Polaris 2003 MSX User Manual

2003

MSX

Owner's Manual

for Vehicle Maintenance

and Safety

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

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All information in this manual is based on the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements that may affect illustrations or explanations.

No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc. Polaris, Polaris The Way Out, and Workmobiles are registered trademarks of Polaris Industries Inc.

Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.

Polaris Recreational Vehicles

S Snowmobiles S All-terrain vehicles (ATVs) S Watercraft S RANGER utility vehicles S Victory motorcycles

Polaris Professional Series Workmobilest

S Utility Task Vehiclest (UTVs) S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs)

WELCOME

We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period. Refer to page 101 for the part numbers of Polaris products for your vehicle.

We take great pride in our Pure Polaris Parts Apparel and Accessories (PAA), available at your Polaris dealership or through our online store at www.purepolaris.com. Have your Pure Polaris products delivered right to your door!

TABLE OF CONTENTS

WELCOME 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 4. . . . . . . . . . . . . . . . .

YOUR RESPONSIBILITIES 5. . . . . . . . . . . . .

IDENTIFICATION NUMBERS 7. . . . . . . . . . . .

SAFETY 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FEATURES and CONTROLS 24. . . . . . . . . . .

EMISSIONS 36. . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION 38. . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE and LUBRICATION 74. . . . .

ENGINE TROUBLESHOOTING 96. . . . . . . . .

POLARIS PRODUCTS 101. . . . . . . . . . . . . . . .

SPECIFICATIONS 102. . . . . . . . . . . . . . . . . . . .

WARRANTY 104. . . . . . . . . . . . . . . . . . . . . . . . .

CALIFORNIA EMISSIONS WARRANTY 107

INDEX 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Do Your Part

Riding your Polaris watercraft will be an enjoyable experience for you, your family and friends, but we must all do our part to ride safely and protect our environment so we can continue to enjoy this sport for many years. Please show respect for our waterways, our wildlife and other people.

Know Your Vehicle

As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner’s manual, which discusses all aspects of your vehicle, including safe operating procedures.

Take Safety Training

When you purchased your new Polaris watercraft, you received a watercraft safety video and an owner’s manual. Please review this information on a regular basis. All operators and passengers should read and understand the owner’s manual before riding.

Store the manual in a waterproof bag in one of the storage areas on the watercraft. If the vehicle is sold, the owner’s manual and video should remain with it. If your owner’s manual is lost or missing, see a Polaris dealer for a replacement.

YOUR RESPONSIBILITIES

Obey the Rules

Familiarize yourself with all boating laws and regulations in your area. Ride only in areas approved for personal watercraft. Avoid riding near waterfront homes, wildlife areas, other boats and swimmers.

Respect Your Neighbors

Some people may find the sound of your watercraft disturbing. Avoid making excessive noise when riding, and don’t make any modifications to your watercraft that may increase the sound or emission level.

Use Care When Refueling

When refueling in or near the water, use care to avoid spilling fuel. If you do spill, wipe it up promptly and dispose of the soiled towels appropriately.

Use Biodegradable Products

Choose biodegradable products for cleaning your watercraft. Avoid environmentally harmful aerosol sprays, and dispose of used products and containers appropriately. Never place used oil and other chemicals (including soiled towels) in the trash, on the ground or down a drain. Contact your local or state office of public works to find out how to dispose of these wastes in your area.

YOUR RESPONSIBILITIES

Age Restrictions

This vehicle is not a toy. Polaris recommends that all operators be 16 years of age or older. Contact local authorities to find out what the legal age requirements are in your area of operation.

Maintenance Requirements

Follow the recommended maintenance program outlined in your owner’s manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.

WARNING

Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris watercraft is not a toy. It’s a high performance powerboat and can be hazardous to operate. A collision or overturn can occur quickly if you fail to take proper precautions. Read and understand your owner’s manual and all warnings before operating a Polaris watercraft.

Your watercraft’s hull and engine identification numbers are important for model identification when registering your watercraft, when obtaining insurance, and when ordering replacement parts. The hull identification number is located on the rear right-hand boarding platform (1). The engine identification number is located at the front of the engine near the stator cover (2).

IDENTIFICATION NUMBERS

Record your vehicle’s identification numbers in the spaces provided and in another location away from the vehicle. If the vehicle is destroyed or stolen, you’ll have the identification numbers required by insurance and/or law enforcement.

NOTE: Check with your insurance agent about obtaining insurance coverage for your watercraft, or see your Polaris dealer.

