msx 110

Personal Watercraft Service Manual

msx 150

Four Stroke Personal Watercraft Service Manual

FOUR STROKE

Part Number 9919062

Printed in U.S.A
 Table of Contents
General Information
Model Information / Safety Warnings / General Information 1
Maintenance
Periodic Maintenance Tables / Maintenance Procedures 2
Engine Removal and Installation
Specifications / Removal and Installation 3
Engine Disassembly, Inspection and Re--Assembly
Specifications / Components / Testing / Troubleshooting / Teardown 4
Fuel / Ignition / Exhaust Systems
Specifications / Components / Testing / Troubleshooting 5
Propulsion System
Specifications / Components / Teardown and Rebuilding / Inspection 6
Hull and Body Systems
Specifications / Components / Teardown and Rebuilding / Inspection 7
Electrical System
Specifications / NGI Gauge / System Interface Box / Starter Motor / Components 8
MSX 110 / 150 Service Manual
PWC Identification Numbers
2004 PWC Publication Part Numbers
General Information
1.1
1.2
1
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
 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.

P L E
1 2 3 4 5 6 7 8 9 10 11 12

Universal Sequential Serial Numbers Certification Model

Manufacture (Alphanumeric) Year Year
I.D.
Month Code: A = January; B = February; etc. Certification Model
Year Of Manufacture: 4 = 2004 Month Decade

HIN (Boarding Platform)

HIN (Inside Engine Compartment)

EMISSIONS DECAL

ENGINE SERIAL NUMBER DECAL

2004 Four Stroke PWC Service Manual 1.3

 GENERAL INFORMATION

2004 PWC Publication Part Numbers

Owner’s Assembly
Model Model Number Parts Book Microfiche
Manual Instructions
MSX 110 (A) W045304CA
MSX 110 (A)
W045304IA
International
MSX 110 (B) W045304CB
MSX 110 (B) 9919055 9919056
W045304IB
International
MSX 110 (C) W045304CC
MSX 110 (C)
W045304IC
International
MSX 150 (A) W045305CA
MSX 150 (A) 9918972 9919173
W045305IA
International
MSX 150 (B) W045305CB
MSX 150 (B)
W045305IB
International
9919057 9919058
MSX 150 (C) W045305CC
MSX 150
W045305IC
International
MSX 150 (D) W045305CD
MSX 150 (D)
W045305ID
International
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

1.4 2004 Four Stroke PWC Service Manual

 GENERAL INFORMATION

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 compo-
nents.
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 impel-
ler 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 gaso-
line. 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 Four Stroke PWC Service Manual 1.5

 GENERAL INFORMATION

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 Low Emission

MSX 110 W045304CB Sarasota Yellow

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. 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 -- .032 in.)
ADVERTISED HORSEPOWER 82 kW (110HP)
ENGINE DISPLACEMENT 750cc

1.6 2004 Four Stroke PWC Service Manual

 GENERAL INFORMATION

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 -- .030 in.)

Electrical
Magneto Generator Output 25A / 350W @ 3000 RPM
Battery 12 Volts / 19A
Fuses 2A -- NGI Gauge / 15A -- Battery / 15A -- Ignition System / 15A -- Fuel Pump
30A -- Alternator / 15A x 3 -- Main Relay
Starting Electric Motor -- One Button Start / One Button Stop

Propulsion
Jet Pump Type Dominator 2 Single Stage Axial Flow w/Six Vane Stainless Steel Stator
Impeller Rotation Counter Clockwise (From Aft)
Coupling Type Three piece coupler
Minimum Depth For Operation 2 ft. (60cm.)
Impeller Type TBA
Impeller Diameter 5.8 in. (148mm)
Reverse System Manual w/3400 RPM Limit

Hull / Body
Hull Design Modified Full V
Hull Material FRC (Fiberglass Reinforced Composite)
Top Deck Material FRC (Fiberglass Reinforced Composite)

2004 Four Stroke PWC Service Manual 1.7

 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. (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

MSX 150 W045305CD Stealth Black

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 emis-
sion standards. Engines meeting these standards have 20% lower emissions than One--Star -- Low Emission
engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines.
Emission Control Information Decals
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 -- .032 in.)
ADVERTISED HORSEPOWER 112 kW (150HP)
ENGINE DISPLACEMENT 750cc

1.8 2004 Four Stroke PWC Service Manual

 GENERAL INFORMATION

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 -- .030 in.)

Electrical
Magneto Generator Output 25A / 350W @ 3000 RPM
Battery 12 Volts / 19A
Fuses 2A -- NGI Gauge / 15A -- Battery / 15A -- Ignition System / 15A -- Fuel Pump
30A -- Alternator / 15A x 3 -- Main Relay
Starting Electric Motor -- One Button Start / One Button Stop

Propulsion
Jet Pump Type Dominator 2 Single Stage Axial Flow w/Six Vane Stainless Steel Stator
Impeller Rotation Counter Clockwise (From Aft)
Coupling Type Three piece coupler
Minimum Depth For Operation 2 ft. (60cm.)
Impeller Type 12 -- 18 3 Blade
Impeller Diameter 5.8 in. (148mm)
Reverse System Manual w/3400 RPM Limit

Hull / Body
Hull Design Modified Full V
Hull Material FRC (Fiberglass Reinforced Composite)
Top Deck Material FRC (Fiberglass Reinforced Composite)

2004 Four Stroke PWC Service Manual 1.9

 GENERAL INFORMATION

Standard Torque Specifications

The following torque specifications are to be used as a general guideline. Use standard torque values for the
appropriate size fastener when torque values are not specified. Always consult the specific manual section
for torque values of fasteners and use of locking agent. When fastener replacement is required, use only
genuine Polaris fasteners.

RECOMMENDED TORQUE SPECIFICATION

STAINLESS STEEL FASTENERS (SAE)
Bolt Size Threads/Inch Torque
8 18 & 32 28 in. lbs.
10 24 & 32 40 in. lbs.
1/4 20 & 28 8 ft. lbs.
5/16 18 & 24 14 ft. lbs.
3/8 16 25 ft. lbs.
3/8 24 28 ft. lbs.
7/16 14 40 ft. lbs.
1/2 13 58 ft. lbs.
1/2 20 70 ft. lbs.

RECOMMENDED TORQUE SPECIFICATION

STAINLESS STEEL FASTENERS (METRIC)
Bolt Size Torque
5mm 45-52 in. lbs.
6mm 66-78 in. lbs.
8mm 13-16 ft. lbs.
10mm 26-30 ft. lbs.
12mm 40-44 ft. lbs.

1.10 2004 Four Stroke PWC Service Manual

 GENERAL INFORMATION

Decimal Equivalent Chart

1/64 . . . . . . . . . . . . . . . . . . . . . . . . . . .0156
1/32 . . . . . . . . . . . . . . . . . . . . . .0312 . . . . . . . . . . . . . . . . . . 1 mm = .0394″
3/64 . . . . . . . . . . . . . . . . . . . . . . . . . . .0469
1/16 . . . . . . . . . . . . . . . .0625
5/64 . . . . . . . . . . . . . . . . . . . . . . . . . . .0781 . . . . . . . . . . . . . . . . . . 2 mm = .0787″
3/32 . . . . . . . . . . . . . . . . . . . . . .0938
7/64 . . . . . . . . . . . . . . . . . . . . . . . . . .1094 . . . . . . . . . . . . . . . . . . 3 mm = .1181″
1/8 . . . . . . . . . . . .1250
9/64 . . . . . . . . . . . . . . . . . . . . . . . . . . .1406
5/32 . . . . . . . . . . . . . . . . . . . . . .1563 . . . . . . . . . . . . . . . . . . 4 mm = .1575″
11/64 . . . . . . . . . . . . . . . . . . . . . . . . . .1719
3/16 . . . . . . . . . . . . . . . .1875 . . . . . . . . . . . . . . . . . . 5 mm = .1969″
13/64 . . . . . . . . . . . . . . . . . . . . . . . . . .2031
7/32 . . . . . . . . . . . . . . . . . . . . . .2188
15/64 . . . . . . . . . . . . . . . . . . . . . . . . . .2344 . . . . . . . . . . . . . . . . . . 6 mm = .2362″
1/4 . . . . . . . . . . . .25
17/64 . . . . . . . . . . . . . . . . . . . . . . . . . .2656 . . . . . . . . . . . . . . . . . . 7 mm = .2756″
9/32 . . . . . . . . . . . . . . . . . . . . . .2813
19/64 . . . . . . . . . . . . . . . . . . . . . . . . . .2969
5/16 . . . . . . . . . . . . . . . .3125 . . . . . . . . . . . . . . . . . . 8 mm = .3150″
21/64 . . . . . . . . . . . . . . . . . . . . . . . . . .3281
11/32 . . . . . . . . . . . . . . . . . . . . .3438 . . . . . . . . . . . . . . . . . . 9 mm = .3543″
23/64 . . . . . . . . . . . . . . . . . . . . . . . . . .3594
3/8 . . . . . . . . . . . .375
25/64 . . . . . . . . . . . . . . . . . . . . . . . . . .3906 . . . . . . . . . . . . . . . . . . 10 mm = .3937″
13/32 . . . . . . . . . . . . . . . . . . . . .4063
27/64 . . . . . . . . . . . . . . . . . . . . . . . . . .4219 . . . . . . . . . . . . . . . . . . 11 mm = .4331″
7/16 . . . . . . . . . . . . . . . .4375
29/64 . . . . . . . . . . . . . . . . . . . . . . . . . .4531
15/32 . . . . . . . . . . . . . . . . . . . . .4688 . . . . . . . . . . . . . . . . . . 12 mm = .4724″
31/64 . . . . . . . . . . . . . . . . . . . . . . . . . .4844
1/2 . . . . . . . . . . . .5 . . . . . . . . . . . . . . . . . . . . . 13 mm = .5118
33/64 . . . . . . . . . . . . . . . . . . . . . . . . . .5156
17/32 . . . . . . . . . . . . . . . . . . . . .5313
35/64 . . . . . . . . . . . . . . . . . . . . . . . . . .5469 . . . . . . . . . . . . . . . . . . 14 mm = .5512″
9/16 . . . . . . . . . . . . . . . .5625
37/64 . . . . . . . . . . . . . . . . . . . . . . . . . .5781 . . . . . . . . . . . . . . . . . . 15 mm = .5906″
19/32 . . . . . . . . . . . . . . . . . . . . .5938
39/64 . . . . . . . . . . . . . . . . . . . . . . . . . .6094
5/8 . . . . . . . . . . . .625 . . . . . . . . . . . . . . . . . . . 16 mm = .6299″
41/64 . . . . . . . . . . . . . . . . . . . . . . . . . .6406
21/32 . . . . . . . . . . . . . . . . . . . . .6563 . . . . . . . . . . . . . . . . . . 17 mm = .6693″
43/64 . . . . . . . . . . . . . . . . . . . . . . . . . .6719
11/16 . . . . . . . . . . . . . . .6875
45/64 . . . . . . . . . . . . . . . . . . . . . . . . . .7031 . . . . . . . . . . . . . . . . . . 18 mm = .7087″
23/32 . . . . . . . . . . . . . . . . . . . . .7188
47/64 . . . . . . . . . . . . . . . . . . . . . . . . . .7344 . . . . . . . . . . . . . . . . . . 19 mm = .7480″
3/4 . . . . . . . . . . . .75
49/64 . . . . . . . . . . . . . . . . . . . . . . . . . .7656
25/32 . . . . . . . . . . . . . . . . . . . . .7813 . . . . . . . . . . . . . . . . . . 20 mm = .7874″
51/64 . . . . . . . . . . . . . . . . . . . . . . . . . .7969
13/16 . . . . . . . . . . . . . . .8125 . . . . . . . . . . . . . . . . . . 21 mm = .8268″
53/64 . . . . . . . . . . . . . . . . . . . . . . . . . .8281
27/32 . . . . . . . . . . . . . . . . . . . . .8438
55/64 . . . . . . . . . . . . . . . . . . . . . . . . . .8594 . . . . . . . . . . . . . . . . . . 22 mm = .8661″
7/8 . . . . . . . . . . . .875
57/64 . . . . . . . . . . . . . . . . . . . . . . . . . .8906 . . . . . . . . . . . . . . . . . . 23 mm = .9055″
29/32 . . . . . . . . . . . . . . . . . . . . .9063
59/64 . . . . . . . . . . . . . . . . . . . . . . . . . .9219
15/16 . . . . . . . . . . . . . . .9375 . . . . . . . . . . . . . . . . . . 24 mm = .9449″
61/64 . . . . . . . . . . . . . . . . . . . . . . . . . .9531
31/32 . . . . . . . . . . . . . . . . . . . . .9688 . . . . . . . . . . . . . . . . . . 25 mm = .9843
63/64 . . . . . . . . . . . . . . . . . . . . . . . . . .9844
1 ............ 1.0

2004 Four Stroke PWC Service Manual 1.11

 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
Nm x .7376 = ft. lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 = in. lbs.
kg-m x 10 = Nm
in. x 25.4 =mm
mm x .03937 = in.
in. x 2.54 = cm
mile (mi.) x 1.6 = km
km x .6214 = mile (mi.)
Ounces (oz.) x 28.35 = Grams (g)
Grams (g) x 0.035 = Ounces (oz.)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (cu in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu in)
Imperial pints (Imp pt) x 0.568 = Liters (l)
Liters (l) x 1.76 = Imperial pints (Imp pt)
Imperial quarts (Imp qt.) x 1.137 = Liters (l)
Liters (l) x 0.88 = Imperial quarts (Imp qt.)
Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.)
US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.)
US quarts (US qt.) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt.)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

°C to °F: 9 (°C + 40) ÷ 5 -- 40 = °F

°F to °C: 5 (°F + 40) ÷ 9 -- 40 = °C

1.12 2004 Four Stroke PWC Service Manual

 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 53 1/2-20 29/64
#1-72 53 9/16-12 31/64
#2-56 51 9/16-18 33/64
#2-64 50 5/8-11 17/32
#3-48 5/64
5/8-18 37/64
#3-56 45
#4-40 43 3/4-10 21/32
#4-48 42 3/4-16 11/16
#5-40 38 7/8-9 49/64
#5-44 37 7/8-14 13/16
#6-32 36 1-8 7/8
#6-40 33 1-12 59/64
#8-32 29 1 1/8-7 63/64
#8-36 29 1 1/8-12 1 3/64
#10-24 24 1 1/4-7 1 7/64
#10-32 21
1 1/4-12 1 11/64
#12-24 17
#12-28 4.6mm 1 1/2-6 1 11/32
1/4-20 7 1 1/2-12 1 27/64
1/4-28 3 1 3/4-5 1 9/16
5/16-18 F 1 3/4-12 1 43/64
5/16-24 I 2-4 1/2 1 25/32
3/8-16 O 2-12 1 59/64
3/8-24 Q 2 1/4-4 1/2 2 1/32
7/16-14 U 2 1/2-4 2 1/4
7/16-20 25/64 2 3/4-4 2 1/2
3-4 2 3/4

Metric Tap Drill Sizes

Tap Size Drill Size Decimal Equivalent Nearest Fraction
3 x .50 #39 0.0995 3/32
3 x .60 3/32 0.0937 3/32
4 x .70 #30 0.1285 1/8
4 x .75 1/8 0.125 1/8
5 x .80 #19 0.166 11/64
5 x .90 #20 0.161 5/32
6 x 1.00 #9 0.196 13/64
7 x 1.00 16/64 0.234 15/64
8 x 1.00 J 0.277 9/32
8 x 1.25 17/64 0.265 17/64
9 x 1.00 5/16 0.3125 5/16
9 x 1.25 5/16 0.3125 5/16
10 x 1.25 11/32 0.3437 11/32
10 x 1.50 R 0.339 11/32
11 x 1.50 3/8 0.375 3/8
12 x 1.50 13/32 0.406 13/32
12 x 1.75 13/32 0.406 13/32

2004 Four Stroke PWC Service Manual 1.13

 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
PW-- 46982 - REQUIRED TOOL
USED TO COMPRESS VALVE SPRINGS WITH ENGINE EITHER
GEAR REMOVAL TOOL
INSTALLED OR REMOVED FROM WATERCRAFT HULL.
USED TO REMOVE BALANCE SHAFT GEAR WHEN USED WITH
PW--46989 GEAR REMOVER BOLT.

PW-- 46983 - REQUIRED TOOL

PISTON RING COMPRESSOR PW-- 47077 - REQUIRED TOOL
USED TO INSTALL PISTONS INTO ENGINE BLOCK CAMSHAFT ALIGNMENT TOOL
INSTALLS INTO CAMSHAFT TO LOCK INTO BDC POSITION.

PW-- 47079 - REQUIRED TOOL

TIMING CHAIN INSTALLATION TOOL
ROUTES TIMING CHAIN THROUGH ENGINE CRANKCASE DUR-
ING INSTALLATION.

PW-- 46984 - REQUIRED TOOL

ENGINE STAND ADAPTER PLATE
PW-- 47054
ENGINE STAND ADAPTER SLEEVE
ATTACHES TO REAR OF ENGINE BLOCK. ALLOWS TECHNI-
CIAN TO ROTATE ENGINE DURING DISASSEMBLY AND RE--
ASSEMBLY.
PW-- 47108 - REQUIRED TOOL
ADAPTER SLEEVE EXPANDS MOUNTING OPTIONS WHEN TIMING CHAIN WEDGE AND HOOK TOOL
USING DIFFERENT ENGINE STANDS.
USED DURING TIMING CHAIN INSTALLATION

1.14 2004 Four Stroke PWC Service Manual

 GENERAL INFORMATION

Service Tools

PW-- 46985 - REQUIRED TOOL

PW-- 47053 - OPTIONAL TOOL TIMING CHAIN LINK REMOVAL / INSTALLATION TOOL
ADAPTER PLATE TABLE MOUNT USED IN REMOVING AND RE--INSTALLING TIMING CHAIN.
USED TO MOUNT ENGINE STAND ADAPTER PLATE TO WORK-
BENCH.

PU-- 46219 - OPTIONAL TOOL

MANUAL OIL PUMP / CONTAINER
USED TO REMOVE OIL FROM OIL TANK

PW-- 43070 - OPTIONAL TOOL

ROLLING ENGINE STAND
ACCEPTS PW-- 46984 ENGINE STAND ADAPTER PLATE

PU-- 47102 - REQUIRED TOOL

MSX 110 / 150 COMM. CABLE ADAPTER
CONNECTS LAPTOP CABLE TO ENGINE WIRING
HARNESS.

DIGITAL WRENCH DIAGNOSTIC SOFTWARE

REQUIRED TOOLS
COMPLETE KIT: PU-- 47063
UPDATE SOFTWARE ONLY: PU-- 47052

2004 Four Stroke PWC Service Manual 1.15

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

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. When checked (n) the procedure must be completed after watercraft operation.

n = Requires basic mechanical and/or electrical knowledge.

J = Requires advanced mechanical and/or electrical knowledge.
R = REPLACE
* = Every 4 years

BREAK IN PERIOD REGULAR INTERVAL END

(Hours) (Hours) PRE SALT
ITEM PROCEDURE OF
RIDE WATER
10 -- 12 25 50 100 YEAR

Spark Plugs Adjust Gap / Clean n nR n

Flame Arrestor Inspect n n
Engine Oil Inspect Level n n n nR
Engine Oil / Filter Replace nR nR nR
Engine Coolant Inspect n n n n
Engine Coolant Replace J*
Compression Inspect J J
Valve Clearance Inspect / Adjust J J
Cooling / Oil / Air
Inspect n n n n
Hoses
Engine Mounts Inspect J J
Engine Fasteners Inspect J J
Intake Manifold Adjust Torque n n
Chassis Fasteners Inspect J J
Freshwater Loop Flush n n n n
Exhaust System Inspect n n n
Throttle Cable Inspect / Adjust / Lubricate n n n n
Reverse Cable Inspect / Adjust / Lubricate n n n n
Steering Cable Inspect / Adjust / Lubricate n n n
Handlebars Inspect / Adjust n n n
ESP Function Inspect n n
Impeller / Pump Inspect / Flush n n n
Sacrificial Anode Inspect n n n n
Drive Couplers Inspect n n
Bilge Area / Drains Inspect / Clean / Flush n n n n n
Battery / Vent Inspect n n n
Electrical Connec-
Inspect n n
tions
Fuel System Inspect J J n
Fuel / Vent Hoses Inspect n n n
Fuel Tank Inspect J n
Fuel Filter Replace J
Fire Extinguisher Inspect n n
Start / Stop Switch Inspect n n

2004 Four Stroke PWC Service Manual 2.1

 MAINTENANCE

Maintenance Notes / Safety Warnings

Gasoline is extremely flammable and explosive under certain conditions.

S Always stop the engine and refuel outdoors or in a well ventilated area.
S Do not smoke or allow open flames or sparks in or near the area where refueling is
performed or where gasoline is stored.
S Do not overfill the tank. Do not fill the tank neck above the fuel tank insert. Leave air space
to allow for fuel expansion.
S If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.
Never try to syphon gasoline using mouth suction.
S If you spill gasoline on your skin or clothing, immediately wash it off with soap and water
and change clothing.
S Never start the engine or let it run in an enclosed area. Engine exhaust fumes are
poisonous and can cause loss of consciousness or death in a short time.

The engine exhaust from this

product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.

Improper repairs or service can create

unsafe conditions that may cause
severe personal injury or death.

The engine and exhaust components

on this product become very hot during
operation and remain so for a period of
time after the engine is stopped.

2.2 2004 Four Stroke PWC Service Manual

 MAINTENANCE

Maintenance -- Specific Tools

TOOL PART NUMBER
Compression Gauge PV--33223
Fuel Pressure Gauge PV--43506
Oil Pressure Gauge PV--43531
Feeler Gauge Commercially Available
Spark Plug Gap Gauge / Feeler Gauge Commercially Available
Fluke 77 Digital Multimeter PV--43568
Fluke Compatible Peak Voltage Tester PV--39991
PWC Four Stroke Flush Kit 2874833
Oil Pump and Containment System PW--46219
Valve Adjustment Tool PW--46991

Maintenance Procedures Fastener Torque Guide

SPECIFIED TORQUE
FASTENER
FOOT POUNDS NEWTON METERS SPECIAL
SPARK PLUG 20 27 AS
IGNITION COILS 7 10
OIL FILTER CAP 17 24
VALVE COVER 7 10
ENGINE MOUNT--TO--HULL 14 Loctitet 262
ENGINE STRAP--TO--ENGINE MOUNT 50 Loctitet 262
STEERING CABLE JAM NUTS 40 in.lbs. 4.5Nm
STEERING CABLE ADJUSTER CLAMP 8 11 Loctitet 242
REVERSE CABLE JAM NUTS 40 in.lbs. 4.5Nm
STEERING CLAMP 8 11 Loctitet 242
SACRIFICIAL ANODE 25 in. lbs. 2.8Nm
PTO DRIVE COUPLER HAND TIGHTEN

Flush Kit
A flush kit will allow the operator to clean the freshwater cooling circuit after riding in saltwater or for performing
routing maintenance procedures. The addition of a flush kit is highly recommended for performing maintenance
procedures such has changing the engine oil.
Polaris PWC Four Stroke Flush Kit PN: 2874833
1. Follow the instructions included within the kit and
install the flush kit in the FRESHWATER cooling
hose located between the water--to--water heat
exchanger and oil storage tank.
NOTE: Only allow the flow of water to the flush
kit after the engine has started, and always turn
off the flow of water before stopping the engine.

2004 Four Stroke PWC Service Manual 2.3

 MAINTENANCE

Maintenance -- Service Products

Polaris Synthetic Marine PS--4 Engine Oil 2874862 -- 12 (1 Quart) Case
2874863 -- 4 (1 Gallon) Case
2874864 -- 55 Gallon Drum
Oil Filter PN: 0451848
Polaris Environmentally Safe Engine Coolant (100% Propylene 2875063 -- 1 Gallon Container (100% Propylene Glycol)
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. / 4 Pack)
2871423 (14 oz. Tube)
Nyogel Di--Electric Grease 2871329
Champion Spark Plug RC7PYCB PN: 0451967
Fuel Filter 2520387 (10 Micron Filter)

2.4 2004 Four Stroke PWC Service Manual

 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. Generously lubricate reverse cable.

Polaris Premium Grease

PN 2871423

2004 Four Stroke PWC Service Manual 2.5

 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.
3. Loosen and remove the steering arm clamp retaining
bolt from the bottom of the steering post. Remove the
clamp, shim(s) and tapered bushing from the post.
4. Carefully pull the steering post assembly up and out of
the steering housing.
NOTE: The steering cable rod--end can remain connected
to the steering clamp. If the rod--end is removed, discard
the Nylok nut.
Steering Post Assembly
1. Apply lithium--based grease to the inside bore of the
upper tapered bushing and steering post. STRIKE PLATE JUST
CLEARS STOP BOLT
2. Insert the post assembly into the steering housing. WASHER

3. Push down on the handlebars. Verify the strike plate

just clears the stop bolt washer and cannot be turned
past the stop bolt.
4. If strike plate hits washer, remove post and install shim
between bushing and strike plate. Repeat step 3. If
plate continues to hit washer, install second and final
shim.
5. Apply lithium--based grease to the inside bore of the
lower tapered bushing and install into steering
housing.
6. The number of shims installed on the lower section of
the post is determined by the number installed on top.
The total number of shims used to install the entire
steering post assembly equals two. (If two shims are
installed on top, then zero shims are installed on the
bottom, etc.)
7. Align slot on steering arm clamp with cutout in post.
Push clamp up against shims while pushing down on
the handlebars. Torque bolt to 8 ft.lbs. (11 Nm).
8. Verify handlebars move without resistance from left to
right and that handlebars cannot be turned past the
steering stop bolt.
9. If steering cable rod--end was removed, reinstall on top ZERO, 1 OR 2 SHIMS
INSTALLED TO RE-
of clamp using a new nut. Torque nut to 8 ft.lbs. (11 MOVE UP AND DOWN
FREEPLAY
Nm)
10. Reconnect wiring harness and throttle cable. Verify
throttle cable freeplay is set to specifications outlined
in chapter two.
11. Reinstall the handlebar grab handle and cover
assembly.

2.6 2004 Four Stroke PWC Service Manual

 MAINTENANCE

Steering Cable Adjustment

1. Open front compartment door. Loosen and remove
adjuster block. Align handlebars with centerline of Straight Edge
watercraft. (Straight)
2. Place a straight edge across horizontal center line Nozzle
of steering nozzle or trim nozzle.
3. Measure distance from straight edge to hull on left Hull Hull
and right side. Be sure to measure at right angles to
the straight edge and at equal distances from the
x x
nozzle. The distance at (X) should be equal when
handlebars are straight.
4. Adjustments can be made at the adjuster block.
Turn block clockwise or counterclockwise until (X)
measurements equal.
Distance should be equal at (X)
5. Tighten adjuster block screws to specification.
Reverse Cable Adjustment
Under normal operation, the reverse cable should not
require adjustment. If the reverse linkage does not func-
tion properly, inspect the cable for damage. Inspect all
linkage, fasteners, brackets, and pivots for wear or dam- Reverse Cable Nut
age. When a new cable is installed the cable must be
adjusted.

1. Place reverse shift lever in reverse position.

2. Loosen cable adjuster nuts.
3. Verify that the gate is in its full down position and
locked.
4. Check gate locking by pulling up on gate when in
down position.
5. Move shift lever to forward position. Reverse gate
must be well above the water stream.
6. Tighten adjuster nuts securely.
7. Seal the cable threads and adjuster nuts with
marine grade silicone sealant (PN 8560054) and
tighten securely. Allow sealant to cure fully before
operating craft.

2004 Four Stroke PWC Service Manual 2.7

 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.
3. Using shop air, spin the paddle wheel located in the rear of the ride plate. Enough air must be directed at the
paddle wheel to generate a speed reading on the gauge above 15 MPH.
4. With the indicated vehicle speed above 15 MPH, quickly turn the handlebars either to the full left or full right
position.
When the procedure is performed, the engine idle should rise above 1400 -- 1500 RPM.

Valve Clearance Adjustment Procedure

NOTE: Always perform procedure when the engine is cold.
Adjusting the valve clearance can be accomplished while the engine is inside the engine compartment.
1. Remove the ignition coils, spark plugs, fuel injector
wiring harness, and cam phase sensor harness
connector from the valve cover.
2. Remove the valve cover from the engine.
3. Insert the lanyard into the stop switch. Rapidly tap the
start button to rotate the engine.
4. Rotate the engine until the MAG cylinder is at TDC --
COMPRESSION stroke.
NOTE: TDC -- COMPRESSION stroke is found when
the both cam lobes are pointed down, away from
the rocker arms, and the piston is at TDC.
5. Verify each rocker arm is loose and not engaged by
the camshaft. Photo A
6. Using a feeler gauge, measure the clearance at each
of the 4 valves between the installed shim and rocker
arm. Record each measurement. (Photo B)
7. If the measured clearance is within specification, no
adjustment is required.
8. If the measured clearance is out of specification, the
valve shim must be replaced with one that will satisfy
the clearance specifications.
VALVE CLEARANCE SPECIFICATION

INTAKE VALVE: .08 -- .15MM (.003 -- .006)

EXHAUST VALVE: .18 -- .25MM (.007 -- 0.10)

Photo B

2.8 2004 Four Stroke PWC Service Manual

 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.

10. Measure the original shim and determine the shim,

smaller or larger, that will satisfy the clearance
specification.
Available valve clearance shims.

