering Post Removal Steering Post Removal 1. Remove handlebar cover fasteners. The grab handle fasteners are located under the cover. If grab handle replacement is required, remove the two fasteners as well. ZERO, 1 OR 2 SHIMS INSTALLED TO AD- 2.

  • Page 207: Steering Cable Removal And Installation

    HULL AND BODY Steering Cable Removal / Installation WARNING: Failure to properly install the steering cable can result in loss of vehicle control possibly causing se- vere injury or death. 1. Remove seat and front storage compartment. 2. Visually inspect the engine compartment. Note the current routing of the steering cable.

  • Page 208: Steering Cable Installation

    HULL AND BODY Steering Cable Installation 1. Insert the new cable through the rear thru--hull fitting from the back of the watercraft following the routing you noted in removal. NOTE: Verify that there are no sharp bends or kinks in the cable before proceeding to the next step.
  • Page 209 HULL AND BODY Steering Cable Adjustment 1. Open front compartment door. Loosen and remove adjuster block. Align handlebars with centerline of watercraft. (Straight) 2. Place a straight edge across horizontal center line of steering nozzle or trim nozzle. 3. Measure distance from straight edge to hull on left and right side.

  • Page 210: Top Deck / Hull Repair

    Repair kits are available through Polaris Industries. Detailed instructions regarding material preparation, setup and cure times are included with each kit. However, sound knowledge of FRC repair is required when working with these kits. Polaris recommends that a dedicated marine--fiberglass repair facility inspect or be consulted with prior to attempting any repairs.

  • Page 211: Electrical System

    MSX 110 / 150 Service Manual Electrical Systems Chassis Electrical and Sensor Specifications ......Battery and Charging System Specifications .

  • Page 212: Electrical Systems

    ELECTRICAL SYSTEMS Chassis Electrical and Sensor Specifications Component Specification FUSES NGI Gauge 2AMP Fuel Pump 10AMP Ignition / ECU 15AMP Regulator / Rectifier 30AMP Main Relay (Lambda Sensor / Fuel Pump / Igni 2 X 15AMP Fuses tion Coils / Fuel Injectors) Main Relay (Switched ECU Battery Supply Input) 15AMP Oil Pressure Switch Continuity Pressure...
  • Page 213 ELECTRICAL SYSTEMS NGI Gauge (Next Generation Instrument) Primary Functions Speedometer Tachometer Engine Hourmeter Clock Trip Odometer Fuel Level Turbo Boost Level Low Oil / Pressure, Fuel, and Low Battery Voltage Warnings High Engine Temperature Warning Check Engine Display Function Overview Speedometer The large numeric speedometer displays vehicle speed.

  • Page 214: Instrument Operation

    ELECTRICAL SYSTEMS NGI Gauge - - Continued Clock The gauge display time in the main display mode without AM / PM displayed. (1:00 to 12:59) Highest Speed / Engine RPM Record Both the highest speed and highest engine RPM are recorded separately. Both are displayed in the speed / tachometer display mode.
  • Page 215 ELECTRICAL SYSTEMS NGI Gauge (Next Generation Instrument) - - ENGINE MIL INDICATORS NGI GAUGE CONNECTOR ENGINE - - CHASSIS CONNECTOR GRN/YEL LT.BLUE GRN/RED ENGINE - - CHASSIS CONNECTOR ECU 200 LT.BLUE GRN/RED GRN/YEL OIL PRESSURE SWITCH (Located beneath water pump above engine mounting strap on exhaust side of engine.) NGI Gauge (Next Generation Instrument) -- ENGINE MIL INDICATORS Legend LT.

  • Page 216: Battery Testing

    ELECTRICAL SYSTEMS Battery Testing WARNING: Whenever installing batteries, care should be taken to avoid the possibility of explosion, resulting in serious burns. Always connect the positive (red) cable first and the negative (black) cable last. When working with batteries, always wear safety glasses or a face shield and protective gloves. Battery electrolyte contains sulfuric acid and is poisonous! Serious burns can result from contact with the skin, eyes or clothing.

  • Page 217: Specific Gravity Test

    ELECTRICAL SYSTEMS Specific Gravity Test A tool such as the battery hydrometer can be used to measure electrolyte strength or specific gravity. As the battery goes through the charge-discharge cycle, the electrolyte goes from a heavy (more acidic) state at full charge to a light (more water) state when discharged.
  • Page 218 ELECTRICAL SYSTEMS Refilling a Low Battery The normal charge/discharge cycle of a battery causes the cells to give off hydrogen and oxygen. These gases are the ingredients of water. Because of the loss of these gases and the lowering of the electrolyte level, it will be necessary to add pure, clean distilled water to bring the fluid to the proper level.

