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msx 150
Polaris msx 150 Service Manual
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ENGINE
DISASSEMBL
Y
/
ASSEMBL
Y
4.30
2004
Four
Str
oke
PWC
Se
rvic
e
Manua
l
Engine
Inspection
Procedures
V
alve
Inspection
Measure
valv
e
mar
gin
t
hickness.
S
O
ut
of
specif
ication:
Replac
e
valv
e
Measure
valv
e
st
em
diameter.
S
O
ut
of
specif
ication:
Replac
e
valv
e
Measure
valv
e
guide
inside
diameter.
S
O
ut
of
specif
ication:
Replac
e
valv
e
guide
84
86
Table of Contents
Table of Contents
3
General Information
4
Pwc Identification Numbers
4
PWC Publication Part Numbers
5
Standard Torque Specifications
11
Decimal Equivalent Chart
12
Conversion Chart
13
Periodic Maintenance Table
18
Safety Warnings
19
Flush Kit
20
Service Products
21
Steering Post Removal / Assembly
23
Steering / Reverse Cable Adjustment
24
E.S.P. Function Testing
25
Valve Clearance Adjustment Procedure
25
Engine Oil Level Check
27
Oil Change Procedure
27
Engine Coolant Inspection / Change Procedure
29
Engine Compression Test
31
Battery Removal
32
Battery Safety
32
Battery Connections
33
Battery Charging
33
Battery Storage
34
Battery Installation
34
Spark Plug
35
Fuses
35
Exhaust Cooling Injector Maintenance
36
Throttle Cable Adjustment
36
Gasoline Safety / Fuel System Maintenance / Fuel Filter
37
Bilge Drain Plugs
38
Bilge Siphon System
38
Impeller Clearance
39
Drain Plugs
42
Off--Season Storage
43
Engine Removal and Installation
45
Engine Installation
54
Engine Specifications
56
Engine Fastener Torque Specifications
58
Service Tools
62
Oil Filter Assembly
63
Valve Cover Assembly
64
Valve Train Assembly
65
Dry Sump Oil Pump Assembly
66
Thermostat Housing
67
High Pressure Oil Pump Assembly
68
Engine Case / Cylinder Head Assembly
70
Piston Assembly
72
Balance Plate / PTO Assembly
74
Engine Disassembly
74
Engine Inspection
84
Chain Tensioner
96
Engine Assembly
98
Engine Cooling System
113
Oil Lubrication System
120
Fuel Hose Routings
129
Vent Hose Routing
130
ECU Mounting Illustration
136
Knock Sensor
150
Wastegate Solenoid
151
Etb Learning Procedure
154
Exhaust System Illustration
156
RPM Limiting Modes
160
Troubleshooting: Engine will Not Turnover
161
Troubleshooting: Engine Turns Over; will Not Start
162
Troubleshooting: Engine Stalls; will Re--Start
163
Troubleshooting: Engine Stalls: will Not Re--Start
164
Troubleshooting: Engine Lacks Performance, RPM Limits
165
Troubleshooting
168
Pump Assembly
171
Ventilation Troubleshooting
172
Cavitation Troubleshooting
172
Bearing Carrier Removal
178
Bearing Carrier Installation
178
Driveshaft Shim Procedure
179
Stator Disassembly
181
Siphon Hose Routing
196
Hull Assembly
197
Compartment Door Assembly
199
Shroud and Storage Assemblies
200
Seat Assembly
201
Steering Control Assembly
202
ESP Switch Assembly
203
PPU Assembly
204
Reverse System Assembly
205
Steering Cable Removal and Installation
207
Steering Cable Installation
208
Top Deck / Hull Repair
210
Electrical System
211
Electrical Systems
212
Instrument Operation
214
Battery Testing
216
Specific Gravity Test
217
Alternator Assembly
219
Charging System
220
Starter Motor
224
Brush Inspection
227
Armature Testing
227
Starter Assembly
228
Starter Solenoid Bench Test
228
Decimal Equivalent Chart
238
Tap Drill Sizes
240
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Polaris msx 150 Specifications
General
Brand
Polaris
Model
msx 150
Category
Boat
Language
English
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