Part Number Shim Thickness

(mm)
0451357 2.50
0451358 2.55
0451359 2.60
0451360 2.65
0451361 2.70
0451362 2.75
0451363 2.80
0451364 2.85
0451365 2.90
0451366 2.95
0451367 3.00
0452023 3.05
0451368 3.10
0451369 3.15
0451370 3.20
0451371 3.25
0451372 3.30
0451373 3.35
0451374 3.40
0451375 3.45
0451376 3.50
0451377 3.55
0451378 3.60
0451379 3.65
0451380 3.70

11. After performing the valve adjustment procedure on the MAG cylinder valves, rapidly tap the start button to
rotate the engine to TDC -- COMPRESSION stroke on the PTO cylinder.
12. Perform the valve adjustment procedure on the PTO cylinder valve train.
13. When completed, reinstall the valve cover. Tighten fasteners to 7 ft.lbs. (10 Nm).
14. Reinstall the phase sensor, ignition coil, and fuel injector wiring harness connectors.

2004 Four Stroke PWC Service Manual 2.9

 MAINTENANCE

Engine Oil Level Check

NOTE: Always check the oil level with the watercraft level and the engine COLD.
1. Start engine and run for no more than 30 -- 45
seconds.
2. Remove the oil dipstick from the top of the oil storage
tank. Wipe clean with shop towel.
3. Re--insert the dip stick into the oil storage tank, but do
not thread into tank. Remove the dipstick, and check OVERFILLED OIL LEVEL
oil level.
MAXIMUM OIL LEVEL (HOT)
The oil level should be between the MIN and MAX marks.
The volume between the MIN and MAX marks is .5 Us
Quarts (.5L).
.5 US Qt. (.5 L)
The oil level will rise as the engine warms up to operating
temperature, but SHOULD NEVER RISE PAST THE
OVERFILLED MARK. Remove oil from tank if level is MINIMUM OIL LEVEL
above MAX mark after warming engine to operating tem-
perature.
Warming the engine up can be accomplished by installing
a flush kit. Never exceed 2000 RPM when connected to
a flush kit.

CAUTION:

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
NEW ENGINE: 3.9 -- 4.2 US QUARTS
3.7 -- 4.0 LITERS
BREAK IN: 12 HOURS
EVERY 25 HOURS AFTER BREAK IN PERIOD

Oil Change Procedure

1. Remove the oil fill cap located on the top of the oil
storage tank.
2. Using a oil extraction / storage tool, insert the hose into
the oil storage tank.
NOTE: To prevent oil foaming, a baffle is located
inside the tank. Verify the hose passes through one
of the baffle holes and reaches the bottom of the
tank.
3. Extract ALL of the oil out of the storage tank into the
storage container. Remove the hose, and replace the
cap when all of the oil is removed.

2.10 2004 Four Stroke PWC Service Manual

 MAINTENANCE

Oil Change Procedure

4. Remove each of the two fuel injector and ignition coil
wiring harness connectors.
5. Remove the upper oil feed hose from the top of the oil
storage tank. Locate either a two--liter plastic bottle or REMOVE THIS HOSE
a 5--foot length of hose with a male--to--male hose
coupler.

6. Insert the oil supply hose into the two--liter bottle inside
the engine compartment, or, insert the coupler into
both ends of the hoses and hang the entire length of
hose over the side of the watercraft. Position this hose
into a oil pan or oil containment container.
7. Insert the safety lanyard into the stop switch. Press
and hold the start button for no more than 15 seconds.
Release the start button for at least 30 seconds.
Repeat this process three to four times, or until little or
no oil is pumped out of the sump and into the container.

8. Locate the oil filter cover cap. Remove the cap and CAP
remove the o--ring and filter element. Replace filter
element and o--ring with new parts.
ELEMENT
9. Reinstall oil filter cover cap and torque to 24 Nm (17
ft.lbs.)
10. Clean oil tank fitting with brake cleaner or acetone,
then reinstall the oil supply hose to the oil storage tank.
Torque gear clamp to 30 in.lbs.
11. Fill to oil tank with 3.4 -- 3.7 qts. (3.3 -- 3.5 L) of Polaris O--RING
PS--4 Synthetic Marine engine oil.
NOTE: Never add more than 3.7 qts. (3.5 L)
12. Reconnect the fuel injector and ignition coil wiring
harness connectors.
13. Start engine and idle for 30 seconds. Stop engine and
re--check engine oil level.
14. Add engine oil until level is at the low mark on dipstick.
NOTE: The oil level will increase as the engine warms up to operating temperature.

2004 Four Stroke PWC Service Manual 2.11

 MAINTENANCE

Engine Coolant Level

The engine, oil cooler, and turbine bearing housing are cooled by an internal cooling system. A 50 / 50 mixture
of propolyne glycol (environmentally safe coolant) and distilled water must be used in warm--weather states. A
60 / 40 mixture of propolyne glycol and distilled water can be used in cold--weather states and where the tempera-
ture can drop below freezing.
The internal cooling system is a self--bleeding design. The lowest point in the circuit is located just below the water
pump housing.
1. The coolant level must be maintained between the
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)
MAX
POLARIS ENVIRONMENTALLY SAFE
COOLANT 50/50 MIXTURE
PN: SEE PAGE 2.4 TO WATER
PUMP MIN
DRY CAPACITY:
CHANGE INTERVAL: 4 Years

Engine Coolant Change Procedure

1. Remove the hose that connects the coolant expansion
tank the water pump cover. The engine coolant will
drain into the engine compartment bilge.
2. Re--attach the hose. Open the two hull bilge plugs.
Place two containers directly under the bilge plugs.
3. Carefully lift the front of the boat to about 15 degrees
up. Allow all of the coolant to exit the engine
compartment.
4. Flush the bilge with clean water, and secure bilge
plugs.
5. Obtain new engine coolant, and slowly fill the
expansion tank to the MAX mark. Allow the system to
purge the air out of the circuits. (Level will go down
over short period of time.)
6. Repeat process two to three times. Never fill level
above MAX mark.
NOTE: The coolant level will drop after the first several operation cycles.

2.12 2004 Four Stroke PWC Service Manual

 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
engine. AIR BLEED

MAX

TO WATER
PUMP MIN

2. Insert a small bolt or plastic plug into the end of the

bleed hose and secure with small gear clamp.

3. Attach a Mity Vact hand pump to the expansion tank

air bleed nipple. Pressurize the expansion tank to 10 --
15 psi (.7 -- 1 bar). The internal engine cooling circuit
should maintain the pressure.

PRESSURE SPECIFICATION

10 -- 15 psi (.7 -- 1 bar)

4. A drop in pressure may indicate a worn or damaged

hose, loose hose connection, or engine--related
mechanical damage.

2004 Four Stroke PWC Service Manual 2.13

 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. Remove both ignition coil packs from the valve cover.
Remove both spark plugs.
2. Remove both fuel injector harness connectors.
3. Install the compression gauge into one of the
cylinders.
4. Insert the lanyard and push the starter button for no
more than 15 seconds. Obtain reading from gauge,
then release gauge pressure.
5. Measure remaining cylinder.
6. Reassemble in reverse order. Tighten fasteners to
specification.

COMPRESSION SPECIFICATION

140 ± 14 PSI (9.6 ± 1 BAR) @ SEA LEVEL

VERIFY BATTERY IS FULLY CHARGED

Fuel System Pressure Test

WARNING

Wear safety glasses or a face shield for eye protection when working on the fuel system.

Test the fuel system by installing a fuel pressure gauge on to the inline Schrader Valvet.
1. Remove Schrader Valvet cap and install pressure
gauge.
2. Start engine. Take reading and remove system
pressure from gauge.
3. Use a shop towel to prevent fuel spills.
4. Re install cap.

FUEL PRESSURE SPECIFICATION

43.5 psi + BOOST (3 bar + BOOST) @ IDLE

Approximately 59 PSI (4.1 bar) @ WOT

2.14 2004 Four Stroke PWC Service Manual

 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.
INTERNAL - Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegeta-
ble oil. Call a physician immediately.
EYES - Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging
or using in closed space. Always shield eyes when working near batteries. KEEP OUT OF THE REACH
OF CHILDREN.

CAUTION:
The battery must be removed from the watercraft for maintenance and charging. Battery electrolyte may spill
and damage the watercraft.

WARNING

Always disconnect the black (negative) cable first. Electrolyte or fuel vapors may be present in the engine compart-
ment and a spark could ignite them which could cause personal injury. When re-installing battery connect black (nega-
tive) cable last.

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. ANTIDOTE: External - Flush
with water. Internal - Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately. Eyes - Flush with water for 15 minutes and get prompt medical
attention.
Battery Removal
1. Remove velcro straps holding electrical box and battery in position.
2. Remove cover from top of battery.
3. Remove battery vent tube from battery.
4. Disconnect black (negative) battery cable first.
5. Disconnect red (positive) battery cable next.
6. Lift battery out of watercraft, being careful not to tip it sideways and spill any electrolyte.

CAUTION:

Battery electrolyte can damage the watercraft finish if spilled. If an electrolyte spill occurs, apply a generous
amount of baking soda to the area and then rinse with fresh water.

2004 Four Stroke PWC Service Manual 2.15

 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-
als which are harmful to a battery. Maintain
Between
Battery Connections Upper and
Battery terminals and connections should be kept free of Lower Level
corrosion. If cleaning is necessary, remove the corrosion Marks
with a stiff wire brush. Wash thoroughly with a solution
of baking soda and water (one tablespoon of baking soda
to one cup of water). Rinse well with tap water and dry
off with clean shop cloths. Coat the terminals and termi-
nal bolts with Nyogeltgrease.

Nyogelt Grease Top View of Battery

PN 2871329 Vent
Tube

Battery Charging Black (-) Red (+)

CAUTION:
The battery must be removed from the watercraft for
maintenance and charging. Battery electrolyte may spill
and damage the watercraft.
Always disconnect the black (negative) cable first. Electrolyte or fuel vapors may be present in the engine compart-
ment and a spark could ignite them which could cause personal injury. When re-installing battery connect black (nega-
tive) cable last.

WARNING
Keep the battery away from sparks and open flames during charging because the battery gives off gases which
are explosive. If you smell fuel do not attempt to charge the battery. When using a battery charger connect the
battery to the charger before turning on the charger. This reduces the possibility of sparks at the terminals which
could ignite the battery gases. Do not connect charger cables to the battery unless the charger is unplugged.
1. Remove caps from cells. Add distilled water if necessary to bring electrolyte up to proper level.
2. Connect battery to a charger. Set charging rate at 1.9 amps (maximum) and charge battery for ten hours.

CAUTION:
During charging, if the electrolyte temperature rises above 115°F (45°C) or if battery feels hot when touched, re-
duce the charging rate to lower the temperature and increase the charging time.
3. After battery is charged, check fluid level. If it has dropped add distilled water to bring electrolyte up to proper
level.
4. Check results of charging. The specific gravity of each cell must be 1.270 at room temperature. The voltage
should be 14.5 - 15.5 V during charging; 12.2 - 12.8 V after charging.

Specific Gravity
1.270 or greater - Each Cell

2.16 2004 Four Stroke PWC Service Manual

 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. Avoid skin contact with electrolyte, Top View of Battery
severe burns could result. Vent
3. Apply Nyogelt grease to each cable bolt. Tube

Nyogelt Grease
PN 2871329 Black (-) Red (+)

4. First, connect and tighten red (positive) cable.

5. Second, connect and tighten black (negative) cable.
6. Apply dielectric grease to each cable end and to terminal post area.
7. Reinstall battery cover and electrical box over battery and reconnect straps.
8. Verify that cables are properly routed.
9. Verify that vent hose is not kinked.

Battery Storage

1. Remove battery. Clean casing and terminals with baking soda and water (one tablespoon of baking soda to
one cup water). Apply dielectric grease to battery terminals and all exposed cable connectors.
2. Top off battery with distilled water and charge to a specific gravity of 1.270 (test each cell). Recharge monthly
as required to prevent battery discharge, sulfation, and freezing.
3. Store battery in a cool, dry place out of direct sunlight.

2004 Four Stroke PWC Service Manual 2.17

 MAINTENANCE

Spark Plug
USE ONLY RESISTOR--TYPE SPARK PLUGS! SEVERE ENGINE PROBLEMS MAY OCCUR IF NON--RE-
SISTOR--TYPE SPARK PLUGS ARE INSTALLED.
1. Inspect electrodes for wear, carbon buildup, or fouling
(wet oily residue). Replace plugs if edges of
electrodes are rounded or eroded.
2. Clean with electrical contact cleaner or a glass bead
spark plug cleaner only. A wire brush or coated Spark Plug Gap
abrasive should not be used.
3. Measure gap with a wire gauge and refer to Spark Plug Gap
specifications. Adjust if necessary by bending the side
electrode carefully. CHAMPION RC7PYCB
.6 -- .7 mm (.025 -- .030 in.)
4. Coat spark plug threads with a small amount of
anti-seize compound.
5. Install spark plug and torque to 18ft.lbs.
6. Make sure spark plug caps are screwed completely
onto end of plug wire.
7. Apply a small amount of Nyogelt grease to inside of
plug caps and install.
8. Push cap onto plug until cap “snaps” into place.
Torque ignition coil fasteners to specification.

Fuses

MODEL FUSES COMPONENT LOCATION

2AMP NGI Gauge
10AMP Fuel Pump
15AMP Ignition System
MSX 110 / 150 15AMP Main Relay Harness Pod
15AMP Main Relay
15 AMP Main Relay
30AMP Alternator

2.18 2004 Four Stroke PWC Service Manual

 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. Be sure hoses are not restricted (kinked or
collapsed internally).
CAUTION:

1. Loosen clamp connecting hose to fitting and remove

hose.

FRESHWATER INJECTOR

2. Inspect and clean orifice.

3. Reinstall cooling hose.

.185″

FRESHWATER INJECTOR

Throttle Cable Adjustment

The throttle cable connects the throttle flipper with the Pedal
Position Unit (PPU). The cable is located underneath the Adjuster
steering helm.
Throttle Cable
1. Turn adjuster clockwise to loosen the throttle flipper
freeplay. Turn counter--clockwise to tighten flipper
freeplay.
Lock Nut
NOTE: Verify throttle cable is not kinked after per-
forming procedure.

2004 Four Stroke PWC Service Manual 2.19

 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.
♦ Do not over fill the tank. (Do not fill the tank neck.)
♦ If you get gasoline on your skin or clothing, immediately wash it off with soap and water and change
clothing.
♦ Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are
poisonous and can cause loss of consciousness and death in a short time.
♦ Shut off fuel valve (if applicable) whenever the watercraft is stored, parked, or transported.
Fuel Lines / Vent Lines
1. Check fuel lines and vent lines for signs of wear, deterioration, damage or leakage. Replace if necessary.
Ensure that clamps are tight.

2. Be sure all lines are routed properly and secured with cable ties away from any moving parts.

CAUTION:

Make sure lines are not kinked or pinched.

Water Separating Filter
The water separating filter requires no maintenance.

In--Line Fuel Filter

The inline fuel filter is located in front of the fuel tank and
is connected to the fuel supply hose. Verify arrow points
towards the engine (downstream) when installing new fil-
ter.

2.20 2004 Four Stroke PWC Service Manual

 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.
3. Inspect all tie straps to be sure they are tight and in .040″ hole must
position. be clear to prevent
siphoning water
into bilge

To pump fitting

Bilge Siphon

Bilge Drain Plugs

1. Inspect bilge plug for cracks or damage from
over-tightening. Keeper Gasket
Strap Bilge Plug
2. Periodically inspect sealing O-ring and replace if Assembly
worn or damaged. Inspect drain plug, gasket,
keeper strap and tightness of screws.

3. Inspect bilge drain plug mounting bolts for proper

torque. Torque mounting bolts to 8 -- 10 in.lbs.
O-Ring Plug

2004 Four Stroke PWC Service Manual 2.21

 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). Inspect pump mounting nuts and ex-
tension housing bolts. Refer to specific torque values
listed in the General Information section or Final Drive/
Jet Pump section.
Scoop / Ride Plate / Intake Grate
Verify fastener torque on the scoop, ride plate, and intake
grate. Inspect all components for damage. Inspect the
scoop sealing area for signs of black exhaust trails which
indicate a leak in the sealant around the scoop. Even a Intake
small leak will ventilate the pump area, creating cavita- Grate
tion of the pump and reducing performance. If a leak is
evident, remove the scoop and re-seal. Refer to Final
Drive/Jet Pump section for procedures. Excess silicone Ride Plate
sealant can be trimmed until flush with edges.
Drive Shaft
Impeller
Impeller Clearance

WARNING

Be sure the lanyard cord and lock plate are removed from
the engine stop switch to kill the ignition or severe injury
could result.
1. Remove intake grate.
2. Use a feeler gauge to measure impeller clearance
along each blade in three spots. If measurement
exceeds service limit, replace impeller. If clearance
is excessive with a new impeller, the pump housing
must be replaced.

Impeller Clearance

Standard .002-.008″.05-.20 mm)

Service Limit .020″ (.5 mm)

2.22 2004 Four Stroke PWC Service Manual

 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.

1. Periodically inspect anode for excessive wear. If wear

exceeds 50% of original size, replace anode.
2. Check bolt to be sure it is tight. If the bolt is loose, the
anode is useless. Remove anode and clean mounting
surfaces on pump and anode.
Zinc Anode
3. Apply dielectric grease to bolt threads and contact
surfaces.

4. Tighten bolt securely.

Nyogelt Grease
PN 2871329

2004 Four Stroke PWC Service Manual 2.23

 MAINTENANCE

Handlebar / Hand Grips

1. Pull and twist on hand grips to ensure they are not loose.
If loose or wore, the handlebar with grip assembly must Top Deck
be replaced.
Grommet Plate
2. Reference chapter six for disassembly procedures.

Handlebar Post Top Plate

1. Move handlebars up and down and side--to--side to
check for excessively worn bushings. If wear is
excessive, steering arm can be re--adjusted on
handlebar shaft. Reference chapter six for further Tapered Bushings
information.

Shim Washers

Steering Arm

Fasteners / Parts / Hoses

Inspect the watercraft for any loose nuts, bolts, fasteners and hoses. Be sure that all hose clamps are tight. Re-
place cracked, damaged, or deteriorating hoses.

Intake Manifold Fastener Re--Torque

During the 12 hour break--in and first 25 hour maintenance check, the intake manifold fasteners must be checked
for the correct torque.
S A = 13 ft.lbs. (18 Nm)
S B = 7 ft.lbs. (10 Nm) A

2.24 2004 Four Stroke PWC Service Manual

 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. Hand tighten.

The drain plugs are designed to allow any water inside of the intercooler or air intake to escape in the event where
the watercraft has rolled over and taken on water.
NOTE: Never operate the watercraft without the drain plugs installed! Severe engine damage may
occur.

2004 Four Stroke PWC Service Manual 2.25

 MAINTENANCE

Off - Season Storage

The off--season storage period is determined to be the time when 1. The watercraft will not be used for 30 or more
days, or, 2. The end of the normal riding season where the watercraft will be “winterized” for storage.
1. Remove the engine oil and replace with new.
S Used oil contains water, and un--burned fuel. When left inside the engine for extended periods of
time, internal engine corrosion can occur.
2. Flush the freshwater cooling circuit.
S Flushing the freshwater cooling circuit will remove salt, vegetation, and any other foreign material
trapped within the circuit.
3. Check the condition of the engine coolant.
S Using a coolant tester, commercially available, test the boil over and freeze temperature of the engine
coolant. A 50/50 mixture of distilled water to propolyne glycol should yield a freeze temperature of
approximately --26_F.
S A 60 / 40 mixture (coolant --to -- distilled water) should be used where the water temperatures remain
cool throughout the year and where the air temperature drops below --26_F.
4. Top off the fuel tank with fresh fuel.
S 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.
S Fuel begins to break down and form varnish after 30 days. Adding stabilizer will prevent fuel from
breaking down.
6. Flush the engine compartment bilge with clean water.
S Cleaning the engine compartment bilge will prevent the growth of bacteria and mold.
7. Store the watercraft with the bow angled upwards at an angle of at least 10 degrees.
S Tilting the bow upwards will drain the water in the exhaust system as well as allowing any water in the
footwells to drain.
8. Always leave the seat loosely installed.
S Fresh air must be allowed to circulate inside of the engine compartment during storage periods.
9. Verify the battery is fully charged. Store the battery in a cool, dry place. Attach a battery tender to the battery,
or charge the battery once of month during the storage period.
10. Thoroughly clean the top deck and hull with mild detergent. Wipe dry and apply wax or furniture polish to hull.

2.26 2004 Four Stroke PWC Service Manual

MSX 110 / 150 Service Manual Engine Removal / Installation
Engine Subassembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 -- 3.8
Engine Mount Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 -- 3.10
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

3
 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:
S Intercooler and associated air intake hoses and components.
S Engine electrical harness.
S Oil storage tank assembly.
S Air intake and throttle body assembly.
S Heat exchanger mounting bracket and coolant--to--fresh water heat exchanger.
S Lubrication and cooling hoses.
S Exhaust pipe and manifold, with turbocharger unit.
S Pump assembly.
The use of an engine hoist or overhead crane system is required to both remove and install the engine assembly.

WARNING

Always disconnect the positive (RED) and negative (BLACK) battery cables from the battery after removing the
engine oil and prior to performing any engine work. Failure to do so may cause severe injury or death.
NOTE: The use of an engine hoist is strongly recommended for working on and removing the en-
gine from the engine compartment. Place masking tape around the engine compartment -- seat mat-
ing surface. Doing so will prevent nicking and scratching of the hull when the engine is removed.
1. Remove the engine oil from the engine. Reference CHAPTER 2.
2. Remove the engine coolant. Reference CHAPTER 2.
3. Remove the pump nozzles and pump stator
assemblies. Pull the driveshaft and rear drive couple PHOTO A
away from the engine drive coupler. Reference
CHAPTER 6. (Photo A)
NOTE: Not all electrical connections can be discon-
nected without removing hoses, pipes or sub--sys-
tems. As components are removed, disconnect any
electrical connections.

2004 Four Stroke PWC Service Manual 3.1

 ENGINE REMOVAL / INSTALLATION
Engine Removal and Installation - Continued
4. Locate the fuel hose quick disconnect on top of the fuel
rail. Wrap a shop towel around the disconnect and PHOTO B
press the two tabs in while pulling up on the connector.
5. Remove the fuel supply and fuel return hoses from the
fuel rail. (Identify hoses for re--assembly.)
6. Remove all of the hoses connected to the oil storage
tank. (Photo B) Identify each hose and its location
during removal.
7. Un--latch the TOP worm gear clamp that secures the oil
storage tank to the rear of the engine.
NOTE: Do not loosen or tighten the lower worm
gear clamp!
8. Lift the oil storage tank up and out of the cradle.
9. Remove the two lower tank hose connections. Identify
each hose and its location during removal. (Photo C)
10. Remove the cyclone--to--sump oil return hose from the PHOTO C
oil separator cyclone.
11. Carefully lift the oil storage tank out of the engine
compartment.

LARGE GEAR CLAMP x1

OIL TANK
(ALL HOSES REMOVED)

MOUNTING PINS x2

RUBBER BUSHINGS x2

REAR ENGINE MOUNT

3.2 2004 Four Stroke PWC Service Manual

 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.

PHOTO D

INTERCOOLER
FASTENERS x2

REAR ENGINE MOUNT MOUNTING

PINS x2

FRESHWATER
INLET / OUTLET

REGULATOR / RECTIFIER

FRONT ENGINE MOUNT

2004 Four Stroke PWC Service Manual 3.3

 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.

PHOTO E

16. Locate the engine coolant outlet elbow located next to

the intake manifold. Rotate the elbow down and
towards the engine. (Photo F)

PHOTO F

17. Remove the intake pipe, pop--off valve, fuel rail w/fuel
injectors, and associated hoses. (Photo G)
18. Remove the intake manifold fasteners. Reference
illustration on next page for fastener locations.

PHOTO G

3.4 2004 Four Stroke PWC Service Manual

 ENGINE REMOVAL / INSTALLATION
Engine Removal and Installation - Continued

MANIFOLD FASTENERS x4

INTAKE MANIFOLD

UPPER--TO--LOWER
BRACKET FASTENERS x3

UPPER BRACKET

LOWER BRACKET

WATER--TO--WATER LOWER BRACKET FASTENERS x2

HEAT EXCHANGER

19. With the fasteners removed, carefully slide the intake

manifold towards the rear of the engine compartment
and out of the watercraft.
20. Slide the heat exchanger towards the rear, then
remove from engine compartment. (Photo H)
21. Remove the two fasteners that secure the lower
bracket to the engine. Remove the lower bracket.

PHOTO H

2004 Four Stroke PWC Service Manual 3.5

 ENGINE REMOVAL / INSTALLATION
Engine Removal and Installation - Continued
STERN

REAR ENGINE MOUNT

LIFTING HOOKS

FRONT ENGINE MOUNT BOW

22. Locate and remove the four engine mounting nuts and
washers.(Photo J) (Front Left Mount Shown)

PHOTO J

3.6 2004 Four Stroke PWC Service Manual

 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.
CAUTION: The lifting hoist must be able to lift at
least 250 lbs. (113 kg.)

PHOTO K

24. Carefully lift the engine upwards. Move the engine

rearward once the engine straps clear the engine
mount studs. With engine pushed back, remove the
intercooler assembly.
25. Reposition the engine in the middle of the
compartment. Carefully rotate the engine on to the
intake--side.(Photo L)
NOTE: An assistant may have to lift the engine up
while the engine is rotated on to its intake.
26. Lay the engine on to the intake side.
NOTE: The exhaust manifold, pipe, and turbine as-
sembly must be removed from the engine in order to
remove the core engine.

PHOTO L

27. Remove the exhaust manifold from the engine. Identify

any hoses or wiring harness components removed
during the process.

PHOTO M

2004 Four Stroke PWC Service Manual 3.7

 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

BOW

29. Reposition the core engine assembly into the center of

the engine compartment.
30. Carefully lift the engine straight up and out of the
compartment. (Photo N)

PHOTO N

3.8 2004 Four Stroke PWC Service Manual

 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

REAR ENGINE MOUNTING STRAP INTAKE--SIDE OF ENGINE

FRONT ENGINE MOUNTING STRAP
1. The engine must remain suspended by the hoist
chains.
2. Remove the front engine mounting strap.
3. Insert a ratchet extension or metal dowel into the
balance plate hole. Rotate the engine until dowel
prevents engine from rotating counterclockwise.
(Photo O)
4. Place a pry bar or large open end wrench across the
coupler fingers. Rotate counter--clockwise to remove
coupler from PTO shaft.
NOTE: Wrapping the pry bar or wrench with a towel
will prevent damage to the coupler fingers.
5. With the balance plate still locked in position, continue
with the removal of the PTO stubshaft and balance
plate assembly.
PHOTO O

2004 Four Stroke PWC Service Manual 3.9

 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. Reference the circled
fastener locations in (PHOTO P).
NOTE: The curved radius found on the engine stand
adapter plate must fit around the PTO seal and oil
pump opening.

PHOTO P

ENGINE STAND ADAPTER PLATE

PW--46984

With the engine stand adapter plate installed, the engine can be secured to a rolling engine stand or work bench
the using the BENCH MOUNT HOLDING FIXTURE, PN: J 03289--20.

Engine Installation
The installation of the engine and engine subsystems is the reverse of their removal. During engine installation,
several important notes must be made.
S Always verify the correct number of engine mounting strap shims are installed on each engine mount-
ing post. The correct number of shims is written next to each mounting post.
S The engine core is the first component that is installed into the engine compartment. Locate the in-
tercooler underneath the top deck after the engine is placed inside the engine compartment, but prior
to fastening the engine straps to the engine mounts. THE INTERCOOLER CANNOT BE
INSTALLED INSIDE THE ENGINE COMPARTMENT AFTER THE MOUNTING STRAP NUTS ARE
INSTALLED.
S Always verify that the engine does not interfere with critical routings such as the steering cable, re-
verse cable, cooling hoses, and main wiring harness.
S Always double--check each oil and cooling hose routing and connection before installing more compo-
nents.
S Reference Chapter 4 and 6 for fastener torque and thread lubricant specifications.

