Polaris 2003 MSX Owner'S Manual Download Page 1

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Owner's Manual

for Vehicle Maintenance

and Safety

Owner's Manual

for Vehicle Maintenance

and Safety

2003

MSX

2003

MSX

Summary of Contents for 2003 MSX

Page 1: ...Owner s Manual for Vehicle Maintenance and Safety Owner s Manual for Vehicle Maintenance and Safety 2003 MSX 2003 MSX ...

Page 2: ...WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm ...

Page 3: ... site just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out S Racing Information Check it out www polarisindustries com owner ...

Page 4: ... make product changes and improvements that may affect illustrations or explanations No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc Polaris Polaris The Way Out and Workmobiles are registered trademarks of Polaris Industries Inc Copyright 2002 Polaris Industries Inc All Rights Reserved Printed in the U S A ...

Page 5: ...the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polari...

Page 6: ...RESPONSIBILITIES 5 IDENTIFICATION NUMBERS 7 SAFETY 8 FEATURES and CONTROLS 24 EMISSIONS 36 OPERATION 38 MAINTENANCE and LUBRICATION 74 ENGINE TROUBLESHOOTING 96 POLARIS PRODUCTS 101 SPECIFICATIONS 102 WARRANTY 104 CALIFORNIA EMISSIONS WARRANTY 107 INDEX 110 ...

Page 7: ...icle is sold the owner s manual and video should remain with it If your owner s manual is lost or missing see a Polaris dealer for a replacement Obey the Rules Familiarize yourself with all boating laws and regulations in your area Ride only in areas approved for personal watercraft Avoid riding near waterfront homes wildlife areas other boats and swimmers Respect Your Neighbors Some people may fi...

Page 8: ...ual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals WARNING Failure to follow the warnings contained in this manual can result in severe injury or death A Polaris watercraft is not a toy It s a high performance powerboat and can be hazardous to operate A collision or overturn can occur quickly if ...

Page 9: ...e identification number is located at the front of the engine near the stator cover 2 Record your vehicle s identification numbers in the spaces provided and in another location away from the vehicle If the vehicle is destroyed or stolen you ll have the identification numbers required by insurance and or law enforcement NOTE Check with your insurance agent about obtaining insurance coverage for yo...

Page 10: ...mbol on your vehicle or in this manual alerts you to the potential for personal injury The safety alert warning indicates a potential hazard that may result in serious injury or death WARNING The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION NOTE A note will alert you to important information or instructions A caution in...

Page 11: ...cal carefully If any decal becomes illegible or comes off contact your Polaris dealer for a replacement Any safety decal needing replacement will be provided by Polaris at no charge The warning decals summarize and highlight key safety and operational information Be sure to read the entire owner s manual for details that affect safe operation of this watercraft ...

Page 12: ...10 SAFETY Safety Decals The general safety warning decal is located on the rear of the watercraft just below the seat ...

Page 13: ...ercraft TAKE EARLY ACTION to avoid collisions Remember PWCs and other boats do not have brakes DO NOT RELEASE THROTTLE WHEN TRYING TO STEER away from objects you need throttle to steer Always check throttle and steering controls for proper operation before starting PWC Follow navigation rules and state and local laws that apply to PWCs See Owner s Manual for more information S Do not follow direct...

Page 14: ...oned upside down so the operator can read it when the boat is capsized RIGHTING CAPSIZED BOAT 7073865 S To prevent injury do not place hands or objects into pump inlet intake grate or nozzle S To prevent major engine damage Make sure engine is stopped by pulling lanyard from engine stop switch and turn boat to upright position in a clockwise direction WARNING ...

Page 15: ...low the left hand mirror Located on the upper shroud near the front compartment door Located on the engine water manifold 7171396 FIRE EXTINGUISHER CONTAINER LOCATED INSIDE Do Not Remove Electrical Part When Starting Or During Operation High Voltage Shock Hazard 7075383 WARNING ...

Page 16: ... Obey all applicable boating rules and regulations This watercraft does not have brakes The watercraft is stopped by releasing the throttle The vehicle will glide to a stop due to the natural drag of the water Allow a minimum of 300 feet 90 m to coast to a stop from full throttle Jet thrust is required to steer and turn the vehicle Never completely release the throttle and attempt to turn at more ...

