2003-2004 POLARIS MSX 140 PERSONAL WATERCRAFT Repair Manual

2003 MSX 140 PERSONAL WATERCRAFT SERVICE MANUAL Foreword This manual is designed primarily for use by Polaris Personal Watercraft service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. The technician should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary impor- tance. This manual includes procedures for disassembly and reassembly, inspection, maintenance, component identification and unit repair, along with service specifications for the 2003 MSX 140 Personal Watercraft. A table of contents is placed at the beginning of each chapter to aid the user in locating specific areas of information. The alphabetic index at the end of the manual will help the user find specific information quickly. Care is taken to ensure that all information in this manual was technically correct at the time of publication. How- ever, all materials and specifications are subject to change without notice. Comments or suggestions about this manual may be directed to: Engineering Services, Technical Writer, Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340. 2003 MSX 140 Personal Watercraft Service Manual (PN 9918121) Copyright 2003 Polaris Sales Inc., Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! DANGER Failure to follow DANGER instructions will result in severe injury or death to the operator, passenger, bystander or person inspecting or servicing the watercraft. WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator, passenger, bystander or person inspecting or servicing the watercraft. CAUTION: A CAUTION indicates special precautions that must be taken to avoid minor personal injury, or watercraft or property damage. NOTE: A NOTE provides key information to clarify instructions. Polaris acknowledges the following products mentioned in this manual: Loctite, Registered Trademark of the Loctite Corporation FLEXLOC, Registered Trademark of SPS Technologies MityVac, Registered Trademark of Neward Enterprises Torx, Trademark of Textron Teflon, Trademark of DuPont Alemite, Trademark of Alemite Corporation FICHT, Registered trademark of BMC Inc. NOTE: All attempts were made to provide the most current information available at the time of printing. Polaris reserves the right to change specifications at any time without incurring obligations. The information contained within this service manual is protected by U.S. and international copyright laws, and is the property of Polaris Industries Inc.

Chapter 1 General Information ............. Chapter 2 Maintenance ............. Chapter 3 Engine / Cooling ............. Chapter 4 Fuel Injection System ............. Chapter 5 Final Drive / Propulsion ............. Chapter 6 Hull / Control Systems ............. Chapter 7 Electrical Systems .............

1 2003 PWC Identification Numbers 1.1 .................................. 2003 Publication / Service Material Part Numbers 1.2 ................... MSX 140 Required Service Tools 1.3 .................................. 2003 MSX 140 General Specifications 1.4 -- 1.5 .............................. MSX 140 Emissions Certification / Decal 1.4 ............................ PWC Service Guidelines / Safety Warnings 1.6 .......................... Standard Torque Specifications 1.7 .................................... Decimal Equivalent Chart 1.8 ......................................... Conversion Chart 1.9 ................................................ Tap Drill Sizes 1.10 ...................................................

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 CERTIFICATION LABEL ENGINE I.D. NUMBER FLYWHEEL COVER General Information 1.1 2003 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: 2 = 2002; 3 = 2003; etc.

General Information 1.2 2003 PWC Publication Part Numbers Model Model Number Owner’s Manual Parts Book Microfiche MSX 140 W035303CA / B 9918124 9918106 9918107 S D = 49 State Domestic (No CARB Exemption). S C = 50 State Domestic (CARB Exemption). S A or B = Color Option. S I = International Watercraft Service Manual Part Numbers Book Part Number 2003 Freedom, Virage, Virage i, Genesis 9918112 2003 MSX 140 9918121 2003 MSX Four Strokes 9918569 2003 PWC Wallcharts 9918115 2003 PWC Flat Rate Manual 9918114 2003 Octane Service Manual Update 9918113 2002 All Models 9917370 2002 PWC Wallcharts 9917372 2002 PWC Flat Rate Manual 9917371 Watercraft Service Video Part Numbers Video Part Number Introduction to FICHT Fuel Injection 9915680 FICHT Diagnostics 9915891 PWC Jet Pump Service 9915819 Generation III Ignition Troubleshooting 9917441

