Polaris msx 110, msx 150 Service Manual

msx 110

msx 150

Four Stroke Personal Watercraft Service Manual

Table of Contents

General Information

Model Information / Safety Warnings / General Information

Maintenance

Periodic Maintenance Tables / Maintenance Procedures

Engine Removal and Installation

Specifications / Removal and Installation

Engine Disassembly, Inspection and Re--Assembly

Specifications / Components / Testing / Troubleshooting / Teardown

Fuel / Ignition / Exhaust Systems

Specifications / Components / Testing / Troubleshooting

Propulsion System

Specifications / Components / Teardown and Rebuilding / Inspection

Hull and Body Systems

Specifications / Components / Teardown and Rebuilding / Inspection

1
2

3
4
5
6
7

Electrical System

Specifications / NGI Gauge / System Interface Box / Starter Motor / Components

8

1

MSX 110 / 150 Service Manual General Information

PWC Identification Numbers 1.1
2004 PWC Publication Part Numbers 1.2
Service Guidelines / Safety Warnings 1.3
MSX 110 General Information 1.4 -- 1.5
MSX 150 General information 1.6 -- 1.7
Standard Torque Specifications 1.8
Decimal Equivalent Chart 1.9
Conversion Chart 1.10
Tap Drill Sizes 1.11
Service Tools 1.12 -- 1.13

P

LE

123456789101112

Universal

Manufacture

I.D.

Sequential Serial Numbers

(Alphanumeric)

Certification

Month

Certification

Year

Model

Decade

Model

Year

HIN (Boarding Platform)

HIN (Inside Engine Compartment)

HIN (Boarding Platform)

HIN (Inside Engine Compartment)

EMISSIONS DECAL

ENGINE SERIAL NUMBER DECAL

GENERAL INFORMATION

1.32004 Four Stroke PWC Service Manual

2004 PWC Identification Numbers

The engine I.D. number and hull I.D. number are used to register the watercraft. They are unique numbers that
distinguish each watercraft from others of the same model.

If the watercraft is ever stolen these numbers will help identify it. The owner should keep a record of these num­bers in a place other than the watercraft.

Month Code: A = January; B = February; etc.
Year Of Manufacture: 4 = 2004

GENERAL INFORMATION

1.4

2004 Four Stroke PWC Service Manual

2004 PWC Publication Part Numbers

Model Model Number

Owner’s

Manual

Parts Book Microfiche

Assembly

Instructions

MSX 110 (A) W045304CA
MSX 110 (A)

International

W045304IA

MSX 110 (B) W045304CB
MSX 110 (B)

International

W045304IB

9919055 9919056

MSX 110 (C) W045304CC
MSX 110 (C)

International

W045304IC

MSX 150 (A) W045305CA
MSX 150 (A)

International

W045305IA

9918972 9919173

MSX 150 (B) W045305CB
MSX 150 (B)

International

W045305IB

MSX 150 (C) W045305CC

9919057991905

8

MSX 150
International

W045305IC

MSX 150 (D) W045305CD
MSX 150 (D)

International

W045305ID

S C = 50 State Domestic (CARB Exemption).
S A / B / C / D = Color Option.
S I = International Model

2004 PWC Service Manual Part Numbers

Book Part Number

2004 Carbureted / DIt Models (All) 9919061
2004 Four Stroke PWC Models (All) 9919062
2004 OCTANE Update Packet 9919065
2004 PWC Flat Rate Manual 9919063
2004 Wallchart Packet TBA

GENERAL INFORMATION

1.52004 Four Stroke PWC Service Manual

Service Guidelines -- Safety Warnings

S Clean inside and outside of watercraft prior to servicing. Clean all parts before installing. Always use a service apron to

prevent damage to footwell and top-- deck fiberglass.

S Watch for sharp edges which can cause personal injury. Protect hands and arms when working with sharp components.
S Always use a soft--faced hammer and extreme care when removing difficult or stuck components.
S Some fasteners are installed with locking agents or lubricants. Use of impact drivers will aid in fastener removal.
S Always follow torques specifications located throughout manual. Fasteners secured with either too little or too much torque

may fail and cause severe property damage, injury or death.

S Always follow torque sequence patterns when found in this manual. Tighten each fastener evenly and to the specified torque

value, and with specified locking agent.

S Always use new gaskets, o--rings and seals, clips, cir--clips, and snap rings when assembling components.
S Never re--use Nyloktor Flex Lockt nuts when assembling components.
S Never re--use Oetikert clamps when removed from fuel lines. Replace with small gear clamps.
S Always use Polaris-- authorized lubricants, greases, and locking agents when assembling components. Failure to do so

may cause severe engine or vehicle damage.

S Always disconnect the black (-- ) negative cable first from the battery when removing the battery. When installing the battery,

attach the red (+) positive cable first, then the black (--) negative cable.

S Wear appropriate clothing, eye protection, and rubber gloves when working with batteries. Battery acid contains sulfuric

acid and is extremely poisonous. Serious burns can result when in contact with skin, clothing, eyes or internal body compo­nents.

S If battery acid is ingested, drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable

oil. Call a physician immediately.

S Flush eyes for15 minutes with water and seek prompt medical attention if acid comes in contact with eyes. Thoroughly wash

affected external body parts that come in contact with battery acid with water.

S Keep hands, arms, legs, feet and hair away from rotating parts, hot engine and exhaust components, drive pump and 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 MSX 110

W045304CA / CB / CC (W 045304IA / IB / I C)

Length: 126 in. (320 cm)....

Width: 48.3 in. (122.6 cm).....

Height: 42.5 in. (108 cm)....

DryWeight: 650lbs. (295 kg)
Category: Midsize..

Riders: 1to3....

Fuel Capacity: 17.8 US Gal. (67.4L)
Emission Certification: Two Star -- Very Low Emission

MSX110 W045304CB Sarasota Yellow

GENERAL INFORMATION

1.6

2004 Four Stroke PWC Service Manual

2004 MSX 110 Emission Certification

The engines in all 2004 MSX 110 Personal Watercraft are certified as Two Star, Very Low Emission engines.

TheTwo Star label identifies engines that meet the California Air Resources Board (CARB) 2004 exhaust emis­sion standards. Engines meeting these standards have 20% lower emissions than One--Star -- Low Emission
engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines.