Page 17: ...ways remain seated Never travel over a ski jump or attempt to jump waves wakes or other objects in the water Doing so may severely damage the watercraft and cause personal injury due to the hard impact a temporary loss of visibility possible loss of control and reduced reaction time Always securely attach the lanyard cord 1 to the operator s left wrist or PFD before starting the watercraft If the ...

Page 18: ... unknown hazards in the water such as debris and hidden objects Riding gloves may also be considered NOTE A helmet may provide increased personal injury protection in some situations such as impact with the watercraft or during a collision with other watercraft or an obstacle However a helmet may not provide adequate protection against all foreseeable impacts and may aggravate some injuries For ex...

Page 19: ...for providing and maintaining the fully charged fire extinguisher in the watercraft Do not operate the watercraft without a fire extinguisher on board Stow your fire extinguisher under the front storage compartment in the cut out area of the flotation foam Know how to reach the extinguisher quickly in case of fire and know how to use it before you operate the personal watercraft If you have any do...

Page 20: ...of operation Always ride with another watercraft when operating in remote areas or in large areas of open water Carry a flare gun on board to signal for help if necessary Protective Apparel Normal swimming attire may not provide adequate protection while riding a watercraft At the rear of the watercraft the jet pump emits a forceful stream of water that can injure body orifices such as mouth eyes ...

Page 21: ...ooling system will also cause the engine to overheat which could lead to serious mechanical damage If the watercraft has been beached or has been sitting in shallow water clear out any sand or small rocks before boarding and restarting the watercraft Remove the particles by bouncing the back of the machine up and down in at least two feet of water If the craft has been beached flush the cooling sy...

Page 22: ... The operator should always alert any passengers before making sudden turns or changes in speed Pre Operation Check Always perform the pre operation check beginning on page 38 before starting and riding the watercraft Make sure all critical components are operating correctly Check fuel and oil levels and all controls especially the throttle lever handlebars and steering nozzle Failure of these cri...

Page 23: ...eds or debris that may have collected in or around the jet pump intake Electrical Shock Hazard Never touch or remove electrical parts while starting or during operation of the watercraft Severe injury or death could result from electrical shock Safe Riding Position Falling off a watercraft can result in serious injury The operator and any passengers should always keep both feet firmly planted on t...

Page 24: ...ition Pregnant women should consult their physicians before riding any watercraft Reboarding the watercraft in deep water can also be strenuous Operators and passengers should be physically fit enough to reboard the watercraft in deep water Practice boarding in chest deep water to be sure you are physically able to reboard if the need arises Boating Under the Influence Operating any watercraft whi...

Page 25: ...reak from operating the watercraft Drink plenty of non alcoholic beverages to prevent dehydration and wear protective riding gear to protect against exposure to weather elements Hypothermia Your life may depend on a clear understanding of the effects of cold water on the human body Many suspected drowning victims actually died from cold exposure hypothermia rather than drowning Hypothermia can beg...

Page 26: ... Gen eration Instrument NGI See page 30 for a detailed explanation of the NGI display 7 Seat Latch The seat latch secures the seat in posi tion When released it provides access to the engine compartment 8 Jet Pump Outlet Nozzle The nozzle is the exit for the jet output Orientation is controlled by the handlebars and determines the direction of craft movement 9 Exhaust Outlet 10 Reverse Gate 11 Dra...

Page 27: ...25 FEATURES AND CONTROLS 1 5 2 4 6 15 16 14 3 8 7 9 10 12 13 11 11 ...

Page 28: ...ection of craft movement 4 Console Storage 5 Seat Engine Compartment Removing the seat provides access to the engine battery electrical box exhaust system and other components 6 Grab Handle The grab handle assists riders while boarding the craft or when riding as passengers 7 Tow Eye Hook Securely attach the tow rope to this hook when pulling skiers wake boarders and tubes 8 Boarding Platform Foot...

Page 29: ...27 FEATURES AND CONTROLS 6 5 3 2 1 7 9 10 4 8 ...

Page 30: ...e EMM 3 Spark plugs 4 Air intake cover 5 Starter solenoid 6 Exhaust silencer 7 Exhaust pipe 8 Exhaust cooling water hose 9 Cooling water manifold 10 Thermostat assembly under end of water manifold 11 Spark arrestor air filter 12 Engine cooling water outlet hose under thermostat assembly 2 1 ...

Page 31: ...29 FEATURES AND CONTROLS Engine Components 3 7 8 6 12 10 9 4 11 5 2 1 ...