General Information 1.3 MSX 140 Required Service Tools Tool Part Number (Must Order From Polaris Tool Vendor) Piston Support Block 2870390 C--Clip Installation Tool 2870773 Piston Pin Puller (800 / 1200cc Engines) PU--45255 Piston Pin Puller Adapter (800 / 1200cc Engines) PU--45248 EMM Laptop Communication Cable 2872454 Deutsch--to--Packard Comm. Adapter PW--45776 Polaris FICHT Diagnostic Software All years and all DIt models. 2874492 EMM Service Power Connector 2872456 TPS Jumper Tool 2872603 Bump Stop Tool 2872604 Fuel Injector Jumper 2872623 Impeller Removal Tool 2871036 Heavy Duty Flywheel Puller 2871043 Fuel Pump Ring Spanner Wrench 2872621 Driveshaft Removal / Installation Tool PW--46593 Driveshaft Alignment Coupler Tool PW--46592 Pump Alignment Tool 2871343 Crankshaft Truing Stand 2870569 Ducati Ignition Test Probes 2201209 Timing Light 2870630 Battery Hydrometer 2870836 Strap Wrench PU--45419 Fluke 77 Digital Multimeter PV--43568

2003 MSX 140 W035303CA or B Length: 126.0 in. (320 cm) .... Width: 48.3 in. (122.6 cm) ..... Height: 42.5 in. (108.0 cm) ..... Draft: N/A ...... Dry Weight: 665 lbs. (303 kg) . Category: Mid--Size .. Riders: 1 to 3 ..... Fuel Capacity:17.8 US Gal. (67.4L) Oil Capacity: 6.0 US Qt. (5.68L) Emission Certification: One Star (Low Emission) General Information 1.4 2003 Polaris PWC Emission Certification The engines in all 2003 MSX 140 Personal Watercraft are certified as One--Star, Low Emission engines. The one--star label identifies engines that meet the California Air Resources Board (CARB) 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-- stroke 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. MSX 140 Emission Decal

General Information 1.5 2003 MSX 140 Model Number W035303CA / B Engine Platform Polaris Libertyt Marine High Output 1200 DIt Engine Model Number W12HO--DFI--01A or B Engine Displacement 1192cc Number of Cylinders 3 Cylinder Lining Material Nicasil Bore & Stroke (mm) 85x70 Compression Ratio (Effective) (6.5:1) Cooling System Water Cooled / Thermostat Pop--Off, self--draining, Direct From Propulsion. Thermostat Opening Temperature 143 F (62 C) Overheat Warning S.L.O.W. (Warning Light, RPM Limit) Induction Type Case Reed Lubrication Oil Injected Oil Requirements Polaris TC--W3 RPM Limiter 7200 RPM Exhaust System Tuned Pipe Sound Reduction PLANETt Fuel Management System Fuel Delivery (3) Injectors (DIt) Fuel Requirement 87 Non--Oxygenated / 89 Oxygenated Idle Speed (In Water) 1150 50 RPM Electrical Ignition System EMM (Engine Management Module) Magneto Generator Output 12A / 160 Watts @ 4500 RPM Spark Plug NGK PZFR6H Spark Plug Gap .028 -- .032(.7 -- .8mm) Timing Degrees BTDC Controlled By EMM Battery 12 Volts / 19 Amps Fuses 15A Battery Fuse / 15A Fuel Pump Fuse / 2A MSX Gauge Fuse 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 Spider Coupler Minimum Depth For Operation 2 ft. (60cm.) Impeller Type NuJet 602 / Progressive Pitch, Radial Blade Impeller Diameter 5.8 in. (148mm) Reverse System Manual w/RPM limiter @3500 RPM. Hull / Body Hull Design Modified--V, Progressive Dihedral Stepped Hull Material FRC (Fiberglass Reinforced Composite) Top Deck Material FRC (Fiberglass Reinforced Composite)

2003-2004 POLARIS MSX 140 PERSONAL WATERCRAFT Repair Manual

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