3.10 2004 Four Stroke PWC Service Manual

MSX 110 / 150 Service Manual Engine Disassembly / Assembly
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 -- 4.2
Engine Fastener Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 -- 4.6
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Valve Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Valve Train Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Dry Sump Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Thermostat Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
High Pressure Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Chain Guide and Chain Tensioner Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Engine Case / Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 -- 4.16

4
Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
Balance Plate / PTO Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
Crankshaft / Balance Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21 -- 4.28
Engine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29 -- 4.42
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.43 -- 4.57
Timing Chain Installation / Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 4.49 -- 4.52
Freshwater / Internal Engine Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . 4.58
Thermostat , Water Pump & Seal Removal / Installation . . . . . . . . . . . . . . . 4.59
Freshwater Cooling Circuit Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.60 -- 4.61
Internal Engine Cooling Circuit Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . 4.62 -- 4.64
Oil Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.65
Crankcase Ventilation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.66
Oil Pump(s) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.66
Oil Lubrication Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.67 -- 4.69
 ENGINE DISASSEMBLY / ASSEMBLY
Engine Specifications

Component Specification
Engine Model Number 110 = ES075WLE--011
150 = ES075WLE--021
Maximum Engine Horsepower 110 and 150
Maximum Engine Torque TBA
Engine Type 8 Valve SOHC Parallel Twin Cylinder w/Balance Shaft-- Four Stroke
Displacement 750cc
Bore X Stroke 85 x 66mm (3.346″ x 2.598″)
Compression Ratio 9.0 : 1
Cylinder Compression @ Sea Level 140 ± 14 psi (9.6 ± 1 bar) @ Sea Level
Recommended Fuel 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)
Dry Engine (After Rebuild) 3.9 -- 4.2 US Quarts (3.7 -- 4.0 Liters)
Cooling System Requirement 50 / 50 Distilled Water and Propolyne Glycol (Warm Weather States)
60 / 40 Propolyne Glycol --To -- Distilled Water (Cold Weather States)
Cooling System Capacity 3.5 US Quarts (3.3 Liter)
Thermostat Opening Temperature 180_ F (82_ C)
System Pressure 14.6 PSI (1 Bar) / 17 PSI (1.2 Bar) Maximum System Pressure
Valve Timing (1mm Valve Lift)
EV OPENS 52_ BBDC
EV CLOSES 2_ ATDC
IV OPENS 14_ BTDC
IV CLOSES 50_ ABDC
Valve Diameter
EV 29.5mm (1.161″)
IV 32.5mm (1.279″)
Valve Seat Contact Width
IV 1.1mm -- 1.2mm (.043″ - .047″)
EV 1.3mm -- 1.4mm (.051″ - .055″)
Valve Face Width
IV 2.0mm
EV 2.0mm
Valve Margin Thickness
IV 5.472mm (.2154″)
EV 5.463mm (.2150″)
Valve Seat Angle 45_
Valve Outer Correction Angle 30_
Valve Inner Correction Angle 75_
Valve Clearance (COLD)
IV 0.08 -- 0.15mm (.003″ - .006″)
EV 0.18 -- 0.25mm (.007″ - .010″)
Valve Stem Diameter
IV 5.465mm -- 5.479mm (.2151″ - .2157″)
EV 5.456mm -- 5.470mm (.2148″ - .2153″)
Valve Guide Inside Diameter
IV 5.5mm -- 5.507mm (.216″)
EV 5.5mm -- 5.509mm (.216″)
Valve Stem Runout .03mm (.001″)
Valve Stem--To--Guide Clearance
IV .021mm -- .044mm (.0008 - .0017″)
EV .030mm -- .053mm (.0011 - .0020″)

2004 Four Stroke PWC Service Manual 4.1

 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″)
OUT--OF--ROUND LIMIT .008mm (.0003″)
WEAR LIMIT N/A
Camshaft Specifications
CAMSHAFT WIDTH 108.85mm -- 109.00mm (4.28″ - 4.29″)
IN CAM LOBE HEIGHT 48.553mm (1.911″)
EX CAM LOBE HEIGHT 48.209mm (1.897″)
MAXIMUM CAMSHAFT RUNOUT .05mm @ Sprocket / .02mm @ Base. (.001″)
RADIAL PLAY .020mm -- .050mm (.001″)
BEARING HOLE I.D. 25.972mm -- 25.988mm (1.02″)
CAMSHAFT AXLE O.D. 19.991mm -- 20mm (.787″)
CAMSHAFT CLAMP I.D. 19.90mm -- 19.98mm (.783″)
Rocker Arm Specifications
BEARING AXIAL PLAY .013mm -- .025mm (.0005″ - .0009″)
ROCKER ARM I.D. 13.980mm -- 13.991mm (.55″)
ROCKER ARM SHAFT O.D. 9.994mm -- 10mm (.393″)
ROCKER ARM HOLDER BORE I.D. 10mm -- 10.009mm (.393″)
ROCKER ARM AXIAL PLAY .16mm -- .26mm (.006″ - .010″)
Crankshaft Specifications
CRANKSHAFT DEFLECTION .02mm -- .04mm (.0007″ - .0015″)
MAIN BEARING CLEARANCE .03mm -- .04mm (.0011″ - .0015″)
BEARING CODES 1.RED 2. YELLOW 3. BLUE 4. GREEN 5. BROWN
Connecting Rod Specifications
BIG END OIL CLEARANCE .01mm -- .064mm (.0003″ - .002″)
SMALL END DIAMETER 20.995mm -- 21.011mm (.826″ - .827″)
BEARING CODES 1.RED 2. YELLOW 3. BLUE 4. GREEN 5. BROWN
Balance Shaft Specifications
AXIAL PLAY .15mm -- .25mm (.005″ - .009″)
RADIAL PLAY .014mm -- .066mm (.0005″ - .002″)
BEARING DIAMETER 24.975mm -- 24.990mm (.983″)
RUN OUT .014mm -- .066mm (.0005″ - .002″)
Piston Specifications
PISTON--TO--CYL CLEARANCE .041mm -- .059mm (.0016″ - .0023″)
PISTON DIAMETER 84.961mm -- 84.979mm (Measured 15mm from bottom, 90_ from pin.
(3.34″ - 3.345″)
WEAR LIMIT .04mm (.001″)
PISTON PIN BOSS I.D. 21.004mm -- 21.009mm (.826″ - .827″)
PIN O.D. 20.995mm -- 21.000mm (.826″)
PIN WEAR LIMIT .05mm (.001″)
Piston Ring Specifications
TOP RING INSTALLED RING GAP .2mm -- .4mm (.07″ - .015″)
TOP RING GROVE CLEARANCE .65mm -- .955mm (.025″ - .037″)
MIDDLE RING INSTALLED RING GAP .2mm -- .4mm (.007″ - .015″)
MIDDLE RING GROVE CLEARANCE .50mm -- .805mm (.019″ - .031″)
OIL RING INSTALLED END GAP .2mm -- .7mm (.007″ - .027″)
OIL RING GROVE CLEARANCE .50mm -- .910mm (.019″ - .035″)
Oil Pump Specifications
OIL PUMP TYPES Trochoid
ROTOR TIP CLEARANCE (PRESSURE) N/A
OIL PRESSURE RELIEF VALVE SPRING FREE LENGTH = 2.7″ (69mm) / PISTON O.D. = .43″ (10.9mm) /
OIL PRESSURE PISTON LENGTH = 1.10″ (27.7 -- 28mm)
21 @ IDLE -- 80 @ MAX PSI (1.5 -- 5.5 BAR)

4.2 2004 Four Stroke PWC Service Manual

 ENGINE DISASSEMBLY / ASSEMBLY
Engine Fastener Torque Specifications

Standard Torque Guide (mm) FT. LBS. Nm

5 2.5 -- 3.6 3.4 -- 4.9
6 4.3 -- 5.7 5.9 -- 7.8
8 10 -- 14 14 -- 19
10 18 -- 25 25 -- 34
12 32 -- 45 44 -- 61
14 54 -- 72 73 -- 98
16 85 -- 114 115 -- 155
18 122 -- 166 165 -- 225
20 166 -- 240 225 -- 325

Engine Specific Fastener Torque Specifications

Component FT. LBS. Nm Notes Fastener(s)

Cylinder Head Nuts
Step 1 15 20
Step 2 30 40 M10 x 1.25
Ste
Step
p3 180_
180 180_
180 Apply Engine Oil to M8 x 50
Threads. M8 x 70
Lower Crankcase Bolts
Step 1 12 16 M8 x 90
Step 3 18 24 -- 25

Gearcover -- to -- Engine Block 7 10 M6 x 20

Plug Elbow Connector 11 15 M12 x 1.5
Hose Connector in Lower Crankcase 30 40 Loctite 577 M18 x 1.5
Oil Filter Cover Cap 17 24
Dry Sump Oil Filter Screen 7 10 Loctite 243 M6 x 20
Dry Sump Cover -- to -- Lower 7 10 M6 x 20
Crankcase M6 x 35
M6 x 60
Dry Sump Pump Gear 28 38 Loctite 272 M8 x 25
Dry Sump Pump -- to -- Cover 7 10 M6 x 20
M6 x 25
Dry Sump Hose Connector 7 10 M6 x 16
Balance Shaft Drive Gear Nut 51 70 Loctite 272 M10
Connecting Rod Bolts
Step 1 7 10
M10 x 1.32
Step 2 14 20
Step 3 90_ 90_
Camshaft Clamps 7 10 M6 x 40
Rocker Arm Holders 9 13 M6 x 20
Exhaust Manifold Studs
Short 13 18 Copper Grease M8 x 69
Long 13 18 M8 x 118
Exhaust Manifold Nuts 17 24 Copper Grease M8 Flange
Valve Cover 7 10 M6 x 45
Tensioner Rail Fastener 17 24 Loctite 243 M8 x 25
Chain Guide Rail Fastener 7 10 Loctite 243 M6 x 25
Chain Tensioner Plug Bolt 51 70

2004 Four Stroke PWC Service Manual 4.3

 ENGINE DISASSEMBLY / ASSEMBLY

Engine Specific Fastener Torque Specifications

Component FT. LBS. Nm Notes Fastener(s)
Water Pump Cover M6 x 20
7 10 Loctite 577 M6 x 30
M6 x 35
Engine Coolant Outlet Manifold 7 10 M6 x 20
Engine Coolant Outlet Manifold Plug 7 10
Turbocharger Coolant Return Banjo
Bolt
Expansion Tank Fasteners 7 10 M6 x 20
Engine Coolant Outlet Manifold -- to --
7 10
Expansion Tank Nozzle

Turbocharger / Intercooler Specific Fastener Torque Specifications

Component FT. LBS. Nm Notes Fastener(s)
Segments 7 10 M6 x 16
Compressor Housing Clamping Lugs 7 10 M6 x 12
Oil Return Flange 7 10 M6 x 16
Turbocharger Lower Crankcase
17 24 M8 x 40
Bracket
Turbocharger Bracket -- to -- Manifold 17 24 M8 x 50
Wastegate Actuator Locknut 7 10
Wastegate Bracket -- to -- Manifold 7 10 Torx E8
Wastegate -- to -- Bracket 7 10 M6
Actuator Arm -- to -- Lever 7 10 M6 x 20
Intercooler Cover 6 9 M6 x 20
Intercooler Mounting Fasteners 7 10 M6 x 35

Intake Manifold Specific Fastener Torque Specifications

Component FT. LBS. Nm Notes Fastener(s)
Airbox / Screen Arrestor Fastener 6 9 M6 x 20
Manifold -- to -- Lower Bracket 7 10 M6 x 25
13 18 M8 x 60
Manifold -- to -- Cylinder Head 7 10 M6 x 30
Lower Bracket -- to -- Lower Crankcase 22 30 M8 x 30
Manifold Drain Fitting 11 15 Loctite 603

Alternator Assembly Specific Fastener Torque Specifications

Component FT. LBS. Nm Notes Fastener(s)
Magnet Rotor Fastener 73 100 M12 x 90
Cable Clamp 3 4 Loctite 272 M4 x 6
Sprague Clutch 7 10 Loctite 272 M6 x 16
Stator Fasteners 7 10 M6 x 35
Stator Cover 7 10 M6 x 20
M6 x 25
M6 x 65
Regulator Fasteners 7 10 M6 x 30

4.4 2004 Four Stroke PWC Service Manual

 ENGINE DISASSEMBLY / ASSEMBLY
Fuel Rail Specific Fastener Torque Specifications

Component FT. LBS. Nm Notes Fastener(s)

Fuel Rail Fasteners 7 10 Loctite 243 M6 x 20

Engine Management Components / Sensor Specific Fastener Torque Specifications

Component FT. LBS. Nm Notes Fastener(s)

Electronic Throttle Body 7 10 M6 x 45
Wastegate Solenoid Bracket 7 10
Knock Sensor 14 20 M8 x 30
Temperature / Pressure Sensor 4 5 M6 x 10
(Intercooler -- Air Intake Pipe)
Temperature / Pressure Sensor 5 7 M6 x 10
(Intake Manifold)
Crank Position / Speed Sensor 7 10 M6 x 10
Oil Pressure Switch 7 10 M10 x 1
Coolant Manifold Temp. Sensor 13 18
Ignition Coil Fasteners 7 10 M6 x 20
Spark Plugs 20 27 Dielectric Grease
Starter Motor Fasteners 7 10 Nyogel M6 x 20

Balance Plate / PTO Specific Fastener Torque Specifications

Component FT. LBS. Nm Notes Fastener(s)

Balance Plate -- to -- Crankshaft 51 70 Loctite 577 M10 x 1 X 45

Engine Mounts Specific Fastener Torque Specifications

Component FT. LBS. Nm Notes Fastener(s)

Front Engine Mount -- to -- Lower 40 55
M10 x 80
Crankcase
Rear Engine Mount -- to -- Crankcase 18 25 M8 x 30
Rear Engine mount -- to -- Crankcase 40 55 M10 x 40
and Lower Crankcase
Intercooler Bracket -- to -- Front Engine 7 10 M6 x 25
Mount
Intercooler Bracket -- to -- Crankcase 40 55 M10 x 60
Oil Storage Tank Bracket 7 10 M6 x 25

2004 Four Stroke PWC Service Manual 4.5

 ENGINE DISASSEMBLY / ASSEMBLY

Oil Storage Tank / Oil Cooler Specific Fastener Torque Specifications

Component FT. LBS. Nm Notes Fastener(s)

Oil Separator Fastener Hand Tighten K80 x30
Separator Oil Return Fitting 7 10 Banjo Bolt
Oil Cooler -- to -- Intercooler Bracket 7 10 M6 x 20
Oil Storage Tank Rollover Valve 7 10 Banjo Bolt
Oil Storage Tank Pullover Gear Clamp 2 3
High Pressure Oil Hose Connections 7 10 M10 x 1
(Turbocharger / Rollover Valve) Banjo Bolt

Gear Clamp Torque Specifications

8 - 16mm = 2 Nm

Over 16mm = 2.4 Nm

NOTE: Some or all clamps may be Oetikert clamps.

4.6 2004 Four Stroke PWC Service Manual

 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.
USED TO ROTATE CRANKSHAFT

PW-- 46991 - REQUIRED TOOL

VALVE COMPRESSOR TOOL
PW-- 46982 - REQUIRED TOOL USED TO COMPRESS VALVE SPRINGS WITH ENGINE EITHER
GEAR REMOVAL TOOL INSTALLED OR REMOVED FROM WATERCRAFT HULL.
USED TO REMOVE BALANCE SHAFT GEAR WHEN USED WITH
PW--46989 GEAR REMOVER BOLT.

PW-- 46983 - REQUIRED TOOL

PISTON RING COMPRESSOR PW-- 47077 - REQUIRED TOOL
USED TO INSTALL PISTONS INTO ENGINE BLOCK
CAMSHAFT ALIGNMENT TOOL
INSTALLS INTO CAMSHAFT TO LOCK INTO BDC POSITION.

PW-- 47079 - REQUIRED TOOL

TIMING CHAIN INSTALLATION TOOL
ROUTES TIMING CHAIN THROUGH ENGINE CRANKCASE DUR-
ING INSTALLATION.
PW-- 46984 - REQUIRED TOOL
ENGINE STAND ADAPTER PLATE
ATTACHES TO REAR OF ENGINE BLOCK. ALLOWS TECHNI-
CIAN TO ROTATE ENGINE DURING DISASSEMBLY AND RE--
ASSEMBLY.

PW-- 47108 - REQUIRED TOOL

TIMING CHAIN WEDGE AND HOOK TOOL
USED DURING TIMING CHAIN INSTALLATION

PW-- 46985 - REQUIRED TOOL

TIMING CHAIN LINK REMOVAL / INSTALLATION TOOL PU-- 46219 - OPTIONAL TOOL
USED IN REMOVING AND RE--INSTALLING TIMING CHAIN. MANUAL OIL PUMP / CONTAINER
USED TO REMOVE OIL FROM OIL TANK

2004 Four Stroke PWC Service Manual 4.7

 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

4.8 2004 Four Stroke PWC Service Manual

 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.
Torque valve cover fasteners in a criss--cross pattern beginning with the four inside fasteners.
Cam phase sensor port faces exhaust--side of engine.
Verify valve cover sealing surface is dry and clean from containments.

2004 Four Stroke PWC Service Manual 4.9

 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. (10 Nm)
Rocker Arm Tower Fastener Torque: 9 ft.lbs. (13 Nm)
VALVE CLEARANCE (COLD) IN: .08 -- 0.15MM (.003 -- .006IN.) / EX: .18 -- .25MM (.007 -- .010IN.)

Verify camshaft orientation during installation. Hole in camshaft is located on the PTO side of engine.
Always replace camshaft sprocket and timing chain together.

4.10 2004 Four Stroke PWC Service Manual

 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. (10 Nm) Apply Loctitet 243 to threads.
Oil Pump Drive Gear Nut Torque: 28 ft.lbs. (38 Nm) Apply Loctitet 272 to threads.
Plug Fastener Torque: 11 ft.lbs. (15 Nm)
Oil Supply Elbow Fastener Torque: 7 ft.lbs. (10 Nm)
Bedplate Fastener Torque: 7 ft.lbs. (10 Nm)

Clean bedplate and lower crankcase mating surfaces prior to apply silicone. Verify surfaces are free from any oil residue.
Apply a thin bead of Three Bondt 1215 to mating surfaces of bedplate and lower crankcase.
Dry sump oil pump is not serviceable. Replace component if operation is suspect.

2004 Four Stroke PWC Service Manual 4.11

 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. (10 Nm)
Thermostat Opening Temperature: 180_F / 82_C

Snap ring chamfer faces outward, towards rear of engine.

Always use new o--rings during installation and reassembly.
Elbow pipe points down and toward the heat exchanger.

4.12 2004 Four Stroke PWC Service Manual

 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.
Snap ring chamfer must face outwards, towards rear of engine when installed.
Verify retaining cap does not move when snap ring is installed.
An audible “click” must be heard and alignment pin must be inserted properly into engine case when installing the timing rotor into the
oil pump bore.
Verify balance shaft timing key is oriented properly inside shaft keyway.

2004 Four Stroke PWC Service Manual 4.13

 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

UPPER CHAIN GUIDE INSTALLED FROM BOTTOM OF UPPER CRANKCASE
(INSTALLED FROM TOP OF CRANKCASE)

ASSEMBLY NOTES
Timing Chain Tensioner Plug Bolt Torque: 51 ft.lbs. (70Nm)
Tensioner Guide Fastener Torque: 17 ft.lbs. (24 Nm) Apply Loctitet 243 to threads.

Replace replace tensioner rail if damaged, or unevenly worn.

Press tensioner into housing until flush with plug to set tensioner. Tensioner should remain in locked position. Activate tensioner by
pushing tensioner in and past flush. Tensioner should activate and extend outwards. Replace if function is incorrect.

4.14 2004 Four Stroke PWC Service Manual

 ENGINE DISASSEMBLY / ASSEMBLY
ENGINE CASE / CYLINDER HEAD ASSEMBLY

COMPONENT LAYOUT CYLINDER HEAD NUTS

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

M8 X 90 (LONG BOLT / OIL PUMP COVER)

M8 X 50

2004 Four Stroke PWC Service Manual 4.15

 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. (20 Nm)
Torque crankcase fasteners in sequence.
12 ft.lbs. (16 Nm) 7 4 2 6
2nd STEP: Torque cylinder head nuts in sequence
30 ft.lbs. (40 Nm)
3rd STEP: Torque cylinder head nuts in sequence.
180_ PTO MAG
Torque crankcase fasteners in sequence.
18 ft.lbs. (24 -- 25 Nm)
5 1 3 8

11
12 10 9

MAG PTO

4.16 2004 Four Stroke PWC Service Manual

 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. BLUE .0787 -- .0789IN. (2.000 -- 2.005mm) 4. GREEN .0789 -- .0791IN. (2.005 -- 2.010mm)
5. BROWN .0791 -- .0793IN. (2.010 -- 2.015mm)
Rod Cap Fastener Torque: 1st Step: 7 ft.lbs. (10 Nm)
2nd Step: 14 ft.lbs. (20 Nm)
3rd Step: Turn 90_
APPLY ENGINE OIL TO FASTENER THREADS PRIOR TO INSTALLATION.
Connecting rod caps feature a “cracked” mating surface. Cap must be marked during removal and installed correctly.

2004 Four Stroke PWC Service Manual 4.17

 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

 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.

2004 Four Stroke PWC Service Manual 4.19

 ENGINE DISASSEMBLY / ASSEMBLY

CRANKSHAFT / COUNTER BALANCER ASSEMBLIES

COMPONENT LAYOUT

CRANKSHAFT PLAIN BEARINGS

BALANCE SHAFT GEAR TIMING KEY

CRANKSHAFT

BALANCE SHAFT

BALANCE SHAFT PLAIN BEARINGS

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 ENGINE DISASSEMBLY / ASSEMBLY
Engine Disassembly Process
1. Remove valve cover from engine. Discard
gaskets.(Photo A) PHOTO A

2. Remove the coolant outlet manifold, oil filter cover, and

electric starter motor from engine case. (Photo B) PHOTO B

3. Remove the two high pressure oil feed hose banjo bolts
from the cylinder head exhaust--side rear mounting PHOTO C
location. (Photo C)
NOTE: The two high pressure oil feed hoses supply
oil to the turbocharger bearing house, and oil supply
shutoff valve located on the top of the oil supply
tank.

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 ENGINE DISASSEMBLY / ASSEMBLY

Engine Disassembly Process

4. Remove the stator cover from the 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. Remove the water pump cover and impeller.

(Photo F)
NOTE: The impeller can be removed by turning the
nut counter--clockwise. Hold the flywheel stationary
while removing the impeller.

PHOTO F

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 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. (Photo H)

PHOTO H

9. Remove the flywheel bolt and washer from the front of

the engine. Install flywheel puller bolt into flywheel
PN--PW--46989. Carefully tighten puller bolt until
flywheel comes off of crankshaft nose. (Photo I)
10. Remove the flywheel timing key and roller bearings
from crankshaft.

PHOTO I

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 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) A
NOTE: The balance shaft gear (C) is removed by us-
ing tool: PN PW--46982 and PW--46989. Gear remov-
al is not required. Only remove if damaged or re-
placement of balance shaft is required.
C

PHOTO J

12. Remove lock pin and rotate engine 180_. Remove the
sump cover. (Photo K)
NOTE: The sump oil pump is attached to the inside
of the sump cover.
13. Install crankshaft hand crank, PN PW--46981 into nose
of crankshaft. Tighten lock nut against crankshaft.

PHOTO K

14. The high pressure oil pump is located on the PTO side
of the engine. It is connected to the balance shaft.
Remove the snap ring from the high pressure oil pump TIMING ROTOR
cover. Carefully extract the cap, outer and inner rotors, O RINGS
SNAP RING
timing key and timing rotor from engine. (Illustration 1)

INNER / OUTER ROTORS

CAP

ILLUSTRATION 1

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 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.
16. Using a flat--head screwdriver, push the rocker arm
pins out enough to expose the detents on the pins.
Remove the pins from the cylinder head. (Photo L)
DETENTS
17. Rotate the engine 360_ counter--clockwise. Perform
steps 15 and 16 on the MAG cylinder valve train.
NOTE: A piston is at TDC on the compression
stroke when the piston is up and there is axial free-
play in each of the rocker arms.

PHOTO L

18. Place rocker arm assemblies and rocker arm pins on a

clean towel or piece of paper. Identify each part for use EXHAUST SIDE
during assembly. (Photo M)
NOTE: The MAG, exhaust--side rocker arm features
a cam phase sensor pickup nose as circled in photo
M.
19. Remove the valve shims. Place valve shims with
corresponding rocker arm and location. PTO MAG
20. Remove the chain tensioner bolt located next to the oil
filter location.

PHOTO M

21. Attach the chain breaker tool, PN--PW--46985.

22. Using the chain breaker tool, carefully press the pin out
of the link plate. Once outer plate is loose, disconnect
the tool and remove the last pin.
23. Remove the two pins from the chain, but do not pull the
chain away from the cam sprocket.

TAPERED PIN
FITTING W/HOLE

VERIFY TAPERED PIN MATES EVENLY WITH EACH CHAIN PIN.

THREADED BOLT FACE MUST FIT SQUARELY ON CHAIN
PLATE.

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 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. To begin, loosen and
remove the four case bolts located in the oil sump
gallery. (Photo O)

PHOTO P

26. The lower case bolt located on the PTO side also holds
the oil pump relief piston cover in place. (Photo P)
27. Once the plate is removed, use a magnet to remove the
spring and piston from inside the bore.

PHOTO Q

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 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.
5 1 3 7

8 4 2 6

PHOTO R

30. Remove the chain guide fastener and chain guide.

(Photo S)

PHOTO S

31. Rotate the engine assembly 180_. Remove the

tensioner chain guide from the crankcase.
32. Using a soft--faced hammer, carefully tap the lower
section of the crankcase loose from upper crankcase.
Once loose, pull the lower crankcase up and away from
the upper case. (Photo T)

PHOTO T

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 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. Match each rod cap with its corresponding
connecting rod. (Photo U)
NOTE: The connecting rod caps are “cracked” dur-
ing manufacture creating a unique mating surface
between the connecting rod and cap. Always verify
that the lower cap matches the connecting rod.
35. Always keep the connecting rod plain bearings, rod
caps, and bolts with the piston assembly the engine
was manufactured with.
PHOTO U

36. Remove the crankshaft assembly from the crankcase.

Remove each crankshaft plain bearing from both
crankcase halves and place with its original crankshaft
journal.
NOTE: Always mark the bearings for identification
during assembly and oil clearance measuring proce-
dures.

PHOTO U

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 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.
S Out of specification: Replace

Measure valve face width.

S Out of specification: Replace valve

Measure valve seat contact width.

1. Apply light coating of Prussian Blue or similar dye
compound to valve face.
2. Install valve into valve guide.
3. Tap valve several times to make a clear impression on
the valve face. Do not rotate valve.
4. Remove valve and measure valve seat width.
S Out of specification: Recondition or re-
place cylinder head.

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 ENGINE DISASSEMBLY / ASSEMBLY

Engine Inspection Procedures

Valve Inspection
Measure valve margin thickness.
S Out of specification: Replace valve

Measure valve stem diameter.

S Out of specification: Replace valve

Measure valve guide inside diameter.

S Out of specification: Replace valve guide

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 ENGINE DISASSEMBLY / ASSEMBLY
Engine Inspection Procedures

Valve Inspection
Measure valve stem runout.
S Out of specification: Replace valve

Measure valve spring free and installed length.

S Out of specification: Replace spring

Cylinder Head Inspection

Measure cylinder head warpage.
S Out of specification: Replace cylinder head

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 ENGINE DISASSEMBLY / ASSEMBLY

Engine Inspection Procedures

Cylinder Block Inspection

Measure cylinder bore size.
S Out of specification: Replace cylinder block
NOTE: Cylinders are plated with NiCaSil.

Measure cylinder for taper and out--of--round limits.

Db
1. BORE = Maximum diameter of Da -- Df.
Da
2. TAPER = Maximum of Da -- De and Db -- Df.
3. Out--of--Round = Maximum of Da -- Db and De -- Df.
S Out of specification: Replace cylinder block Dd

Dc

Df

De

Camshaft Inspection
Measure camshaft width.
S Out of specification: Replace camshaft

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 ENGINE DISASSEMBLY / ASSEMBLY
Engine Inspection Procedures

Camshaft Inspection
Measure cam lobe height.
S Out of specification: Replace camshaft

Measure camshaft runout.

S Out of specification: Replace camshaft

Measure camshaft bearing hole inside diameter.

S Out of specification: Replace camshaft
NOTE: Bearings must be removed to measure I.D.

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 ENGINE DISASSEMBLY / ASSEMBLY

Engine Inspection Procedures

Camshaft Inspection
Measure camshaft axle outside diameter.
S Out of specification: Replace axle

Measure camshaft axle clamp inside diameter.

S Out of specification: Replace cylinder head

Rocker Arm Inspection

Measure rocker arm axial play.
S Out of specification: Replace rocker arm

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 ENGINE DISASSEMBLY / ASSEMBLY
Engine Inspection Procedures

Rocker Arm Inspection

Measure rocker arm shaft outside diameter.
S Out of specification: Replace rocker arm shaft

Measure rocker arm post bore inside diameter.

S Out of specification: Replace rocker arm post

Crankshaft Inspection
Measure crankshaft deflection.
S Out of specification: Replace crankshaft

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 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
across the journal surface. Install lower crankcase
halve with journal bearings installed.
3. Loosely install lower crankcase bolts, turn engine up on
stand.
4. Install old cylinder head gasket, cylinder, and the
cylinder head nuts. Torque nuts and bolts to specified
torque and tightening sequence.
5. Carefully remove components and measure each
compressed piece of Plastigauge .
6. Reference bearing replacement guide if bearing oil
clearance is out of specification.
S Out of specification: Replace main bear-
ings, crankcase, or crankshaft.

Crankshaft Main Bearing Replacement Guide

Replacement of the crankshaft main bearings is required when the bearing oil clearance is out of specification.
Use this guide to select new bearings.
NOTE: Bearing color code is imprinted on the side of each bearing.
.0011″ -- .0015″ (.03mm -- .04mm)
SPECIFIED OIL CLEARANCE: ___________________
MEASURED OIL CLEARANCE: __________________
ORIGINAL INSTALLED BEARING COLOR / THICKNESS: _____________________

REPLACEMENT BEARING THICKNESS

RED .0677 - .0679 (1.721 - 1.726mm)
YELLOW .0679 - .0681 (1.726 - 1.731mm)
BLUE .0681 - .0683 (1.731 - 1.736mm)
GREEN .0683 - .0685 (1.736 - 1.741mm)
BROWN .0685 - .0687 (1.747 - 1.746mm)
If the measured clearance is within specification, replace with new bearings with the same color code.
If the oil clearance is outside of specification, install the BLUE color--coded bearings and re--measure oil clear-
ance. If the measured clearance is too small, install either a RED or YELLOW bearing. If the measured clearance
is too large, install either a BROWN or GREEN bearing.
If the used bearings reveal an oil clearance of .04 and .05mm, install new bearings with the same color code.