Page 32: ...ns S Speedometer S Clock S Tachometer S Engine Hourmeter S Trip Odometer S Oil Level S Fuel Level S Low Oil Pressure Fuel Battery Voltage Warnings S High Engine Temperature Warning S Check Engine Warning Accessible Functions S Tachometer S Engine Hourmeter S Trip Odometer ...

Page 33: ...uel Level Fuel level is displayed with an 8 bar LCD graphic The level is displayed in 1 8th increments When the display is 1 8th one bar or less a LOW FUEL symbol and red LED warning light will blink to alert the operator to the low fuel condition Refill the fuel tank Engine Hourmeter The NGI retains and displays up to 999 9 hours Additional hours will not reset the gauge to zero The gauge begins ...

Page 34: ...NAVIGATION MODE displays SPEED TRIP ODOMETER and ENGINE HOURS CLOCK SET In the main mode press and hold the RESET button until the hour digits flash approximately six seconds Press the RESET button to advance the hour digits Press the MODE button to stop the hour flash and begin the minute digits flash Press the RESET button to advance one minute Press the MODE button to set the clock and exit the...

Page 35: ...el level reaches 1 8 level S LOW OIL Oil level reaches 1 7 level S LOW BATTERY VOLTAGE Battery voltage is at or below 10 9 vDC S HIGH TEMPERATURE Temperature is monitored by EMM S CHECK ENGINE Check engine warning is triggered by EMM Regardless of warning each warning will display a related ISO symbol on the screen and a blinking red LED warning ...

Page 36: ...mmediately Clean the jet pump and impeller as outlined on page 24 If the cause of overheating is identified and corrected normal operation can be resumed by releasing and reapplying the throttle If the engine continues to overheat after cleaning the jet pump and impeller take the watercraft to an authorized Polaris dealer for service A clogged intake and or impeller can cause engine overheating an...

Page 37: ...accessories from wetsuits and life vests to accessory mirrors touring and towing gear and performance parts Contact your Polaris dealer or visit www polarisindustries com to see our full line of available products Optional Equipment See page 101 for a list of Polaris products for servicing your watercraft S U S Coast Guard approved fire extinguisher UL 5 B C Rating PN 2871012 S Registration number...

Page 38: ...rmed by any marine SI engine repair establishment or individual Refer to the California Emission Control System Limited Warranty beginning on page 107 California Star Labels A star label has been applied to your personal watercraft in accordance with the requirements of the California Air Resources Board The star label means cleaner marine engines Cleaner Air and Water for healthier lifestyle and ...

Page 39: ...the U S EPA s 2006 standards for marine engines Two Stars Very Low Emission The two star label identifies engines that meet the Air Resources Board s 2004 exhaust emission standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines Three Stars Ultra Low Emission The three star label identifies engines that meet the Air Resources Board s 2008 exhaust emissio...

Page 40: ...d result Always inspect the vehicle as outlined in the checklist before each use to ensure it s in proper and safe operating condition See page 75 for additional inspection information Always remove the lanyard from the engine stop switch before performing the pre operation inspection WARNING WARNING Starting or operating the watercraft with a fuel leak can result in an explosion causing serious i...

Page 41: ...cover seat Remove and ventilate engine compartment before starting engine Re secure latches Item What To Do Battery Check fluid level condition vent hose must be clear and open Hull Inspect hull for damage or cracks clean off any marine growth Drain plugs bilge Inspect clean be sure each plug is tight secure and doesn t leak Loose parts hoses Inspect for loose parts hoses and connections tighten a...

Page 42: ...a 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 S If gasoline spills on your skin or clothing im mediately wash it off with soap and water and change clothing S Never start the engine or let it run in an en closed area Gasoline powered engine exhaust fumes are poisonous...

Page 43: ...ith water if fuel or oil spills in those areas Use fresh seasonal gasoline that has been stored in a clean container For the best performance from gasoline purchase only what is needed for a month or less of operation NOTE If the fuel or oil levels become low a warning light will flash on the NGI display Proceed to shore and refuel CAUTION Using a non recommended fuel may cause serious engine dama...

Page 44: ...e oil fill cap and check the oil level 3 Add the recommended oil Fill to within several inches of the fill hole opening NOTE Do not fill all the way to the opening Wipe up any spills immediately 4 Visually inspect the oil for water or foreign matter If either is present see your Polaris dealer for service A warning light on the NGI display will flash if oil is low 1 8 tank or less Add oil promptly...