Emission Control Information Decals

Theemission 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

GENERAL INFORMATION

1.72004 Four Stroke PWC Service Manual

2004 MSX 110
Model Number

W045304CA / CB / CC (W045304IA / IB / IC)

Engine

Platform Polaris Libertyt Marine Intercooled Turbocharged Four Stroke
Engine Model Number ES075WLE--011
Engine Displacement 750cc
Number of Cylinders 2
Cylinder Lining Material Nicasil
Bore & Stroke (mm) 85 x 66
Compression Ratio (Effective) 9.0:1
Cylinder Compression @ Sea Level 140 ± 14.5 psi (9.6 ± 1 bar) -- Both spark plugs removed, engine turnover @ 300 RPM.
Cooling System Closed loop with engine coolant--to--freshwater heat exchanger.
Thermostat Opening Temperature 82_C
Overheat Warning Engine Overheat / Exhaust Manifold Overheat Switch -- RPM Limit / NGI Warning
Induction Type Intercooled Turbocharger
Lubrication Dry Sump
Oil Requirements Polaris Synthetic PWC Four Stroke Engine Oil (15W--50)
RPM Limiter 7800 to 8400 RPM -- Determined by ECU
Exhaust System Exhaust pipe w/water jacket and water injector.
Sound Reduction Turbo PLANETt

Engine Management System

Fuel Delivery Bosch Multi--Point Fuel Injection
Recommended Fuel Premium Unleaded Fuel (91 / 92 / 93 Octane)
Idle Speed (In Water) 1550 ± 50 RPM
Ignition System EMS Bosch ME 7.4.4
Timing Degrees BTDC 22 Degrees BTDC
Spark Plug Champion RC7PYCB
Spark Plug Gap .6 -- .7mm (.025 -- .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)

MSX 150 W045305CD Stealth Black

2004 MSX 150

W045305CA / CB / CC / CD (W045305IA / IB / IC / I D)

Length: 126 in. (320 cm)....

Width: 48.3 in. (122.6 cm).....

Height: 42.5 in. (108 cm)....

DryWeight: 660 lbs. (301 kg)
Category: Midsize..

Riders: 1to3....

Fuel Capacity: 17.8 US Gal. (67.4L)
Emission Certification: Two Star -- Very Low Emission

GENERAL INFORMATION

1.8

2004 Four Stroke PWC Service Manual

2004 MSX 150 Emission Certification

The engines in all 2004 MSX 150 Personal Watercraft are certified as Two Star, Very Low Emission engines.

TheTwo Star label identifies engines that meet the California Air Resources Board (CARB) 2004 exhaust emis­sion standards. Engines meeting these standards have 20% lower emissions than One--Star -- Low Emission
engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines.

Emission Control Information Decals

Theemission 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 112kW(150HP)

ENGINE DISPLACEMENT 750cc

GENERAL INFORMATION

1.92004 Four Stroke PWC Service Manual

2004 MSX 150
Model Number

W045305CA / CB / CC / CD (W045305IA / IB / IC / ID)

Engine

Platform Polaris Libertyt Marine Intercooled Turbocharged Four Stroke
Engine Model Number ES075WLE--011
Engine Displacement 750cc
Number of Cylinders 2
Cylinder Lining Material Nicasil
Bore & Stroke (mm) 85 x 66
Compression Ratio (Effective) 9.0:1
Cylinder Compression 140 ± 14.5 psi (9.6 ± 1 bar) -- Both spark plugs removed, engine turnover @ 300 RPM.
Cooling System Closed loop with engine coolant--to--freshwater heat exchanger.
Thermostat Opening Temperature 82_C
Overheat Warning Engine Overheat / Exhaust Manifold Overheat Switch -- RPM Limit / NGI Warning
Induction Type Intercooled Turbocharger
Lubrication Dry Sump
Oil Requirements Polaris Synthetic PWC Four Stroke Engine Oil (15W--50)
RPM Limiter 7800 to 8400 RPM -- Determined by ECU.
Exhaust System Exhaust pipe w/water jacket and water injector.
Sound Reduction Turbo PLANETt

Engine Management System

Fuel Delivery Bosch Multi--Point Fuel Injection
Recommended Fuel Premium Unleaded Fuel (91 / 92 / 93 Octane)
Idle Speed (In Water) 1550 ± 50 RPM
Ignition System EMS Bosch ME 7.4.4
Timing Degrees BTDC 22 Degrees BTDC
Spark Plug Champion RC7PYCB
Spark Plug Gap .6 -- .7mm (.025 -- .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)

GENERAL INFORMATION

1.10

2004 Four Stroke PWC Service Manual

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.

GENERAL INFORMATION

1.112004 Four Stroke PWC Service Manual

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.........................

11.0............

GENERAL INFORMATION

1.12

2004 Four Stroke PWC Service Manual

Conversion Chart

Unit of Measure Multiplied by Converts to

ft. lbs. x12 =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 x10 =Nm
in. x 25.4 =mm
mm x .03937 =in.
in. x2.54 =cm
mile (mi.) x1.6 =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) x1.76 = Imperial pints (Imp pt)
Imperial quarts (Imp qt.) x 1.137 = Liters (l)
Liters (l) x0.88 = 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) x0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

°Cto°F: 9 (°C + 40) ÷ 5--40=°F
°Fto°C: 5 (°F + 40) ÷ 9--40=°C

GENERAL INFORMATION

1.132004 Four Stroke PWC Service Manual

SAE Tap Drill Sizes

Thread Size Drill Size Thread Size Drill Size

#0-80 3/64
#1-64 53
#1-72 53
#2-56 51
#2-64 50
#3-48 5/64
#3-56 45
#4-40 43
#4-48 42
#5-40 38
#5-44 37
#6-32 36
#6-40 33
#8-32 29
#8-36 29
#10-24 24
#10-32 21
#12-24 17
#12-28 4.6mm
1/4-20 7
1/4-28 3
5/16-18 F
5/16-24 I
3/8-16 O
3/8-24 Q
7/16-14 U
7/16-20 25/64

1/2-13 27/64
1/2-20 29/64
9/16-12 31/64
9/16-18 33/64
5/8-11 17/32
5/8-18 37/64
3/4-10 21/32
3/4-16 1 1/16
7/8-9 49/64
7/8-14 13/16
1-8 7/8
1-12 59/64
1 1/8-7 63/64
1 1/8-12 1 3/64
11/4-7 17/64
1 1/4-12 1 11/64
11/2-6 111/32
1 1/2-12 1 27/64
13/4-5 19/16
1 3/4-12 1 43/64
2-4 1/2 1 25/32
2-12 1 59/64
2 1/4-4 1/2 2 1/32
21/2-4 21/4
23/4-4 21/2
3-4 2 3/4

Metric Tap Drill Sizes

Tap Size Drill Size Decimal Equivalent Nearest Fraction

3x.50
3x.60
4x.70
4x.75
5x.80
5x.90
6 x 1.00
7 x 1.00
8 x 1.00
8 x 1.25
9 x 1.00
9 x 1.25
10 x 1.25
10 x 1.50
11 x 1.50
12 x 1.50
12 x 1.75

#39
3/32
#30
1/8
#19
#20
#9
16/64
J
17/64
5/16
5/16
11/ 32
R
3/8
13/32
13/32

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3125

0.3437

0.339

0.375

0.406

0.406

3/32
3/32
1/8
1/8
11/ 64
5/32
13/64
15/64
9/32
17/64
5/16
5/16
11/ 32
11/ 32
3/8
13/32
13/32

GENERAL INFORMATION

1.14

2004 Four Stroke PWC Service Manual

Service Tools

PW-- 46981 -- REQUIRED TOOL
CRANKSHAFT HAND CRANK (BARRING TOOL)

USED TO ROTATE CRANKSHAFT

PW-- 46982 -- REQUIRED TOOL
GEAR REMOVAL TOOL

USED TO REMOVE BALANCE SHAFT GEAR WHEN USED WITH
PW--46989 GEAR REMOVER BOLT.