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 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. Install lower rod caps with journal bearings
installed.
3. Torque rod bolts to specified torque.
4. Remove caps and measure each compressed piece of
Plastigauge .
5. Reference bearing replacement guide if bearing oil
clearance is out of specification.
S Out of specification: Replace connecting rod bearings
Measure small end inside diameter.
S Out of specification: Replace connecting rod

Connecting Rod Bearing Replacement Guide

Replacement of the connecting rod bearings is required when the bearing oil clearance is out of specification.
Use this guide to select new bearings.
NOTE: Bearing color code is imprinted on the side of each bearing.
.0003″ -- .002″ (.01mm-- .064mm )
SPECIFIED OIL CLEARANCE: ___________________
MEASURED OIL CLEARANCE: __________________
ORIGINAL INSTALLED BEARING COLOR / THICKNESS: _____________________

REPLACEMENT BEARING THICKNESS

RED .0783 - .0785 (1.990 - 1.995mm)
YELLOW .0785 - .0787 (1.995 - 2.000mm)
BLUE .0787 - .0789 (2.000 - 2.005mm)
GREEN .0789 - .0791 (2.005 - 2.010mm)
BROWN .0791 - .0793 (2.010 - 2.015mm)
If the measured clearance is within specification, replace with new bearings with the same color code.
If the oil clearance is outside of specification, install the BLUE color--coded bearings and re--measure oil clear-
ance. If the measured clearance is too small, install either a RED or YELLOW bearing. If the measured clearance
is too large, install either a BROWN or GREEN bearing.
If the used bearings reveal an oil clearance of .04 and .05mm, install new bearings with the same color code.

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 ENGINE DISASSEMBLY / ASSEMBLY

Engine Inspection Procedures

Balance Shaft Inspection

Measure balance shaft runout at several locations.
S Out of specification: Replace balance
shaft

Measure bearing diameter.

S Out of specification: Replace balance shaft

Piston Inspection
Measure piston diameter.
S Out of specification: Replace piston

15mm

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 ENGINE DISASSEMBLY / ASSEMBLY
Engine Inspection Procedures

Piston Inspection
Measure piston pin boss inside diameter.
S Out of specification: Replace piston

Measure piston pin outside diameter.

S Out of specification: Replace piston pin
Confirm piston--to--cylinder clearance specification.
S Out of specification: Replace piston pin

Measure installed ring end gap.

S Out of specification: Replace rings or
cylinder block

Feeler Gauge

Cylinder

Piston Ring

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 ENGINE DISASSEMBLY / ASSEMBLY

Engine Inspection Procedures

Piston Inspection
Measure piston ring grove clearance.
S Out of specification: Replace piston ring
or piston Piston

Ring

Feeler Gauge

High Pressure Oil Pump Inspection

Measure relief spring free length and piston dimensions.
S Out of specification: Replace spring and
piston

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 ENGINE DISASSEMBLY / ASSEMBLY
Engine Inspection Procedures

Chain Tensioner
Verify chain tensioner function.
1. Push tensioner into housing until flush with threaded FULLY EXTENDED
housing. Tensioner should lock into place. (6 audible
clicks should be heard when tensioner is pushed in
from fully extended position.)
2. Once locked, push tensioner inward. Tensioner should
activate and spring outwards.
S Replace tensioner assembly if tensioner
will not lock, then engage when pushed
inward from locked position.
PUSH FLUSH TO LOCK
PUSH PAST FLUSH TO
ENGAGE

Chain Tensioner Guides

Visually inspect both chain guides.
S Replace guides if any cracking or abnor-
mal wear and tear is found.
NOTE: Tensioner chain guide shown.

INSPECT FOR WEAR

Starter Motor Clutch

Inspect clutch function.
S Clutch should move freely when rotated
clockwise.
S Clutch should not rotate freely when ro- =NO TURN
tated counter clockwise.
S Inspect rollers for wear and tear. Re-
place assembly if found.

=TURN FREELY

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 ENGINE DISASSEMBLY / ASSEMBLY

Engine Inspection Procedures

Timing Chain
Inspect timing chain.
S 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. Push lever down,
and withdraw valve keepers.
2. The valve will now fall out of the bottom of the cylinder.
Always keep the valve with its original location.

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 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:
S Upper / Lower Crankcase
S Cylinder Head
S Bedplate
S Lower Sump
S Crankshaft / Balance Shaft
4. After cleaning parts, blow dry with compressed air.
5. With the engine facing up on stand, lubricate cylinders
with engine oil.
6. Obtain both piston assemblies. Lubricate piston
assemblies with engine oil.
7. Install the upper and oil control rings with the markings
facing upwards.
UPPER RINGS
SPRING

OIL CONTROL RING

8. Place ring compressor tool, PN--PW--46983 on top of

one cylinder. Align the ring end gaps as outlined in the PISTON MARK
photo. The piston mark will face the INTAKE SIDE of GAP
the engine once installed into the cylinder.

GAP

GAP

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 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.
12. Select and install the connecting rod, crankshaft main
bearings, and balance shaft bearings. (Selection is
made using bearing selection process described in this
chapter.)
13. Coat all bearings and journals with engine oil. Install CHAIN GUIDE
water pump drive gear into crankcase.
14. Install the chain tensioner guide into the exhaust--side
of the crankcase. Tighten fastener to specification.

15. Install the balance shaft with the gear facing the front of
the engine.
NOTE: Verify bearing surfaces are centered within
journals. BALANCE SHAFT

DRIVE GEAR

16. Install crankshaft so that the two single--dot alignment

marks located on the balance shaft gear and
crankshaft gear face each other.
NOTE: Verify bearing surfaces are centered within
journals.
17. Coat bearing surfaces with engine oil.

SINGLE--DOT ALIGNMENT MARKS

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 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. Loosely install each
fastener, then tighten evenly.
20. Torque connecting rod cap bolts to specification.

21. Verify the lower and upper crankcase mating surfaces

are free from engine oil or foreign material.
22. Apply a thin, even bead of Three Bond 1213t case
sealant to the upper crankcase mating surface.

23. Apply sealant as outlined in photo.

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 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. Carefully install the lower crankcase on to the upper

crankcase.

26. Loosely install two of the four lower crankcase

fasteners.

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 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.
28. Rotate the engine 180_ so the pistons face upwards.

29. Clean the cylinder head mating surface free from oil
and foreign material. Install a new cylinder head gasket
with the part numbers and markings facing up and the
larger coolant slots located on the exhaust--side of the
engine.
NOTE: Always use a new cylinder head gasket, re-
gardless of original condition.

30. Install the cylinder head over the stud bolts with the
exhaust manifold studs facing the oil filter side of the
engine.
31. Apply engine oil to stud threads and loosely install the
cylinder head nuts.

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 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. Rotate the engine 180_. (Cylinder Head Up)
36. Tighten cylinder head nuts and lower crankcase
fasteners to specification as outlined on page 4.15.
37. Rotate the engine 180_. (Cylinder Head Down)
38. Proceed with the TIMING CHAIN INSTALLATION /
TDC PROCEDURE.

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 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:
S Timing Chain Installation Guide PN--PW--47079
S Timing Chain Hook / Stuffer PN--PW--47108
S Crankshaft Turning Hand Crank PN--PW--46981
S Camshaft Alignment Tool PN--PW--47077

Timing Chain Installation

1. Remove the rocker arm pins and rocker arms from
the cylinder head.
2. Install the Crankshaft Hand Crank Tool into the
nose of the crankshaft. Set the jam nut so the
crankshaft can be turned left or right.
3. Rotate the crankshaft until double--dot alignment
marks on each gear face each other. (The
engine will be set to BDC when the two sets of
double dots face each other.)

4. Install the the Timing Chain Installation Guide,

PN--PW--47079, into the two bedplate fastener
bores.
NOTE: The Timing Chain Installation Guide tool
will guide the chain around the crankcase bends
while preventing the chain from catching on the
balance shaft sprocket.

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 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. Insert the stuffer end of the Timing Chain Hook /

Stuffer, PN--PW--47108, tool into the chain gallery.
NOTE: The stuffer wedge will prevent the chain
from catching on the sprocket.

7. Allow three to four chain links to fall past the

cylinder head parting line.
NOTE: Verify the chain is not caught on the bal-
ance shaft sprocket and that the marks on the
gears are still in alignment!

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 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.

10. Carefully drop the chain UNDERNEATH the

crankshaft and around the chain guide.
NOTE: Do not drop the chain around the OUT-
SIDE of the crankshaft. When performed prop-
erly, the chain should drop easily through the
engine and protrude from the cylinder head.

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 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 the 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.

13. Wrap chain around camshaft sprocket and secure

links with new pins and plate assembly.
NOTE: Do not use the chain crimper to as-
semble chain links at this time.
14. Rotate the engine 180_. (Cylinder Head Up)
15. Carefully rotate the crankshaft until the timing
marks on the gears are pointing at each other. The
valve train should resemble the illustration below.

LEVEL LEVEL

TDC
MAG
OVERLAP
STROKE

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 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. DO NOT OVER--PRESS THE
PLATE.

2. Verify the chain tensioner is set in the locked position.

To set the chain tensioner, grasp end in palm of hand,
and press assembly down on a hard surface. The FULLY EXTENDED
tensioner is set in the locked position when it is flush
with the tensioner housing.
3. Install the chain tensioner into the crankcase. Tighten
housing cap to specification.

PUSH FLUSH TO LOCK

PUSH PAST FLUSH TO
ENGAGE

4. Insert the blade of a flat head screwdriver between the

tensioner and the tensioner rail guide.

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 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.
7. Once activated, there should be no slack present in the
timing chain.

8. Install low pressure pump and screen into bedplate.

Clean bedplate and lower crankcase mating surfaces.
9. Apply a thin bead of Three Bond 1215t to the mating SCREEN
surface and Install the bedplate. Tighten fasteners to
specification. DRIVE GEAR
10. Install the high pressure oil pump assembly as outlined
on page 4.12. PUMP
11. Rotate the engine 180_. (Cylinder Head Up)

BEDPLATE

12. Coat the gears located at the front of the engine with
engine oil. STARTER MOTOR GEAR
13. Install the starter motor gear, low pressure oil pump
idler gear.

IDLER GEAR

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 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. Apply a thin bead of Three Bond 1215t to the front
gear cover mating surface.
18. Install the front gear cover. Tighten fasteners to
specification.

19. Install the water pump impeller. Tighten impeller nut to

specification.
20. Install water pump housing and coolant hose. Tighten
fasteners to specification.

2004 Four Stroke PWC Service Manual 4.55

 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.
24. Apply Loctitet 262 to flywheel bolt, and install.

FLYWHEEL
STARTING GEAR

25. 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.

26. Tighten flywheel bolt to specification.

4.56 2004 Four Stroke PWC Service Manual

 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. Reinstall the two high--pressure oil supply hoses and

banjo bolt to the top of the cylinder head.
30. Tighten banjo bolt to specification.

NOTE: Before installing the valve cover and gaskets, the valve clearance must be checked. Follow
the procedure outlined in chapter two. Replace any valve clearance shims that are out of specifica-
tion or worn.
After completing the valve clearance adjustment, reinstall the valve cover using new gaskets and o rings.

2004 Four Stroke PWC Service Manual 4.57

 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.
The second cooling circuit is the INTERNAL ENGINE circuit. The internal engine cooling circuit is responsible
for cooling the cylinder head, oil cooler, and turbocharger bearing house. Heat absorbed into the internal engine
circuit is dissipated to the freshwater circuit inside of the water--to--water heat exchanger.

Freshwater Cooling Circuit

OIL STORAGE EXHAUST

JET PUMP INTERCOOLER
TANK MANIFOLD

TURBINE JACKET
PIPE JACKET

HEAT EXCHANGER WATER--TO--WATER

DRAIN HOSE HEAT EXCHANGER EXHAUST PIPE
WATER INJECTOR
PUMP BOX OUTLET

Internal Engine Cooling Circuit

BLEED HOSE
ET

TURBOCHARGER

TOP OF CYLINDER WATER--TO--WATER

OUTLET RAIL TS
HEAD HEAT EXCHANGER
(INTAKE SIDE)

BOTTOM OF CYLINDER
HEAD
WATER PUMP OIL COOLER
(INTAKE SIDE) TS = THERMOSTAT
ET = EXPANSION TANK

Cooling System Specifications

Internal Engine Coolant 50/50 Distilled Water / Propolyne Glycol
Internal Engine Coolant Capacity 3.5 US Quarts (3.3 Liters)
Thermostat Opening Temperature 180_ F (82_ C)
Internal Engine Circuit Operating Pressure 14.6 psi (1 Bar)
Exhaust Stream Injector Orifice Size .185″

4.58 2004 Four Stroke PWC Service Manual

 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. Carefully twist and pull the elbow out of the rail.
3. Inspect the o rings. Replace if found worn or damaged.
4. Remove and replace thermostat.
5. Insert thermostat with bleed hole up.
6. Reinstall the elbow. Reinstall the snap ring. Verify the
snap ring chamfer faces out when installing.

Water Pump Removal / Installation

NOTE: The engine must be removed to access the water pump housing.
1. The water pump cover can be removed by 4 fasteners
that mount the cover to the front gear cover.
GEAR COVER
2. Always replace the o ring with new during reassembly.
MECHANICAL SEAL ASSEMBLY
3. The impeller can be removed by holding the crankshaft
stationary while turning the impeller nut
counter--clockwise. O RING
4. Tighten fasteners to specified torque outlined at
beginning of chapter.

IMPELLER
COVER

1. To replace the impeller shaft and mechanical seal,

remove the front gear cover.
IMPELLER
2. Carefully extract mechanical seal components out of WASHER
the gear cover.
3. Press new gasket with washer recess facing out,
washer with groves facing gasket, and new mechanical
seal, with spring--end facing outward into cover using
light and even force.
GASKET
4. The impeller shaft sits inside crankcase bore. Replace MECHANICAL SEAL
shaft if worn or damaged.
5. Tighten fasteners to specified torque outlined at
beginning of chapter.

2004 Four Stroke PWC Service Manual 4.59

 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

(TO HEAT EXCHANGER)

4.60 2004 Four Stroke PWC Service Manual

 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)

2004 Four Stroke PWC Service Manual 4.61

 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-
TER OUTLET RAIL
TO EXPANSION
TANK)

ENGINE COOLANT
HOSE (FROM HEAT EX-
CHANGER TO OIL
COOLER -- THERMO-
STAT OPEN)

ENGINE COOLANT HOSE

(FROM HEAT EXCHANGER
TO OIL COOLER -- THERMO-
STAT CLOSED)

ENGINE COOLANT HOSE (FROM

WATER PUMP TO TURBO)

ENGINE COOLANT HOSE

(FROM WATER OUTLET RAIL TO OIL COOLER)
ENGINE COOLANT HOSE
(FROM OIL COOLER TO WATER PUMP HOUSING)

4.62 2004 Four Stroke PWC Service Manual

 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)

2004 Four Stroke PWC Service Manual 4.63

 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

(FROM HEAT EXCHANGER TO OIL
COOLER -- THERMOSTAT OPEN)

4.64 2004 Four Stroke PWC Service Manual

 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. The high pressure pump draws oil in from the oil storage tank, and supplies oil to all of
the internal engine components. The low pressure pump supplies approximately twice the amount of oil to the
oil storage tank than what the high pressure pump requires. This ensures a constant supply of oil.
A small amount of pressurized oil is supplied to the turbocharger bearing house and oil storage tank anti--siphon
valve. The anti--siphon valve is located on top of the oil storage tank. The valve works by preventing oil from
the tank to back--feed into the engine in the even that oil pressure is lost. (Watercraft Rollover)

Low Pressure Oil Circuit

ENGINE OIL STORAGE

SUMP OIL COOLER TANK

High Pressure Circuit

OIL STORAGE CRANKCASE

TANK MAIN BEARINGS
BALANCE SHAFT
BEARINGS

HIGH
PRESSURE OIL FILTER PISTON OIL JETS
PUMP
ANTI SIPHON VALVE
CYLINDER HEAD
VALVE TRAIN
RELIEF VALVE TURBO
DRAIN TO SUMP

2004 Four Stroke PWC Service Manual 4.65

 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. Heavy elements such as oil and unburned fuel are collected at the bottom of the separator and
are routed back to the crankcase sump. The remaining vapors are collected at the top of the separator and routed
to the air intake flame arrestor where they are drawn into the intake air stream and burned.

Crankcase Ventilation Circuit

OIL
FLAME ARRESTOR
SEPARATOR

OIL STORAGE
TANK

CRANKCASE
SUMP

Low Pressure Pump Removal / Installation

NOTE: The engine must be removed to access the low pressure pump.
1. Remove the crankcase bedplate from the lower
crankcase.
2. Remove the fasteners securing the screen to the SCREEN
bedplate and pump.
3. Remove the pump from the bedplate. DRIVE GEAR

NOTE: The low pressure pump is not serviceable

and must be replaced as one component is when PUMP
operation is suspect.

BEDPLATE

High Pressure Pump Removal / Installation

NOTE: The engine must be removed to access the high pressure pump.
1. Remove snap ring. Carefully extract rotor cover from
crankcase. INNER ROTOR
TIMING ROTOR
2. Extract outer and inner rotors from bore. Remove RETAINING CAP
timing rotor from shaft.
3. Carefully remove timing key.
NOTE: Always use a new timing key and o rings
during pump assembly.
NOTE: Verify snap ring bevel faces outward.
OUTER ROTOR
O--RINGS

SNAP RING
(CHAMFER
FACES OUT)

4.66 2004 Four Stroke PWC Service Manual

 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

OIL SEPARATOR -- TO -- AIR INTAKE SUPPLY HOSE -- OIL
OIL TANK -- TO -- OIL
PRESSURE PUMP

RETURN HOSE -- OIL

OIL SEPARATOR -- TO -- SUMP

BOW

SUPPLY HOSE -- OIL

OIL COOLER -- TO -- OIL TANK

RETURN HOSE -- OIL

TURBO--TO--SUMP

SUPPLY HOSE -- OIL

SUMP -- TO -- OIL COOLER

LEFT--SIDE

2004 Four Stroke PWC Service Manual 4.67

 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

 ENGINE DISASSEMBLY / ASSEMBLY
High Pressure Oil Supply

GREEN = LOW PRESSURE / PRE FILTRATION

BLUE = HIGH PRESSURE / PRE FILTRATION
RED = HIGH PRESSURE / POST FILTRATION

2004 Four Stroke PWC Service Manual 4.69

MSX 110 / 150 Service Manual Fuel Injection / Ignition / Exhaust Systems
Bosch Engine Management System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Engine Management System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Air Inlet Hose Routings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Fuel Hose Routings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Vent Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Fuel Tank Assembly Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Fuel Supply / Vent Hose Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Fuel Rail / Injector Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Electronic Throttle Body Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Spark Plug / Ignition Coil Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
ECU Mounting Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
ECU Wiring Harness Connector Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 -- 5.14
Engine Management Sensor Circuit Drawings w/Trouble Codes . . . . . . . . . . . . . . 5.15 -- 5.27
ECU Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
ECU Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
Electronic Throttle Body / PPU Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30
Exhaust System Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger / Wastegate Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge Air Cooler Overview / Turbocharger Troubleshooting . . . . . . . . . . . . . . . .
RPM Limiting Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting: Engine Will Not Turnover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.31
5.32
5.34
5.35
5.36
-- 5.33
5
Troubleshooting: Engine Turns Over; Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . 5.37
Troubleshooting: Engine Stalls; Will Re--Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38
Troubleshooting: Engine Stalls: Will Not Re--Start . . . . . . . . . . . . . . . . . . . . . . . . . 5.39
Troubleshooting: Engine Lacks Performance, RPM Limits . . . . . . . . . . . . . . . . . . 5.40 -- 5.42
Troubleshooting: General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
 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.
The Engine Control Unit (ECU) is responsible for controlling and monitoring the density of each cylinders’ air
charges, the mass of injected fuel, and ignition timing.
In order to accomplish these tasks, the ECU relies on the following sensors and feedback systems:
Throttle Flipper Position (PPU)
Electronic Throttle Body Position (ETB)
Lambda Sensor (O2 Sensor)
Cam Phase Sensor
Engine Speed Sensor (Crankshaft Position Sensor)
Engine Coolant Sensor
Knock Sensor
Manifold Pressure Sensor
BATTERY
Boost Pressure / Air Temp. Sensor VOLTAGE
Battery Voltage
PPU POSITION
The ECU has direct control over the following components:
ETB VALVE
Fuel Injectors APERTURE
Ignition Coils INTAKE AIR TEMP
Electronic Wastegate Solenoid
BOOST
Electronic Throttle Body DC Motor (ETB) PRESSURE
Fuel Pump and Main Relay
INTAKE MANIFOLD
O2 Sensor Heating Element PRESSURE
ENGINE TEMP.

KNOCK SENSOR

CAM PHASE
SENSOR
ENGINE SPEED
SENSOR
O2 SENSOR

DIAGNOSTIC
CONNECTION

ELECTRONIC THROTTLE
BODY DC MOTOR ECU
(ETB)

FUEL PUMP
RELAY
SPARK PLUGS
MAIN RELAY
FUEL INJECTORS
TACHOMETER

WASTEGATE O2 SENSOR
SOLENOID HEATER

2004 Four Stroke PWC Service Manual 5.1

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Fuel Injection and Ignition System Specifications

Component Specification
Fuel Injection Type Sequential Port Fuel Injection
Throttle Body Type Electronic Throttle Body
Throttle Body Marking Bosch DV--E5
ETB Throttle Position Sensor 1 Tested Using Diagnostic Software
Operating Voltage Range .3 to .7 vDC @ LOWER MECHANICAL STOP
ETB Throttle Position Sensor 2 4.45 to 4.85 vDC @ UPPER MECHANICAL STOP
Operating Voltage Range Tested Using Diagnostic Software
4.3 to 4.7 vDC @ LOWER MECHANICAL STOP
(Range between lower and upper mechanical stop points.) .15 to .55 vDC @ UPPER MECHANICAL STOP
PPU Position Sensor 1 Tested Using Diagnostic Software
Operating Voltage Range (0% to 80% OPEN) .325 to .475 vDC @ 0% / 3.5 to 3.9 vDC @ 80%
PPU Position Sensor 2 Tested Using Diagnostic Software
Operating Voltage Range (0% to 40% OPEN) .125 to .275 vDC @ 0% / 1.7 to 2.0 vDC @ 40%
Idle Speed
In Water / Out of Water 1550 ± 50 RPM
Spark Plug Type Champion RC7PYCB
Spark Plug Gap .6 -- .7mm (.025 -- .030in.)
Fuel Pump Output Pressure 3 Bar + Boost (43.5 psi + Boost)
Fuel Pressure Regulator Type Bosch DR 2.1
Ignition Coil Type Bosch ZS--K--1
Primary Coil Resistance .73Ω ± 10%
Secondary Coil Resistance N/A -- Diode Protected
Fuel Injector Type Bosch EV--6E
Fuel Injector Resistance 12Ω
Engine Speed Sensor Resistance 860Ω ± 10% @ 68_F (20_C)
Engine Speed Sensor Gap .8mm ± .5mm (.03 in. ± .02 in.)
Cam Phase Sensor Resistance Tested Using Diagnostic Software
Cam Phase Sensor Gap .8 mm (.03 in.)
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]
[1800 -- 1900 MB ABSOLUTE]
MSX 150
[1.3 BAR (18 psi) for more than 400ms. GAUGE]
[2300 MB ABSOLUTE]
Wastegate Solenoid Resistance Tested Using Diagnostic Software 28.5 -- 32Ω
Boost Pressure / Air Temp. Sensor Resistance Tested Using Diagnostic Software
Manifold Pressure Sensor Resistance Tested Using Diagnostic Software
Knock Sensor Resistance 4.9MΩ ± 20%
Engine Coolant Temperature Sensor Resistance 2.5KΩ ± 5% @ 68_F (20_C)
Exhaust Coolant Temperature Switch Resistance 1.4Ω
Oxygen Sensor
Resistance between housing and ANY sensor pin. (New Condi
tion @ 23_C / 50% humidity and heater off.) ² 30MΩ
Resistance between heater and sensor signal circuit. (New Con
dition @ 23_C / 50% humidity and heater off.) ² 30MΩ (Between Pins 1 or 2 and Pin 3)

@ 350_C exhaust temperature. ² 1MΩ

5.2 2004 Four Stroke PWC Service Manual

 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 5.3

 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.
Both hoses are routed underneath steering cable at helm location.
Both hoses are routed over the steering cable at engine compartment location.

5.4 2004 Four Stroke PWC Service Manual

 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 5.5

 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. (14 -- 20 Nm)
Large Worm Gear Clamp Torque: 35 in.lbs. (4 Nm)

Verify tank pad is installed.

Replace tank hold--down straps if worn or damaged.

5.6 2004 Four Stroke PWC Service Manual

 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. Arrow on filter cartridge points downstream, towards fuel rail.
Verify hose routings are free from sharp bends and kinks. Never locate hoses near sharp objects.
Check valve opening pressure: 1.5 PSI.
Vacuum Relief Valve will allow air flow to pass when differential vacuum is equal to , or less than 3 HG.

2004 Four Stroke PWC Service Manual 5.7

 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. Never allow foreign material to enter fuel injector screens.
Clean fuel injector nozzles and screens with clean fuel.

5.8 2004 Four Stroke PWC Service Manual

 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
Electronic Throttle Body Fasteners: 7 ft.lbs. (10 Nm)
Intake Manifold -- To -- Cylinder Head Fasteners: 7 ft.lbs. (10 Nm)
Manifold Pressure Sensor Fastener Torque: 5 ft.lbs. (7 Nm)
Manifold -- To -- Lower Bracket Fastener Torque: (M6 x 25): 7 ft.lbs. (10 Nm) / M8 x 60 17 ft.lbs. (24Nm) Apply Loctitet 242 to
threads.
Lower Bracket -- To -- Crankcase Fastener Torque: 22 ft.lbs. (30 Nm)
High Pressure Air Banjo Fitting Torque: 7 ft.lbs. (10 Nm)

Never re--use o--rings or gaskets.

Verify heat exchanger mount pads are installed.

2004 Four Stroke PWC Service Manual 5.9

 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

 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.

2004 Four Stroke PWC Service Manual 5.11

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
ECU C100 Harness Connector (Grey Color Code)

ECU C100 Harness Connector Interface Description (As viewed from terminal side.)

PIN WIRE COLOR PIN FUNCTION SENSOR / SENSOR PIN #

H1 BLACK Electronic Ground Splice 8
C1 BLUE/WHT Manifold Pressure Signal Manifold Pressure Sensor / 4
B1 BLUE/WHT Engine Speed Sensor Signal Engine Speed Sensor / 1
H2 BLK/OR Fuel Injector Output Signal PTO Fuel Injector / 2
G2 BLK/OR Fuel Injector Output Signal MAG Fuel Injector / 2
C2 BLK/WHT Sensor Reference Ground (Splice 4)
Manifold Pressure Sensor / 1
Boost Pressure Intake Temp. Sensor / 1
B2 BLU/BLK Engine Speed Sensor Signal Engine Speed Sensor / 2
A2 BLK/WHT Sensor Reference Ground Cam Phase Sensor / 1
F3 BLK/GRN Fuel Pump Relay Signal Main Relay / 7
C3 RED/GRN 5 Volt Reference Output (Splice 5)
Signal Cam Phase Sensor / 3
Manifold Pressure Sensor / 3
Boost Pressure -- Intake Temp. Sensor / 3
B3 BLK/WHT O2 Reference Ground Lambda Sensor / 3
A3 BLU/YEL O2 Signal Input Lambda Sensor / 4

5.12 2004 Four Stroke PWC Service Manual

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
ECU C200 Harness Connector (Brown Color Code)

ECU C200 Harness Connector Interface Description (As viewed from terminal side.)

PIN WIRE COLOR PIN FUNCTION SENSOR / SENSOR PIN #

B4 BLU/WHT Ignition Switch Input System Interface Box / C
C4 GRN/RED Check Engine MIL Lamp Engine -- Chassis Connector / G
L4 BLACK Electronic Ground Splice 7
M4 BLACK Fuel Injection Ground Splice 8
A3 BLK/WHT Engine Speed Sensor Ground Engine Speed Sensor / 3
E3 PUR/WHT ESP Signal Input Engine -- Chassis Connector / B
K3 GRN/YEL Engine High Temp. MIL Engine -- Chassis Connector / H
Output
A2 BLU/RED Pedal Position 2 Input PPU Interface Box / A
E2 GRN/YEL Reverse Switch Signal Input System Interface Box / B
H2 BLU/YEL Diagnostic K--Line Diagnostic Connector / A
J2 GREY Engine Speed Signal (TACH.) (Splice 12)
Output System Interface Box / G
Engine -- Chassis Connector / K
A1 GRY/RED Pedal Position 1 Input PPU Interface Box / C
B1 RED/GRN Pedal Position Supply Voltage (Splice 11)
Pedal Position Unit / 3, 6
PPU Interface Box / B
K1 BLK/WHT Pedal Position Reference (Splice 10)
Ground Pedal Position Unit / 4, 5
PPU Interface Box / E

2004 Four Stroke PWC Service Manual 5.13

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
ECU C300 Harness Connector (Black Color Code)

ECU C300 Harness Connector Interface Description (As viewed from terminal side.)