Page 45: ... of the craft up and down several times to flush out any sand and debris that may be in the pump 1 2 3 4 WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When disconnecting cables always disconnect the negative black cable first When reconnecting always connect the negative black cable last CAUTION A clogged intake or the in...

Page 46: ... prior to starting the engine Pull or squeeze the throttle several times to be sure the throttle lever moves freely through its full range It should spring back to its original position when released Engine and Storage Compartments If the craft is operated in salt water spray the inside of the hull engine and components with waterproof lubricant spray after every use See page 101 for part numbers ...

Page 47: ...ercraft NOTE The seat is not a personal flotation device PFD and will not provide life saving flotation Always wear a PFD when operating or riding a watercraft Fire Extinguisher The operator of the watercraft is required by law to carry a fire extinguisher on board Always keep a fully charged and working fire extinguisher inside the fire extinguisher holder which is located inside the storage area...

Page 48: ...o weak to start the engine or shows signs of loss of power Use a trickle charger to maintain the battery s charge during the off season Doing so will ensure a good battery at the end of the storage period and a longer life for the battery NOTE The Polaris Battery Tendert battery charger can be left connected during the storage period and will automatically charge the battery if the voltage drops b...

Page 49: ...e the drain plugs and carefully flush out the bilge with fresh water Allow the bilge to drain completely Wipe out the bilge with dry shop towels and reinstall the drain plugs After launching the craft remove the seat and check for leaks Riding Gear Be sure all operators and passengers have the appropriate riding gear including a PFD see page 16 Make sure all trailing objects are securely tied back...

Page 50: ...gine stop switch 2 to test operation The engine should stop immediately If it doesn t press the stop switch to stop the engine Do not ride the watercraft See your Polaris dealer for service before operating the watercraft 3 If removing the lanyard lock plate successfully stopped the engine in the previous step start the engine again and allow it to run for a few seconds Depress the engine stop but...

Page 51: ...e break in period for your new Polaris watercraft is defined as the time it takes to use the first full tank of gasoline No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully CAUTION Excessive heat build up d...

Page 52: ...at the lowest possible speed for the first five minutes of operation 7 Gradually open the throttle to half speed half throttle 8 Vary throttle speeds up to 3 4 speed during the break in period first full tank of fuel CAUTION If the engine is operated while the watercraft is in very shallow water sand weeds and debris may be sucked into the jet intake and could cause damage to the impeller or injur...

Page 53: ...o obtain this information when registering your watercraft Right of way and Give way In nautical terms the stand on privileged vessel has the right of way and the give way burdened vessel must yield or give way Stand on Vessel The vessel with the right of way has the duty to continue its course and speed except to avoid an immediate collision By maintaining course and speed other vessels should be...

Page 54: ...y encounter other vessels S Overtaking passing S Meeting approaching another vessel head on S Crossing traveling across another vessel s path Meeting Vessels When meeting another power vessel head on and a collision appears likely neither vessel has the right of way Both vessels are obligated to alter course to avoid an accident Keep the other vessel to your port left side and take evasive action ...

Page 55: ...r vessels are crossing each other s path close enough to run the risk of collision the vessel having the other on the starboard right side must give way For example if the other vessel 4 is on your vessel s 3 starboard right side you must give way If the other vessel is on your port left side your vessel is the stand on vessel and should maintain its course and direction The other vessel must give...

Page 56: ... stay clear of fishing ves sels S In a narrow channel a non motorized craft should not interfere with the safe passage of a power vessel Fishing Vessel Right of Way All vessels that are fishing with nets lines or trawls are considered fishing vessels under International Rules Vessels with trolling lines are not considered fishing vessels Fishing vessels have the right of way regardless of position...

Page 57: ...rakes DO NOT RELEASE THROTTLE WHEN TRYING TO STEER away from objects You need throttle for proper steering Always check throttle and steering controls for proper operation before starting the craft Follow navigation rules and all state and local laws that apply to personal watercraft Reading Buoys and Markers United States waters are marked for safe navigation through the use of buoys and markers ...

Page 58: ... beginning on page 57 Stopping the Engine Do not turn off the engine until the watercraft has stopped moving Your craft requires engine power for steering so after the engine has stopped you ll lose all steering control of the watercraft 1 Release the throttle lever When the engine has slowed to an idle and the craft has stopped moving push in the stop button The engine should stop immediately You...

