Polaris MSX 140 PWC Repair Service Manual 2003

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This workshop service repair manual PDF download for the 2003 MSX 140 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.


2003 Polaris MSX 140 – W035303CA / B


Chapter 1 General Information
Chapter 2 Maintenance
Chapter 3 Engine / Cooling
Chapter 4 Fuel Injection System
Chapter 5 Final Drive / Propulsion
Chapter 6 Hull / Control Systems
Chapter 7 Electrical Systems
MSX 140 Wiring Diagram


File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9918121
Total Pages : 185

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.

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2003 MSX 140 Personal Watercraft Service Manual (PN 9918121)
Chapter 1 General Information
2003 PWC Identification Numbers
2003 PWC Publication Part Numbers
Watercraft Service Manual Part Numbers
MSX 140 Required Service Tools
2003 MSX 140 W035303CA or B
2003 Polaris PWC Emission Certification

PWC Service Guidelines — Safety Warnings
Standard Torque Specifications
Conversion Chart
Chapter 2 Maintenance
Recommended Maintenance Products
Oil and Lubricants
Fuel System Maintenance Products
General Maintenance Products
Retaining / Sealing Products
Periodic Maintenance Schedule
Maintenance Notes
General Lubrication
Throttle Cable / Throttle Flipper
Steering Cable / Steering Joints
Steering Nozzle
Reverse System
Seat Latch / Hooks
Throttle / Choke Shafts
Electrical Components

Battery Safety
Battery Removal
Battery Connections
Battery Charging
Battery Installation
Battery Storage
Spark Plugs
DI Model Spark Plug Replacement (Ficht)

Connections and Fuses
Engine Mounts
Compression Test
Engine Break-In
Cylinder Head Re-Torque
Cylinder Base Gasket Re-Torque
Exhaust Manifold
Ignition Coil Inspection and Maintenance
Exhaust Cooling Orifice/Screen Cleaning
Thermostat/Pop Off Valve Cleaning
Oil Filter
Oil Pump Adjustment
Throttle / Choke Cable Inspection
Throttle Cable Adjustment
Fuel system

Fuel Lines / Vent Lines
Water Separating Filter
Idle Speed — DI Models
Air Intake
Cooling System
Cooling System Flushing and Salt Water Maintenance
Flushing Procedure DI Flush Kit: PN 2873623
External Engine Corrosion Prevention
Off Season Storage Procedures
Engine Draining
Fuel System Storage
Engine Fogging Procedure
Fire Extinguisher
Bilge Siphon System

Bilge Drain Plugs
Final Drive / Propulsion
Cooling Water Pickup Screen
Scoop / Ride Plate / Intake Grate
Impeller Clearance
Pump Housing Inspection
Sacrificial Anode
Hull / Control Systems
Handlebar / Hand Grips
Handlebar Post
Fasteners / Parts / Hoses
Seat Adjustment
Chapter 3 Engine / Cooling
Specifications, Clearances

Engine Torque Specifications
DFI Engine Torque Sequences
DFI Air Intake Assembly
DFI Throttle Body Assembly
DFI Exhaust Manifold Assembly
DFI Engine Mount Assembly
DFI Water Outlet Manifold Assembly
DFI Ignition Coil Assembly
DFI Oil Pump Assembly
DFI Cylinder Head Assembly
DFI Stator / Flywheel Assembly
DFI Cylinder Assembly
DFI Crankcase Assembly
DFI Crankshaft and Piston Assembly
Engine Removal
Engine Installation
DFI Engine Disassembly
air intake manifold
oil pump
flywheel cover
remove the flywheel
Remove starter drive
remove the stator assembly
water outlet manifold
remove the cylinder head bolts
remove each cylinder
Remove pistons

Remove crank
case bolts
DFI Engine Inspection
Connecting Rod Small End Inspection
Piston Inspection/Measurement
Crankshaft Main Bearing Inspection
Connecting Rod (Big End) Side Clearance
Connecting Rod (Big End) Radial Clearance
Crankshaft Truing
DFI Engine Assembly
Install inner bearing on PTO end
Install new PTO seals on crankshaft
Crankcase Assembly