PIN WIRE COLOR PIN FUNCTION SENSOR / SENSOR PIN #

B4 BLU/GRN Throttle Position 2 Electronic Throttle Body / 5
C4 BLU/RED Temp. Switch Input Temp. Switch / A
D4 BLK/WHT Sensor Reference Ground Engine Temp. Sensor / 2
E4 BLU/RED Engine Temp. Signal Input Engine Temp. Sensor / 1
F4 BLU/OR Boost Pressure Signal Boost Pressure -- Intake Temp. Sensor / 4
G4 BLK/RED Sensor Reference Ground Wastegate Solenoid / 1
H4 BLACK Ignition Ground (Splice 6)
Ignition Coils / 2
B3 BLK/WHT Knock Sensor Ground Knock Sensor / 2
C3 BLU/RED Knock Sensor Signal Knock Sensor / 1
F3 BLU/RED Cam Phase Sensor Signal Cam Phase Sensor / 2
G3 GREEN Ignition Driver 1 PTO Ignition Primary / 1
H3 ORANGE Ignition Driver 2 MAG Ignition Primary / 1
A2 BLU/YEL Intake Air Temp. Signal Boost Pressure -- Intake Temp. Sensor / 2
E2 BROWN O2 Heating Supply Lambda Sensor / 2
F2 BLK/GRN Main Relay Output Main Relay / 10
G2 RED/PUR Switched Battery Supply Input Main Relay / 2
A1 BLU/OR Throttle Position 1 Input Electronic Throttle Body / 6
B1 BLK/WHT Throttle Position Ref. Ground Electronic Throttle Body / 2
C1 RED/GRN Throttle Position Supply Voltage Electronic Throttle Body / 3
G1 RED/WHT Throttle Plate Positive Voltage Electronic Throttle Body / 4
H1 BLK/RED Throttle Plate Negative Voltage Electronic Throttle Body / 1

5.14 2004 Four Stroke PWC Service Manual

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Electronic Throttle Body Circuit

ECU 300 (Black)

A B C D E F G H
C1 TPS Supply Voltage
4

3
B1 Ground Reference
2
H1 Throttle Valve Negative Terminal
1

A B C D E F G H J K L M
4 3 1 2
3

G1 Throttle Valve Positive Terminal

B4 Throttle Position Sensor 2

A B C D E F G H
4

3 A1 Throttle Position Sensor 1

2

ECU 100 (Grey)

Circuit Trouble Codes

P -- Code Description Summary

P0120 Throttle Position Sensor: Plausibility Error Indicates the readings from the two TPS sensors do not agree.
P0122 Throttle Position Sensor: Open or Short to Indicates an open, or short to ground condition in one of the TPS
Ground signal circuits.
P0123 Throttle Position Sensor: Short to Battery Indicates a short to battery voltage condition in one of the TPS
signal circuits.
P1601 Throttle Valve Learning: Position Out of Range Indicates the low mechanical position during learning was out of
range.
P1602 Throttle Valve Learning: Conditions Not Met Indicates environmental conditions during learning were out of
range.
P1603 Throttle Valve Learning: Signal Error Indicates the throttle valve was not able to move far enough to
complete the learning process.
P1604 Throttle Valve Learning: Battery Voltage Too Low Battery voltage was too low to complete the learning process.
P1900 Throttle Valve Servo: Plausibility Error The throttle valve servo is unable to reach the desired throttle
valve opening.
P1901 Throttle Valve Servo: Setting Out of Range (Low) The throttle valve servo is unable to reach the desired throttle
valve opening.
P1902 Throttle Valve Servo: Setting Out of Range The throttle valve servo is unable to reach the desired throttle
(High) valve opening.
P1903 Throttle Valve Servo: Signal Error The throttle valve servo is unable to reach the desired throttle
valve opening.

2004 Four Stroke PWC Service Manual 5.15

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Pedal Position (PPU) Circuit

ECU 300 (Black)

A1 Pedal Position Sensor 1
A B C D E F G H
4
B1 PPU Voltage Supply PPU
3
A2 Pedal Position Sensor 2 A BC
2 IFB
1
F E D

A B C D E F G H J K L M
4

2
Splice 10
1
1
2
Splice 11 3
A B C D E F G H

3
4

K1 PPU Ground Reference

4 Pedal
5
Position
2

1
6
B1 PPU Voltage Supply Unit
ECU 100 (Grey)

Circuit Trouble Codes

P -- Code Description Summary

P0220 Pedal Position Sensor #1: Plausibility Error Indicates the signals from the two pedal position sensors do not
agree.
P0222 Pedal Position Sensor #1: Short to Ground Pedal position sensor # 1 signal is too low. Can be caused by a
short to ground in the pedal position sensor #1 circuit.
P0223 Pedal Position Sensor #1: Open or Short to Bat- Pedal position sensor #1 signal is too high. Can be caused by a
tery open circuit or short to battery voltage.
P0225 Pedal Position Sensor #2: Plausibility Error Indicates the signals from the two pedal position sensors do not
agree.
P0227 Pedal Position Sensor #2: Short to Ground Pedal position sensor #2signal is too low. Can be caused by a
short to ground in the pedal position sensor #2 circuit.
P0228 Pedal Position Sensor #2: Open or Short to Bat- Pedal position sensor #2 signal is too high. Can be caused by a
tery open circuit or short to battery voltage.

5.16 2004 Four Stroke PWC Service Manual

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Fuel Injection Circuit

ECU 300 (Black)

To Main Relay Terminal 4

A B C D E F G H
4

2
Splice 1
8
1
15
7
14
6
13
5
12
4
A B C D E F G H J K L M
11
4
Injector 1 3
3 10
2
2 (PTO) 9
1
1

A B C D E F G H
4
G2 Injector 1 (PTO) Control
3

2 H2 Injector 2 (MAG) Control

1
Injector 2
(MAG)
ECU 100 (Grey)

Circuit Trouble Codes

P -- Code Description Summary

P0261 Injector #1: Short to Ground Fuel injector #1 driver circuit is shorted to ground. Operating the
engine with this code can cause serious engine damage.
P0262 Injector #1: Short to Battery Fuel injector #1 circuit is shorted to battery voltage.
P0264 Injector #2: Short to Ground Fuel injector #2 driver circuit is shorted to ground. Operating the
engine with this code can cause serious engine damage.
P0265 Injector #2: Short to Battery Fuel injector #2 circuit is shorted to battery voltage.
P1260 Injector #1: Open Load The #1 fuel injector circuit is open.
P1263 Injector #2: Open Load The #2 fuel injector circuit is open.

2004 Four Stroke PWC Service Manual 5.17

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Ignition Coil Circuit
ECU 300 (Black)
Splice 6
H4 Ignition Ground
Ignition
A B C D E F G H

3
4
Coil 2
H3 Ignition Coil 2
1
2

(MAG) Control
1
(MAG)
2
3
A B C D E F G H J K L M
4
8
3 15
7
2
14
6
1
13
Splice 2 5
12
4
11

G3 Ignition Coil 1
1 3
10
A B C D E F G H
4 (PTO) Control 2 2

1
9
3
3
2
Ignition Ignition Power
1

Coil 1 To Main Relay

ECU 100 (Grey)
(PTO) Terminal 5

Circuit Trouble Codes

P -- Code Description Summary

P0351 Ignition Coil #1: Plausibility Error Both ignition coil circuits are shorted to ground.
P0352 Ignition Coil #2: Plausibility Error Both ignition coil circuits are shorted to ground.
P1351 Ignition Coil #2: Short to Ground Ignition coil #2 circuit is shorted to ground.
P1352 Ignition Coil #1: Short to Ground Ignition coil #1 circuit is shorted to ground.
P1353 Ignition Coil #2: Short to Battery Ignition coil #2 circuit is shorted to battery voltage.
P1354 Ignition Coil #1: Short to Battery Ignition coil #2 circuit is shorted to battery voltage.

5.18 2004 Four Stroke PWC Service Manual

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Lambda Sensor Circuit

ECU 300 (Black)

A B C D E F G H
4

1
E2 O2 Heating Control
O2 Heating Power
To Main Relay
A B C D E F G H J K L M
4
Terminal 13
3 1 1
2
2 2
1
3 3
4 4

A3 O2 Signal
A B C D E F G H
4
O2
3

2
B3 O2 Ground
1

Exhaust
ECU 100 (Grey)

Circuit Trouble Codes

P -- Code Description Summary

P0030 Heated Oxygen Sensor Circuit: Open Load The O2 heater circuit is open.
P0031 Heated Oxygen Sensor Circuit: Short to Ground The O2 heater circuit is shorted to ground.
P0032 Heated Oxygen Sensor Circuit: Short to Battery The O2 heater circuit is shorted to battery voltage.
P0130 Oxygen Sensor Circuit: Signal Error TBD
P0131 Oxygen Sensor Circuit: Plausibility Error Indicates the O2 sensor signal is outside an acceptable range.
P0132 Oxygen Sensor Circuit: Short to Battery Indicates the O2 sensor signal is too high.
P0133 Oxygen Sensor Circuit: Slow Response The O2 sensor signal is slow to respond to fuel mixture changes.
P0134 Oxygen Sensor Circuit: Low Output The O2 sensor signal has not changed for a long period of time.
P0135 Heated Oxygen Sensor Circuit: Plausibility Error The O2 sensor signal is outside an acceptable range.

2004 Four Stroke PWC Service Manual 5.19

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Boost / Air Temperature Circuit
ECU 300 (Black)

A B C D E F G H
4
F4 Boost Pressure Signal
3

A2 Air Temperature Signal

1
A B C D E F G H J K L M
4
2
3

2 3
1
4
Splice 5
A B C D E F G H C3 5--Volt Reference
Boost/Air Temp
4

1 Splice 4 Sensor
C2 Ground Reference

ECU 100 (Grey)

Circuit Trouble Codes

P -- Code Description Summary

P0112 Intake Air Temperature: Short to Ground The intake air temp. signal is shorted to ground or open.
P0113 Intake Air Temperature: Short to Battery The intake air temp. signal is shorted to battery voltage.
P0237 Boost Pressure Sensor: Open or Short to The boost pressure signal is shorted to ground or open.
Ground
P0238 Boost Pressure Sensor: Short to Battery The boost pressure signal is shorted to battery voltage.

5.20 2004 Four Stroke PWC Service Manual

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Manifold Pressure Circuit
ECU 300 (Black)

A B C D E F G H
4

2
Manifold Pressure
1 Sensor
1
A B C D E F G H J K L M
4 2
3

2 3
1

4
Splice 5
A B C D E F G H

3
4
C3 5--Volt Reference
2

1 C2 Ground Reference Splice 4

C1 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
range.
P0106 Intake Manifold Pressure: Signal Error the intake manifold pressure is outside an acceptable range, but
not shorted to ground or battery voltage.
P0107 Intake Manifold Pressure: Short to Ground The intake manifold pressure signal is shorted to ground.
P0108 Intake Manifold Pressure: Short to Battery The intake manifold pressure signal is shorted to battery voltage.

2004 Four Stroke PWC Service Manual 5.21

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Engine Coolant Temperature Sensor Circuit

ECU 300 (Black)

A B C D E F G H
4

3
E4 Engine Temperature Signal
2

1
1
2
D4 Engine Temperature Ground
A B C D E F G H J K L M
4

2 Coolant
1

Temperature Sensor

A B C D E F G H
4

ECU 100 (Grey)

Circuit Trouble Codes

P -- Code Description Summary

P0116 Engine Temperature: Signal Error Indicates the engine temp. signal is outside an acceptable range,
but not shorted to ground or battery voltage.
P0117 Engine Temperature: Short to Ground The engine temp. signal is shorted to ground.
P0118 Engine Temperature: Open or Short to Battery The engine temp. signal is shorted to battery voltage.

5.22 2004 Four Stroke PWC Service Manual

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Engine Crankshaft Position (Engine Speed) Sensor Circuit

ECU 300 (Black)

A B C D E F G H
4

B1 Crank Signal A
A B C D E F G H J K L M 1
3
4

B2 Crank Signal B Crankshaft

2
1
2

A3 Ground Reference
Sensor
3

1 A B C D E F G H
4

2 3

2
3
1

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.
P0336 Engine Speed Sensor: Signal Error The engine speed sensor signal is not valid.
P0337 Engine Speed Sensor: Low Limit The engine speed signal voltage is outside the acceptable range.
P0338 Engine Speed Sensor: High Limit The engine speed signal voltage is outside the acceptable range.

2004 Four Stroke PWC Service Manual 5.23

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Camshaft Position Circuit

ECU 300 (Black)

A B C D E F G H
4

A2 Ground Reference
A B C D E F G H J K L M
4 1 Camshaft
3 F3 Camshaft Signal
2 2 Sensor
C3 5-- Volt Supply
1

A B C D E F G H
4

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.
P0341 Camshaft Sensor Circuit: Signal Error Indicates a problem with the camshaft sensor signal switch from
high to low.
P0342 Camshaft Sensor Circuit: Short to Ground The camshaft sensor signal is shorted to ground.
P0343 Camshaft Sensor Circuit: Open or Short to Bat- The camshaft sensor signal is shorted to open or battery voltage.
tery

5.24 2004 Four Stroke PWC Service Manual

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Knock Sensor Circuit

ECU 300 (Black)

A B C D E F G H
4

C3 Knock Signal
A B C D E F G H J K L M
4
1
3

2
2
1
B3 Ground Reference

A B C D E F G H
Knock Sensor
4

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.
P0328 Knock Sensor Signal High The knock sensor signal is too high.

2004 Four Stroke PWC Service Manual 5.25

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Wastegate Solenoid Circuit

ECU 300 (Black)

A B C D E F G H
4

G4 Wastegate Solenoid Control

3

2
Wastegate
1
Solenoid
Wastegate Power

A B C D E F G H J K L M Splice 1
4

8
1
15
7
14
6
13
5
12
A B C D E F G H 4
4 11
3
To Main Relay Terminal 4 3
10
2
2
9
1
1

ECU 100 (Grey)

Circuit Trouble Codes

P -- Code Description Summary

P0243 Wastegate Solenoid: Open Circuit Indicates an open circuit within the control circuit.
P0245 Wastegate Solenoid: Short to Ground Indicates the control circuit is shorted to ground.
P0246 Wastegate Solenoid: Short to Battery Indicates the control circuit is shorted to battery voltage.

5.26 2004 Four Stroke PWC Service Manual

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Fuel Pump / Main Relay Circuit

ECU 300 (Black)

A B C D E F G H
4

8
15
7
14
A B C D E F G H J K L M
4 6 Main
3 13
2
5
12
Relay
1 4
11
3
F3 Fuel Pump Relay Driver
10
2
9
A B C D E F G H 1
4

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.
P0231 Fuel Pump: Short to Ground Indicates the fuel pump relay is shorted to ground. Can be
caused by a faulty relay, damaged wiring, damaged fuel pump, or
ECU failure.
P0232 Fuel Pump: Short to Battery Indicates the fuel pump relay circuit is shorted to battery voltage.
Can be caused by a faulty relay, damaged wiring, damaged fuel
pump, or ECU failure.

2004 Four Stroke PWC Service Manual 5.27

 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. Unlock connector by pushing tab in, then rotate

connector upwards. Re--install by pressing
connector into ECU, then rotate connector down
until audible “click” is heard.

Adaptation
The ECU runs in a closed--loop configuration between
idle speed and 4000 RPM when not under accelera-
tion. During the closed--loop configuration, the lambda
sensor relays the amount of oxygen within the exhaust
stream to the ECU. The ECU adjusts the fuel supply
to achieve “lambda 1”.
The ECU operates in the open--loop mode whenever
the engine is accelerating or engine RPM exceeds
4000 RPM. In this mode, the ECU delivers the exact
amount of fuel the engine requires to satisfy the torque
demands of the operator for maximum performance.
Over time, normal wear and tear will occur to internal
engine components. The ECU will constantly learn
and adapt to the changing combustion characteristics
and maintain optimum engine performance.

5.28 2004 Four Stroke PWC Service Manual

 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.
P0172 Fuel System: Minimum Adaption Level Reached Occurs when the engine is running at part--load and the O2 sen-
sor indicates a constant RICH fuel condition for an extended
period of time. Can be caused by a faulty O2 sensor, plugged air
intake, leaky injector, or other mechanical failure.
P0234 Turbocharger Overboost Condition Boost pressure has exceeded 33 psi (2.3 BAR) of more than 400
milliseconds.
P0560 Battery Voltage Plausibility Error Battery voltage drops below 10.5 Vdc during operation.
P0562 Battery Voltage: Low Battery voltage drops below 10.5 Vdc during operation.
P0563 Battery Voltage: High Battery voltage exceeds regulated limit.
P0601 Main Microcontroller Reset
P0604 Ram Memory Failure
Replace
R eplace ECU
P0605 ROM Memory Failure
P0606 ECU: EEPROM Memory or Checksum Error

Electronic Throttle Body (ETB) / Pedal Position Unit (PPU)

A unique function of the Bosch ME-- Motronic 7.4.4 Engine Management System is its use of a “Fly--By--Wire”
or Electronic Throttle Control (ETC) system. In this system, the throttle flipper is not directly connected to the
the throttle plate, but rather a pedal position unit or PPU.
Four components make up the ETC system:
S Pedal Position Unit (PPU)
S Engine Control Unit (ECU
S Electronic Throttle Body (ETB)
S PPU Interface Box (IFB)
The PPU and ETB use two position sensors each to relay and verify the exact position of each component to the
ECU. The ECU continuously monitors all four position sensors. In the event that any one sensor fails, the ECU
will go into the LIMP--HOME mode, illuminate the CHECK ENGINE MIL light, and store the applicable trouble
code.
ETB Learning Procedure
The ECU must perform the ECU / ETB learning procedure when ever the ECU or ETB is replaced with a new
part. During the procedure, the ECU sweeps the throttle plate from full open to full close and “learns” the unique
characteristics of the ETB.
1. Engine must be OFF, and lanyard removed from stop switch.
2. The PPU must be at absolute 0. (Increase the throttle flipper cable freeplay to ensure PPU is set to
absolute zero and that cable is not kinked.)
3. Verify the battery voltage is at or above 10.1 Vdc, and that the engine temp. is between 42 and 176_F.
The outside ambient temp. must be at least 42_F.
4. Install the new ETB or ECU.
5. Insert the lanyard into the stop switch for AT LEAST 30 seconds.
6. Remove lanyard and wait for AT LEAST 2 minutes.
7. Insert lanyard and re--start engine. Re--set the throttle flipper cable freeplay to what it was prior to
performing process.

2004 Four Stroke PWC Service Manual 5.29

 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 Wrencht diagnostic software.

VERIFY BATTERY IS FULLY CHARGED

INSERT LANYARD INTO STOP SWITCH. TROUBLESHOOT START/STOP SWITCH,

DOES THE ELECTRICAL SYSTEM MAIN RELAY, ECU, AND ASSOCIATED
POWER UP? WIRING HARNESSESS AND CONNEC-
TIONS.
YES NO VERIFY SIFB IS NOT IN “SLEEP” MODE.”

MOVE THROTTLE FLIPPER FROM PERFORM ETB LEARNING PROCEDURE PROCESS.

CLOSED TO OPEN. DOES ETB CHECK ALL PPU AND ETB WIRING HARNESSESS AND CONNECTIONS.
THROTTLE PLATE MOVE WITH FLIP-
PER? CONNECT DIGITAL WRENCHt SOFTWARE TO ECU. VERIFY ETB LEARNING PROCEDURE
DISPLAYS “TRUE”.
YES NO VERIFY ETB THROTTLE PLATE IS NOT OBSTRUCTED BY FOREIGN MATERIAL.

CONNECT DIGITAL WRENCHt SOFT- REPAIR ANY BROKEN CONNECTION

WARE TO ECU. ARE THE FOLLOWING VERIFY COMPONENTS ARE RECEIVING
SPECIFICATIONS TRUE? 5 Vdc REFERENCE SIGNAL FROM ECU
PPU POSITION SENSOR 1 & 2 OPER- REPLACE COMPONENT THAT IS OUT
ATING VOLTAGES OF SPECIFICATION.
ETB THROTTLE POSITION SENSOR 1 &
2 OPERATING VOLTAGES

YES NO
MONITOR OPERATING VOLTAGES AS VERIFY COMPONENTS ARE RECEIVING
THROTTLE FLIPPER IS MOVED FROM 5 Vdc REFERENCE SIGNAL FROM ECU.
CLOSED TO OPEN POSITIONS. DO
THE VOLTAGES MOVE SMOOTHLY REPLACE COMPONENT THAT IS OUT
WITHOUT DIPPING OR JUMPING OF SPECIFICATION.
AHEAD?

YES NO
LOCATE PPU AND ETB WIRING HAR- REPAIR OR REPLACE AFFECTED WIR-
NESSESS. VISUALLY INSPECT ALL ING HARNESS OR CONNECTOR.
WIRES AND CONNECTIONS. “WIGGLE”
HARNESS CONNECTIONS.
PROBLEM(S) FOUND?

YES NO
VISUALLY INSPECT THE ETB AND PPU REPLACE ETB GASKET IF DAMAGED.
COMPONENTS FOR PHYSICAL DAM-
AGE. INSPECT ETB MOUNTING SUR- REPLACE ANY COMPONENT THAT IS
FACE FOR GASKET INTEGRITY. MECHANICALLY DAMAGED.

DAMAGE FOUND?

YES NO
POOR PERFORMANCE OR RUNABIL-
ITY ISSUE CANNOT BE ATTRIBUTED
TO PPU OR ETB COMPONENTS OR
FUNCTIONS.
TROUBLESHOOTING ENDED.

5.30 2004 Four Stroke PWC Service Manual

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Exhaust System

OUTLET PIPE

EXHAUST PIPE

PLANETt RESONATOR

4 5
EXHAUST SILENCER

2 3
1

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. (30 Nm) Apply anti--seize lubricant to threads.
Large Gear Clamp Torque: 35 in.lbs. (4 Nm)

Tighten exhaust pipe fasteners in sequence shown in illustration.

2004 Four Stroke PWC Service Manual 5.31

 FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
Turbocharger
WARNING!
The turbocharger generates excessive heat and houses rotating parts which can cause severe injury and
burns. Never touch any part of the turbocharger assembly while the engine is running. Allow the engine
to completely cool before working with any component. Do not allow objects such as clothing, hair or
fingers to come into contact with, or enter the compressor impeller while the engine is running.

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:
S Turbine
S Compressor (Impeller)
S Bearing House
S Wastegate Solenoid
S Wastegate Actuator
The turbine is directly exposed to exiting exhaust gases. The exhaust gases from each cylinder increase in speed
as engine RPM increases and expand inside of the turbine housing. These gases are forced around the turbine
housing and out into the exhaust pipe, thus rotating the turbine.
A compressor impeller is connected to the turbine via a shaft. The shaft’s bearings are lubricated with engine
oil and the bearing house is cooled by engine coolant. The compressor impeller draws fresh air into the compres-
sor housing. The fresh air is compressed, then routed on to the intake system. At WOT, the turbine / impeller
shaft can reach speeds in excess of 130,000 RPM.
The turbocharger bearing house is lubricated by the engine oil circuit and cooled by the engine coolant circuit.
The exhaust manifold and turbine housing are cooled by the freshwater cooling circuit. A loss or failure in any
one of the circuits will cause severe turbocharger and engine damage.

Wastegate
The amount of pre--compressed intake air generated by the compressor impeller is called boost pressure. Intake
boost pressure rises and falls in direct relation to turbine / impeller speed. Excessive boost pressure is a destruc-
tive force and therefore is constantly monitored and adjusted by the ECU.
The wastegate solenoid and wastegate actuator are two critical components responsible for allowing the ECU
to control boost pressure.
During operation, a small amount of pre--compressed air is routed to the wastegate solenoid. The wastegate
solenoid is electronically controlled by the ECU. Once opened by the ECU, the wastegate solenoid routes pre--
compressed air to the wastegate actuator.
The wastegate actuator houses a belows, spring, and actuator arm. The actuator arm is connected to a small
door located inside of the turbine housing. The actuator arm is held in the closed position by the spring. The
belows is exposed to boost pressure whenever the wastegate solenoid is opened. The actuator arm is pushed
open when the boost pressure acting upon the belows overcomes the spring pre--load. This action opens the
small door inside the turbine housing allowing the exhaust gases to bypass the turbine blades.
Allowing the exhaust gasses to bypass the turbine blades decreases the turbine / impeller shaft RPM, and lowers
boost pressure.

5.32 2004 Four Stroke PWC Service Manual

 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

2004 Four Stroke PWC Service Manual 5.33

 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.
The cooler the air, the more lbs./min of air the compressor will pump into the engine.
Turbocharger / Charge Air Cooler -- Troubleshooting
A basic understanding of the turbocharger and charge air cooler must be obtained prior to troubleshooting each
component.
It is important to realize the engine WILL NOT achieve maximum RPM, and thus maximum performance if either
component is not working correctly.
Important Facts:
S The 110 and 150 engine platforms utilize the same turbocharger assembly.
S The 110 engine’s charge air cooler is smaller and thus, less efficient than the 150’s larger charge air
cooler. The incoming air in a 150 engine will be denser and contain more oxygen then that in a 110
engine.
S The 110 engine does not utilize the air intake purge valve. The purge valve prevents boost spiking.
Boost spiking occurs when boost pressure rises abruptly when the throttle plate is closed by the oper-
ator.
S The turbocharger is responsible for using spent exhaust gas energy to pre--compress incoming fresh
air.
S The charge air cooler is responsible for lowering the pre--compressed fresh air’s ambient tempera-
ture.
S During operation, carbon build up will occur on the turbocharger’s turbine blades. This is normal.
Never attempt to clean the turbine blades. Doing so will affect the balance and heat absorption char-
acteristics of each blade and may cause turbocharger failure.
Turbocharger / Charge Air Cooler Troubleshooting

USE THE DIGITAL WRENCHt SOFT- INSPECT TURBINE AND COMPRESSOR BLADES FOR MECHANICAL /
VISUALLY INSPECT ALL AIR INTAKE
WARE TO VERIFY WOT BOOST PRES- PHYSICAL DAMAGE. REPLACE TURBOCHARGER ASSEMBLY IF ANY
HOSES FOR LEAKS.
SURE. DOES THE TURBOCHARGER DAMAGE IS FOUND.
GENERATE THE SPECIFIED AMOUNT? INSPECT PURGE VALVE (150 ENGINE)
INSPECT THE CHARGE AIR COOLER FOR PROPER OPERATION.
FOR CRACKING OR LEAKING.
FRESHWATER INLET PRESSURE SHOULD BE AT LEAST 4 PSI.
PROBLEM SOLVED?
NO NO REPLACE CHARGE AIR COOLER IF OUTLET AIR TEMP. @ WOT IS > THAN
THE FRESHWATER TEMP. + 59_ F (15_ C.)
INSPECT THE WASTEGATE SOLENOID AND WASTEGATE FOR PROPER
OPERATION.
VERIFY THE BOOST REFERENCE HOSE LOCATED BETWEEN THE COM-
PRESSOR HOUSING AND WASTEGATE SOLENOID AND BETWEEN THE
SOLENOID AND WASTEGATE IS NOT BLOCKED WITH OIL OR FOREIGN
MATERIAL.
DOES THE TURBOCHARGER MAKE A REPLACE THE TURBOCHARGER AS-
“WHINING ” OR “HOWLING” SOUND AS SEMBLY.
IT SPINS UP OR SPINS DOWN.
CHANGE THE ENGINE OIL AND FILTER
VERIFY THE QUALITY OF THE ENGINE
COOLANT.
YES

5.34 2004 Four Stroke PWC Service Manual

 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

RPM
Idle RPM 1550 ± 50 Normal Operation
Maximum Engine RPM 7800 -- 8400 Rev Limiter Function
Limp--Home Mode 1750 Failure with either the ECU, ETB, or PPU components.
Reverse Mode Anti--Submerge Protection Operator moves reverse handle from forward to position
3400
to either neutral or reverse positions.
Overboost Protection Mode* 110: Boost exceeded .8 -- .9 BAR for more than 400ms.
4700 -- 4800
150: Boost exceeded 1.3 BAR for more than 400ms.
Engine Temperature Overheat Protection* The engine coolant temperature exceeds safe operating
1600 -- 1800
range.
Exhaust Manifold Temperature Overheat Protection The exhaust manifold freshwater cooling temperature
1800
exceeds safe operating range.

* = Indicates a TORQUE REDUCTION running mode. The ECU limits engine RPM by limiting the amount of
torque generated by the engine. Stated RPM limit is an approximation and changes with current engine operating
conditions.
The throttle plate opening (aperture), ignition timing, and fuel supply are controlled by the ECU to limit engine RPM
in all modes except in the LIMP--HOME MODE.
Ignition timing is gradually retarded as the engine RPM reaches the established RPM limiter specification. If RPM
exceeds 7600 RPM, ignition timing is retarded and fuel supply to one or both cylinders is reduced.
The limp--home mode occurs whenever a problem is detected as a safety issue in the Electronic Throttle Circuit.
The ECU will cut power to the ETB in the event of a PPU, TPS, or wiring failure. When in the limp--home mode,
the throttle plate returns to it default, non--power position. This position represents 6% open or approximately
1750 RPM.

Cold-- Start Protection

The ECU will limit engine RPM to idle speed during a cold startup. Full power will return when the engine coolant
temperature exceeds 140_F (60_C). The cold--start protection will last approximately 30 seconds after initial
startup depending on current conditions.

2004 Four Stroke PWC Service Manual 5.35

 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.
Clean battery of any foreign material or cor-
rosion in or around battery terminals.
Verify battery connections are clean and
tight.
Fuses Verify 15AMP ignition fuse located in chas- Loose or blown fuse.
sis harness pod is not blown.
Mechanical failure within drive system, im- Inspect the propulsion driveline. Verify im- Mechanical driveline failure or propulsion
peller jammed or locked. peller, driveshaft, and drive couplers rotate system jammed by foreign material.
freely without binding.
Start Button Circuit Inspect: No power to start switch
Tether attachment No power to solenoid
Battery and harness connection and LH No power from solenoid to starter
control assembly.
Solenoid Connections
Solenoid Operation
Engine electrical grounding
Start switch function
Electrical harness between LH control as-
sembly and engine wiring harness / ECU.
Starter Motor Function Inspect Starter motor requires excessive voltage to
Starter motor for electrical or mechanical rotate
functions. Starter motor is mechanically jammed either
Starter drive gears for proper operation. by foreign material or gears.
Sprague clutch is broken or jammed.