Purchase Date:

Vehicle Model Number:

Engine ID Number:

Hull ID Number:

SAFETY

Signal Words and Symbols

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE:

A note will alert you to important information or instructions.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

Safety Decals

Important warning and instruction decals have been placed on the watercraft for your protection. Read and follow the instructions on each decal carefully. If any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needing replacement will be provided by Polaris at no charge.

The warning decals summarize and highlight key safety and operational information. Be sure to read the entire owner’s manual for details that affect safe operation of this watercraft.

SAFETY

Safety Decals

The general safety/warning decal is located on the rear of the watercraft, just below the seat.

Safety Decals

The collision warning decal is located on the dash of your watercraft.

SAFETY

Collisions result in more INJURIES AND DEATHS than any other type of accident for personal watercraft (PWC). TO AVOID COLLISIONS: SCAN CONSTANTLY for people, objects and other watercraft. Be alert for conditions that

limit your visibility or block your vision of others. OPERATE DEFENSIVELY at safe speeds and keep a safe distance away from people, objects, and other watercraft.

S Do not follow directly behind PWCs or other boats. S Do not go near others to spray or splash them with water. S Avoid sharp turns or other maneuvers that make it hard for others to

avoid you or understand where you are going.

S Avoid areas with submerged objects or shallow water.

TAKE EARLY ACTION to avoid collisions. Remember PWCs and other boats

do not have brakes. DO NOT RELEASE THROTTLE WHEN TRYING TO STEER away from

objects - you need throttle to steer. Always check throttle and

steering controls for proper operation before starting PWC.

Follow navigation rules and state and local laws that

apply to PWCs.

See Owner’s Manual for more

information.

SAFETY

Safety Decals

The fuel warning decal is located near the fuel tank fill cap.

The capsize warning decal is located at the rear of the watercraft, positioned upside down so the operator can read it when the boat is capsized.

WARNING

RIGHTING CAPSIZED BOAT

S To prevent injury, do not place

hands or objects into pump inlet, intake grate or nozzle.

S To prevent major engine damage:

Make sure engine is stopped by pulling lanyard from engine stop switch and turn boat position in a clockwise direction

to upright

7073865

Informational Decals

The Coast Guard exemption decal is located below the left-hand mirror.

WARNING

SAFETY

Located on the upper shroud near

the front compartment door:

FIRE EXTINGUISHER CONTAINER

LOCATED INSIDE

Located on the engine water manifold:

Do Not Remove Electrical Part When Starting Or During Operation.

High Voltage Shock Hazard.

7171396

7075383

SAFETY

Operator Safety

WARNING

Failure to follow the warnings and instructions contained throughout this manual and on your vehicle can result in severe injury or death.

Read and understand your owner’s manual and all warning decals before operating a Polaris watercraft.

Any operator of a Polaris watercraft must know and practice the following guidelines for personal safety and the safety of passengers. Never permit a guest to operate this watercraft unless the guest has read and understands all warning decals and the owner’s manual.

Operator Guidelines

This watercraft is not a toy. It’s a high performance powerboat, and operating it requires learned and practiced skills. All operators and passengers should become familiar with proper operating techniques before attempting maneuvers. Always operate the watercraft at a speed appropriate for water conditions and for your level of experience.

The minimum recommended age for operators of this watercraft is 16 years, but operators between 16 and 18 years of age may require close adult supervision. Obey all applicable boating rules and regulations.

This watercraft does not have brakes. The watercraft is stopped by releasing the throttle. The vehicle will glide to a stop due to the natural drag of the water.

Allow a minimum of 300 feet (90 m) to coast to a stop from full throttle.

Jet thrust is required to steer and turn the vehicle.

Never completely release the throttle and attempt to turn at more than a trolling speed. The watercraft will not turn. Practice until you’re comfortable with turning and stopping, and be sure you’ve mastered the skills before carrying a passenger.

Learn and observe all local, state, and federal boating regulations and speed limits. Boating laws and navigational rules are designed for the safety of everyone sharing the waterways.

Operator Safety

Your Polaris watercraft is capable of towing, but please be aware that towing can cause reduced steering control. Be extremely careful when towing other watercraft, skiers or objects behind this watercraft, as they have a significant impact on handling and steering. Observe local and state laws regarding water skiing and towing.

Do not allow passengers to stand on the boarding platform while the watercraft is running or in motion. Passengers should always remain seated.

Never travel over a ski jump or attempt to jump waves, wakes or other objects in the water. Doing so may severely damage the watercraft and cause personal injury due to the hard impact, a temporary loss of visibility, possible loss of control and reduced reaction time.

