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2004 Polaris MSX110, MSX150 PWC Original Service Manual

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Number of pages: 241
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Original 2004 Polaris MSX110 MSX150 Personal Watercraft service manual

This is a complete Service Manual in English for the Polaris MXS 110 and MSX 150 Personal Watercraft.
This is the same manual that dealers and professional mechanics use to repair your watercraft.

Illustrated in color, service manual includes high resolution images, detailed diagrams and complete description of the procedures and all aspects of repair and maintenance.

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Full list of manual chapters:

TABLE OF CONTENTS
CHAPTER 1-GENERAL INFORMATION
    SERVICE GUIDELINES/SAFETY WARNINGS
    MSX 110 GENERAL INFORMATION
    MSX 150 GENERAL INFORMATION
    STANDARD TORQUE SPECIFICATIONS
    CONVERSION CHART
    TAP DRILL SIZES
    SERVICE TOOLS
CHAPTER 2-MAINTENANCE
    PERIODIC MAINTENANCE TABLE
    SAFETY WARNINGS
    FLUSH KIT
    SERVICE PRODUCTS
    STEERING/REVERSE SYSTEM LUBRICATION
    STEERING/POST REMOVAL/ASSEMBLY
    STEERING/REVERSE CABLE ADJUSTMENT
    E.S.P. FUNCTION TESTING
    VALVE CLEARANCE ADJUSTMENT PROCEDURE
    ENGINE OIL LEVEL CHECK
    OIL CHANGE PROCEDURE
    ENGINE COOLANT INSPECTION/CHANGE PROCEDURE
    COOLING SYSTEM PRESSURE TEST
    ENGINE COMPRESSION/FUEL SYSTEM PRESSURE TESTS
    BATTERY SAFETY AND MAINTENANCE
    SPARK PLUG
    FUSES
    EXHAUST COOLING INJECTOR MAINTENANCE
    THROTTLE CABLE ADJUSTMENT
    GASOLINE SAFETY/FUEL SYSTEM MAINTENANCE/FUEL FILTER
    BILGE SYSTEM/SIPHONS
    PROPULSION SYSTEM MAINTENANCE
    HNDLEBAR MAINTENANCE/INTAKE MANIFOLD RE-TORQUE PROCEDURE
    DRAIN PLUGS
    OFF-SEASON STORAGE
CHAPTER 3-ENGINE REMOVAL/INSTALLATION
    ENGINE SUBASSEMBLY REMOVAL
    ENGINE MOUNT REMOVAL
    ENGINE INSTALLATION
CHAPTER 4-ENGINE DISASSEMBLY/ASSEMBLY
    ENGINE SPECIFICATIONS
    ENGINE FASTENER TORQUE SPECIFICATIONS
    SERVICE TOOLS
    OIL FILTER ASSEMBLY
    VALVE COVER ASSEMBLY
    DRY SUMP OIL PUMP ASSEMBLY
    THERMOSTAT HOUSING
    HIGH PRESSURE OIL PUMP ASSEMBLY
    CHAIN GUIDE AND CHAIN TENSIONER ASSEMBLY
    ENGINE CASE/CYLINDER HEAD ASSEMBLY
    PISTON ASSEMBLY
    VAVLE ASSEMBLY
    BALANCE PLATE/PTO ASSEMBLY
    CRANKSHAFT/BALANCE SHAFT ASSEMBLY
    ENGINE DISASSEMBLY
    ENGINE ASSEMBLY
    TIMING CHAIN INSTALLATION/TIMING PROCEDURE
    FRESHWATER/INTERNAL ENGINE COOLING SYSTEMS
    THERMOSTAT, WATER PUMP and SEAL REMOVAL/INSTALLATION
    FRESHWATER COOLING CIRCUIT ILLUSTRATIONS
    OIL LUBRICATION SYSTEM