PW-- 46983 -- REQUIRED TOOL
PISTON RING COMPRESSOR

USED TO INSTALL PISTONS INTO ENGINE BLOCK

PW-- 46984 -- REQUIRED TOOL
ENGINE STAND ADAPTER PLATE
PW-- 47054
ENGINE STAND ADAPTER SLEEVE

ATTACHES TO REAR OF ENGINE BLOCK. ALLOWS TECHNI­CIAN TO ROTATE ENGINE DURING DISASSEMBLY AND RE-­ASSEMBLY.

ADAPTER SLEEVE EXPANDS MOUNTING OPTIONS WHEN
USING DIFFERENT ENGINE STANDS.

PW-- 46989 -- REQUIRED TOOL

MAGNET ROTOR / GEAR REMOVER BOLT
USED TO REMOVE MAGNET ROTOR AND BALANCE SHAFT GEAR WHEN
USED WITH PW-- 46982.

PW-- 46991 -- REQUIRED TOOL
VALVE COMPRESSOR TOOL

USED TO COMPRESS VALVE SPRINGS WITH ENGINE EITHER
INSTALLED OR REMOVED FROM WATERCRAFT HULL.

PW-- 47077 -- REQUIRED TOOL
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 DUR­ING INSTALLATION.

PW-- 47108 -- REQUIRED TOOL
TIMING CHAIN WEDGE AND HOOK TOOL

USED DURING TIMING CHAIN INSTALLATION

GENERAL INFORMATION

1.152004 Four Stroke PWC Service Manual

Service Tools

PW-- 47053 -- OPTIONAL TOOL
ADAPTER PLATE TABLE MOUNT

USED TO MOUNT ENGINE STAND ADAPTER PLATE TO WORK­BENCH.

PW-- 46985 -- REQUIRED TOOL
TIMING CHAIN LINK REMOVAL / INSTALLATION TOOL

USED IN REMOVING AND RE--INSTALLING TIMING CHAIN.

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

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

PU--47102 -- REQUIRED TOOL
MSX 110 / 150 COMM. CABLE ADAPTER
CONNECTS LAPTOP CABLE TO ENGINE WIRING
HARNESS.

2

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.................................................

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

2.12004 Four Stroke PWC Service Manual

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

ITEM

PROCEDURE

BREAK IN PERIOD

(Hours)

REGULAR INTERVAL

(Hours)

PRE

SALT

END

OF

ITEMPROCEDURE

10 -- 12 25 50 100

RIDEWATER

O

F

YEAR

Spark Plugs Adjust Gap / Clean n n R 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

Hoses

Inspect n n n n

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
BilgeArea/Drains Inspect / Clean / Flush n n n n n
Battery / Vent Inspect n n n
Electrical Connec-

tions

Inspect n n

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

MAINTENANCE

2.2

2004 Four Stroke PWC Service Manual

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.

MAINTENANCE

2.32004 Four Stroke PWC Service Manual

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

FASTENE

R

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 J AM 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.

MAINTENANCE

2.4

2004 Four Stroke PWC Service Manual

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

Glycol)

2875063 -- 1 Gallon Container (100% Propylene 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)

MAINTENANCE

2.52004 Four Stroke PWC Service Manual

Steering Cable / Steering Joints

1. Expose inner linkage and apply grease.

Steering Nozzle

1. Apply light film of grease to exposed steering
linkage and pivot points.

Reverse System

1. Generously lubricate reverse cable.

Polaris Premium Grease
PN 2871423

Polaris Premium Grease
PN 2871423

Polaris Premium Grease
PN 2871423

MAINTENANCE

2.6

2004 Four Stroke PWC Service Manual

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.

2. Disconnect the throttle cable from the throttle flipper,
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.

2. Insert the post assembly into the steering housing.

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
of clamp using a new nut. Torque nut to 8 ft.lbs. (11
Nm)

10. Reconnect wiring harness and throttle cable. Verify
throttle cable freeplay is set to specifications outlined
in chapter two.

1 1. Reinstall the handlebar grab handle and cover

assembly.

ZERO, 1 OR 2 SHIMS

INSTALLED TO AD-

JUST STRIKE PLATE

CLEARANCE

STRIKE PLATE JUST
CLEARSSTOPBOLT

WASHER

ZERO, 1 OR 2 SHIMS

INSTALLED TO RE-

MOVE UP AND DOWN

FREEPLAY

Hull

Hull

Nozzle

Straight Edge

Distance should be equal at (X)

x

x

MAINTENANCE

2.72004 Four Stroke PWC Service Manual

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
the straight edge and at equal distances from the
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.

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 func­tion properly, inspect the cable for damage. Inspect all
linkage, fasteners, brackets, and pivots for wear or dam­age. 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.

Reverse Cable Nut

VALVE CLEARANCE SPECIFICATION

INTAKE VALVE: .08 -- .15MM (.003 -- .006)
EXHAUST VALVE: .18 -- .25MM (.007 -- 0.10)

MAINTENANCE

2.8

2004 Four Stroke PWC Service Manual

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.

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.

Photo A

Photo B

MAINTENANCE

2.92004 Four Stroke PWC Service Manual

Valve Clearance Adjustment Procedure -- Continued

9. Install the V alve 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

1 1. 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.

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

ENGINE OIL SPECIFICA TION

MAINTENANCE

2.10

2004 Four Stroke PWC Service Manual

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
oil level.

The oil level should be between the MIN and MAX marks.
The volume between the MIN and MAX marks is .5 Us
Quarts (.5L).

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
above MAX mark after warming engine to operating tem­perature.

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.

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.

OVERFILLED OIL LEVEL

MAXIMUM OIL LEVEL (HOT)

MINIMUM OIL LEVEL

.5 US Qt. (.5 L)

REMOVE THIS HOSE

CAP

ELEMENT

O--RING

MAINTENANCE

2.112004 Four Stroke PWC Service Manual

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
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

remove the o--ring and filter element. Replace filter
element and o--ring with new parts.

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.

1 1. Fill to oil tank with 3.4 -- 3.7 qts. (3.3 -- 3.5 L) of Polaris

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.

POLARIS ENVIRONMENTALLY SAFE
COOLANT 50/50 MIXTURE

PN: SEE PAGE 2.4
DRY CAPACITY:
CHANGE INTERVAL: 4 Y ears

ENGINE COOLANT SPECIFICATION
(Warm --Weather States)

MIN

MAX

AIR BLEED

TO WATER
PUMP

MAINTENANCE

2.12

2004 Four Stroke PWC Service Manual

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 tempera­ture 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.)

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.

MIN

MAX

AIR BLEED

TO WATER
PUMP

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

PRESSURE SPECIFICATION

MAINTENANCE

2.132004 Four Stroke PWC Service Manual

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.

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.