Piston Installation

Cylinder Installation
Install cylinder heads
Attach and torque water outlet manifold bolts
Press a new seal into the stator housing
Install the stator housing to the engine
Install stator
Install Bendix

Install flywheel
Install flywheel cover
Install oil pump
Install starter
Insert reed valves
Attach intake manifold to engine
DFI Crankshaft Indexing
DFI Cooling System
Thermostat Pop Off Assembly
DFI Exhaust Cooling Orifice / Screen Cleaning
DFI Exhaust System
Chapter 4 Fuel Injection System
Fuel System

Fuel Supply / Vent Hose Routings
Fuel Tank Assembly
Oil Tank Assembly
Fuel Pump Assembly
Fuel Injection System — Components
Fuel Injection Wiring Diagram
EMM Connectors
S.L.O.W. Warning System (Speed Limiting Overheat Warning)
S.L.O.W. Service Codes
Service Codes
Service Codes — Failure Modes
Ficht Fuel Injection System – Diagnostic Software
Laptop To EMM Connections
Understanding the EMM communication cable
Service Power Connector
Using the Polaris Diagnostic Software: PODIAG
Communication Problems — Diagnostic Cable
EMM Communication Notes
FICHT Troubleshooting
Service Specifications
2003 EMM Information Specifications
2003 EMM / Fuel Injector Part Numbers
Chapter 5 Final Drive / Propulsion
Jet Pump

Pump Specifications
Final Drive / Propulsion Quick Reference Guide
Fastener Guide – Final Drive / Propulsion
Ventilation Troubleshooting
Cavitation Troubleshooting
Jet Pump Assembly diagram
Jet Pump Stator Assembly
Driveshaft / Bearing Carrier Assembly
Pump Induction Assembly
Jet Pump Pump Removal
Jet Pump Assembly
Jet Pump Housing Removal
Jet Pump Housing Installation
Drive shaft Bearing Carrier Removal
Drive shaft Bearing Carrier Installation
Impeller Clearance
Drive Shaft Inspection
Stator Disassembly
Impeller Removal Tool
Stator Assembly
Jet Pump Alignment – Overview
Pump Alignment Process
Engine Alignment Inspection (Vertical)
Sacrificial Anode
Intake Scoop / Ride Plate
Intake Scoop / Ride Plate Removal and Installation
Chapter 6 Hull / Control Systems
Hull Specifications
Paint Codes / Colors
Fastener Guide – Hull / Control Systems
MSX Hull Assembly
MSX Compartment Door Assembly
Shroud and Storage Assemblies
MSX Seat Assembly
MSX Steering Control Assembly
MSX Reverse System Assembly
Handlebar Cover / Steering Post
Handlebar Cover Removal
Steering Post Removal
Steering Post Assembly
Steering Cable Removal / Installation
Steering Cable Installation
Steering Cable Adjustment
Reverse Cable Adjustment
Hull repair
Paint Ordering Information
Top Deck and Hull Gelcoat Repair
Top Deck / Hull Repair
Footpad Removal
Footpad Application
Chapter 7 Electrical Systems
Spark Plug Specifications
Alternator Output Specifications
Ignition Timing / CDI Specifications
Battery Specifications
Domestic Engine Degrees-to-Piston Position Conversion Chart
Start / Stop / Gauge System
Enhanced Steering Performance (E.S.P.)
Owner’s Manual Supplement
Technical Overview
E.S.P. (Enhanced Steering Performance) wiring diagram

RPM Limiter System
RPM Limiter System Diagram
RPM Limiters
Reverse Switch Testing
Start Switch Testing
Stop Switch Testing
Mode Switch Testing
Oil Level Switch Testing
Fuel Level Switch Testing
Paddle Wheel Testing
Starting Motor Solenoid Testing
MSX NGI digital Gauge
Displayed Warnings
Battery Testing
Load Test
Off-season Storage
Charging Procedure
Starter Motor
Brush Replacement
Armature Testing
Starter Motor — Assembly
Starter Solenoid Bench Test
MSX 140 Wiring Diagram



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Polaris MSX 140 PWC Repair Service Manual 2003.pdf

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