  • Page 219: Alternator Assembly

    ELECTRICAL SYSTEMS Alternator Assembly STARTER GEAR NEEDLE BEARING SPEED SENSOR WHEEL MAGNET ROTOR STARTER GEAR FRONT COVER SPRAGUE CLUTCH STARTER MOTOR ALTERNATOR ALTERNATOR COVER ASSEMBLY NOTES Starter Motor Fastener Torque: 7ft.lbs. (10 Nm) Apply Nyogel to fasteners. Front Gear Cover Fastener Torque: 7 ft.lbs. (10 Nm) Speed Sensor Wheel / Sprague Clutch Fastener Torque: 7 ft.lbs.

  • Page 220: Charging System

    ELECTRICAL SYSTEMS Charging System RED/YEL ALTERNATOR VOLTAGE REGULATOR SPARE SPARE STARTER RELAY CHARGING SYSTEM -- LEGEND 12V BATTERY VOLTAGE BLACK CHASSIS GROUND RED/PUR FUSE PROTECTED / SWITCHED BATTERY VOLTAGE YEL/RED STARTER RELAY SIGNAL PURPLE SWITCHED ECU VOLTAGE 2004 Four Stroke PWC Service Manual...
  • Page 221 ELECTRICAL SYSTEMS Start / Stop Electrical System RED/PUR TETHER SWITCH PURPLE STARTER RELAY YEL/RED YEL/RED START SWITCH START SWITCH / STOP - - TETHER PURPLE YEL/RED ENGINE HARNESS- - TO- - CHASSIS HARNESS CONNECTOR PURPLE RED/YEL ECU 100 SYSTEM INTERFACE BOX ECU 200 BLU/WHT ECU 300...
  • Page 222 ELECTRICAL SYSTEMS System Interface Box (SIFB) The primary function of the SIFB is to power--down the ignition system in the event that the lanyard is left inserted in the stop switch for more than two minutes. Without the SIFB, the ignition system would remain powered--up by the battery, and the battery would completely discharge.
  • Page 223 ELECTRICAL SYSTEMS System Interface Box (SIFB) ENGINE/CHASSIS HARNESS CONNECTOR PURPLE SYSTEM INTERFACE BOX YEL/GRN YEL/GRN RED/YEL ECU 200 BLU/WHT GRN/YEL RED/PUR BLACK MAIN RELAY SYSTEM INTERFACE BOX (SIFB) -- LEGEND RED/PUR 12V BATTERY VOLTAGE BLACK GROUND GRN/YEL REVERSE SWITCH SIGNAL (FROM IFB) BLU/WHT IGNITION SWITCHED VOLTAGE (FROM IFB) TACHOMETER SIGNAL...

  • Page 224: Starter Motor

    ELECTRICAL SYSTEMS Starter Motor REAR HOUSING BRUSHES O RING BRUSH PLATE THRUST WASHERS (AR QTY.) HOUSING THRUST WASHER (1 QTY.) ARMATURE COMMUTATOR O RING PHENOLIC WASHER FRONT HOUSING O RING ASSEMBLY NOTES Through Bolt Torque: 36 in.lbs. (4 Nm) Brush Length Service Limit: 5/ 16″ (8mm) Verify all parts are clean thoroughly prior to assembly.
  • Page 225 ELECTRICAL SYSTEMS Starter Motor - - Disassembly 1. Remove starter motor and disassemble. Mark end covers and housing for proper reassembly. 2. Remove housing through bolts. 3. Remove brush end bushing dust cover and armature thrust washers. Keep washers in order for reassembly.
  • Page 226 ELECTRICAL SYSTEMS Starter Motor - - Disassembly - - Continued 5. Measure resistance between starter input terminal and insulated brushes. Reading should be .3 ohms or less. Remember to subtract meter lead resistance. 6. Measure resistance between insulated brush and starter housing.

  • Page 227: Brush Inspection

    ELECTRICAL SYSTEMS Starter Motor - - Inspection Brush Inspection 1. Measure length of each carbon brush. Replace brush assembly when worn to 5/16″ (8 mm) or less. The brushes must slide freely in their holders. Carbon Brush Service Limit 5/16 (8mm) Brush Replacement 1.