Page 59: ...nyard lock plate to the engine stop switch on the handlebars by pushing the lock plate around the barrel of the switch Be sure the lanyard is not tangled around the handlebars or controls NOTE The engine will not start if the lanyard lock plate is removed from the engine stop switch CAUTION If the engine is run while the watercraft is in very shallow water sand weeds and debris may be sucked into ...

Page 60: ... the engine does not start within 10 seconds release the starter switch Wait 10 seconds before trying again to avoid damaging the starter If the engine does not start after several attempts refer to the troubleshooting section of this manual beginning on page 96 WARNING Starting the engine immediately generates a forward thrust which could cause an unprepared operator to fall from the machine caus...

Page 61: ...Water Operator Only Make sure the watercraft engine is turned off when boarding in deep water 1 Swim to the rear of the watercraft Grip the boarding handle near the rear of the seat 2 Pull yourself up onto the boarding platform 3 Move up to the seat and straddle it 4 Attach the lanyard lock plate to the engine stop switch and see that the lanyard wrist band is secure on your left wrist before star...

Page 62: ...he lanyard wrist band to the left wrist or PFD Do not start the engine yet NOTE During boarding the passenger should steady the watercraft while the operator boards The operator can then help balance it while the passenger boards 2 The passenger should move or swim to the rear of the vehicle 3 The passenger should pull him herself on board using the grab handle Both operator and passenger should t...

Page 63: ...jet pump and turning the handlebars at the same time Do not release the throttle when trying to steer High thrust makes the watercraft turn more sharply Lower thrust makes the watercraft turn less sharply Making sharp turns at high speeds may cause the watercraft to spin out and may cause rider s to be ejected from the watercraft Make gradual turns when operating at higher speeds Always look behin...

Page 64: ...could take the watercraft as much as 300 feet 90 m to come to a stop after the throttle is released This distance is approximate and is supplied only for reference Use good judgement and always allow plenty of room for stopping After releasing the throttle coast toward the desired stopping area with the engine idling You may need to use the throttle again for steering control NOTE Push the engine ...

Page 65: ...t the impeller jet pump area for sand and debris 4 Move the watercraft to at least two feet 60 cm of water and push the rear of the watercraft up and down in the water to help flush sand and debris out of the pump CAUTION Sand pebbles weeds and debris can enter the jet pump and cause severe damage to components Ingestion of sand into the cooling system may cause the engine to overheat and could re...

Page 66: ...states to operate the watercraft in or near the surf line WARNING Riding the watercraft in rough water conditions could cause loss of control resulting in severe injury or death to the operator and or passenger Avoid riding in rough water and or adverse weather conditions Do not jump waves with the watercraft CAUTION Operating with excessive throttle can result in cavitation damage to the impeller...

Page 67: ...e hose from the pump box to the exhaust pipe Clamp it off as near to the T fitting as possible To tow the craft securely attach about 20 feet 6 m of tow rope to the eye located on the bow Slowly tow the watercraft to shore CAUTION Failure to clamp off the cooling water inlet hose before towing may result in hydrolock a condition caused by water being drawn or forced into the engine Always clamp of...

Page 68: ...e 6 If the engine fails to start shortly after being uprighted make no further attempts to start it Severe engine damage could result Follow the procedures for a submerged waterlogged engine on page 72 WARNING This watercraft does not right itself if it has been capsized If the operator is unable to right a capsized watercraft operator and passengers may be stranded which could lead to serious inj...

Page 69: ...on to the rear grab handle All passengers should read the owner s manual and follow all safety warnings Passengers must wear an approved personal flotation device and other recommended safety gear They should be good swimmers and they should be in good physical condition as reboarding in deep water can be strenuous A passenger should firmly hang on to the operator s PFD or the seat strap and keep ...

Page 70: ...ove the drain plugs to drain any water in the bilge 5 Remove the seat and rinse the engine compartment with a generous amount of fresh water After the water has drained wipe the engine compartment bilge dry with clean towels 6 If the craft is used in salt water Polaris recommends that the inside of the hull engine and components be sprayed with T 9 metal protectant after each use See page 101 7 Re...

Page 71: ...laris dealer for service NOTE Whenever possible avoid operating the watercraft in weedy areas If it s unavoidable vary the watercraft speed as weeds tend to accumulate more rapidly at steady and trolling speeds WARNING Serious injury and damage to the watercraft will result if the jet pump and impeller are cleaned while the engine is running Always stop the engine remove the lanyard lock plate and...