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

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

140 ± 14 PSI (9.6 ± 1 BAR) @ SEA LEVEL
VERIFY BATTERY IS FULLY CHARGED

COMPRESSION SPECIFICATION

43.5 psi + BOOST (3 bar + BOOST) @ IDLE
Approximately 59 PSI (4.1 bar) @ WOT

FUEL PRESSURE SPECIFICATION

MAINTENANCE

2.14

2004 Four Stroke PWC Service Manual

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.

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.

MAINTENANCE

2.152004 Four Stroke PWC Service Manual

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 compart­ment and a spark could ignite them which could cause personal injury. When re-installing battery connect black (nega­tive) 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.

Maintain
Between
Upper and
Lower Level
Marks

MAINTENANCE

2.16

2004 Four Stroke PWC Service Manual

Replenishing Battery Fluid

The fluid level should be kept between the upper and low­er level marks.

To refill use only distilled water. Tap water contains miner­als which are harmful to a battery.

Battery Connections

Battery terminals and connections should be kept free of
corrosion. If cleaning is necessary, remove the corrosion
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 termi­nal bolts with Nyogeltgrease.

Battery Charging

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 compart­ment and a spark could ignite them which could cause personal injury. When re-installing battery connect black (nega­tive) 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.

Top View of Battery

Vent
Tube

Red (+)

Black (-)

Nyogelt Grease

PN 2871329

Specific Gravity

1.270 or greater - Each Cell

MAINTENANCE

2.172004 Four Stroke PWC Service Manual

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,
severe burns could result.

3. Apply Nyogelt grease to each cable bolt.

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. T opoff 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.

Top View of Battery

Vent
Tube

Red (+)

Black (-)

Nyogelt Grease

PN 2871329

MAINTENANCE

2.18

2004 Four Stroke PWC Service Manual

Spark Plug

USE ONLY RESISTOR--TYPE SPARK PLUGS! SEVERE ENGINE PROBLEMS MAY OCCUR IF NON-- RE­SISTOR--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
abrasive should not be used.

3. Measure gap with a wire gauge and refer to
specifications. Adjust if necessary by bending the side
electrode carefully.

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.
Tor que ignition coil fasteners to specification.

Fuses

MODEL FUSES COMPONENT LOCATION

2AMP NGIGauge

10AMP Fuel Pump

15AMP Ignition System

MSX 110 / 150

15AMP Main Relay

Harness Pod

15AMP Main Relay

15 AMP Main Relay

30AMP Alternator

Spark Plug Gap

Spark Plug Gap

CHAMPION RC7PYCB

.6 -- .7 mm (.025 -- . 030 in.)

MAINTENANCE

2.192004 Four Stroke PWC Service Manual

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.

2. Inspect and clean orifice.

3. Reinstall cooling hose.

Throttle Cable Adjustment

The throttle cable connects the throttle flipper with the Pedal
Position Unit (PPU). The cable is located underneath the
steering helm.

1. Turn adjuster clockwise to loosen the throttle flipper
freeplay. Turn counter--clockwise to tighten flipper
freeplay.

NOTE: Verify throttle cable is not kinked after per­forming procedure.

FRESHWATER INJECTOR

.185″

FRESHWATER INJECTOR

Lock Nut

Adjuster

Throttle Cable

MAINTENANCE

2.20

2004 Four Stroke PWC Service Manual

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 fil­ter.

MAINTENANCE

2.212004 Four Stroke PWC Service Manual

Bilge Siphon System

1. Clean bilge siphon pickup screens whenever debris
are present.

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
position.

Bilge Drain Plugs

1. Inspect bilge plug for cracks or damage from
over-tightening.

2. Periodically inspect sealing O-ring and replace if
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.

View From
Inside Hull

Screen

To pump fitting

.040″ hole must
be clear to prevent
siphoning water
into bilge

Bilge Siphon

Plug

O-Ring

Keeper
Strap

Gasket

Bilge Plug
Assembly

MAINTENANCE

2.22

2004 Four Stroke PWC Service Manual

Cooling Water Pickup Screen

Inspect the screen in the pump stationary nozzle for de­bris and clean if necessary.

Fasteners

Inspect all fasteners in the pump area and make sure
they are tight. These include the steering nozzle mount­ing bolts, steering cable bolt, trim nozzle mounting bolts
(where applicable), and all reverse mechanism fasteners
(where applicable). Inspect pump mounting nuts and ex­tension 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
small leak will ventilate the pump area, creating cavita­tion 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
sealant can be trimmed until flush with edges.

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.

Screen

Ride Plate

Impeller

Drive Shaft

Intake
Grate

Impeller Clearance

Standard .002-.008″.05-.20 mm)
Service Limit .020″ (.5 mm)

MAINTENANCE

2.232004 Four Stroke PWC Service Manual

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 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. 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.

3. Apply dielectric grease to bolt threads and contact
surfaces.

4. Tighten bolt securely.

Zinc Anode

Nyogelt Grease

PN 2871329

MAINTENANCE

2.24

2004 Four Stroke PWC Service Manual

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
be replaced.

2. Reference chapter six for disassembly procedures.

Handlebar Post

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
information.

Fasteners / Parts / Hoses

Inspect the watercraft for any loose nuts, bolts, fasteners and hoses. Be sure that all hose clamps are tight. Re­place 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)

Grommet Plate

Top P lat e

Tapered Bushings

Shim Washers

Steering Arm

Top Deck

A

B

MAINTENANCE

2.252004 Four Stroke PWC Service Manual

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.

MAINTENANCE

2.26

2004 Four Stroke PWC Service Manual

Off -- Season Storage

Theoff-- s eason 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 A60/40 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. T op off the fuel tank with fresh fuel.

S Afull 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.

3

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...............................................

PHOTO A

ENGINE REMOVAL / INSTALLATION

3.12004 Four Stroke PWC Service Manual

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 en­gine from the engine compartment. Place masking tape around the engine compartment -- seat mat­ing 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
away from the engine drive coupler. Reference
CHAPTER 6. (Photo A)

NOTE: Not all electrical connections can be discon­nected without removing hoses, pipes or sub--sys­tems. As components are removed, disconnect any
electrical connections.

PHOTO B

PHOTO C

ENGINE REMOVAL / INSTALLATION

3.2

2004 Four Stroke PWC Service Manual

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
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
oil separator cyclone.

1 1. Carefully lift the oil storage tank out of the engine

compartment.

LARGE GEAR CLAMP x1

OIL TANK

(ALL HOSES REMOVED)

RUBBER BUSHINGS x2

REAR ENGINE MOUNT

MOUNTING PINS x2

PHOTO D

ENGINE REMOVAL / INSTALLATION

3.32004 Four Stroke PWC Service Manual

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 en­gine assembly is moved rearward.

FRONT ENGINE MOUNT

REGULATOR / RECTIFIER

INTERCOOLER

FASTENERS x2

MOUNTING
PINS x2

FRESHWATER
INLET / OUTLET

REAR ENGINE MOUNT

PHOTO E

PHOTO F

PHOTO G

ENGINE REMOVAL / INSTALLATION

3.4

2004 Four Stroke PWC Service Manual

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.

