2003-2004 Polaris MSX110/ MSX150 Personal Watercraft Service Manual

msx 110 msx 150 Four Stroke Personal Watercraft Service Manual

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

P L E 1 2 3 4 5 6 7 8 9 10 11 12 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 1.3 2004 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 numbers 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 9919057 9919058 MSX 150 (C) W045305CC 9919057 9919058 MSX 150 International W045305IC MSX 150 (D) W045305CD MSX 150 (D) International W045305ID S C = 50 State Domestic (CARB Exemption). S A / B / C / D = Color Option. S I = International Model 2004 PWC Service Manual Part Numbers Book Part Number 2004 Carbureted / DIt Models (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 1.5 2004 Four Stroke PWC Service Manual Service Guidelines -- Safety Warnings S Clean 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. S Watch for sharp edges which can cause personal injury. Protect hands and arms when working with sharp components. S Always use a soft--faced hammer and extreme care when removing difficult or stuck components. S Some fasteners are installed with locking agents or lubricants. Use of impact drivers will aid in fastener removal. S Always 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. S Always follow torque sequence patterns when found in this manual. Tighten each fastener evenly and to the specified torque value, and with specified locking agent. S Always use new gaskets, o--rings and seals, clips, cir--clips, and snap rings when assembling components. S Never re--use Nyloktor Flex Lockt nuts when assembling components. S Never re--use Oetikert clamps when removed from fuel lines. Replace with small gear clamps. S Always use Polaris--authorized lubricants, greases, and locking agents when assembling components. Failure to do so may cause severe engine or vehicle damage. S Always 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. S Wear 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 components. S If 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. S Flush 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. S Keep hands, arms, legs, feet and hair away from rotating parts, hot engine and exhaust components, drive pump and impeller and engine induction when engine is running. S Never attempt engine or driveline inspections and/or repairs without first removing lanyard and battery cables. S Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme care when handling gasoline. Do not smoke or allow open flames in or near the area where refueling is performed or where gasoline is stored. S Always refuel the watercraft outdoors and in a well--ventilated area. Do not fill the tank to the fuel cap. S If you get gasoline or oil on your skin or clothing, wash it off immediately with soap and water and change clothing. S The 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. S Never 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) .... Dry Weight: 650lbs. (295 kg) Category: Midsize .. Riders: 1 to 3 .... Fuel Capacity: 17.8 US Gal. (67.4L) Emission Certification: Two Star -- Very LowEmission MSX 110 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. The Two Star label identifies engines that meet the California Air Resources Board (CARB) 2004 exhaust emission 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 The emission 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 -- .032in.) ADVERTISED HORSEPOWER 82 kW (110HP) ENGINE DISPLACEMENT 750cc

GENERAL INFORMATION 1.7 2004 Four Stroke PWC Service Manual 2004 MSX 110 Model Number W045304CA / CB / CC (W045304IA / IB / IC) Engine Platform Polaris Libertyt Marine 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 -- .030in.) Electrical Magneto Generator Output 25A / 350W @ 3000 RPM Battery 12 Volts / 19A Fuses 2A -- NGI Gauge/ 15A -- Battery / 15A -- IgnitionSystem/ 15A -- FuelPump 30A -- Alternator / 15A x 3 -- MainRelay 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) .... Dry Weight: 660 lbs. (301 kg) Category: Midsize .. Riders: 1 to 3 .... 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. The Two Star label identifies engines that meet the California Air Resources Board (CARB) 2004 exhaust emission 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 The emission 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 -- .032in.) ADVERTISED HORSEPOWER 112 kW (150HP) ENGINE DISPLACEMENT 750cc

GENERAL INFORMATION 1.9 2004 Four Stroke PWC Service Manual 2004 MSX 150 Model Number W045305CA / CB / CC / CD (W045305IA / IB / IC / ID) Engine Platform Polaris Libertyt Marine 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 -- .030in.) Electrical Magneto Generator Output 25A / 350W @ 3000 RPM Battery 12 Volts / 19A Fuses 2A -- NGI Gauge/ 15A -- Battery / 15A -- IgnitionSystem/ 15A -- FuelPump 30A -- Alternator / 15A x 3 -- MainRelay 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)

2003-2004 Polaris MSX110/ MSX150 Personal Watercraft Service Manual

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