5.36 2004 Four Stroke PWC Service Manual

 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.
Clean battery of any foreign material or cor-
rosion in or around battery terminals.
Verify battery connections are clean and
tight.
Ignition System Insert lanyard into STOP switch. An audible Inserting the lanyard into the STOP switch
series of relay switching and clicking should provides battery voltage to the START but-
be heard. ton and to the ECU.
Move the throttle flipper from closed to open If the starter motor turns when the START
several times. The throttle plate must move button is pushed, then the START/STOP
in conjunction with each throttle flipper switch is OK should be providing battery
movement. voltage to the ECU via the PURPLE circuit.
Verify that no 15AMP fuses are blown in the
engine fuse block.
Main Relay Provide battery voltage to PIN 3 and ground Defective relay. During normal operation,
PIN 10. Continuity should be seen between the ECU grounds PINS 7 and 10 to close
PINS 11 and 2. the main ECU power relay and fuel pump
Provide battery voltage to PIN 3 and ground driver relay.
PINS 10 and 7. Continuity should be seen The fuel pump driver relay also supplies
between PINS 15 / 8 and 13, 6, 5, 4, and 7. battery voltage to the lambda sensor, igni-
tion coils, fuel injectors and wastegate sole-
noid.
ECU (Engine Management System) Use the Digital Wrencht diagnostic soft- Failed ECU or EMS components preventing
ware to review current data values and engine from starting.
download any trouble codes.
Repair any problems that are triggering
trouble codes.
Fuel System Verify fresh fuel is in the fuel tank. Low or no fuel in tank.
Verify fuel rail pressure is meeting specifica- Damaged fuel injectors.
tion. Damaged fuel delivery system of fuel pump.
Test each fuel injector for correct resistance.
Check 10AMP fuel pump fuse located in the
chassis harness fuse block.
Check condition of fuel filter. If foreign ma-
terial is found in tank, clean tank and re-
place fuel filter.
Propulsion System Verify there are no damaged parts in the Mechanical failure causing high friction load
inlet pump or impeller housing. on starting system.
Starting System Verify condition of starter motor. Voltage drop cannot exceed 10.5 vDC while
Check voltage drop when START button is pushing START button.
pressed.
Mechanical Condition of Engine Check spark plug for correct plug and prop- Incorrect spark plug usage can cause seri-
er gap. ous engine damage.
Check cylinder compression and compare Cylinders with low compression will cause
against specification. hard staring issues and poor performance.

2004 Four Stroke PWC Service Manual 5.37

 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.
Clean battery of any foreign material or cor-
rosion in or around battery terminals.
Verify battery connections are clean and
tight.
Alternator / Charging System Connect multimeter to positive and negative Faulty alternator or voltage regulator.
battery terminals. Start engine. Voltage at Poor battery condition. (Battery cannot take
battery terminals should be at least 14 vDC. or hold charge.)
Air Intake System Inspect for blockage in intake hoses.
Look for signs of water intrusion.
Fuel System Inspect:
Fuel Filter
Fuel Level
Fuel Pump
Fuel Pressure
Fuel Hoses
Fuel Tank Vent Hose
Fuel Pump Wiring Connections and Con-
nectors.
ECU (Engine Management System) Use the Digital Wrencht diagnostic soft-
ware to check for trouble codes and operat-
ing data.
Oil Lubrication System Verify the oil level is not over the MAXIMUM
mark on the dipstick. Remove any excess
oil from the oil tank.
Clean or replace the boost / air temp. and
manifold pressure sensors if oil level ex-
ceeded the MAXIMUM mark.

5.38 2004 Four Stroke PWC Service Manual

 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.
Clean battery of any foreign material or cor-
rosion in or around battery terminals.
Verify battery connections are clean and
tight.
Cooling System Inspect coolant level. Engine overheat -- seizure.
Inspect cooling hoses for kinks, leaks, or
loose clamps.
Inspect water--to--water heat exchanger.
Look for oil in the engine coolant, or engine
coolant in the engine oil.
Oil Lubrication System Inspect oil level. Lack of lubrication engine seizure.
Inspect oil hoses for kinks, leaks, or loose
clamps.
Inspect oil cooler.
Look for engine coolant in oil or freshwater
in the engine oil.
Main Relay Check function of relay when lanyard is
installed in STOP switch.
Air Intake System Check intake hoses for blockage.
Check for signs of water intrusion.
Fuel Management and Ignition System Check all components and connectors.
(ECU) use the digital Wrencht diagnostic software
to download any trouble codes are view cur-
rent engine data.
Exhaust System Check all exhaust hoses for blockage.
Check Planett resonator for blockage.
Engine Condition Check cylinder compression.
Verify correct spark plug is being used.
Fuel System Check condition of fuel in fuel tank. Fill with
fresh fuel.
Check operation of fuel pump, and fuel in-
jectors.
Check fuel rail pressure.
Check all fuel hoses and vent lines for
kinks, leaks, or incorrect routings.

2004 Four Stroke PWC Service Manual 5.39

 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. ing or connected. ETB not learned. nections.
Perform ECU reset procedure by inserting
lanyard, then disconnecting main relay. Re-
connect main relay and wait at least one
minute. ECU will re--learn ETB.
Use diagnostic software to inspect throttle
position function and accuracy.
Replace PPU or ETB.
Engine idle RPM above 1600 RPM. Air leak at manifold or after ETB assembly. Verify all hose connections at throttle body
and air intake manifold.
Verify ETB is mounted securely to manifold.
Verify drain plug, sensors, and banjo fittings
are installed securely on intake manifold.
Engine RPM limited to 1800 ± 50 AND ECU is in LIMP HOME MODE. Use diagnostic software to find any trouble
CHECK ENGINE MIL light is ON. codes associated with ETB, or PPU compo-
nents.
Check ETB and PPU wiring harness con-
nections.
Replace PPU or ETB.
Engine RPM limited to 2000 ± 50 and WA- Exhaust manifold thermoswitch is detecting DO NOT RUN WATERCRAFT FOR MORE
TER TEMPERATURE WARNING indicator a water temperature of 60_C or higher. THAN 30 SECONDS!
is ON. Check all freshwater hose connections.
Verify there are no kinks or cuts on any of
the hoses.
Check pump assembly for weeds or foreign
material.
Flush the freshwater cooling circuit using
flush kit.
Engine RPM limited to 2000 ± 200 and WA- Exhaust manifold thermoswitch is detecting Condition caused by heat soak within ex-
TER TEMPERATURE WARNING indicator a water temperature of 60_C or higher. haust manifold.
is ON after watercraft has re--started after Full power will return once freshwater circuit
sitting off of five to ten minutes. fills and cools exhaust manifold.
(Will only occur on models with ECUs using
Level 5 software.)
Engine RPM limited to 3000 ± 50 and the Engine cooling circuit is too hot. Internal DO NOT RUN WATERCRAFT FOR MORE
WATER TEMPERATURE WARNING indi- engine temperature at or above 87_C. THAN 30 SECONDS!
cator is ON. Check the engine coolant level and test
condition of coolant boil over protection us-
ing coolant hydrometer.
check the engine cooling system circuit for
leaks, plugs, etc.
Perform a cooling system pressure--leak
test.
Perform a cylinder compression test.
Verify there is no oil in the coolant, or cool-
ant in the oil.
Engine RPM is limited to 3400 ± 50 RPM Reverse or ESP mode RPM limit. Engine Verify reverse gate is in the UP position.
with NO WARNING INDICATORS ON. runs fine between idle speed and 3400 Check reverse switch wiring harness con-
RPM. nections.
Test reverse switch for proper operation.
Test the ESP system.
Check ESP wiring harness connections.

5.40 2004 Four Stroke PWC Service Manual

 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. lanyard.
If problem persists, check air intake system
hoses for leaks.
Use diagnostic software and check for
trouble codes.
Check all boost control hoses.
Check operation of wastegate solenoid.
Check wastegate linkage and wastegate
operation.
Verify oil level is not over MAXIMUM.
Clean boost control hose banjo bolt fitting.
Engine RPM is limited to 4500 -- 5500 after ECU will limit engine RPM in the event that Full power will return once engine warms
initially starting engine. the internal engine temperature is below up.
60C. This is a protection feature.
Engine RPM is limited to 6000 to 6500. Air leak within air intake system or boost Check all hoses associated with air intake
control system. system and boost control system.
Check for air leaks.
Use diagnostic software to check for trouble
codes and operating parameters.
Engine RPM is limited to 6800 to 7000. ECU is detecting either or knock sensor fail- Use PREMIUM GRADE fuel to obtain maxi-
ure or a auto--ignition condition exists. (Pis- mum engine performance. 91, 92, or 93 oc-
ton Knock) tane recommended.
ECU will retard engine timing up to 9 de- Check for foreign material or water within
grees BTDC when knock sensor fails or de- fuel system.
tects auto--ignition. If condition persists, Check boost control hose connected to fuel
ECU will open wastegate solenoid and drop pressure regulator.
boost pressure.
Use diagnostic software to check for trouble
codes.
Verify correct impeller is installed.
Boat fails to reach top speed. All of the above + Use diagnostic software to download trouble
Turbocharger not making enough boost codes.
pressure. Check the spark plugs for proper gap, etc..
Mechanical failure with engine, engine sub- Check ignition coils.
system, or pump assembly. Check the engine and chassis wiring har-
Environmental Conditions. nessess for damage.
Check and perform all maintenance--related
issues.
Perform the boost pressure check by con-
necting a pressure gauge to the air intake
manifold drain fitting.
If boost pressure is lower than specification,
check the following:
Check air intake system for leaks.
Check or replace Boost sensor
Check boost control hoses.
Check or replace wastegate solenoid.
Visually inspect the turbocharger turbine
and compressor wheels and blades. Re-
place turbocharger is blades are damaged
or worn.
Use PREMIUM GRADE fuel to obtain maxi-
mum engine performance. 91, 92, 93 oc-
tane recommended.

2004 Four Stroke PWC Service Manual 5.41

 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.
ECU Use Digital Wrencht diagnostic software to
download any trouble codes and monitor
engine performance data.
Electrical Wiring Harness Inspect engine and chassis electrical har-
nessess. Verify all connectors are clean
and tight.
PPU and ETB Operation Follow troubleshooting procedures outlined
within this chapter.
Exhaust System Inspect system of blockage.
Inspect system for exhaust leaks.
Fuel Delivery System Inspect fuel level and fuel quality.
Verify fuel pressure meets specification.
Inspect all fuel and vent hose connections
and routings. Inspect for leaks.
ECU -- Engine Management System Inspect all sensors for proper operation and
correct data values using Digital Wrench
diagnostic software.
Mechanical Condition of Engine Verify correct spark plug is use with correct
gap.
Check cylinder compression.
Propulsion System Verify impeller is not worn.
Check for driveline obstruction or worn/bro-
ken parts.
Turbocharger / Charge Air Cooler Follow troubleshooting procedures outlined
within this chapter.

5.42 2004 Four Stroke PWC Service Manual

 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: Wastegate / Boost Control
Condition of wastegate control hoses.
Condition of wastegate solenoid and waste-
gate.
Perform electrical diagnostics on wastegate
solenoid using Digital Wrencht diagnostic
software.
Check for oil intrusion into wastegate control
hoses.
No Diagnostic Communication Verify system “wakes up” after inserting the
lanyard into the STOP switch.
Push START button to re--set SIFB box.
Check condition of main relay.
Check condition of START / STOP switch
assembly.
Inspect communication cables.

2004 Four Stroke PWC Service Manual 5.43

MSX 110 / 150 Service Manual Propulsion
Pump Specifications / Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . 6.1
Fastener Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Ventilation / Cavitation Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Pump Assembly Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Stator Assembly Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
Driveshaft Assembly Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Pump Induction Assembly Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Pump Removal and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
Bearing Carrier Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Driveshaft Shim Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
Driveline Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
Stator Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 -- 6.14
Driveshaft Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 -- 6.19

6
Sacrificial Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
Intake Scoop / Ride Plate Removal and Installation . . . . . . . . . . . . . . . . . . . 6.21 -- 6.22
 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.

Pump Specifications
MSX 110 MSX 150
Pump Extension YES 4″ YES 4″
Pump Wedge 5432841 (4_) 5432841 (4_)
Stationary Nozzle 1350013 1350013
Impeller (# of blades)* TBA 12 -- 18 3 Blade
Drive Coupler** Three--Piece Coupler Three--Piece Coupler
Bearing Carrier Sealed Bearings Sealed Bearings
1590349 1590349
Driveshaft 22.247″± 0.15″ 22.247″± 0.15″
5631257--329 5631257--329
Ride Plate MSX MSX
5631328--067 5631328--067
Inlet Grate 4--Bar 4--Bar
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.
Driveshaft Bearing Carrier Inspect at preseason and at year end.
Impeller Wear Inspect at preseason, every six months, and at year
end. Inspect stator cone at preseason and at year
end.
Steering / Reverse / Trim Pivot Bushings Service Limit: .335in. Inspect at 100 hour intervals.
Sacrificial Anode Service Limit: Replace when 50 % worn. Inspect at
pre--ride.
Pump Housing Seals / O--rings Replace all seals and o--rings whenever pump assem-
bly is removed from watercraft. Apply grease and/or
silicone to applicable parts as outlined in this chapter.
Inlet Screen Inspect at pre--ride, preseason, and at end of year.
Siphon Bilge / Bilge System Inspect screens / pump mounting at pre--ride, presea-
son and at end of year.
Drive Coupler Shroud Inspect at pre--ride, preseason and at end of year.
Pump Assembly Fasteners Inspect at preseason and at end of year.

2004 Four Stroke PWC Service Manual 6.1

 PROPULSION

Fastener Guide -- Final Drive / Propulsion

Torque
Component(s)
Component(s) Remarks
Remarks
FT.LBS. Nm
Driveshaft / Bearing Carrier
Bearing Carrier -- To -- Hull 14 19 Tighten in criss--cross pattern.
Coupler Guard 35 (In. Lbs.) 3.9 Apply Loctitet 242

Pump Assembly
Zinc Anode 25 (In. Lbs.) 2.8 Apply Loctitet 242
Impeller Torque 100 138 Apply Loctitet 242
Verify impeller rotates freely three times.
Tail Cone 40 (In. Lbs.) 4.5
Steering Nozzle 14 19 Apply Loctitet 242
Reverse Nozzle 14 19 Apply Loctitet 242
Pump Assembly -- To -- Pump Housing Bolts 1st Step: 1st Step: Apply Loctitet 242. Tighten in criss--cross pat-
2ft.lbs. 2.7 tern.
2nd Step: 2nd Step:
14ft.lbs. 19
Pump Housing Bolts 28 38 Tighten in correct order:
Top Right / Bottom Left / Bottom Right / Top Left

Ride Plate / Inlet Grate

Inlet Grate / Ride Plate 8 11 Apply light amount of marine silicone to threads.
Paddle Wheel 30 (In. Lbs.) 3
Paddle Wheel Thru--Hull Nut 25 (in. Lbs.) 2.8 Apply light amount of marine silicone to threads.

6.2 2004 Four Stroke PWC Service Manual

 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. An improperly sealed intake scoop is the most common cause of ventilation. Make sure the scoop has a com-
plete bead of Marine Grade silicone sealer all the way around without any gaps or pin holes.
2. Ride plate -- The ride plate must be completely sealed in the area around the intake scoop, and also in the area
where the hull meets the pump cavity.
3. Driveshaft bearing housing or through hull fitting -- If the drive shaft bearing carrier seals are worn or damaged,
air may be drawn into the pump from the engine compartment. Also inspect the through-hull fitting. The entire
circumference of the fitting must be sealed to prevent water from entering the hull, and air from entering the pump.
4. Incorrectly mounted pump. This can be caused by an improperly installed intake scoop or a misaligned pump
(there should be no detectable gap between pump housing and hull).

Cavitation Troubleshooting
Cavitation results when a low pressure area is created in the vicinity of the impeller blades, causing the surround-
ing water to boil or more accurately, the gas bubbles within the water implode with a destructive force. Cavitation
may be caused by cracked, damaged, bent or broken impeller blades, or an excessively worn impeller or housing
(check impeller clearance).
Ventilation or cavitation can drastically reduce the amount of output thrust produced by the pump. Evidence of
either problem may appear as burn marks on the impeller and stator vanes in the pump.

2004 Four Stroke PWC Service Manual 6.3

 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. (2.8 Nm)
Impeller Torque: 100 ft.lbs. (138 Nm) Apply Loctitet 242 to threads.
Tail Cone Fastener Torque: 40 in.lbs. (4.5 Nm)
Pump Mounting Bolts Torque: 1st Step: 2 ft.lbs. / 2nd Step: 14 ft.lbs. (2.7 / 19 Nm)
Steering Nozzle Fastener Torque: 14 ft.lbs. (19 Nm) Apply Loctitet 242.
Reverse Nozzle Fastener Torque: 14 ft.lbs. (19 Nm) Apply Loctitet 242.

Thru--hull lock plate must be installed with flat against steering cable thru--hull nut.
Apply anti--seize to pump component mating surfaces.
Apply premium grease to o--rings prior to assembly.
Pump assembly must be flush against hull to prevent leakage or ventilation. Apply liberal amount of marine--grade silicone to mating surfaces.
Verify presence of o--ring between pump stator and tail cone.
CAUTION: DO NOT ALLOW SILICONE TO ENTER WATER HOSE OR PIPE ORIFICES. SERIOUS ENGINE DAMAGE MAY OCCUR!

6.4 2004 Four Stroke PWC Service Manual

 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.
Bearing spacer length is critical to driveline operation. Replace if length is smaller than service limit.
Seal springs and / or seal lips must not be folded over, stretched, torn, etc. by impeller spacer during stubshaft installation.

2004 Four Stroke PWC Service Manual 6.5

 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.

Bumper MUST be installed between impeller and driveshaft.
Use light film of premium grease on carrier seals and shaft to assist in driveshaft installation.
Apply small amount of Premium grease to tapered spacer inside diameter.

During assembly, perform the driveshaft shim procedure as outlined on page 6.10.

6.6 2004 Four Stroke PWC Service Manual

 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. (3 Nm)
Paddle Wheel Thru--Hull Nut Torque: 25in.lbs. (2.8 Nm)
Ride Plate Fastener Torque: 8 ft.lbs. (11 Nm)
Intake Grate Fastener Torque: 8ft.lbs. (11Nm)

Apply continuous bead of marine--grade silicone to all mating surfaces of the hull, inlet scoop, front and sides of ride plate, and front and rear
sections of inlet grate. Ventilation will occur if gaps are present at mating surfaces.
CAUTION: DO NOT ALLOW SILICONE TO ENTER WATER HOSE OR PIPE ORIFICES. SERIOUS ENGINE DAMAGE MAY OCCUR!

2004 Four Stroke PWC Service Manual 6.7

 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.

Pump Removal
1. Remove lanyard cord. Proceed with disconnecting the
battery by removing negative(--) cable.
2. Disconnect reverse and steering linkage from nozzles.
Discard cotter pin and nylock nuts.
3. Using a criss--cross pattern, remove the four (4) pump
mounting bolts.
4. With the mounting bolts removed, each component
can be removed from the assembly. These
components are:
S Steering nozzle w/reverse gate.
S Stator assembly w/impeller.
S 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.

Pump Housing Removal

1. Remove the pump components as described above.
2. Access the pump housing mounting bolts from inside the engine compartment. Remove the nuts, washers,
and steering cable locking plate.
3. Attempt to remove the housing from the hull using a small prybar. Do not damage the pump housing or hull
mating surfaces. If the housing will not come loose without excessive force, the ride plate and inlet grate must
be remove from the hull.
4. Follow ride plate and inlet grate removal procedures outlined in this chapter if components require removal.
5. With components removed, re--attempt removing the housing.
6. Always use light force when using a prybar against the hull and housing mating surfaces.

Pump Housing Installation

The mating surfaces between the hull and pump housing must be cleaned prior to installing the housing. Clean
surfaces with alcohol.
To install the housing, follow the procedures listed on page 5.15 and 5.16.

6.8 2004 Four Stroke PWC Service Manual

 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. Obtain strap wrench and driveshaft removal tool. Have an assistant secure the aft (Rear) drive coupler.
4. Using the driveshaft removal tool, PN PW--46593, carefully loosen the driveshaft from the coupler.
5. Carefully pull the driveshaft through the rear of the craft.
6. Loosen and remove the four (4) bearing carrier mounting bolts. Remove bearing carrier.

Bearing Carrier Installation

Installation is the reverse of removal with the following exceptions:
1. Begin the installation process by installing the aft (Rear) drive coupler. Press coupler firmly into rubber
dampener.
2. Mount the bearing carrier to the hull loosely. DO NOT torque the mounting bolts at this time.
3. Carefully insert the driveshaft through the bearing carrier and engage the drive coupler.
4. Have an assistant hold the drive couplers.
5. Using the driveshaft removal tool, slowly install the driveshaft into the coupler. (A drill or air wrench can be
used if set on lowest speed setting.)
6. Secure bearing carrier to hull. Follow torque specifications and sequence outlined on page 5.2.

2004 Four Stroke PWC Service Manual 6.9

 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.
3. Push couplers together with rubber dampener
installed.
4. Measure “X” as outlined in illustration below.
5. Reference specification table and remove or add
shims.

Pump Housing -- To -- End of Driveshaft Number of Shims From NOMINAL Total Number of Shims
(INCHES)
X < 2.110 +2 4
2.110 < X < 2.195 +1 3
2.195 < X < 2.280 0 2
2.280 < X < 2.365 --1 1
X > 2.365 --2 0

6.10 2004 Four Stroke PWC Service Manual

 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. Disconnect battery ground (--) cable.
2. Remove intake grate and check impeller to housing
clearance with a feeler gauge. Measure clearance
at leading edge, middle, and trailing edge of each
blade. Replace impeller if clearance exceeds
service limit at any point. If clearance exceeds
service limit with a new impeller, replace pump
housing.

Impeller Clearance

Std: .002 - .008″ (.05 -.20 mm)

Service Limit: .020″ (.5 mm)

Drive Shaft Inspection

1. Clean driveshaft and support in V - blocks as shown
(C). Measure runout by rotating shaft and Place dial indicator
observing dial indicator at point (B). Replace if at (B)
runout exceeds the service limit.
NOTE: Excessive driveshaft runout can cause vibra-
C
tion, bearing, and spline failure. See Pump/Final Drive
Troubleshooting at the end of chapter 2.
B
Drive Shaft Runout
Support in V-blocks C
Service Limit: .005″ (.13mm) at (C)

2. Inspect driveshaft splines and threads inside

engine drive coupler and impeller carefully for wear
or damage. Replace worn parts. Rubber bumpers
control driveshaft end play. Replace if worn,
cracked or damaged.
NOTE: If driveshaft, impeller, or coupler threads are
worn or damaged, improper pump-to-hull, or pump-to-
engine alignment should be suspected. Refer to Pump/
Drive shaft Alignment on pages 5.13 -- 5.14 for more in-
formation.

Drive Shaft End Play

.100-.200″ (2.54-5.08mm)

2004 Four Stroke PWC Service Manual 6.11

 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. It is normal for a small amount
of water to be inside the cone during operation.

2. Mount stub shaft flat surfaces in a vise to prevent the

impeller and stator from rotating.

3. Install impeller removal tool and turn counterclockwise

to remove. The impeller removal tool can be identified
by (3) knurled sections on the shaft.

Impeller Removal Tool

Impeller Removal Tool has 3 knurled sections

PN 2871036

Impeller Tool Diameter:

.852″ (21.65mm)

6.12 2004 Four Stroke PWC Service Manual

 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. Drive out
bearings by taping on inner races.

7. Measure spacer with a Vernier caliper. Replace if worn

beyond service limit. If the spacer is too short, the
bearings will be side--loaded and premature wear will
result.

Bearing Spacer Length

Service Limit: 1.730″ (43.94 mm)

2004 Four Stroke PWC Service Manual 6.13

 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. Warm the impeller housing evenly with
a heat gun or a propane torch. DO NOT OVERHEAT.
1. Press or drive bottom bearing into place until it bottoms
against the shoulder in the pump housing. Apply
grease to center bearing spacer and install. Verify that
bearing spacer is centered, and install second bearing.

CAUTION:

Do not drive on the inner race. Bearing damage

will result. Drive on outer race only.
2. Place impeller spacer onto inner race of front bearing.

3. Apply marine grease to seal lips and also between the

two seals. Install two new oil seals over impeller
spacer with lips up and visible (toward impeller). Press
seals to bottom of chamfer on seal bore (about 1/8″/.32
cm beyond end of bore).
WARNING: Never allow the impeller spacer to push up
through the two seals when inserting the stub shaft.
If spacer pushes though seals, the seal lips will be
compromised and allow water into bearing housing.

4. Grease and install two new O-rings on stub shaft.

Mount stub shaft flats in a vise. Grasp stator assembly
with thumbs over impeller spacer. Carefully lower
assembly over stub shaft. Verify that stub shaft has
not pushed impeller spacer up through seals.
NOTE: If impeller spacer has pushed up through
seals, push into place slowly and carefully to prevent
dislodging seal springs.
5. Hand thread impeller onto stub shaft. Torque to
specifications. Rotate impeller by hand to insure
proper rotation.

Impeller Torque
100 ft. lbs. (138 Nm)
Apply Loctite 242 to threads.

6.14 2004 Four Stroke PWC Service Manual

 PROPULSION
Driveshaft Alignment
1. Disconnect the NEGATIVE (--) first, then POSITIVE
(+) battery cables from the battery. DO NOT (Illustration 1)
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. Remove the
pump sections.
4. Back--up the drive couplers using a large pipe
wrench or strap wrench and remove the driveshaft
using the DRIVESHAFT REMOVAL /
INSTALLATION TOOL, PN PW--46593. Remove the
driveshaft from the watercraft.
NOTE: Do not damage the drive coupler fingers.

(Photo A)

5. Remove the bearing carrier from the pump box.

(Illustration 2) (Illustration 2)
6. Install a small dowel or socket extension into the PTO
balance plate hole.
7. Rotate engine until dowel or extension jams against
crankcase mounts.

2004 Four Stroke PWC Service Manual 6.15

 PROPULSION

Driveshaft Alignment
8. Remove the pump--side drive coupler and rubber
dampener. Using a pipe wrench or strap wrench, (Illustration 3)
carefully remove the engine--side drive coupler.
(Illustration 3)
NOTE: Do not damage the fingers on the drive coupler.
ENGINE--SIDE
COUPLER

PUMP--SIDE
COUPLER

RUBBER DAMPENER

9. Install the DRIVESHAFT ALIGNMENT COUPLER

TOOL, PN PW--46592, on the PTO end of the DRIVESHAFT ALIGNMENT
COUPLER TOOL
crankshaft. Hand tighten tool. PW--46592

10. Locate the pump stator assembly. Remove the tail

cone from the assembly. 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.
DRIVESHAFT ALIGNMENT
TOOL 2871343
(Photo B)

11. Mount the stub shaft flats in a vice. Using the

IMPELLER REMOVAL TOOL
IMPELLER REMOVAL TOOL, PN 2871036, remove 2871036
the impeller from the pump stator assembly. (Photo
C)
12. Carefully lift the pump stator assembly up and off of
the stub shaft while the stub shaft is still secured in
the vice.

(Photo C)

6.16 2004 Four Stroke PWC Service Manual

 PROPULSION
Driveshaft Alignment - All Models
13. Carefully insert the tapered--end of the PUMP
PUMP STATOR HOUSING
ALIGNMENT TOOL, PN 2871343, through the pump
stator. Securely mount the pump stator to the pump
housing. (Photo D)

DRIVESHAFT ALIGNMENT
TOOL 2871343
(Photo D )

14. THE TAPERED END MUST FIT EASILY INTO THE

BORE USING LIGHT PUSHING FORCE. THE DRIVESHAFT ALIGNMENT
COUPLER TOOL
SHAFT MUST FULLY ENGAGE AND HIT THE PW--46592
CRANKSHAFT END. (Photo E)
If the Driveshaft Alignment Tool slides in and out of
the Driveshaft Alignment Coupler Tool as outlined in
STEP 16, adjustments to the engine strap mounting
shims ARE NOT REQUIRED.
In this case, remove the tools and proceed with the
REASSEMBLY PROCEDURES.
In the case where the Driveshaft Alignment Tool
DRIVESHAFT ALIGNMENT
DOES NOT fit into the Driveshaft Alignment Coupler TOOL 2871343
Tool as outlined in STEP 16; proceed with the (Photo E )
ALIGNMENT PROCEDURE.

