Polaris MSX 110 & MSX 150 PWC Repair Service Manual 2004

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This workshop service repair manual PDF download for the 2004 MSX 110 & MSX 150 Polaris Personal Watercraft has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

2004 Polaris MSX 110 (A) – W045304CA
2004 Polaris MSX 110 (A) International – W045304IA
2004 Polaris MSX 110 (B) – W045304CB
2004 Polaris MSX 110 (B) International – W045304IB
2004 Polaris MSX 110 (C) – W045304CC
2004 Polaris MSX 110 (C) International – W045304IC
2004 Polaris MSX 150 (A) – W045305CA
2004 Polaris MSX 150 (A) International – W045305IA
2004 Polaris MSX 150 (B) – W045305CB
2004 Polaris MSX 150 (B) International – W045305IB
2004 Polaris MSX 150 (C) – W045305CC
2004 Polaris MSX 150 International – W045305IC
2004 Polaris MSX 150 (D) – W045305CD
2004 Polaris MSX 150 (D) International – W045305ID

TABLE OF CONTENTS :

CHAPTER 1-GENERAL INFORMATION
CHAPTER 2-MAINTENANCE
CHAPTER 3-ENGINE REMOVAL/INSTALLATION
CHAPTER 4-ENGINE DISASSEMBLY/ASSEMBLY
CHAPTER 5-FUEL INJECTION/IGNITION/EXHAUST SYSTEMS
CHAPTER 6-PROPULSION
CHAPTER 7-HULL AND BODY
CHAPTER 8-ELECTRICAL SYSTEMS
WIRING DIAGRAMS
INDEX

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9919062
Total Pages : 241

This polaris watercraft manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.

This polaris service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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

 

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Polaris MSX 110 & MSX 150 PWC Repair Service Manual 2004.pdf

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