Page 72: ...dry store the seat on the craft as outlined in step 1 3 When storing the watercraft make sure the nose is positioned upward at a 20_ angle for drainage 4 Check the screen in the pump stationary nozzle for plugging See instructions on page 90 WARNING Serious injury and damage to the watercraft will result if the jet pump and impeller are cleaned while the engine is running Always stop the engine re...

Page 73: ...the watercraft body Be sure the trailer matches the watercraft s weight and design and that it meets trailer laws and regulations in your area We recommend the use of a Polaris watercraft cover for protection from rocks and other debris while transporting 1 Tie the watercraft securely to the trailer at the bow and stern Use additional cables if necessary There should be no movement between the wat...

Page 74: ...emove the drain plugs drain the water from the bilge and bring the watercraft to an authorized Polaris dealer for service NOTE Only mechanically experienced individuals should attempt to remove water from a waterlogged engine Use the procedure on page 73 All others should take the watercraft to an authorized Polaris dealer for service If this is not possible call your Polaris dealer for further in...

Page 75: ...rizontal While assistants hold the watercraft in this position turn the driveshaft by hand to rotate the engine and allow the water to run out 5 Upright the watercraft and inspect and dry the spark plug holes Install new spark plugs 6 Install the air intake 7 Check the battery vent hose for obstructions and drain any water from the hose 8 Check the fuel and oil for the presence of water If water i...

Page 76: ... After washing the engine compartment of the watercraft protect the metal components with a T9 Metal Protectant or another non flammable metal protectant Do not use flammable sprays or protectants in the engine compartment Do not use petroleum based protectants or lubricants in the engine compartment as most are flammable and may also deteriorate rubber components 1 ...

Page 77: ...ance and lubrication Fogging kits should be added to all Polaris watercraft The engine should be fogged if the watercraft will not be used for more than 48 hours Maintenance Schedule Key Perform every 15 hours or monthly when operated in salt water Perform daily when operated in salt water Spider rubber coupler driveshaft and bearing carrier seals and bearing Perform pre season annually at 50 hour...

Page 78: ...mbly spring I C I C R Water inlet and outlet hoses and clamps I I I R Spark plugs Compression test I I Spark Plugs replace every 100 hours R I R Engine fastener re torque cyl head cyl base exhaust I I Oil pump adjustment I I ELECTRICAL Battery condition fluid level I I Battery vent hose condition routing must be clear I I Battery and starter cables clean connections tight I I I Ground cables condi...

Page 79: ...system oil and fuel check valves hose routing I Fuel system pressure vacuum test I Air intake silencer I C JET PUMP Drive shaft spider coupler bearing carrier seals bearings I I I I Drive shaft shroud condition I I Siphon system pick up screens and hoses I C I C Cooling water inlet screen hoses clamps I C I C Jet pump intake grate fasteners and condition I I Impeller condition and impeller clearan...

Page 80: ...lly freely fasteners I I Hull clean and inspect for cracks damage or leaks I C I Drain Plug Condition I I Bilge system inspection should not leak I I I Seat and compartment seals condition of seal I A I A Fire extinguisher I I Inspect and tighten all fasteners including throttle body mounts en gine mounts exhaust system all hose clamps inspect muffler bat tery oil and fuel tank fastening devices p...

Page 81: ... Make sure the seals are put back in the proper location after applying grease Drive Line The drive line consists of a drive shaft spider coupler and a bearing carrier with a sealed bearing inside It does not require routine greasing However grease is required during reassembly of the system when it s been disassembled for service Grease must be applied to the drive shaft before it s installed thr...

Page 82: ...s exposed portions of cable and shafts at the throttle bodies Grease often if used in salt water Electrical Connections Apply dielectric grease to battery posts and exposed cable connections Steering Nozzle Pivot Shaft Lubricate the steering nozzle shaft pivot connections 1 Steering Handle Pivot Shaft Lubricate the handle pivot shaft and bushing 2 Tighten the steering shaft if it s loose 1 2 ...

Page 83: ...S A yellow tip is caused by salt water mist ingestion This conductive coating will eventually cause foul ing This is a normal situation NOTE If the spark plug tip is black or grey have the watercraft serviced by an authorized Polaris dealer as soon as possible S A black tip indicates several potential problems the wrong spark plug wrong heat range is being used excessive idling occurs the carburet...