2004 Four Stroke PWC Service Manual 6.17

 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.
3.
BAR HITS LOW / WEDGES LOW IN DRIVESHAFT ALIGNMENT COUPLER TOOL
SIDE VIEW

REAR ENGINE MOUNT FRONT ENGINE MOUNT

ADDING SHIMS TO FRONT

REMOVING SHIMS FROM REAR = HIGHER FRONT
= LOWER REAR

RESULTING EFFECT = ENGINE PITCHES DOWN FROM FRONT TO REAR

4.
BAR HITS HIGH / WEDGES HIGH IN DRIVESHAFT ALIGNMENT COUPLER TOOL
SIDE VIEW

REAR ENGINE MOUNT FRONT ENGINE MOUNT

REMOVING SHIMS FROM FRONT

ADDING SHIMS TO REAR = LOWER FRONT
= HIGHER REAR

RESULTING EFFECT = ENGINE PITCHES UP FROM REAR TO FRONT

5.
BAR HITS LEFT / WEDGES LEFT IN DRIVESHAFT ALIGNMENT COUPLER TOOL
REMOVE SHIMS
FROM LEFT SIDE

ADD SHIMS TO RIGHT SIDE

TOP VIEW
REAR ENGINE MOUNT FRONT ENGINE MOUNT

RESULTING EFFECT = ENGINE REAR TURNS LEFT

6.
BAR HITS RIGHT / WEDGES RIGHT IN DRIVESHAFT ALIGNMENT COUPLER TOOL
ADD SHIMS TO LEFT SIDE

REMOVE SHIMS FROM RIGHT SIDE

TOP VIEW REAR ENGINE MOUNT FRONT ENGINE MOUNT

RESULTING EFFECT = ENGINE REAR TURNS RIGHT

6.18 2004 Four Stroke PWC Service Manual

 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. Hand--tighten coupler on to crankshaft.
4. Insert rubber dampener into engine--side drive
coupler.
5. Insert pump--side drive coupler into rubber
dampener. Apply light film of Premium Grease to
inner threads.
6. Have an assistant insert driveshaft through rear of
boat. As driveshaft enters engine compartment, BUMPER
carefully fit bearing carrier on to front of shaft. (A light
film of grease will aid in installation.)
7. Install thrust washer, and two shim washers over HULL LINE
front of driveshaft after it has passed through the
bearing carrier. (The beveled side MUST fit flush with
DRIVESHAFT
driveshaft bevel.) (Illustration 4) BEARING
CARRIER
8. Guide the front of the driveshaft into the drive coupler
end. Have an assistant insert and screw driveshaft
into the drive coupler from the rear of the boat. Keep
the beveled end of the thrust washer flush with the
GASKET
beveled end of the driveshaft as the shaft is being
screwed into the coupler.
(Illustration 4) THRUST WASHER
9. Perform the DRIVESHAFT SHIM PROCEDURE
outlined on page 6.10.
10. Once driveshaft is screwed into coupler, push the
bearing carrier back against the pump wall. Do not
install the mounting screws at this time.
11. If the impeller was removed from the pump stator, the
assembly will have to be re--built with new seals, and
o--rings.
12. Reassemble the pump sections to the pump housing. Apply a light film of grease to the pump section mating
surfaces.
13. Install the four pump mounting bolts. Tighten to 2 ft.lbs. (2.7 Nm) in a criss--cross pattern. Torque bolts to 14
ft.lbs. (19 Nm), following the same criss--cross pattern.
14. Mount the bearing carrier to the pump wall. Torque the bearing carrier screws to 14 ft.lbs. (19 Nm) using a
criss--cross pattern.
15. Re--install the coupler guard. Apply Loctitet 242 to screws and torque to 35 in.lbs. (3.9 Nm)
16. Re--install the two siphon hoses to the pump nozzle. Use new panduit straps to secure hoses.
17. Re--install the reverse linkage retaining pin using a new cotter pin.
18. Using a new Nylokt nut, re--install the steering cable rod--end linkage. Apply Loctitet 242 to screw threads
and torque nut to 8 ft.lbs. (11 Nm)
19. Apply liberal amounts of Nyogelt to battery terminals and re--install the POSITIVE (+) lead first, then
NEGATIVE (--) lead to the battery.
20. Re--install the PTO spark plug. Torque plug to 18 ft.lbs. (24 Nm)

2004 Four Stroke PWC Service Manual 6.19

 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.

1. Periodically inspect anode for excessive wear.

2. Check bolt to be sure it is tight. If the bolt is loose,
remove anode and clean mounting surfaces on pump
and anode.
3. Apply dielectric grease to bolt threads and contact
surfaces.
4. Tighten bolt securely.
NOTE: During preventative maintenance, verify that
the anode is tightened securely to the pump housing.
Replace sacrificial anode whenever anode shows
signs of erosion.

Sacrificial Anode Bolt Torque

25in.lbs. (2.9Nm)

6.20 2004 Four Stroke PWC Service Manual

 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
bolts. Inlet Grate Mounting Bolt

2. Insert a length of 2x4 wood through the water inlet

housing from the rear of the watercraft. Rest the
2x4 on top of the ride plate.
3. Using your foot, apply downward force to the 2x4.
Ride Plate
This will remove the ride plate from the hull along
Mounting
with the inlet grate.
Bolts
4. Remove the pump mount assembly by removing
the 4 mounting nuts from inside the hull. Gently
pry the pump mount assembly from the hull.
5. Using the same method, remove the inlet scoop.
WARNING: Some inlet scoops are made of plastic.
Use less force when removing.

Installation
1. Begin the installation process by removing all silicone from the ride plate, inlet scoop, pump mount assembly,
and inlet grate mating surfaces.
2. Prepare mating surfaces by wiping surfaces down with isopropyl alcohol or acetone.
WARNING: All silicone residue and must be removed prior to reassembly. All mating surfaces must be cleaned
with isopropyl alcohol or acetone. One the installation has begun, it must be finished quickly due to the silicone
curing time. Never leave your work during this process. Do not allow silicone to sit open for longer than 4 minutes
with out attaching a component.
3. Apply continuous bead of marine grade silicone to all
mating surfaces of the hull, scoop, front and side
edges of ride plate, and front and rear sections of the
inlet grate. PN 8560054. Cavitation may occur if
silicone is not continuously applied.

Marine Grade Silicone

PN 8560054

Marine Grade Silicone

2004 Four Stroke PWC Service Manual 6.21

 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.
WARNING: Do not allow silicone to enter the water in-
let pipe or bilge siphon inlet. Severe engine damage
may occur if the water inlet pipe is obstructed.
Apply Silicone
3. Attach pump mount to hull.

Pump Assembly Mounting Nuts

28ft.lbs. (39Nm)
Apply anti--seize lubricant to threads.
Use criss--cross pattern when fastening.

4. Attach inlet grate to hull. Loosely thread the inlet

grate mounting bolt.
5. Apply a layer of silicone to the inlet grate tab that
fits into the ride plate.
6. Attach the ride plate to the hull. Loosely thread
mounting bolts from from to back in a criss--cross
pattern.

Water Inlets
Inlet Grate Mounting Bolt: 8ft.lbs. (11Nm)
Apply Loctite 242 to threads
Ride Plate Mounting Bolts: 8ft.lbs. (11Nm)
Apply Loctite 242 to threads.

NOTE: Wipe off all excess silicone away from compo-

nents. Allow 24 hours before operating watercraft to
allow silicone to cure.

Apply Silicone

Marine Grade Silicone

PN 8560054

6.22 2004 Four Stroke PWC Service Manual

MSX 110 / 150 Service Manual Hull and Body
Hull Specifications / Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Fastener Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Steering / Reverse Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Siphon Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Hull Assembly Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 -- 7.6
Compartment Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
Shroud and Storage Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
Steering Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
E.S.P. Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
PPU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
Reverse System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
Handlebar / Steering Post Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
Steering Cable Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15 -- 7.16
Steering / Reverse Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
Top Deck / Hull Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18

7
 HULL AND BODY
Hull Specifications
MSX 110 MSX 150
Hull Design Modified -- V Progressive Dihedral Stepped
Hull Material / Process
Fiberglass R
Fiberglass Reinforced
einforced C
Compound
ompound (FRC)
Top Deck Material / Process

Paint Codes / Colors

Paint Numbers*
MSX 110 MSX 150
A -- P441
A -- P292
Hood / Shroud / Glove B -- P444
B -- P443
Box C -- P445
C -- P465
D -- P464
Top Deck P403
P207
P207
Hull P070
Footwell Pads P318

* Polaris paints can only be ordered through the an authorized Polaris dealership.
S P070 . . . . . . . . . . . . . BLACK
S P207 . . . . . . . . . . . . . WHITE
S P292 . . . . . . . . . . . . . HAVASU RED
S P318 . . . . . . . . . . . . . CHARCOAL
S P403 . . . . . . . . . . . . . MATRIX SILVER ALLOY
S P441 . . . . . . . . . . . . . CATALINA BLUE C;EAR METALLIC
S P443 . . . . . . . . . . . . . SARASOTA YELLOW CLEAR METALLIC
S P444 . . . . . . . . . . . . . SOLAR RED CLEAR METALLIC
S P445 . . . . . . . . . . . . . TURBO SILVER CLEAR METALLIC
S P464 . . . . . . . . . . . . . STEALTH BLACK
S P465 . . . . . . . . . . . . . BIONIC COPPER CLEAR METALLIC
CAUTION: Prior to reassembling certain parts of the hull and body, note whether the use of Loctitet thread lock-
ing agent is authorized. Some hull and body parts cannot not come into contact with Loctitet thread locking prod-
ucts.

2004 Four Stroke PWC Service Manual 7.1

 HULL AND BODY

Fastener Guide - Hull / Control Systems

HULL / BODY
Torque
Where Used Remarks
FT.LBS Nm
LH & RH / Upper Console Shrouds 23 31
Console Shroud Assembly -- To -- Top Deck 5 7
Mesh Screens 10 (In.Lbs.) 1
Windscreen 22 (In.Lbs.) 2.5
Splash Guard 40 (In.Lbs.) 4.5
Compartment Door--To--Hinge 40 (In.Lbs.) 4.5
Top Deck--To--Hinge Assembly 14 19
Compartment Door Plunger Base 8 11
Grab Rail 10 4
Bilge Plugs 8 -- 10 (In.Lbs.) 1
Rub Rail Inserts 25 (In.Lbs.) 2.8
Front Bumper 25 (In.Lbs.) 2.8
Sponsons 70 (In.Lbs.) 6 Apply Marine--Grade Silicone to Holes.
Rub Rails 25 (In.Lbs.) 2.8
Gauge--To--Door Fasteners 14 (In.Lbs.) 1.5
Seat Post Latch 41 -- 57 (In. Lbs.) 4.5 -- 6
Rear Seat Plunger Nut 18 11 Apply Loctitet 262.
Seat U--Bolt Nuts 8 11 Apply Loctitet 262.
Mirrors 22 (In.Lbs.) 2.5

STEERING SYSTEM / HANDLEBAR ASSEMBLY

Handlebar Cover / Pad 20 (In. Lbs.) 2
Steering Housing --To-- Top Deck 14 19
Steering Cable Adjuster Clamp 8 11 Apply Loctitet 242.
Steering Arm Clamp 8 11 Apply Loctitet 242.
Throttle Block 20 (In.Lbs.) 2
Rod End --To -- Nozzle 8 11 Apply Loctitet 242.
Handlebar Grab Handle 35 (In.Lbs.) 4
Rod End -- To -- Steering Arm Clamp 8 11
ESP Cam 5 7 Apply Loctitet 242.

REVERSE MECHANISM ASSEMBLY

Reverse Assembly --To -- Top Deck 6 8
Reverse Cable Retainer Plate 22 (In.lbs.) 2.5
Reverse Arm 40 (In.lbs.) 4.5
Reverse Cable Thru--Hull Lock Nut 16 21 Apply Loctitet 242.
Reverse Cable Jam Nut 40 (In.Lbs.) 4.5 Apply Loctitet 242.
Reverse Gate Pivot Fasteners 14 19 Apply Loctitet 242.

7.2 2004 Four Stroke PWC Service Manual

 HULL AND BODY
Steering Cable Routing

CABLE PROTECTION COVER

Reverse Cable Routing

CABLE PROTECTION COVER

2004 Four Stroke PWC Service Manual 7.3

 HULL AND BODY

Siphon Hose Routings

SECURE WITH ZIP TIES

7.4 2004 Four Stroke PWC Service Manual

 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. (2.8 Nm)
Grab Handle Bolt Torque: 10 ft.lbs. (4 Nm)
Seat Post Plunger Nut Torque: 18 ft.lbs. (25 Nm) .
Sponson Fastener Torque: 70 in.lbs. (6 Nm) Apply marine grade silicone to holes.

2004 Four Stroke PWC Service Manual 7.5

 HULL AND BODY

Hull Assembly -- Continued

1.02″ -- 1.09″

BILGE PLUGS

Ref.A

FIRE EXTINGUISHER
SEAT U BOLT (Ref. A)

TIE DOWN LOOPS

AIR INLET DUCTS (2QTY.) BOW LOOP

HULL ASSEMBLY NOTES

Bilge Plug Fastener Torque: 8 -- 10 in.lbs. (1 Nm)
Tie Down Loop Torque: 8 ft.lbs. (11 Nm)
Bow Loop Nuts: 8 ft.lbs. (11 Nm)
Seat U Bolt Nuts: 8 ft.lbs. 11 Nm)
Worm Gear Clamp Torque: 25 In.lbs. (2.8 Nm)
Apply Loctite 242t to all threaded fasteners. (THIS PAGE ONLY)

7.6 2004 Four Stroke PWC Service Manual

 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. (11 Nm)
Compartment Door--To--Fasteners: 8 ft.lbs. (11 Nm)
Hinge Base--To--Top Deck Fasteners: 14 ft.lbs. (19 Nm)

2004 Four Stroke PWC Service Manual 7.7

 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. (1 Nm)
Shroud Assembly -- To -- Deck Fastener Torque: 5 ft.lbs. (7 Nm)

7.8 2004 Four Stroke PWC Service Manual

 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.

2004 Four Stroke PWC Service Manual 7.9

 HULL AND BODY

Steering Control Assembly

GRAB HANDLE

START / STOP SWITCH

DECK PLATES

HANDLEBAR COVER
STEERING
HOUSING
STEERING POST

THROTTLE BLOCK

SHIMS

ROD END

STEERING CABLE ADJUSTER / CLAMP

ROD END

STEERING NOZZLE

STEERING CLAMP

STEERING CONTROL ASSEMBLY NOTES

Handlebar Cover Fasteners: 20 in.lbs. (2 Nm)
Steering Housing--To--Top Deck: 14 ft.lbs. (19 Nm)
Steering Cable Adjuster Clamp: 8 ft.lbs. (11 Nm) Apply Loctite 242t.
Steering Arm Clamp: 8 ft.lbs. (11 Nm) Apply Loctite 242t.
Throttle Block: 20 in.lbs. (2 Nm)
Rod Ends: 8 ft.lbs. (11 Nm) Apply Loctite 242t.
Handlebar Grab Handle: 35 in.lbs. (4 Nm)
ESP Cam--To--Steering Clamp: 5 ft.lbs. (7 Nm) Apply Loctite 242t.

REFERENCE HANDLEBAR REMOVAL AND INSTALLATION PROCEDURES ON PAGE 7.14 FOR STEERING POST SHIM LOCATIONS
AND INSTALLATION NOTES.

7.10 2004 Four Stroke PWC Service Manual

 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. (11 Nm)

2004 Four Stroke PWC Service Manual 7.11

 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

 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. (8 Nm)

REVERSE CABLE
REED SWITCH

REVERSE ARM

40 in.lbs. (4.5 Nm)

22 in.lbs. (2.5 Nm)

ASSEMBLY NOTES
Reverse Cable Retainer Plate Fastener Torque: 22 in.lbs. (2.5 Nm)
Reverse Arm Fastener Torque: 40 in.lbs. (4.5 Nm)
Reverse Assembly -- To -- Top Deck Nut Torque: 6 ft.lbs. (8 Nm)
Reverse Cable Thru--Hull Lock Nut Torque: 16 ft.lbs. (21 Nm) Apply Loctitet 242 to threads.
Reverse Cable Jam Nut Torque: 40 in.lbs. (4.5 Nm)
Reverse Gate Pivot Fastener Torque: 14 ft.lbs. (19 Nm) Apply Loctitet 242 to threads.

Apply Premium All Season Grease to exposed parts of reverse cable.

Apply Lithium--based grease to reverse assembly moving parts.

2004 Four Stroke PWC Service Manual 7.13

 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. Disconnect the throttle cable from the throttle flipper, JUST STRIKE PLATE
CLEARANCE
and the left--hand control wiring harness.
3. Loosen and remove the steering arm clamp retaining
bolt from the bottom of the steering post. Remove the
clamp, shim(s) and tapered bushing from the post.
4. Carefully pull the steering post assembly up and out of
the steering housing.

NOTE: The steering cable rod--end can remain connected

to the steering clamp. If the rod--end is removed, discard
the Nylok nut.

Steering Post Assembly

1. Apply lithium--based grease to the outside taper of the
upper tapered bushing and steering post. STRIKE PLATE JUST
CLEARS STOP BOLT
2. Insert the post assembly into the steering housing. WASHER

3. Push down on the handlebars. Verify the strike plate

just clears the stop bolt washer and cannot be turned
past the stop bolt.
4. If strike plate hits washer, remove post and install shim
between bushing and strike plate. Repeat step 3. If
plate continues to hit washer, install second and final
shim.
5. Apply lithium--based grease to the outside taper of the
lower tapered bushing and install into steering
housing.
6. The number of shims installed on the lower section of
the post is determined by the number installed on top.
The total number of shims used to install the entire
steering post assembly equals two. (If two shims are
installed on top, then zero shims are installed on the
bottom, etc.)
7. Align slot on steering arm clamp with cutout in post.
Push clamp up against shims while pushing down on
the handlebars. Torque bolt to 8 ft.lbs. (11 Nm).
8. Verify handlebars move without resistance from left to
right and that handlebars cannot be turned past the
steering stop bolt.
ZERO, 1 OR 2 SHIMS
9. If steering cable rod--end was removed, reinstall on top INSTALLED TO RE-
MOVE UP AND DOWN
of clamp using a new nut. Torque nut to 8 ft.lbs. (11 FREEPLAY
Nm)
10. Reconnect wiring harness and throttle cable. Verify
throttle cable freeplay is set to specifications outlined
in chapter two.
11. Reinstall the handlebar grab handle and cover
assembly.

7.14 2004 Four Stroke PWC Service Manual

 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.
3. Loosen and remove the steering linkage from the
steering nozzle. Discard the nylock nut.

4. Prior to removing the thru--hull nut, loosen, but do not

remove, the lockplate nut. With the lockplate loose,
use an adjustable--locking wrench to remove the
thru--hull nut.

5. Locate and disconnect the rod end that is bolted to the

steering arm underneath the shroud and top deck.
Discard the nylock nut.
6. Remove the jam nut and rod end from the steering
cable. Remove the adjuster clamp from the steering
housing. Remove adjuster nut from steering cable.
7. Working from the front of the watercraft to the back,
push the steering cable through the rear thru--hull
opening.

2004 Four Stroke PWC Service Manual 7.15

 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.
2. Slide the black thru--hull nut onto the steering cable
from inside the engine compartment.
3. Apply marine--grade silicone to the thru--hull fitting
threads.
4. Tighten the thru--hull fitting nut to 52 in.lbs. (6 Nm)
5. Turn locking plate flat towards thru--hull nut face.
Tighten nut to 28 ft.lbs. (39 Nm)
6. Lightly grease the upper steering linkage.
7. Thread steering cable into adjusting nut. Loosely fit
adjusting nut bracket onto steering column base.
8. Install steering cable rod--end on top side of steering
arm clamp. Using a new Nylok nut, torque nut to 8
ft.lbs (11 Nm).
9. Follow steering cable alignment procedures on page
6.13.
10. When finished, verify adjusting nut clamp fasteners
are torqued to 8 ft.lbs. (11 Nm)

7.16 2004 Four Stroke PWC Service Manual

 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. Be sure to measure at right angles to Straight Edge
the straight edge and at equal distances from the
nozzle. The distance at (X) should be equal when Nozzle
handlebars are straight.
4. Adjustments can be made at the adjuster block. Hull Hull
Turn block clockwise or counterclockwise until (X)
measurements equal.
x x
5. Tighten adjuster block screws to specification.

Distance should be equal at (X)

Reverse Cable Adjustment

Under normal operation, the reverse cable should not
require adjustment. If the reverse linkage does not func-
tion properly, inspect the cable for damage. Inspect all
linkage, fasteners, brackets, and pivots for wear or dam- Reverse Cable Nut
age. When a new cable is installed the cable must be
adjusted.

1. Place reverse shift lever in reverse position.

2. Loosen cable adjuster nuts.
3. Verify that the gate is in its full down position and
locked.
4. Check gate locking by pulling up on gate when in
down position.
5. Move shift lever to forward position. Reverse gate
must be well above the water stream.
6. Tighten adjuster nuts securely.
7. Seal the cable threads and adjuster nuts with
marine grade silicone sealant (PN 8560054) and
tighten securely. Allow sealant to cure fully before
operating craft.

2004 Four Stroke PWC Service Manual 7.17

 HULL AND BODY

Top Deck / Hull Repair

The hull and top deck are manufactured using Fiberglass Reinforced Compound (FRC).
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.
Footpad Removal
1. Peel off the footwell pad that is to be replaced. Use a
heat gun to soften the adhesive.
WARNING: Use the heat gun on its lowest heat setting.
Do not heat the footwell pad or hull for more than a second.
Waiving the heat gun back and forth once is sufficient to
soften the adhesive. Prolonged heating will permanently
damage the hull.
2. With the footwell pad removed, apply Goo Gonet and
remove all old adhesive from the hull. If scraping is
required, only use a soft plastic material.
3. Remove Goo Gonet with mild detergent soap. Wipe
surface with acetone. Allow Acetone to completely
dry.
Footpad Application
4. Peel a small portion of backing material away from the
new footwell pad, and immediately apply to deck.
5. Work the pad with your fingertips until the entire pad is
pressed onto the deck surface. Constant pressure
activates the adhesive and works out any air bubbles
out from under the pad.
6. Allow for 24 hours for adhesive to cure.
NOTE: Do not allow the pad temperature to exceed 80°F,
or below 60°F for at least 24 hours. Always cover the wa-
tercraft when exposed to direct sunlight for long periods
time.

7.18 2004 Four Stroke PWC Service Manual

MSX 110 / 150 Service Manual Electrical Systems
Chassis Electrical and Sensor Specifications . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Battery and Charging System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
NGI Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 -- 8.3
NGI Gauge Wiring Illustration / MIL Indicators . . . . . . . . . . . . . . . . . . . . . . . 8.4
Battery Testing / Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 -- 8.7
Alternator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
Charging System Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
Start / Stop Electrical System Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
System Interface Box Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11 -- 8.12
Starter Motor Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
Starter Motor Disassembly / Assembly / Troubleshooting . . . . . . . . . . . . . . 8.14 -- 8.18

8
 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 11 -- 16 psi (.8 -- 1.1 BAR)
Fuel Level Sender 33Ω (FULL) / 240Ω ( EMPTY)
Starter Solenoid 5 -- 6Ω

Battery and Charging System Specifications

Component Specification
Battery Type YB16CL--B
Voltage 12 Volts
Nominal Capacity @ 10 Hour Rate 19 AH
Filling Specific Gravity 1.265 ± .010 @ 77°F (25°C)
Fully Charged Specific Gravity 1.280 ± .010 @ 77°F (25°C)
CCA @ 0°F (--18°C) 240 AMPS
Recommended Charging Current 1.9 AMPS
Electrolyte Volume 41.0 oz.
Reserve Capacity 25 minutes
Charging System 3 Phase Alternator w/external voltage regulator.
Alternator Output Voltage (No Load)
1200 RPM 21.3 Vac
2500 RPM 43.5 Vac
5000 RPM 87.0 Vac
Alternator Coil Resistance
@ 87_F (37_C) 285 mΩ
@ 248_F (120_C) 385 mΩ
Alternator Output
1200 RPM 10 AMPS
2500 RPM 20 AMPS
5000 RPM 25 AMPS
Nominal Voltage 12 Vdc
Nominal Current 25 -- 30 AMPS
Maximum Electrical Power 350 Watts @ 5000 RPM
Regulated Voltage 14.3 -- 14.6 Vdc
Minimum Voltage w/charged battery: 14.1 Vdc
Starter Motor Draw
No Load 45A / 10.9 Vdc
Load 120A / 9 Vdc
Stalled 390A / 2.25 Vdc
Starter Motor Brush Length
Service Limit 5/16″ (8mm)

2004 Four Stroke PWC Service Manual 8.1

 ELECTRICAL SYSTEMS

NGI Gauge (Next Generation Instrument)

Primary Functions
S Speedometer
S Tachometer
S Engine Hourmeter
S Clock
S Trip Odometer
S Fuel Level
S Turbo Boost Level
S Low Oil / Pressure, Fuel, and Low Battery Voltage Warnings
S High Engine Temperature Warning
S Check Engine Display
Function Overview
Speedometer
The large numeric speedometer displays vehicle speed. The gauge receives signals via a paddle wheel located
on the ride plate. The gauge interprets these signals and computes actual vehicle speed. Maximum displayed
speed is 65 MPH (99Km/H). Vehicle speed over these maximums will not be displayed. Additionally, vehicle
speed at, or below 3 MPH (5 Km/H), will be displayed as 0 MPH (0 Km/H).
Tachometer
Engine RPM is displayed on the gauge. The gauge has the ability to display between 0 and 9990 RPM. The gauge
receives the tachometer signal from the ECU. Display tolerance is ± 100 RPM.
Fuel Level
Current fuel level is displayed via a 8 bar LCD graphic. Levels are displayed in 1/8th increments. When the fuel
level displayed is 1/8 or less, a LOW FUEL symbol and red LED warning light will begin blinking warning the opera-
tor to re--fill the fuel tank.
Engine Hourmeter
Engine hours are numerically displayed on the gauge. Maximum engine hours retained and displayed by the
gauge is 999.9. Hours obtained after 999.9 will not reset the gauge to zero. The gauge begins to record engine
hours whenever the engine RPM is 500 RPM or higher. Memory retention is approximately 10 years.

NOTE: Fuel and Turbo LCD Bars shown at maximums in photo.

8.2 2004 Four Stroke PWC Service Manual

 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.
Trip Odometer
The gauge will display accumulated miles or kilometers traveled. The gauge will only begin recording distance
traveled when engine RPM is at or above 500 RPM.
Turbo Boost
Turbo boost pressure levels are displayed via a 7 bar LCD graphic.
NOTE: Displayed turbo boost is generated by the RPM signal, not manifold pressure. Engine can-
not obtain maximum RPM without full boost pressure.

Instrument Operation
DISPLAY MODE:
There are 3 different display modes that the gauge uses to display information to the operator. The 3 modes are:
MAIN MODE, SPEED / TACHOMETER MODE, AND NAVIGATION MODE. Press and release the MODE button
on the left handlebar control to advance through the 3 display modes. High speed record will display for 3 seconds
when entering the speed / tachometer display mode, then revert to real time speed / tachometer. Pressing the
MODE button a second time will advance to the trip odometer, while a third will return to the clock display.
CLOCK SET:
In the main mode, press and hold the RESET button until the hour digits flash. (Approximately 6 seconds.) Press
RESET button to advance hour digits. Press the MODE button to stop hour digits flash and begin minute digits
flash. Press RESET button to advance 1 minute. Press MODE button to set clock and exit clock set mode.
TRIP ODOMETER RESET
To reset the trip odometer, press and hold the RESET button until the trip odometer is reset to 000.0 miles / km.
HIGH SPEED RECORD DISPLAY
Press the RESET button to display the high speed record when in the speed / tachometer display mode. To reset
the high speed record, press and hold RESET button again for about 2 seconds or until the display is reset.
CHANGING UNITS OF MEASURE
To toggle between standard and metric units of measure, press and hold the MODE button for 10 seconds.
Displayed Warnings
The gauge will alert the operator for the following conditions:
S LOW FUEL (Fuel level reaches 1/8 level.)
S LOW OIL PRESSURE
S LOW BATTERY VOLTAGE (Battery voltage is at or below 10.9 vDC.)
S HIGH TEMPERATURE (Temperature is monitored by ECU.)
S CHECK ENGINE (Check engine warning is triggered by ECU.)
Regardless of warning, all warnings will have their respective ISO symbol displayed on the screen as well as a
blinking red LED warning lamp.
NOTE: Warning display icons have a 10 ±1 second OFF delay time interval.

2004 Four Stroke PWC Service Manual 8.3

 ELECTRICAL SYSTEMS

NGI Gauge (Next Generation Instrument) - ENGINE MIL INDICATORS

NGI GAUGE CONNECTOR

E F

C B A
E D B A
GRN/YEL ENGINE - CHASSIS CONNECTOR

F G H J K
C B A
LT.BLUE
D E

GRN/RED

ECU
E D B A
ENGINE - CHASSIS CONNECTOR
F G H J K

ECU 200
LT.BLUE
GRN/RED
C4
GRN/YEL
K3

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. BLUE OIL PRESSURE SWITCH SIGNAL (LOSS OF PRESSURE CLOSES SWITCH. NO COMMUNICATION WITH ECU)
GRN/RED CHECK ENGINE MIL WARNING LAMP SIGNAL
GRN/YEL ENGINE OVERHEAT / EXHAUST MANIFOLD OVERHEAT SWITCH MIL WARNING LAMP

Rev. A 1/12/2004

8.4 2004 Four Stroke PWC Service Manual

 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.
ANTIDOTE: External - Flush with water. Internal - Drink large quantities of water or milk. Follow with milk of
magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes - Flush with water for 15 minutes and
get prompt medical attention.
Preparing A New Battery For Service
NOTE: Do not service the battery unless it will be put into regular service within 30 days.
To assure maximum service life and performance from a battery, it must have proper initial servicing. To service a
new battery, the following steps must be taken:
S Remove vent plug from vent fitting.
S Fill battery with electrolyte to upper level marks on case.
S Set battery aside and allow it to cool and stabilize for 1/2 hour.
S Add electrolyte to bring level back to upper level mark on case. NOTE: This is the last
time that electrolyte should be added. If the level becomes low after this point, add only
distilled water.
S Charge battery at 1/3 of its amp/hr rating for up to 2 hrs. NOTE: This charge rate is to
be used only on new batteries during the first-time charge. After this charge, they should
be charged at the normal charge rate of 1/10 of amp/hr.
S Check specific gravity of each cell with a hydrometer to assure each has a reading of
1.270 or higher.
Battery Testing
There are three tests which can easily be made to determine a battery’s condition. Whenever the complaint is
related to either the starting or charging systems, the battery should be checked first.
OCV - Open Circuit Voltage Test

Battery voltage should be checked with a digital multitester. Readings of 12.4 DCV or less require further battery
testing and charging.
NOTE: Lead-acid batteries should be kept at or as near full charge as possible. If the battery is stored or used
in a partially charged condition, hard crystal sulfation will form on the plates, reducing their efficiency and possibly
ruining the battery.