  • Page 228: Starter Assembly

    ELECTRICAL SYSTEMS Starter Assembly 1. Install brush plate to field magnet housing aligning index tab. 2. Install O-ring, two small phenolic spacers, large phenolic washer, flat washer, lock washer, and terminal nut. 3. While holding brush springs away from brushes, push brushes back and hold in place.
  • Page 229 ELECTRICAL SYSTEMS Starter Motor - - Troubleshooting Condition: Starter fails to turn motor or motor turns slowly. CAUTION: Make sure that engine crankshaft is free to turn before proceeding. With the tester on Vdc, place the tester black lead Remove battery, test and/or service. Install a on the battery negative (-) terminal and the tester fully charged shop battery to continue the test.
  • Page 233 CHASSIS WIRING HARNESS -- LEGEND TETHER SWITCH START SWITCH 12V BATTERY VOLTAGE BLACK CHASSIS GROUND RED/PUR RED/PUR FUSE PROTECTED / SWITCHED BATTERY VOLTAGE YEL/RED STARTER RELAY SIGNAL PUR/WHT ESP SIGNAL CLOSED WHEN TETHER INSTALLED PURPLE SWITCHED ECU VOLTAGE OR/BLK NGI MODE SWITCH SIGNAL RVS SWITCH MODE SWITCH Y/GRN...
  • Page 234 MAIN RELAY CIRCUITS -- LEGEND 12V BATTERY VOLTAGE BLACK GROUND RED/PUR FUSE PROTECTED / RELAY SWITCHED BATTERY VOLTAGE PURPLE SWITCHED ECU VOLTAGE FROM TETHER SWITCH ENGINE HARNESS SPLICE 3 BLK/GRN SWITCHED ECU RELAY CONTROL FUSE SPLICE BLOCK LT.BLUE OIL PRESSURE SWITCH SIGNAL GRN/RED CHECK ENGINE MIL SIGNAL RED/PUR...
  • Page 235 IGNITION / FUEL INJECTION CIRCUITS -- LEGEND BLACK CHASSIS GROUND / IGNITION GROUND MAIN RELAY RED/PUR FUSE PROTECTED / RELAY SWITCHED BATTERY VOLTAGE BLK/GRN SWITCHED ECU RELAY CONTROL BLK/OR FUEL INJECTOR DRIVER CONTROLS GREEN PTO IGNITION DRIVER ORANGE MAG IGNITION DRIVER BLK/RED WASTEGATE SOLENOID REFERENCE GROUND Rev.
  • Page 236 ENGINE MANAGEMENT SENSOR CIRCUITS -- LEGEND SPLICE 4 SPLICE 4 BLACK CHASSIS GROUND RED/PUR FUSE PROTECTED / RELAY SWITCHED BATTERY VOLTAGE BLK/WHT SENSOR REFERENCE GROUND RED/GRN 5V SENSOR REFERENCE SIGNAL BLU/WHT SENSOR RETURN SIGNAL (MANIFOLD PRESSURE SENSOR, SPEED SENSOR,) BLU/BLK ENGINE SPEED SIGNAL BLU/YEL LAMBDA SENSOR RETURN SIGNAL / INTAKE AIR TEMP .
  • Page 237 PEDAL POSITION UNIT / ELECTRONIC THROTTLEBODY LEGEND BLK/WHT REFERENCE GROUND RED/GRN 5V SUPPLY VOLTAGE PEDAL POSITION UNIT (P .P .U.) P .P .U. INTERFACE BOX BLU/RED P .P .U. POSITION 2 RETURN SIGNAL GRY/RED P .P .U. POSITION 1 RETURN SIGNAL BLU/OR E.T.B.

  • Page 238: Decimal Equivalent Chart

    ECU Harness Connectors, 5.28 ECU Overview, 5.1, 5.29 Adaptation, 5.28 Electrical Specifications Battery and Charging System, Armature Testing, 8.16 Chassis, Electronic Throttle Body / PPU Overview, 5.29 Engine Compression Test, 2.14 Engine Coolant Change Procedure, 2.12 Battery Charging, 2.16 Engine Coolant Inspection, 2.12 Battery Connections, 2.16...
  • Page 239 Flush Kit, Maintenance Service Products, Footpad Removal / Application, 7.18 Maintenance Specific Tools, Fuel / Water Separator, 2.20 MSX 110 Emission Information, MSX 110 General Information, 1.6–1.7 Fuel Filter, 2.20 MSX 150 Emission Information, Fuel Injection / Ignition system Specifications, MSX 150 General Information, 1.8–1.9...

  • Page 240: Tap Drill Sizes

    System Interface Box, 8.11 Diagnostics Mode, 8.11 Replenishing Battery Fluid, 2.16 Reverse Cable Adjustment, 2.7, 7.17 Reverse System Assembly, 7.13 Tap Drill Sizes, 1.13 Routings Air Inlet Hoses, Throttle Cable Adjustment, 2.19 Bilge Siphon Hoses, Trouble Codes Fuel Hoses, Boost / Air Temp. Sensor, 5.20 Reverse Cable, Camshaft Position Sensor,...
  • Page 241 Part Number 9919062 Printed in U.S.A...

This manual is also suitable for:

Msx 150

Table of Contents

Save PDF