SAFETY

Always securely attach the lanyard cord (1) to the operator’s left wrist or PFD before starting the watercraft. If the operator falls off, the engine will immediately lose power.

Be sure the lanyard cord is free and not wrapped around the handlebars or controls. When the

watercraft is not in service, disconnect the lanyard from the engine stop switch to prevent accidental starting of the engine.

SAFETY

Operator Safety

WARNING

Failure to wear protective clothing while operating a watercraft can result in serious injury. The jet pump emits a forceful stream of water that can injure body orifices. Falling off the watercraft while operating at higher speeds may also lead to injury. Always wear the recommended protective gear while riding on any watercraft.

Safe Riding Gear

Always wear protective clothing when operating or riding a personal watercraft. Consider attaching a whistle to your lanyard to summon help in emergency situations.

1 - Personal Floatation Device

The operator and passenger must always wear an approved personal flotation device (PFD) at all times to prevent accidental drowning. Polaris recommends a vest-type PFD (U.S. Coast Guard type 1, 2, or 3). NOTE: The seat of the watercraft is not a PFD.

2 - Eye Protection

Wear adequate eye protection to protect against water spray, sun, insects and other objects. To protect prescription eyewear and sunglasses against loss or damage, wear goggles that fit securely over them.

3 - Suit/Shoes/Gloves

We recommend that all riders wear a wet/dry suit and watercraft shoes to protect against the force of the water, as well as exposure and unknown hazards in the water, such as debris and hidden objects. Riding gloves may also be considered.

NOTE: A helmet may provide increased personal injury protection in some situations, such as impact with the watercraft or during a collision with other watercraft or an obstacle. However, a helmet may not provide adequate protection against all foreseeable impacts and may aggravate some injuries. For example, if a rider falls off a moving watercraft while wearing a helmet, the helmet could catch the water and cause choking, severe and permanent injuries or death. A helmet may also increase the possibility of an accident if it reduces your visibility or ability to hear or if its weight contributes to fatigue.

Operator Safety

Overloading the Watercraft

WARNING

Overloading a watercraft will significantly reduce vehicle stability and control, which could result in an accident and lead to severe injury or death. Never allow more than the specified rider capacity on the watercraft.

Polaris watercraft are designed to carry an operator and up to three passengers, depending on the model. Check the specifications section beginning on page 102 to determine your boat’s rider capacity.

When more than one person is riding, the watercraft handles differently, which means that the operator must have enough prior riding experience to handle the watercraft with one or more passengers aboard.

SAFETY

Fire Safety

Federal regulation requires that all watercraft carry an approved fire extinguisher. The operator is responsible for providing and maintaining the fully charged fire extinguisher in the watercraft. Do not operate the watercraft without a fire extinguisher on board.

Stow your fire extinguisher under the front storage compartment in the cut-out area of the flotation foam. Know how to reach the extinguisher quickly in case of fire, and know how to use it before you operate the personal watercraft.

If you have any doubts about your ability to extinguish a fire, swim away from the craft as quickly as possible. Immediately seek help from other boaters or people on shore.

SAFETY

Operator Safety

Weather and Darkness

Be aware of severe weather conditions. Observe weather forecasts and conditions before venturing out, and do not operate the watercraft when visibility is poor and when the water is rough. Operation of the watercraft in poor weather conditions can result in an accident and lead to severe injury, hypothermia or death.

Never operate the watercraft after sunset, before sunrise or in any condition of darkness. The vehicle is not equipped with lights, which makes it unsafe and illegal to operate in darkness. Consult local regulations concerning allowed hours of operation.

Always ride with another watercraft when operating in remote areas or in large areas of open water. Carry a flare gun on board to signal for help if necessary.

Protective Apparel

Normal swimming attire may not provide adequate protection while riding a watercraft. At the rear of the watercraft, the jet pump emits a forceful stream of water that can injure body orifices, such as mouth, eyes, ears, rectum and vagina. In addition, falling off the watercraft while operating at higher speeds may lead to injury due to impact with the water. All riders must wear wet suit bottoms or clothing that provides equivalent protection.

NOTE: If a passenger falls from the watercraft, release the throttle immediately. Do not exceed idle speed if any person is within 50 feet (15 m) of the rear of the watercraft.

Operator Safety

Obstacles and Shallow Water

Always be on the lookout for dangerous obstacles above and below the water surface, especially in shallow water. Use extra caution when riding in unfamiliar areas.

Never ride in water that is less than two feet (60 cm) deep, and do not operate at more than an idle speed in water that is less than six feet deep. Colliding with an underwater object could result in severe injury or death. Ingesting sand into the cooling system will also cause the engine to overheat, which could lead to serious mechanical damage.