2004 Four Stroke PWC Service Manual 8.5

 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. The hydrometer can measure state of charge and
differences between cells in a multi-cell battery. Readings of 1.270 or greater should be observed in a fully
charged battery. Differences of more than .025 between the lowest and highest cell readings indicate a need to
replace the battery.

Open Circuit Voltage

STATE OF CONVENTIONAL YUMICRON
CHARGE LEAD-ACID TYPE
100% Charged 12.60V 12.70V
75% Charged 12.40V 12.50V
50% Charged 12.10V 12.20V
25% Charged 11.90V 12.0V
1.10
0% Charged less than 11.80V less than 11.9V
Detail A 1.15
Specific Gravity
1.20

STATE OF CONVENTIONAL YUMICRON 1.25

CHARGE* LEAD-ACID TYPE 1.30
100% Charged 1.270 1.275
75% Charged 1.210 1.225
50% Charged 1.160 1.175
25% Charged 1.120 1.135
0% Charged less than 1.100 less than 1.115
* At 80_F
NOTE: Subtract .01 from the specific gravity reading at 40_ F.

Battery Hydrometer

PN 2870836

Load Test

A battery may indicate a full charge condition in the OCV test and the specific gravity test, but still not have the
storage capacity necessary to properly function in the electrical system. For this reason a battery capacity or load
test should be conducted whenever poor battery performance is encountered.

NOTE: This test cannot be performed with an engine or starting system that is not working properly.

1. Attach a multitester to the battery. The reading should be 12.4 DCV or greater.

2. Engage electric starter and view registered battery voltage while cranking engine. Continue the test for 15
seconds. During this cranking period, the observed voltage should not drop below 9.5 volts. If the beginning
voltage is 12.4 or higher and the cranking voltage drops below 9.5 volts during the test, replace the battery.

8.6 2004 Four Stroke PWC Service Manual

 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. After filling, charge the battery to
raise the specific gravity to the fully charged (1.270 or greater) position.
Off-season Storage
To prevent battery damage during extended periods of non-use, the following basic battery maintenance items
must be performed:

S Remove battery from machine and wash case and battery tray with a mild solution of
baking soda and water. Rinse with lots of fresh water after cleaning. NOTE: Do not
get any of the baking soda into the battery or the acid will be neutralized.
S Using a wire brush or knife, remove any corrosion from cables and terminals.
S Make sure electrolyte is at proper level. Add distilled water if necessary.
S Charge at a rate no greater than 1/10 of the battery’s amp/hr capacity until the electro-
lyte’s specific gravity reaches 1.270 or greater.
S Store battery either in machine with cables disconnected, or store in a cool dry place.
NOTE: Stored batteries lose their charge at the rate of 1% per day. They should be
recharged to a full charge every 60 to 90 days during a non-use period. If stored during
the winter months, the electrolyte will freeze at a higher temperature as the battery dis-
charges. The chart below indicates freezing points by specific gravity.

ELECTROLYTE FREEZING
POINTS
Specific Gravity Freezing
of Electrolyte Point
1.265 -75qF
1.225 -35qF
1.200 -17qF
1.150 +5q F
1.100 +18qF
1.050 +27qF
Charging Procedure
Charge the battery with a charger no larger than 1/10 of the battery’s amp/hr rating for as many hours as needed to
raise the specific gravity to 1.270 or greater.

WARNING

The gases given off by a battery are explosive. Any spark or open flame near a battery can cause an explosion
which will spray battery acid on anyone close to it. Battery acid will cause burns to skin. In case of contact with
battery acid, wash the affected area with large quantities of cool water and seek immediate medical attention.

2004 Four Stroke PWC Service Manual 8.7

 ELECTRICAL SYSTEMS

Alternator Assembly

STARTER GEAR

NEEDLE BEARING

SPEED SENSOR WHEEL

MAGNET ROTOR

STARTER GEAR

STARTER MOTOR FRONT COVER SPRAGUE CLUTCH

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. (10 Nm) Apply Loctitet 272 to threads.
Magnet Rotor Bolt Torque: 73 ft.lbs. (100 Nm) Apply engine oil to bolt threads.
Alternator Fastener Torque: 7 ft.lbs. (10 Nm)
Alternator Cover Fastener Torque: 7 ft.lbs. (10 Nm)

8.8 2004 Four Stroke PWC Service Manual

 ELECTRICAL SYSTEMS
Charging System

D
BLK
B

RED/YEL A

ALTERNATOR

VOLTAGE
REGULATOR

RED

A B C D E F

SPARE 30A SPARE

STARTER RELAY
A

RED

- +

CHARGING SYSTEM -- LEGEND

RED 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 8.9

 ELECTRICAL SYSTEMS

Start / Stop Electrical System

RED/PUR

RED
B A
2A
TETHER SWITCH
C D
10A
F E
- + 15A A

PURPLE C
STARTER RELAY
YEL/RED YEL/RED
A B

START SWITCH
B BLK
START SWITCH / STOP - TETHER
PURPLE

RED
YEL/RED

RED

D F ENGINE HARNESS-- TO-- CHASSIS

HARNESS CONNECTOR

D F

PURPLE RED/YEL
ECU
ECU 100

H C A

SYSTEM INTERFACE BOX

ECU 200
BLU/WHT
B4

BLK
L4

ECU 300
START / STOP CIRCUITS -- LEGEND
RED 12V BATTERY VOLTAGE
BLACK GROUND
RED/PUR FUSE PROTECTED / SWITCHED BATTERY VOLTAGE
YEL/RED STARTER RELAY SIGNAL
RED/YEL STARTER RELAY SIGNAL
PURPLE SWITCHED ECU VOLTAGE
BLU/WHT SWITCHED ECU VOLTAGE
Rev. B 1/19/2004

8.10 2004 Four Stroke PWC Service Manual

 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.
A secondary function of the SIFB is to convert the reverse switch signal so the ECU can interpret the signal when
the reverse switch is closed, thereby limiting engine RPM.

How It works
The SIFB will disconnect the ECU ignition circuit and go
into the “sleep” mode in the event that the lanyard is left
installed in the stop switch for more than two minutes. This
also holds true whenever the operator pushes the stop but-
ton momentarily while the engine is running.
In the event that the operator removes the lanyard from the
stop switch while the engine is running, the SIFB does
nothing.
To power--up the ECU after the SIFB has entered the
“sleep” mode, the operator must re--insert (if removed) the
lanyard into the stop switch, and press the start button.
NOTE: The SIFB remains in the mode in which it
was put into by the operator’s last action. For ex-
ample, the SIFB will allow the ECU to power--up im-
mediately when the lanyard is installed if the opera-
tor’s last action was removing the lanyard to kill the
engine.
Conversely, if the operator’s last action was leaving
the lanyard in the stop switch for more than two
minutes or stopping the engine by pushing the stop
button, the ECU will not power--up until the SIFB
“sees” a start signal generated by the operator
pushing the start button.

SIFB Diagnostics Mode

There will be situations where a user will want to defeat the sleep mode function of the SIFB. One such situation
is when a technician is connected to the ECU with the Digital Wrencht diagnostic software program.
To enter the SIFB diagnostic mode, follow these steps:
1. Insert the lanyard into the stop switch, and start the engine. Stop the engine by removing the lanyard.
2. Wait for15 seconds, then re--insert the lanyard. Quickly push the STOP button three times within the first
three seconds, then tap the START button.
The SIFB is now in the diagnostics mode. Power will be supplied to the ECU for as long as the lanyard remains
installed.
To exit the diagnostics mode, remove the safety lanyard from the STOP switch and wait for at least 15 seconds.
NOTE: To verify the ignition system is powered--up after inserting the lanyard into the stop switch,
move the throttle flipper from full closed to full open while the engine is off. The throttle plate can
always be heard moving with the flipper movement when the ignition system has power.

2004 Four Stroke PWC Service Manual 8.11

 ELECTRICAL SYSTEMS

System Interface Box (SIFB)

ENGINE/CHASSIS HARNESS CONNECTOR

PURPLE

SYSTEM INTERFACE BOX

YEL/GRN
E D B A
F G H J K
A B C D E F G H

YEL/GRN
GRY

ECU RED/YEL

ECU 200
J2 GRY
B4 BLU/WHT
E2 GRN/YEL
RED/PUR

BLACK 11 3 15 8

MAIN RELAY
R2 R1

2 10 13 6 5 4 7

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)
GRY TACHOMETER SIGNAL
RED/YEL IGNITION SWITCHED VOLTAGE (FROM START BUTTON)
YEL/GRN REVERSE SWITCH SIGNAL (FROM REVERSE SWITCH)
PURPLE IGNITION SWITCHED VOLTAGE (FROM TETHER SWITCH)

Rev. A 11/05/2003

8.12 2004 Four Stroke PWC Service Manual

 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.
Always use new o rings during reassembly.

2004 Four Stroke PWC Service Manual 8.13

 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.

4. Remove drive end cover and armature. Remove

thrust washer, phenolic washer, and shim washers.
Keep washers in order for reassembly.

8.14 2004 Four Stroke PWC Service Manual

 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. Reading should be infinite. (OL).
Inspect insulation on brush wires for damage and
repair or replace as necessary.

7. Slide positive brush springs to the side, pull brushes

out of their guides and remove brush plate. Slide brush
end frame off end of starter. NOTE: The electrical
input post must stay with the field coil housing.

8. Measure resistance between ground brush and brush

plate. Resistance should be .3 ohms or less.

2004 Four Stroke PWC Service Manual 8.15

 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. Remove terminal nut with lock washer, flat washer,
large phenolic washer, 2 small phenolic spacers, and
sealing O-ring. Inspect O-ring and replace if damaged.

2. Slide positive brush springs to the side, pull brushes

out of their guides and remove brush plate.
Cleaning
CAUTION:

Some cleaning solvents may damage the insulation in the

starter. Care should be exercised when selecting an ap-
propriate solvent. If the commutator needs cleaning use
only an electrical contact cleaner.

Armature Testing
1. Using a digital multitester, measure resistance
between each of the segments of the commutator. The
reading should indicate .3 ohms or less.
2. Measure resistance between commutator and
armature shaft. Reading should be infinite (OL).
Inspect surface of commutator wear or discoloration.
Replace if excessively worn or damaged.

3. Place armature in a growler. With growler on, position

a hacksaw blade lengthwise, 1/8″ (.3 cm) above
armature coil laminates. Rotate armature 360°. If the
hacksaw blade is drawn toward the armature on any
point, the armature is faulty and must be replaced.

4. Inspect permanent magnets in starter housing. Make

sure they are not cracked or separated from housing.

CAUTION:

Use care when handling starter housing. Do not drop or

strike the housing as magnet damage is possible. If mag-
nets are damaged, starter must be replaced.

8.16 2004 Four Stroke PWC Service Manual

 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.

4. Slide armature into field magnet housing.

Release brushes.

5. Lightly grease drive end bushing and reinstall

drive end frame on armature. Inspect seal for
wear or damage. Replace drive end cap if
necessary.

6. Be sure wire insulation is in place around

positive brush wire and pushed completely into
slot on phenolic plate.

7. Using a non-petroleum grease, lubricate brush

end bushing and install shims.

Nyogelt Grease PN 2871329

8. Align brush plate and install cover and screws.

9. Reinstall bolts and tighten evenly and securely.

10. Lightly grease pinion shaft and install pinion,

spring stopper, and snap ring.

Starter Solenoid Bench Test

To measure the resistance of the pull-in coil, connect
one meter lead to the Yellow/Red wire and the other
to ground. The resistance should be 2.8-3.6 ohms.
Refer to Electric Starter System Testing in this
section to further test the solenoid.

2004 Four Stroke PWC Service Manual 8.17

 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.
red lead on the battery positive (+) terminal. (Continue on with left column.)
Reading should be 12.4 V or greater.
Is it?
No!
Yes#
Disconnect the red engagement coil wire from the With the black tester lead on ground, check for
starter solenoid. Connect the black tester wire to voltage at the large relay in terminal, the circuit
an appropriate ground and the red lead to the red breaker in and out terminals, and across both
harness wire at the solenoid. Push the start sides of the start switch with the switch on start.
button. The meter should read battery voltage. Repair or replace any defective part(s).
Does it?
No!
Yes#
Reconnect the solenoid. Connect the tester black Clean the battery to solenoid cable ends or
lead to the battery positive terminal and the red replace the cable.
tester lead to the solenoid end of the
battery-to-solenoid cable. Push the start button.
The reading must be less than .1 Vdc. Is it?
No!
Yes#
Connect the black tester lead to the solenoid end Replace the starter solenoid.
of the battery-to-solenoid cable and the red tester
lead to the solenoid end of the solenoid-to-starter
cable. Push the start button. The reading must
be less than .1 Vdc. Is it?
No!
Yes#
Connect the black tester lead to the solenoid end Clean the solenoid-to-starter cable ends or
of the solenoid-to-starter cable and the red tester replace the cable.
lead to the starter end of the same cable. Push
the start button. The reading must be less than
.1 Vdc. Is it?
No!
Yes#
Connect the black tester lead to the starter frame. Clean the ends of the engine-to-battery negative
Connect the red tester lead to the battery cable or replace the cable.
negative terminal. Push the start button.
Reading should be less than .1 Vdc. Is it?
No!
Yes#
If all these tests indicate a good condition, yet the
starter still fails to turn, or turns slowly, the starter
must be removed for static testing and inspection.

8.18 2004 Four Stroke PWC Service Manual

 62456_Foldouts
WIRING DIAGRAMS

3/5/04
MSX 110 / 150 Chassis Harness

8:34 PM
Page 1
 62456_Foldouts
WIRING DIAGRAMS

MSX 110 / 150 Engine Harness

3/5/04
8:34 PM
Page 2
 62456_Foldouts
WIRING DIAGRAMS

3/5/04
MSX 110 / 150 Engine Harness

8:34 PM
Page 3
62456_Foldouts 3/5/04 8:34 PM Page 5
CHASSIS WIRING HARNESS -- LEGEND
TETHER SWITCH START SWITCH
RED 12V BATTERY VOLTAGE
BLACK CHASSIS GROUND
RED/PUR RED/PUR FUSE PROTECTED / SWITCHED BATTERY VOLTAGE
YEL/RED STARTER RELAY SIGNAL
CLOSED WHEN TETHER INSTALLED PUR/WHT ESP SIGNAL
PURPLE SWITCHED ECU VOLTAGE
RVS SWITCH MODE SWITCH OR/BLK NGI MODE SWITCH SIGNAL
Y/GRN REVERSE SWITCH SIGNAL
PUR/YEL PADDLEWHEEL SIGNAL
YEL/RED GRAY TACHOMETER SIGNAL (2 PULSE)
LT.BLUE OIL PRESSURE SWITCH SIGNAL
Y/GRN A B A B PINK FUEL LEVEL SIGNAL
GRN/YEL ENGINE TEMPERATURE SWITCH
GRN/RED CHECK ENGINE MIL LAMP SIGNAL
Rev. A 11/05/2003
RED/PUR
PURPLE
RED/PUR
OR/BLK
NGI GAUGE
GRAY GRAY
ESP SWITCH
PUR/WHT PUR/WHT E F
RED
E D B A A B C B A
PUR/WHT
YEL/RED
F G H J K RED/PUR
ENGINE - CHASSIS C B A
CONNECTOR
GRN/RED GRN/RED
D E
LT.BLUE BLUE
GRN/YEL GRN/YEL
RED/PUR
PINK
RED RED
BLACK
YEL/RED
RED/PUR
RED
A B FUEL PUMP
PUR/YEL
BLACK
B A C D E F
- + 1 2 3 4 BLACK
BATTERY STARTER RELAY 2A 10A 15A BLACK
PADDLE WHEEL
PINK
62456_Foldouts 3/5/04 8:34 PM Page 6
MAIN RELAY CIRCUITS -- LEGEND
RED 12V BATTERY VOLTAGE
BLACK GROUND
RED/PUR FUSE PROTECTED / RELAY SWITCHED BATTERY VOLTAGE
RED PURPLE SWITCHED ECU VOLTAGE FROM TETHER SWITCH
SPLICE 3 ENGINE HARNESS
FUSE SPLICE BLOCK BLK/GRN SWITCHED ECU RELAY CONTROL
LT.BLUE OIL PRESSURE SWITCH SIGNAL
RED RED/PUR GRN/RED CHECK ENGINE MIL SIGNAL
C D
15A PUR/WHT ESP SIGNAL
-- + RED RED/PUR GRN/YEL ENGINE TEMP. MIL SIGNAL / EXHAUST PIPE WATER TEMP. MIL SIGNAL
E F
15A GREY TACHOMETER SIGNAL
BATTERY RED B
A 15A
Rev. B 1/12/2004
STARTER RELAY
MAG FUEL INJECTOR
RED/PUR
RED/PUR
RED/PUR
H G F E WASTEGATE SOLENOID
SPLICE 1
A B C D RED/PUR
SYSTEM IFB CONNECTOR RED/PUR
11 3 15 8
MAIN RELAY
ECU PTO FUEL INJECTOR
ECU 100
R2 R1
MAG IGNITION COIL PTO IGNITION COIL
BLK/GRN
F3
2 10 13 6 5 4 7
BLK/GRN
ECU 200 RED/PUR
GRN/RED
C4 SPLICE 2
E3
PUR/WHT RED/PUR
GRN/YEL RED/PUR
K3
RED/PUR RED/PUR
J2
GREY
RED/PUR
LAMBDA SENSOR
PUR/WHT
ECU 300 OIL PRESSURE SWITCH
BLK/GRN E D B A
F2
F G H J K
G2
RED/PUR
GRN/RED
GRN/YEL LT.BLUE
GREY
ENGINE/CHASSIS HARNESS CONNECTOR
62456_Foldouts 3/5/04 8:34 PM Page 7
IGNITION / FUEL INJECTION CIRCUITS -- LEGEND
MAIN RELAY BLACK CHASSIS GROUND / IGNITION GROUND
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
R2 R1 Rev. B 1/12/2004
SPLICE 1 SPLICE 1 SPLICE 1
2 10 13 6 5 4 7
RED/PUR
ECU
ECU 100
H2 BLK/OR PTO FUEL INJECTOR MAG FUEL INJECTOR WASTEGATE SOLENOID
G2
BLK/OR
BLK/OR
BLK/OR
BLK/RED
SPLICE 2 SPLICE 2
ECU 300 F2 BLK/GRN
G2
RED/PUR
GREEN RED/PUR
G3
G4
BLK/RED
ORANGE SPLICE 6 SPLICE 6
H3
H4
BLACK
PTO IGNITION COIL MAG IGNITION COIL
GREEN
ORANGE
SPARK PLUG SPARK PLUG
62456_Foldouts 3/5/04 8:34 PM Page 8
SPLICE 4 SPLICE 4 ENGINE MANAGEMENT SENSOR CIRCUITS -- LEGEND
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. SIGNAL
BLU/RED SENSOR RETURN SIGNAL (PHASE SENSOR, KNOCK SENSOR, TEMP.SENDER, TEMP. SW.)
BOOST BLU/OR BOOST PRESSURE SIGNAL
MANIFOLD PRESSURE CAM BROWN LAMBDA SUPPLY VOLTAGE
PRESSURE PHASE
AIR SENSOR
TEMP. Rev. A 11/05/2003
SPLICE 5 SPLICE 5 SPLICE 5
ECU ECU 100 C2 BLK/WHT
C3
RED/GRN
BLK/WHT
A2
C1
BLU/WHT
MAIN RELAY
BLU/WHT
B1
ENGINE
BLU/BLK
B2 SPEED
BLU/YEL SENSOR
A3
BLK/WHT
B3
R2 R1
ECU 200 A3 BLK/WHT
2 10 13 6 5 4 7
BLU/YEL
BLK/WHT
RED/PUR
F3 BLU/RED
BLU/OR LAMBDA SENSOR
F4
BLU/YEL
BLU/YEL
A2
ECU 300 BLK/WHT BLK/WHT
B3 KNOCK SENSOR
BLU/RED
C3
BLK/WHT
D4
BLU/RED TEMP. SENDER
E4
BLU/RED TEMP. SWITCH
C4
E2
BROWN BROWN
62456_Foldouts 3/5/04 8:34 PM Page 9
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. POSITION 1 RETURN SIGNAL
BLU/GRN E.T.B. POSITION 2 RETURN SIGNAL
RED/WHT E.T.B. THROTTLE PLATE POSITIVE (+) VOLTAGE
BLK/RED E.T.B. THROTTLE PLATE NEGATIVE (--- ) VOLTAGE
6 5 4 3 2 1 A B C D E F
Rev. A 11/05/2003
ECU
SPLICE 11
SPLICE 11 SPLICE 11
ECU 200
K1
BLK/WHT
B1
RED/GRN
SPLICE 10 SPLICE 10
A2
BLU/RED
GRY/RED
A1
ECU 300 A1
BLU/OR
B4 BLU/GRN
RED/WHT
G1
C1
RED/GRN
B1
BLK/WHT
H1
BLK/RED
1 2 3 4 5 6
ELECTRONIC THROTTLEBODY (E.T.B.)
 A ECU Harness Connectors, 5.28
ECU Overview, 5.1, 5.29
Adaptation, 5.28 Electrical Specifications
Armature Testing, 8.16 Battery and Charging System, 8.1
Chassis, 8.1
Electronic Throttle Body / PPU Overview, 5.29
B Engine Compression Test, 2.14
Battery Charging, 2.16 Engine Coolant Change Procedure, 2.12
Battery Connections, 2.16 Engine Coolant Inspection, 2.12

Battery Installation, 2.17 Engine Disassembly, 4.21–4.28

Engine Inspection Procedures, 4.29–4.42
Battery Maintenance
Off Season Storage, 8.7 Engine Management Circuit Diagrams
Refilling , 8.7 Boost / Air Temperature, 5.20
Camshaft Position Sensor, 5.24
Battery Safety, 2.15
Electronic Throttle Body, 5.15
Battery Testing, 8.5–8.6 Engine Coolant Temperature Sensor, 5.22
Bearing Carrier Installation, 6.9 Engine Speed Sensor, 5.23
Fuel Injectors, 5.17
Bearing Carrier Removal, 6.9 Fuel Pump Relay, 5.27
Bilge Siphon System, 2.21 Ignition Coils, 5.18
Intake Manifold Pressure, 5.21
Brush Inspection, Starter Motor, Charging Proce- Knock Sensor, 5.25
dure, 8.7 O2 Sensor, 5.19
Brush Replacement, Starter Motor, 8.16 Pedal Position Unit, 5.16
Wastegate Solenoid, 5.26
Engine Oil Change Procedure, 2.10–2.11
C Engine Oil Level Check, 2.10
Cavitation Troubleshooting, 6.3 Engine Removal and Installation, 3.1–3.10

Charger Air Cooler / Intercooler Overview, 5.34 ESP Function Testing, 2.8

Cold Start Protection Mode, 5.35 ETB Learning Procedure, 5.29

Exhaust Water Injector Maintenance, 2.19
Conversion Chart, 1.12
Exploded View
Cooling System Pressure Test, 2.13
Alternator Assembly, 8.8
Chain Guides / Chain Tensioner, 4.14
Crankshaft / Counter Balancer, 4.20–4.21
D Dry sump Oil Pump, 4.11
ECU Mounting, 5.11
Decimal Equivalent Chart, 1.11 Engine Case / Cylinder Head, 4.15–4.16
Drain Plugs Intercooler / Intake Manifold, 2.25 ETB / Intake Manifold, 5.9
Exhaust System, 5.31
Driveshaft / Bearing Carrier Exploded View, 6.6 Flywheel / PTO Stub Shaft, 4.19
Driveshaft Inspection, 6.11 Fuel Delivery System, 5.7
Fuel Rail / Injectors, 5.8
Driveshaft Shim Procedure, 6.10 Fuel Tank, 5.6
High Pressure Oil Pump, 4.13
Ignition Coils, 5.10
E Intake / Exhaust Valves, 4.18
Oil Filter, 4.8
ESP Switch Assembly, 7.11 Piston, 4.17
 Starter Motor, 8.13
Thermostat Housing Water Manifold, 4.12
I
Valve Cover, 4.9 Impeller Clearance, 6.11
Valve Train, 4.10
Intake Manifold Fastener Re---Torque Procedure,
2.24
Intake Scoop / Ride Plate Removal and Installa-
F tion, 6.21–6.22

Fastener Guide
Final Drive / Propulsion, 6.2
Hull and Body, 7.2
M
Final Drive / Propulsion Quick Reference Guide, Maintenance, Bilge Drain Plug, 2.21
6.1 Maintenance Safety Warnings, 2.2
Flush Kit, 2.3 Maintenance Service Products, 2.4
Footpad Removal / Application, 7.18 Maintenance Specific Tools, 2.3
Fuel / Water Separator, 2.20 MSX 110 Emission Information, 1.6
Fuel Filter, 2.20 MSX 110 General Information, 1.6–1.7
Fuel Injection / Ignition system Specifications, 5.2 MSX 150 Emission Information, 1.8

Fuel System Pressure Test, 2.14 MSX 150 General Information, 1.8–1.9

Fuses, 2.18
N
G NGI Gauge, 8.2–8.3

Gasoline Safety Guidelines, 2.20

General Lubrication
O
Reverse System, 2.5 Off Season Storage, 2.26
Steering Cable and Steering Joints, 2.5
Steering Nozzle, 2.5
P
H Paint Codes, 7.1
Periodic Maintenance Table, 2.1
Handlebar / Steering Post Removal and Installa- PPU Assembly, 7.12
tion, 7.14
Pump / Propulsion Specifications, 6.1
Handlebar Maintenance, 2.24
Pump Assembly Exploded View, 6.4
Harness Connectors
ECU C100, 5.12 Pump Housing Installation, 6.8
ECU C200, 5.13 Pump Housing Removal, 6.8
ECU C300, 5.14
Pump Induction Assembly Exploded View, 6.7
Compartment Door Assembly, 7.7 Pump Maintenance, 2.22–2.23
Hull Assembly, MSX, 7.5–7.6 Pump Removal, 6.8
Hull Repair, 7.18 PWC Identification Numbers, 1.3
Hull Specifications, 7.1 PWC Publication Part Numbers, 1.4
 R 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
T
Routings Tap Drill Sizes, 1.13
Air Inlet Hoses, 5.3 Throttle Cable Adjustment, 2.19
Bilge Siphon Hoses, 7.4
Fuel Hoses, 5.4 Trouble Codes
Reverse Cable, 7.3 Boost / Air Temp. Sensor, 5.20
Steering Cable, 7.3 Camshaft Position Sensor, 5.24
Vent Hose, 5.5 ECU / Engine Management System, 5.29
Engine Coolant Temp. Sensor, 5.22
RPM Limiting Modes / RPMs, 5.35 Engine Speed Sensor, 5.23
ETB / Electronic Throttle Body, 5.15
Fuel Injectors, 5.17
S Fuel Pump Driver, 5.27
Ignition Coils, 5.18
Sacrificial Anode, 6.20 Intake Manifold Pressure Sensor, 5.21
Safety Warning Guidelines, 1.5 Knock Sensor, 5.25
O2 / Lambda Sensor, 5.19
Seat Assembly, 7.9 PPU / Pedal Position Unit, 5.16
Shroud and Storage Assemblies, 7.8 Wastegate Solenoid, 5.26
Spark Plug, 2.18 Troubleshooting
Special Service Tools, 1.14–1.15 Charge Air Cooler, 5.34
Engine Turns Over; Will Not Start, 5.37
Special tools, Engine, 4.7 Engine Will Not Turn Over, 5.36
Specifications Engine Lacks Performance / RPM Limits,
Engine, 4.1–4.2 5.40–5.43
Engine Fasteners, 4.3–4.6 Engine Stall; Will Not Re---Start, 5.39
Engine Stalls; Will Re---Start, 5.38
Standard Torque Specifications, 1.10 ETB / PPU, 5.30
Starter Assembly, 8.17 Turbocharger / Wastegate Overview, 5.32–5.33
Starter Motor Cleaning, 8.16
Starter Solenoid Bench Test, 8.17
Starter Motor Disassembly and Assembly, V
8.14–8.18
Valve Clearance Adjustment Procedure, 2.8–2.9
Stator Assembly, 6.14
Ventilation Troubleshooting, 6.3
Stator Assembly Exploded View, 6.5
Stator Disassembly, 6.12–6.14
Steering Cable Adjustment, 2.7, 7.17 W
Steering Cable Installation, 7.16 Wiring Diagram
Steering Cable Removal and Installation, 7.15–7.16 Charging System, 8.9
NGI Gauge MIL Indicators, 8.4
Steering Control Assembly, 7.10 Start / Stop System, 8.10
Steering Post Removal and Installation, 2.6 System Interface Box, 8.12
 msx 110

Personal Watercraft Service Manual

msx 150

Four Stroke Personal Watercraft Service Manual

FOUR STROKE

Part Number 9919062

Printed in U.S.A