Page 84: ...le 1 4 to 1 2 turn beyond finger tight is close to the correct torque Push the cap down on the plug until it clicks NOTE Apply dielectric grease to the inside of the spark plug cap to prevent corrosion Before installing a used plug wipe off the threads and apply dielectric grease Also clean the gasket surface WARNING Removing a spark plug while the engine or exhaust system is hot could result in s...

Page 85: ...ded cleaning or polishing products could seriously damage the appearance and or integrity of your watercraft s gelcoat surface We recommend the use of the Polaris products listed on page 101 See your Polaris dealer for additional information about the care of your watercraft ...

Page 86: ...heat soaked engines S The first 2 cycle oil in the industry to meet category 4 low temperature viscosity tests S Reduced odor virtually no odor and doesn t cause eye burn S Smokeless S 100 synthetic formula offers superior lubrication along with friction modifiers to maximize wear protection S Compatible mixable with all Polaris 2 cycle oils Polaris Premium Gold Synthetic Lubricant S Lower smoke S...

Page 87: ...ervice Throttle Cable Inspection 1 Depress and release the throttle lever It should return to its initial position smoothly If it doesn t see your authorized Polaris dealer for service 2 Throttle lever free play should not exceed 020 060 5 1 5 mm If it does see your authorized Polaris dealer for service Fuses The NGI is protected by a 2 amp fuse There are also two 15 amp inline fuses on the chassi...

Page 88: ...ery fluid level often The fluid level should be kept between the upper and lower level marks 1 To refill use only distilled water Tap water contains minerals that are harmful to batteries WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or m...

Page 89: ...raft being careful not to tip it sideways and spill electrolyte WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last 1 CAUTION If electrolyte spills immediately wash it off with a ...

Page 90: ...e Increase the charging time 3 After the battery is charged check the fluid level If it dropped add distilled water to bring the electrolyte up to the proper level 4 Check the results of charging The specific gravity of each cell must be 1 26 at room temperature The voltage should be 14 5 15 5 V during charging and 12 2 12 8 V after charging WARNING Batteries produce explosive gases Any sparks in ...

Page 91: ... a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Battery Storage 1 Remove the battery Clean the casing and terminals with baking soda and water one tablespoon of baking soda to one cup water Apply dielectric grease or petroleum jelly to ...

Page 92: ... of the jet pump Its purpose is to screen out grass and debris that could enter the coolant system After using the watercraft visually inspect the screen for buildup of contaminants Clean as required by flushing engine and or screen with fresh water See flushing procedure on page 91 If the screen cannot be cleaned by flushing see your Polaris dealer for additional cleaning CAUTION Failure to perfo...

Page 93: ...tem 1 Attach a garden hose to the female coupler hose attachment 2 Snap the male and female coupler together 3 Start the watercraft engine and immediately turn on the water faucet 4 Rev the engine intermittently for one minute to completely flush the cooling system 5 Turn off the water faucet 6 When all water has exited the cooling system turn off the engine NOTE This step should not take longer t...

Page 94: ... Clean to the fuel tank then top off with fresh fuel 3 Fog the engine with rust preventing oil Follow the recommended procedures on page 93 NOTE Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system If you prefer to drain the fuel tank use the following procedure 1 Drain the fuel tank with a siphon or pump 2 Leave the fuel cap loose to prevent condensat...

Page 95: ...nd spray Polaris fogging oil into the hole in the intake cover 2 to ensure that all internal parts are properly coated Spray the oil for two to three seconds in each hole and repeat to flood the engine with fogging oil Immediately stop the engine 3 Replace the caps in the air intake cover CAUTION Failure to fog the engine can result in serious engine corrosion during off season or extended storage...

Page 96: ...nspect and thoroughly clean the jet pump intake outlet and impeller area If damage to these areas is visible see your Polaris dealer for service 4 After cleaning protect the watercraft by hand polishing with a regular furniture polish or non abrasive silicone wax Protect the seat and handlebar unit with a vinyl protector 5 Spray the exterior of the engine with T9 metal protectant 6 Cover the water...

Page 97: ...le oil into each cylinder 2 Inspect the spark plugs and apply dielectric grease to the threads Install new plugs if necessary 3 Lubricate the throttle and steering cables as outlined on page 79 4 Lubricate all areas recommended in the maintenance section beginning on page 79 5 Remove and store the battery as outlined beginning on page 86 ...