16. Locate the engine coolant outlet elbow located next to
the intake manifold. Rotate the elbow down and
towards the engine. (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 H

ENGINE REMOVAL / INSTALLATION

3.52004 Four Stroke PWC Service Manual

Engine Removal and Installation -- Continued

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.

UPPER--TO--LOWER
BRACKET FASTENERS x3

WATER--TO--WATER
HEAT EXCHANGER

INTAKE MANIFOLD

LOWER BRACKET

UPPER BRACKET

MANIFOLD FASTENERS x4

LOWER BRACKET FASTENERS x2

PHOTO J

ENGINE REMOVAL / INSTALLATION

3.6

2004 Four Stroke PWC Service Manual

Engine Removal and Installation -- Continued

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

BOW

STERN

REAR ENGINE MOUNT

FRONT ENGINE MOUNT

LIFTING HOOKS

PHOTO K

PHOTO L

PHOTO M

ENGINE REMOVAL / INSTALLATION

3.72004 Four Stroke PWC Service Manual

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.)

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 as­sembly must be removed from the engine in order to
remove the core engine.

27. Remove the exhaust manifold from the engine. Identify
any hoses or wiring harness components removed
during the process.

PHOTO N

ENGINE REMOVAL / INSTALLATION

3.8

2004 Four Stroke PWC Service Manual

Engine Removal and Installation -- Continued

28. Illustration of exhaust manifold--to--engine assembly.

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)

MANIFOLD MOUNTING NUTS

AND WASHERS x8

MANIFOLD / TURBO UNIT

WASTEGATE

BOW

STERN

REAR ENGINE MOUNTING STRAP

FRONT ENGINE MOUNTING STRAP

MOUNT FASTENERS x5

ALIGNMENT DOWELS

MOUNT FASTENERS x4

INTAKE--SIDE OF ENGINE

PHOTO O

ENGINE REMOVAL / INSTALLATION

3.92004 Four Stroke PWC Service Manual

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.

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 P

ENGINE STAND ADAPTER PLATE
PW--46984

ENGINE REMOVAL / INSTALLATION

3.10

2004 Four Stroke PWC Service Manual

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.

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.

4

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.............................

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

4.12004 Four Stroke PWC Service Manual

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
Dry Engine (After Rebuild)

3.4 -- 3.7 US Quarts (3.3 -- 3.5 Liters)

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

Thermostat Opening Temperature
System Pressure

3.5 US Quarts (3.3 Liter)

180_ F(82_ C)

14.6 PSI (1 Bar) / 17 PSI (1.2 Bar) Maximum System Pressure

Valve Timing (1mm Valve Lift)

EV OPENS
EV C LOSES
IV OPENS
IV CLOSES

52_ BBDC

2_ ATDC

14_ BTDC

50_ ABDC
Valve Diameter

EV
IV

29.5mm (1.161″)

32.5mm (1.279″)

Valve Seat Contact Width

IV
EV

1.1mm -- 1.2mm (.043″ -- .047″)

1.3mm -- 1.4mm (.051″ -- .055″)

ValveFaceWidth

IV
EV

2.0mm

2.0mm

Valve Margin Thickness

IV
EV

5.472mm (.2154″)

5.463mm (.2150″)
Valve Seat Angle 45_
Valve Outer Correction Angle 30_
Valve Inner Correction Angle 75_
Valve Clearance (COLD)

IV
EV

0.08 -- 0.15mm (.003″ -- .006″)

0.18 -- 0.25mm (.007″ -- .010″)
Valve Stem Diameter

IV
EV

5.465mm -- 5.479mm (.2151″ -- .2157″)

5.456mm -- 5.470mm (.2148″ -- .2153″)
Valve Guide Inside Diameter

IV
EV

5.5mm -- 5.507mm (.216″)

5.5mm -- 5.509mm (.216″)
Valve Stem Runout .03mm (.001″)
Valve Stem--To--Guide Clearance

IV
EV

.021mm -- .044mm (.0008 -- .0017″)
.030mm -- .053mm (.0011 -- .0020″)

ENGINE DISASSEMBLY / ASSEMBLY

4.2

2004 Four Stroke PWC Service Manual

Engine Specifications -- Continued

Component Specification

Valve Spring Free Length

INTAKE
EXHAUST

38.2mm (1.5″)

38.2mm (1.5″)
Valve Spring Installed Length

INTAKE
EXHAUST

32mm (1.26″)

32mm (1.26″)
Cylinder Head Warpage Limit .04mm (.001″)
Cylinder Specifications

BORE SIZE
TAPER LIMIT
OUT-- OF-- ROUND LIMIT
WEAR LIMIT

85.00 -- 85.01mm (3.34″)

.008mm (.0003″)

.008mm (.0003″)

N/A
Camshaft Specifications

CAMSHAFT WIDTH
IN CAM LOBE HEIGHT
EX CAM LOBE HEIGHT
MAXIMUM CAMSHAFT RUNOUT
RADIAL PLAY
BEARING HOLE I.D.
CAMSHAFT AXLE O .D.
CAMSHAFT CLAMP I.D.

108.85mm -- 109.00mm (4.28″ -- 4.29″)

48.553mm (1.911″)

48.209mm (1.897″)

.05mm @ Sprocket / .02mm @ Base. (.001″)

.020mm -- .050mm (.001″)

25.972mm -- 25.988mm (1.02″)

19.991mm -- 20mm (.787″)

19.90mm -- 19.98mm (.783″)

Rocker Arm Specifications

BEARING AXIAL PLAY
ROCKER ARM I.D.
ROCKER ARM SHAFT O.D.
ROCKER ARM HOLDER BORE I.D.
ROCKER ARM AXIAL PLAY

.013mm -- .025mm (.0005″ -- .0009″)

13.980mm -- 13.991mm (.55″)

9.994mm -- 10mm (.393″)

10mm -- 10.009mm (.393″)

.16mm -- .26mm (.006″ -- .010″)
Crankshaft Specifications

CRANKSHAFT DEFLECTION
MAIN BEARING CLEARANCE
BEARING CODES

.02mm -- .04mm (.0007″ -- .0015″)

.03mm -- .04mm (.0011″ -- .0015″)

1.RED 2. YELLOW 3. BLUE 4. GREEN 5. BROWN

Connecting Rod Specifications

BIG END OIL CLEARANCE
SMALL END DIAMETER
BEARING CODES

.01mm -- .064mm (.0003″ -- .002″)

20.995mm -- 21.011mm (.826″ -- .827″)

1.RED 2. YELLOW 3. BLUE 4. GREEN 5. BROWN

Balance Shaft Specifications

AXIAL PLAY
RADIAL PLAY
BEARING DIAMETER
RUN OUT

.15mm -- .25mm (.005″ -- .009″)

.014mm -- .066mm (.0005″ -- .002″)

24.975mm -- 24.990mm (.983″)

.014mm -- .066mm (.0005″ -- .002″)
Piston Specifications

PISTON--TO--CYL CLEARANCE
PISTON DIAMETER

WEAR LIMIT
PISTON PIN BOSS I.D.
PIN O.D.
PIN WEAR LIMIT

.041mm -- .059mm (.0016″ -- .0023″)

84.961mm -- 84.979mm (Measured 15mm from bottom, 90_ from pin.