2 ft. (60cm) Minimum

SAFETY

If the watercraft has been beached or has been sitting in shallow water, clear out any sand or small rocks before boarding and restarting the watercraft. Remove the particles by bouncing the back of the machine up and down in at least two feet of water. If the craft has been beached, flush the cooling system.

CAUTION

Failure to flush the cooling system after the watercraft has been beached could result in serious engine damage. Always follow the recommended flushing procedures and flush the cooling system any time the watercraft has been beached.

SAFETY

Operator Safety

Turning and Accelerating

Turning and accelerating without checking for other boats and objects in your path can cause an accident and result in severe injury or death. Always look

behind the watercraft and to each side before accelerating and before making sudden turns. Always

be aware of obstacles, swimmers and other watercraft.

Quick turns or abrupt changes in speed can cause passengers to lose their balance and be ejected from the vehicle, which could result in injury. The operator should always alert any passengers before making sudden turns or changes in speed.

Pre-Operation Check

Always perform the pre-operation check (beginning on page 38) before starting and riding the watercraft. Make sure all critical components are operating correctly. Check fuel and oil levels and all controls, especially the throttle lever, handlebars, and steering nozzle. Failure of these critical components can result in an accident and lead to severe injury or death.

Service and Maintenance

Routine service and adjustments to the watercraft are critical for the safe operation and extended life of the watercraft. Follow the maintenance and service recommendations outlined in this manual.

Operator Safety

Jet Pump Water Intake Safety

Contact with the jet pump or driveline components of the watercraft can result in severe injury, death or drowning. Do not allow hands, feet, ropes, straps, clothing or long hair to come in contact with the jet pump water intake (1) on the bottom of the watercraft while the engine is running.

Never insert any object into the intake or outlet (2) of the jet pump, and never start or operate the watercraft with the inlet grate, ride plate (3), or any guards or shields removed.

To prevent serious injury due to accidental starter engagement, be sure the engine is off and the safety lanyard is disconnected before removing weeds or debris that may have collected in or around the jet pump intake.

SAFETY

Electrical Shock Hazard

Never touch or remove electrical parts while starting or during operation of the watercraft. Severe injury or death could result from electrical shock.

Safe Riding Position

Falling off a watercraft can result in serious injury. The operator and any passengers should always keep both feet firmly planted on the floorboards while the watercraft is in motion. The passenger should face forward and firmly hang on to the operator’s waist, except in towing situations, when the spotter faces the rear and uses the grab handle to hold on.

Lifting the Watercraft

Severe back injury or other injury could result from attempting to lift the watercraft without assistance. Never attempt to lift the watercraft without the aid of a trailer and winch or another heavy lifting device.

SAFETY

Operator Safety

Operator Awareness

A collision can cause severe injury or death. Always be aware of other watercraft, swimmers and other obstacles while operating the watercraft. Always maintain a safe distance, especially if you’re an inexperienced operator. Do not exceed idle speed if any person is within 50 feet (15 m) of the rear of the watercraft.

Operator Fitness

Safe operation of this rider-active craft requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control, which could result in serious injury or death.

Riding personal watercraft is strenuous. All riders should be in good physical condition. Pregnant women should consult their physicians before riding any watercraft.

Reboarding the watercraft in deep water can also be strenuous. Operators and passengers should be physically fit enough to reboard the watercraft in deep water. Practice boarding in chest-deep water to be sure you are physically able to reboard if the need arises.

Boating Under the Influence

Operating any watercraft while under the influence of alcohol or drugs could result in an accident and lead to severe injury or death.

More than half of all the people who drown have consumed alcohol prior to their accident. Even if you’re not intoxicated, any amount of alcohol can be a threat to your safety and the safety of others. The equivalent of one beer will impair your balance, vision, judgment and reaction time, making you a potential danger to yourself and others.

Do not operate any watercraft while under the influence of alcohol or drugs.

Operator Safety

Vehicle Modifications

Modifications to this machine could create safety hazards and reduce vehicle reliability as well as make it unsafe or illegal to operate. Do not modify this watercraft or any of its components. Any modifications to the watercraft will void your warranty.

Operator Fatigue and Dehydration

Long hours of boating with exposure to noise, vibration, sun, glare and wind can result in operator fatigue and dehydration. These conditions can affect your balance, vision, judgment and reaction time. Fatigue and dehydration can increase your risk of an accident resulting in bodily injury or death. Combining alcohol consumption with this condition greatly increases your risk of causing an accident.

