Polaris msx 110

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ASSEMBLY NOTES

PPU -- To -- Top Deck Fastener Torque: 22 in.lbs. (2.5 Nm)

PPU Assembly

22 in.lbs. (2.5 Nm)

HULL AND BODY

7.12

2004 Four Stroke PWC Service Manual

PPU Assembly

Main Page

Table of Contents3
General Information4
Pwc Identification Numbers4
PWC Publication Part Numbers5
Standard Torque Specifications11
Decimal Equivalent Chart12
Conversion Chart13
Periodic Maintenance Table18
Safety Warnings19
Flush Kit20
Service Products21
Steering Post Removal / Assembly23
Steering / Reverse Cable Adjustment24
E.S.P. Function Testing25
Valve Clearance Adjustment Procedure25
Engine Oil Level Check27
Oil Change Procedure27
Engine Coolant Inspection / Change Procedure29
Engine Compression Test31
Battery Removal32
Battery Safety32
Battery Connections33
Battery Charging33
Battery Storage34
Battery Installation34
Spark Plug35
Fuses35
Exhaust Cooling Injector Maintenance36
Throttle Cable Adjustment36
Gasoline Safety / Fuel System Maintenance / Fuel Filter37
Bilge Drain Plugs38
Bilge Siphon System38
Impeller Clearance39
Drain Plugs42
Off--Season Storage43
Engine Removal and Installation45
Engine Installation54
Engine Specifications56
Engine Fastener Torque Specifications58
Service Tools62
Oil Filter Assembly63
Valve Cover Assembly64
Valve Train Assembly65
Dry Sump Oil Pump Assembly66
Thermostat Housing67
High Pressure Oil Pump Assembly68
Engine Case / Cylinder Head Assembly70
Piston Assembly72
Balance Plate / PTO Assembly74
Engine Disassembly74
Engine Inspection84
Chain Tensioner96
Engine Assembly98
Engine Cooling System113
Oil Lubrication System120
Fuel Hose Routings129
Vent Hose Routing130
ECU Mounting Illustration136
Knock Sensor150
Wastegate Solenoid151
Etb Learning Procedure154
Exhaust System Illustration156
RPM Limiting Modes160
Troubleshooting: Engine will Not Turnover161
Troubleshooting: Engine Turns Over; will Not Start162
Troubleshooting: Engine Stalls; will Re--Start163
Troubleshooting: Engine Stalls: will Not Re--Start164
Troubleshooting: Engine Lacks Performance, RPM Limits165
Troubleshooting168
Pump Assembly171
Ventilation Troubleshooting172
Cavitation Troubleshooting172
Bearing Carrier Removal178
Bearing Carrier Installation178
Driveshaft Shim Procedure179
Stator Disassembly181
Siphon Hose Routing196
Hull Assembly197
Compartment Door Assembly199
Shroud and Storage Assemblies200
Seat Assembly201
Steering Control Assembly202
ESP Switch Assembly203
PPU Assembly204
Reverse System Assembly205
Steering Cable Removal and Installation207
Steering Cable Installation208
Top Deck / Hull Repair210
Electrical System211
Electrical Systems212
Instrument Operation214
Battery Testing216
Specific Gravity Test217
Alternator Assembly219
Charging System220
Starter Motor224
Brush Inspection227
Armature Testing227
Starter Assembly228
Starter Solenoid Bench Test228
Decimal Equivalent Chart238
Tap Drill Sizes240

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