(3.34″ -- 3.345″)

.04mm (.001″)

21.004mm -- 21.009mm (.826″ -- .827″)

20.995mm -- 21.000mm (.826″)

.05mm (.001″)
Piston Ring Specifications

TOP RING INSTALLED RING GAP
TOP RING GROVE CLEARANCE
MIDDLE RING INSTALLED RING GAP
MIDDLE RING GROVE CLEARANCE
OIL RING INSTALLED END GAP
OIL RING GROVE CLEARANCE

.2mm -- .4mm (.07″ -- .015″)

.65mm -- .955mm (.025″ -- .037″)

.2mm -- .4mm (.007″ -- .015″)

.50mm -- .805mm (.019″ -- .031″)

.2mm -- .7mm (.007″ -- .027″)

.50mm -- .910mm (.019″ -- .035″)
Oil Pump Specifications

OIL PUMP TYPES
ROTOR TIP CLEARANCE (PRESSURE)
OIL PRESSURE RELIEF VALVE
OIL PRESSURE

Trochoid

N/A

SPRING FREE LENGTH = 2.7″ (69mm) / PISTON O.D. = .43″ (10.9mm) /

PISTON LENGTH = 1.10″ (27.7 -- 28mm)

21 @ IDLE -- 80 @ MAX PSI (1.5 -- 5.5 BAR)

ENGINE DISASSEMBLY / ASSEMBLY

4.32004 Four Stroke PWC Service Manual

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 Fasten er Torque Specifications

Component FT. LBS. Nm Notes Fastener(s)

Cylinder Head Nuts

Step 1
Step 2
Ste

p

3

15
30

180_

20
40

180_

Apply Engine Oil to

M10 x 1.25

M8

x

50

Step3

Lower Crankcase Bolts

Step 1
Step 3

180

12
18

180

16

24 -- 25

ApplyEngineOilt

o

Threads.

M8x50

M8 x 70
M8 x 90

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

Crankcase

7 10 M6 x 20

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
Step 2
Step 3

7

14

90_

10
20

90_

M10 x 1.32

Camshaft Clamps 7 10 M6 x 40
Rocker Arm Holders 9 13 M6 x 20
Exhaust Manifold Studs

Short
Long

13
13

18
18

Copper Grease

M8 x 69

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

ENGINE DISASSEMBLY / ASSEMBLY

4.4

2004 Four Stroke PWC Service Manual

Engine Specific Fasten er Torque Specifications

Component FT. LBS. Nm Notes Fastener(s)

Water Pump Cover

7 10 Loctite 577

M6 x 20
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 --

Expansion Tank Nozzle

7 10

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

Bracket

17 24 M8 x 40

Turbocharger Bracket -- to -- Manifold 17 24 M8 x 50
Wastegate Actuator Locknut 7 10
Wastegate Bracket -- to -- Manifold 7 10 Torx E 8
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

13

10
18

M6 x 25

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

ENGINE DISASSEMBLY / ASSEMBLY

4.52004 Four Stroke PWC Service Manual

Fuel Rail Specific Fastener Torque Specification s

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

(Intercooler -- Air Intake Pipe)

4 5 M6 x 10

Temperature / Pressure Sensor
(Intake Manifold)

5 7 M6 x 10

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 M10x1X45

Engine Mounts Specific Fastener Torque Specifications

Component FT. LBS. Nm Notes Fastener(s)

Front Engine Mount -- to -- Lower
Crankcase

40 55

M10 x 80

Rear Engine Mount -- to -- Crankcase 18 25 M8 x 30
Rear Engine mount -- to -- Crankcase

and Lower Crankcase

40 55 M10 x 40

Intercooler Bracket -- to -- Front Engine
Mount

7 10 M6 x 25

Intercooler Bracket -- to -- Crankcase 40 55 M10 x 60
Oil Storage T ank Bracket 7 10 M6 x 25

ENGINE DISASSEMBLY / ASSEMBLY

4.6

2004 Four Stroke PWC Service Manual

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 T ank Pullover Gear Clamp 2 3
High Pressure Oil Hose Connections

(Turbocharger / Rollover Valve)

7 10 M10 x 1

Banjo Bolt

Gear Clamp Torque Specifications

8 -- 16mm = 2 Nm

Over 16mm = 2.4 Nm

NOTE: Some or all clamps may be Oetikert clamps.

ENGINE DISASSEMBLY / ASSEMBLY

4.72004 Four Stroke PWC Service Manual

Service Tools

PW-- 46981 -- REQUIRED TOOL
CRANKSHAFT HAND CRANK (BARRING TOOL)

USED TO ROTATE CRANKSHAFT

PW-- 46982 -- REQUIRED TOOL
GEAR REMOVAL TOOL

USED TO REMOVE BALANCE SHAFT GEAR WHEN USED WITH
PW--46989 GEAR REMOVER BOLT.

PW-- 46983 -- REQUIRED TOOL
PISTON RING COMPRESSOR

USED TO INSTALL PISTONS INTO ENGINE BLOCK

PW-- 46984 -- REQUIRED TOOL
ENGINE STAND ADAPTER PLATE

ATTACHES TO REAR OF ENGINE BLOCK. ALLOWS TECHNI­CIAN TO ROTATE ENGINE DURING DISASSEMBLY AND RE-­ASSEMBLY.

PW-- 46985 -- REQUIRED TOOL
TIMING CHAIN LINK REMOVAL / INSTALLATION TOOL

USED IN REMOVING AND RE--INSTALLING TIMING CHAIN.

PW-- 46989 -- REQUIRED TOOL

MAGNET ROTOR / GEAR REMOVER BOLT
USED TO REMOVE MAGNET ROTOR AND BALANCE SHAFT GEAR WHEN
USED WITH PW-- 46982.

PW-- 46991 -- REQUIRED TOOL
VALVE COMPRESSOR TOOL

USED TO COMPRESS VALVE SPRINGS WITH ENGINE EITHER
INSTALLED OR REMOVED FROM WATERCRAFT HULL.

PW-- 47077 -- REQUIRED TOOL
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 DUR­ING INSTALLATION.

PW-- 47108 -- REQUIRED TOOL
TIMING CHAIN WEDGE AND HOOK TOOL

USED DURING TIMING CHAIN INSTALLATION

PU--46219 -- OPTIONAL TOOL
MANUAL OIL PUMP / CONTAINER

USED TO REMOVE OIL FROM OIL TANK

ENGINE DISASSEMBLY / ASSEMBLY

4.8

2004 Four Stroke PWC Service Manual

OIL FILTER ASSEMBLY

EXHAUST--SIDE OF ENGINE

SEALING O--RING

FILTER CARTRIDGE

FILTER CAP

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

ENGINE DISASSEMBLY / ASSEMBLY

4.92004 Four Stroke PWC Service Manual

VAL V E COVER ASSEMBLY

SPARK PLUG O--RINGS

VALVE COVER GASKET

CAM PHASE

SENSOR PORT

ASSEMBLY NOTES

Valve Cover Fastener T orque 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.