Learn to recognize the early symptoms of fatigue, and allow your body to recover by taking a break from operating the watercraft. Drink plenty of non-alcoholic beverages to prevent dehydration, and wear protective riding gear to protect against exposure to weather elements.

SAFETY

Hypothermia

Your life may depend on a clear understanding of the effects of cold water on the human body. Many suspected drowning victims actually died from cold exposure (hypothermia) rather than drowning.

Hypothermia can begin in water as warm as 80° F. (27° C). It’s a condition in which the body loses heat faster than it can produce it. Violent shivering develops, which may give way to confusion and a loss of body movement. Hypothermia can result in severe injury or death in a very short time.

To avoid hypothermia:

S Dress warmly. S Wear proper gear and stay as dry as possible. S Seek a warm environment at the first sign of

hypothermia (mild shivering).

If you fall into the water:

S Do not discard clothing. S While wearing your life jacket, draw your knees up

toward your chest and hold them there with your arms in the Heat Escape Lessening Posture (HELP).

FEATURES AND CONTROLS

1. Starter Button - Depress and hold the starter button to start the engine. Release it as soon as the engine starts. Do not depress for more than ten seconds at a time. NOTE: The lanyard and lock plate must be attached to the engine stop switch to start the engine

2. Stop Switch/Lanyard - Push this switch down or disconnect the lanyard plate to stop the engine quickly.

3. Safety Lanyard Wrist Cord - The lock plate end is attached to the stop switch. The wrist band is attached to the operator’s wrist or PFD. The engine will not start unless both are attached.

4. Gauge Mode Button - This button operates the display change for the NGI. See page 30.

5. Throttle - Squeeze the throttle lever toward the handlebar to increase speed. Release the lever to slow the craft and return the engine to idle. NOTE: The throttle lever installed on your MSX is finger-operated, but Polaris also offers an accessory thumb-operated lever. See your Polaris dealer for more information.

6. Instrumentation - Instrumentation is New Generation Instrument (NGI). See page 30 for a detailed explanation of the NGI display.

7. Seat Latch - The seat latch secures the seat in position. When released, it provides access to the engine compartment.

8. Jet Pump Outlet Nozzle - The nozzle is the exit for the jet output. Orientation is controlled by the handlebars and determines the direction of craft movement.

9. Exhaust Outlet

10. Reverse Gate

11. Drain Plugs - When water gets into the bilge, it can be drained through the drain plugs. Remove the watercraft from the water before draining the bilge. Be sure the plugs are securely installed before launching the craft.

12. Fuel Tank Fill - The fuel fill is located under the front compartment door. Turn the cap counterclockwise to remove, clockwise to replace.

13. Oil Fill - The oil fill is located under the front compartment door. Turn the cap counterclockwise to remove, clockwise to replace.

14. Jet Pump Intake Grate - The grate protects the impeller and drive shaft and protects riders from contact with components.

15. Drive Shaft - Beneath the intake grate, the drive shaft transmits power from the engine to the impeller.

16. Ride Plate - The ride plate covers and protects the jet pump and provides leveling control for the craft.

FEATURES AND CONTROLS

1. Front Compartment Door- The door provides access to the fire extinguisher, oil tank, fuel fill, oil fill and main storage space.

2. Fire Extinguisher Compartment - Located under the front compartment door and under the storage bucket in the left side flotation foam, this compartment provides secure storage for the fire extinguisher.

3. Handlebars - The handlebars control the orientation of the jet pump outlet nozzle, which in turn controls the direction of craft movement.

4. Console Storage

5. Seat/Engine Compartment - Removing the seat provides access to the engine, battery, electrical box, exhaust system, and other components.

6. Grab Handle - The grab handle assists riders while boarding the craft or when riding as passengers.

7. Tow Eye/Hook - Securely attach the tow rope to this hook when pulling skiers, wake boarders and tubes.

8. Boarding Platform/Footwell Pads - The boarding platform assists riders while boarding. The footwell pads are the place for the operator’s and passenger’s feet while riding the watercraft.

9. Sponson -The sponson enhances vehicle stability and turning ability in water.

10. Reverse Operation Handle

FEATURES AND CONTROLS

Engine Components (under seat)

1. Battery

2. Engine Management Module (EMM)

3. Spark plugs

4. Air intake cover

5. Starter solenoid

6. Exhaust silencer

7. Exhaust pipe

8. Exhaust cooling water hose

9. Cooling water manifold

10. Thermostat assembly (under end of water manifold)

11. Spark arrestor/air filter

12. Engine cooling water outlet hose (under thermostat assembly)

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