    CRANKCASE VENTILATION SYSTEM
    OIL PUMP(S) REMOVAL AND INSTALLATION
    OIL LUBRICATION ILLUSTRATIONS
CHAPTER 5-FUEL INJECTION/IGNITION/EXHAUST SYSTEMS
    BOSCH ENGINE MANAGEMENT SYSTEM OVERVIEW
    ENGINE MANAGEMENT SYSTEM SPECIFICATIONS
    AIR INLET HOSE ROUTINGS
    FUEL HOSE ROUTINGS
    VENT HOSE ROUTING
    FUEL TANK ASSEMBLY ILLUSTRATION
    FUEL SUPPLY/VENT HOSE ILLUSTRATION
    FUEL RAIL/INJECTOR ILLUSTRATION
    ELECTRONIC THROTTLE BODY ILLUSTRATIONS
    SPARK PLUG/IGNITION COIL ILLUSTRATION
    ECU MOUNTING ILLUSTRATION
    ECU WIRING HARNESS CONNECTOR ILLUSTRATIONS
    ENGINE MANAGEMENT SENSOR CIRCUIT DRAWINGS W/TROUBLE CODES
    ECU CONNECTORS
    ECU TROUBLE CODES
    ELECTRONIC THROTTLE BODY/PPU TROUBLESHOOTING
    EXHAUST SYSTEM ILLUSTRATION
    TURBOCHARGER/WASTEGATE OVERVIEW
    CHARGE AIR COOLER OVERVIEW/TURBOCHARGER TROUBLESHOOTING
    RPM LIMITING MODES
    TROUBLESHOOTING: ENGINE WILL NOT TURNOVER
    TROUBLESHOOTING: ENGINE TURNS OVER; WILL NOT START
    TROUBLESHOOTING: ENGINE STALLS; WILL RE-START
    TROUBLESHOOTING: ENGINE STALLS: WILL NOT RE-START
    TROUBLESHOOTING: ENGINE LACKS PERFORMANCE, RPM LIMITS
    TROUBLESHOOTING: GENERAL
CHAPTER 6-PROPULSION
    VENTILATION/CAVITATION TROUBLESHOOTING
    PUMP ASSEMBLY ILLUSTRATION
    STATOR ASSEMBLY ILLUSTRATION
    DRIVESHAFT ASSEMBLY ILLUSTRATION
    PUMP INDUCTION ASSEMBLY ILLUSTRATION
    PUMP REMOVAL AND ASSEMBLY
    BEARING CARRIER REMOVAL AND INSTALLATION
    DRIVESHAFT SHIM PROCEDURE
    DRIVELINE INSPECTIONS
    STATOR DISASSEMBLY ANS ASSEMBLY
    DRIVESHAFT ALIGNMENT PROCEDURE
    SACRIFICIAL ANODE
    INTAKE SCOOP/RIDE PLATE REMOVAL AND INSTALLATION
CHAPTER 7-HULL AND BODY
    HULL SPECIFICATIONS/PAINT CODES
    FASTENER GUIDE
    STEERING/REVERSE CABLE ROUTING
    SIPHON HOSE ROUTING
    HULL ASSEMBLY ILLUSTRATION
    COMPARTMENT DOOR ASSEMBLY
    SHROUD AND STORAGE ASSEMBLIES
    SEAT ASSEMBLY
    STEERING CONTROL ASSEMBLY
    PPU ASSEMBLY
    REVERSE SYSTEM ASSEMBLY
    HANDLEBAR/ STEERING POST REMOVAL
    STEERING CABLE REMOVAL AND INSTALLATION
    STEERING/REVERSE CABLE ADJUSTMENT
    TOP DECK/HULL REPAIR
CHAPTER 8-ELECTRICAL SYSTEMS
    CHASSIS ELECTRICAL AND SENSOR SPECIFICATIONS
    BATTERY AND CHARGING SYSTEM SPECIFICATIONS
    NGI GAUGE
    NGI GAUGE WIRING ILLUSTRATION/MIL INDICATORS
    BATTERY TESTING/MAINTENANCE
    ALTERNATOR ASSEMBLY
    CHARGING SYSTEM ILLUSTRATION
    START/STOP ELECTRICAL SYSTEM ILLUSTRATION
    SYSTEM INTERFACE BOX OVERVIEW
    STARTER MOTOR ILLUSTRATION
    STARTER MOTOR DISASSEMBLY/ASSEMBLY/TROUBLESHOOTING
WIRING DIAGRAMS
INDEX
    A-E
    F-P
    R-W

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