VALVE CO VER FASTENERS
M6 X 45

ENGINE DISASSEMBLY / ASSEMBLY

4.10

2004 Four Stroke PWC Service Manual

VALVE TRAIN ASSEMBLY

ASSEMBLY NOTES

Camshaft Bearing Fastener Torque: 7 ft.lbs. (10 Nm)
Rocker Arm Tower Fastener Torque: 9 ft.lbs. (13 Nm)
VAL VE 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.

CAMSHAFT SPROCKET

BEARING AXLE

AXLE CAPS

VALVE SHIMS

ROCKER ARM PINS

VALVE STEM SEAL

SHORT ROC KER ARM

LONG ROCKER ARM

LONG ROCKER ARM

SHORT ROC KER ARM

CENTERING SLEEVES

SPRINGS

(SPRING BASE AND RETAIN-

ING CAPS NOT SHOWN)

ENGINE DISASSEMBLY / ASSEMBLY

4.112004 Four Stroke PWC Service Manual

DRY SUMP OIL PUMP ASSEMBLY

COMPONENT LAYOUT

ASSEMBLY NOTES

Screen Fastener Torque: 7 ft.lbs. (10 Nm) Apply Loctitet 243 to threads.
Oil Pump Fastener T orque: 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.

FILTER SCREEN

DRY SUMP OIL PUMP

LOWER SUMP BEDPLATE

PLUG

OIL SUPPLY ELBOW (TO OIL COOLER)

DRIVE GEAR

ENGINE DISASSEMBLY / ASSEMBLY

4.12

2004 Four Stroke PWC Service Manual

THERMOSTAT HOUSING ASSEMBLY

SNAP RING

(CHAMFER FACES OUT)

ELBOW PIPE

O-- RING

THERMOSTAT

O-- RING

O-- RING

WATER PIPE

BLEED HOSE FITTING

INTAKE--SIDE OF ENGINE

= COOLANT FLOW WHEN THERMOSTAT OPENS

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.

WA TER PIPE FASTENERS
M6 X 20

ENGINE DISASSEMBLY / ASSEMBLY

4.132004 Four Stroke PWC Service Manual

HIGH PRESSURE OIL PUMP ASSEMBLY

ASSEMBLY NOTES

UseLIBERAL 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.

SNAP RING

(CHAMFER FACES OUT)

RETAINING CAP

O-- RINGS

OUTER ROTOR

INNER ROTOR

TIMING ROTOR

BALANCE SHAFT TIMING KEY

BALANCE SHAFT

PTO--END OF ENGINE

ENGINE DISASSEMBLY / ASSEMBLY

4.14

2004 Four Stroke PWC Service Manual

EXHAUST--SIDE CHAIN GUIDE / TENSIONER ASSEMBLY

COMPONENT LAYOUT

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.

UPPER CHAIN GUIDE
(INSTALLED FROM TOP OF CRANKCASE)

TIMING CHAIN
(MUST USE CHAIN BREAKER TO
DISASSEMBLE AND REASSEMBLE)

TENSIONER CHAIN GUIDE
INSTALLED FROM BOTTOM OF UPPER CRANKCASE

TENSIONER PLUG

TENSIONER

M6 X 25
LOCTITEt 243

M8 X 25
LOCTITEt 243

ENGINE DISASSEMBLY / ASSEMBLY

4.152004 Four Stroke PWC Service Manual

ENGINE CASE / CYLINDER HEAD ASSEMBLY

COMPONENT LAYOUT

CYLINDER HEAD NUTS

ROCKER ARM TOWER FASTENERS
M6 X 20

ROCKER ARM TOWERS

CYLINDER HEAD

HEAD GASKET

UPPER CRANKCASE

LOWER CRANKCASE

CENTERING SLEEVES

M8 X 50

M8 X 70

M8 X 90 (LONG BOLT / OIL PUMP COVER)

WASHERS

PRESSURE RELIEF PISTON

RELIEF SPRING

RELIEF VALVE COVER PLATE

ENGINE DISASSEMBLY / ASSEMBLY

4.16

2004 Four Stroke PWC Service Manual

ENGINE CASE / CYLINDER HEAD ASSEMBLY -- CONTINUED

ASSEMBLY NOTES

1

2

3

4

5

67

8

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)

2nd STEP: Torque cylinder head nuts in sequence

30 ft.lbs. (40 Nm)

3rd STEP: Torque cylinder head nuts in sequence.

180_

Torque crankcase fasteners in sequence.

18 ft.lbs. (24 -- 25 Nm)

910

11

12

MAG PTO

MAGPTO

ENGINE DISASSEMBLY / ASSEMBLY

4.172004 Four Stroke PWC Service Manual

PISTON ASSEMBLY

COMPONENT LAYOUT

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)

RodCap 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.

OIL CONTROL RING

UPPER RINGS

PISTON PIN

CONNECTING ROD BEARINGS

CONNECTING ROD

RODCAP FASTENERS
M10 X 1.32
ENGINE OIL

ENGINE DISASSEMBLY / ASSEMBLY

4.18

2004 Four Stroke PWC Service Manual

VALVE ASSEMBLIES

COMPONENT LAYOUT

VALVE SHIM

VALVE KEEPER

VALVE

SPRING BUCKET

SPRING RETAINER

SPRING

ENGINE DISASSEMBLY / ASSEMBLY

4.192004 Four Stroke PWC Service Manual

BALANCE PLATE / PTO ASSEMBLY

COMPONENT LAYOUT

ASSEMBLY NOTES

Balance Plate Fastener Torque: 51 ft.lbs. (70 Nm) Apply Loctitet 577 to threads.

CRANKSHAFT

BALANCE PLATE

FASTENERS
M10X1X45
LOCTITEt 577

STUB SHAFT

WASHERS

FLANGE SEAL

ENGINE DISASSEMBLY / ASSEMBLY

4.20

2004 Four Stroke PWC Service Manual

CRANKSHAFT / COUNTER BALANCER ASSEMBLIES

COMPONENT LAYOUT

CRANKSHAFT PLAIN BEARINGS

CRANKSHAFT

BALANCE SHAFT GEAR TIMING KEY

BALANCE SHAFT PLAIN BEARINGS

BALANCE SHAFT

PHOTO A

PHOTO B

PHOTO C

ENGINE DISASSEMBLY / ASSEMBLY

4.212004 Four Stroke PWC Service Manual

Engine Disassembly Process

1. Remove valve cover from engine. Discard
gaskets.(Photo A)

2. Remove the coolant outlet manifold, oil filter cover, and
electric starter motor from engine case. (Photo B)

3. Remove the two high pressure oil feed hose banjo bolts
from the cylinder head exhaust--side rear mounting
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.

PHOTO D

PHOTO E

PHOTO F

ENGINE DISASSEMBLY / ASSEMBLY

4.22

2004 Four Stroke PWC Service Manual

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.

5. Photo of stator inside of cover. (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 G

PHOTO H

PHOTO I

ENGINE DISASSEMBLY / ASSEMBLY

4.232004 Four Stroke PWC Service Manual

Engine Disassembly Process

7. Remove the front engine gear cover. (Photo G)

NOTE: Place drain pan underneath cover to catch oil.

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)

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 J

A

B

C

PHOTO K

ILLUSTRATION 1

TIMING ROTOR

INNER / OUTER ROTORS

ORINGS

CAP

SNAP RING

ENGINE DISASSEMBLY / ASSEMBLY

4.24

2004 Four Stroke PWC Service Manual

Engine Disassembly Process

1 1. Photo of front of engine. Remove the starter motor

drive gear assembly (A) and oil pump drive gear (B).
(Photo J)

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

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.

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
cover. Carefully extract the cap, outer and inner rotors,
timing key and timing rotor from engine. (Illustration 1)

PHOTO L

PUSH WITH
SCREWDRIVER
HERE

DETENTS

PHOTO M

PTO

MAG

EXHAUST SIDE

TAPEREDPIN

FITTING W/HOLE

VERIFY TAPERED PIN MATES EVENLY WITH EACH CHAIN PIN.
THREADED BOLT FACE MUST FIT SQUARELY ON CHAIN
PLATE.

ENGINE DISASSEMBLY / ASSEMBLY

4.252004 Four Stroke PWC Service Manual

Engine Disassembly Process

15. Rotate the engine assembly 180_ so that the valve train
is up. Using the hand crank, crank the engine until the
PTO piston is at TDC on the compression stroke.
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)

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 free­play in each of the rocker arms.

18. Place rocker arm assemblies and rocker arm pins on a
clean towel or piece of paper. Identify each part for use
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.

20. Remove the chain tensioner bolt located next to the oil
filter location.

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.

PHOTO O

PHOTO P

PHOTO Q

ENGINE DISASSEMBLY / ASSEMBLY

4.26

2004 Four Stroke PWC Service Manual

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.

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)

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 R

42 68

13 75

PHOTO S

PHOTO T

ENGINE DISASSEMBLY / ASSEMBLY

4.272004 Four Stroke PWC Service Manual

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.

30. Remove the chain guide fastener and chain guide.
(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 U

CRACKED MATING SURFACE

PHOTO U

ENGINE DISASSEMBLY / ASSEMBLY

4.28

2004 Four Stroke PWC Service Manual

Engine Disassembly Process

33. Remove the balance shaft from the crankcase.
Remove the PTO crankshaft case seal and discard.
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” dur­ing 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.

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 proce­dures.

ENGINE DISASSEMBLY / ASSEMBLY

4.292004 Four Stroke PWC Service Manual

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. T ap 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.

ENGINE DISASSEMBLY / ASSEMBLY

4.30

2004 Four Stroke PWC Service Manual

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

ENGINE DISASSEMBLY / ASSEMBLY

4.312004 Four Stroke PWC Service Manual

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 Insp ectio n

Measure cylinder head warpage.

S Out of specification: Replace cylinder head

Da

Db

Dc

De

Dd

Df

ENGINE DISASSEMBLY / ASSEMBLY

4.32

2004 Four Stroke PWC Service Manual

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.

1. BORE = Maximum diameter of Da -- Df.

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

Camshaft Inspection

Measure camshaft width.

S Out of specification: Replace camshaft

ENGINE DISASSEMBLY / ASSEMBLY

4.332004 Four Stroke PWC Service Manual

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.

ENGINE DISASSEMBLY / ASSEMBLY

4.34

2004 Four Stroke PWC Service Manual

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

ENGINE DISASSEMBLY / ASSEMBLY

4.352004 Four Stroke PWC Service Manual

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

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)

SPECIFIED OIL CLEARANCE: ___________________
MEASURED OIL CLEARANCE: __________________
ORIGINAL INSTALLED BEARING COLOR / THICKNESS: _____________________

.0011″ -- .0015″ (.03mm -- .04mm)

ENGINE DISASSEMBLY / ASSEMBLY

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2004 Four Stroke PWC Service Manual

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.

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.

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)

SPECIFIED OIL CLEARANCE: ___________________
MEASURED OIL CLEARANCE: __________________
ORIGINAL INSTALLED BEARING COLOR / THICKNESS: _____________________

.0003″ -- .002″ (.01mm-- .064mm )

ENGINE DISASSEMBLY / ASSEMBLY

4.372004 Four Stroke PWC Service Manual

Connecting Rod Inspection

Measure big end oil clearance.

NOTE: Do not move crankshaft or connect­ing rods until measurement process is com­pleted.

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. T orque 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.

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.

15mm

ENGINE DISASSEMBLY / ASSEMBLY

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2004 Four Stroke PWC Service Manual

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

Cylinder

Piston Ring

Feeler Gauge

ENGINE DISASSEMBLY / ASSEMBLY

4.392004 Four Stroke PWC Service Manual

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

Piston

Ring

Feeler Gauge

ENGINE DISASSEMBLY / ASSEMBLY

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2004 Four Stroke PWC Service Manual

Engine Inspection Procedures

Piston Inspection

Measure piston ring grove clearance.

S Out of specification: Replace piston ring

or piston

High Pressure Oil Pump Inspection

Measure relief spring free length and piston dimensions.

S Out of specification: Replace spring and

piston

FULLY EXTENDED

PUSH FLUSH TO LOCK
PUSH PAST FLUSH TO
ENGAGE

INSPECT FOR WEAR

=TURN FREELY

=NO TURN

ENGINE DISASSEMBLY / ASSEMBLY

4.412004 Four Stroke PWC Service Manual

Engine Inspection Procedures

Chain Tensioner

Verify chain tensioner function.

1. Push tensioner into housing until flush with threaded
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.

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.

Starter Motor Clutch

Inspect clutch function.

S Clutch should move freely when rotated

clockwise.

S Clutch should not rotate freely when ro-

tated counter clockwise.

S Inspect rollers for wear and tear. Re-

place assembly if found.

ENGINE DISASSEMBLY / ASSEMBLY

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2004 Four Stroke PWC Service Manual

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.

UPPER RINGS

OIL CONTROL RING

SPRING

PISTON MARK

GAP

GAP

GAP

ENGINE DISASSEMBLY / ASSEMBLY

4.432004 Four Stroke PWC Service Manual

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.

8. Place ring compressor tool, PN--PW--46983 on top of
one cylinder. Align the ring end gaps as outlined in the
photo. The piston mark will face the INTAKE SIDE of
the engine once installed into the cylinder.

CHAIN GUIDE

RING COMPRESSOR

BALANCE SHAFT

DRIVE GEAR

SINGLE--DOT ALIGNMENT MARKS

ENGINE DISASSEMBLY / ASSEMBLY

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2004 Four Stroke PWC Service Manual

Engine Assembly

9. Carefully install each piston assembly into the
cylinders. Take care in not scratching the cylinder bore.

10. Install the intake--side chain guide. Tighten fastener to
specification.

1 1. 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
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.

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.

ENGINE DISASSEMBLY / ASSEMBLY

4.452004 Four Stroke PWC Service Manual

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.