Page 98: ...noid connections Check all connections and tighten Lanyard lock plate not in place Install lock plate under shut off switch Engine Turns Over But Doesn t Start Possible Cause Solution Out of fuel Refuel Old or non recommended fuel Replace with new fuel Fouled or defective spark plugs Inspect plugs replace as needed Crankcase filled with water or fuel See your Polaris dealer Clogged fuel filter Rep...

Page 99: ...tions Check all connections and tighten Water present in fuel Replace with new fuel Clogged exhaust pipe screen fitting Clean screen fitting Water in exhaust pipe Drain exhaust Low battery voltage Recharge battery to 12 5 VDC Possible Lean Fuel Mixture Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter ...

Page 100: ...Inspect and clean cooling system Clogged exhaust pipe screen fitting Clean screen fitting Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect clean and or replace spark plugs Incorrect spark plug gap Set gap to specs or replace plugs Old or non recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Broken reed petals valves Se...

Page 101: ...Solution Weak spark Replace spark plugs and or wires Incorrect fuel or fuel mixture Replace with recommended fuel Water present in fuel or oil tank Replace with recommended fluids Clogged fuel filter See your Polaris dealer Clogged jet pump intake Clean intake Clogged exhaust and or cooling system Clean exhaust flush cooling system Hydrolock See your Polaris dealer Too much load weight on craft Re...

Page 102: ...et pump intake Clean intake Cavitation impeller damaged or worn See your Polaris dealer Unusual Noise or Vibration From Propulsion System Possible Cause Solution Weeds or debris lodged in impeller Clean the impeller Damaged driveshaft See your Polaris dealer Damaged pump bearings See your Polaris dealer ...

Page 103: ...be 2871423 Starter Grease 2871460 Nyogel Grease 2871329 General Maintenance Products Fogging Oil 12 oz Aerosol 2870791 Quart 2871517 Carb Throttle Body Cleaner 2872890 Multi Purpose Lubricant 2872891 Electrical Contact Cleaner 2872892 Engine Degreaser 2872893 Revival Detailing Kit 2871589 Restore Polish Swirl and Scuff Remover 2871966 Finish Wax 2871965 Vinyl and Rubber Protectant 2871964 T 9 Meta...

Page 104: ...Gap 028 002 71 mm 05 mm Starting System Electric Starter Battery 12V 19A ENGINE Engine Type Polaris Marine 1200 HO DI Induction Type Case Reed Exhaust System New Tuned Pipe Water Cooled Lubrication Oil Injected Sound Reduction PLANETt Oil Type TC W3 or Synthetic 2 Cycle Oil Cylinders 3 Bore x Stroke 85 mm x 70 mm Displacement 1192 Rated Horsepower 140 RPM Limiter Operation 7200 Ignition System FIC...

Page 105: ... Steel Stator Transmission Direct Drive Reverse System Standard Impeller Diameter 5 83 in 148 mm FEATURES Instrumentation New Generation Instrument NGI Ski Tow Hook Stainless Steel Standard Throttle Finger Trigger Reversible Mirrors Standard Bilge Pump Siphon Sponsons Matrix Blade Footwell Pads Hydro Turft Seat Single Child Grab Handle Standard Accessories MSX Knee Pads Tow Pylon ...

Page 106: ...anty covers the parts and labor charges for repair or replace ment of defective parts which are covered by this warranty This war ranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within t...

Page 107: ...uthorized lubricants chemi cals or fuels that are not compatible with watercraft In addition this warranty does not cover stress cracks submersion or growth of marine organisms on hull and deck The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE T...

Page 108: ...lso have other rights which vary from state to state If any of the above terms are void because of state or federal law all oth er warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oils for your Polaris vehicle 2 Damage resulting from the use of non recommended lubricants may not be covere...

Page 109: ... to all applicable regulations adopted by the California Air Resources Board Free from defects in material and workmanship that cause the fail ure of a warranted part to be identical in all material respects to that part as described in Polaris application for certification In practical terms a defect exists when a deficiency in materials or workmanship causes an emission related part to not funct...

Page 110: ...er of this watercraft You are responsible for presenting your watercraft engine to a Polaris authorized dealer as soon as a problem exists Notice must be given to an authorized Polaris dealer of any apparent defect s within a reason able time after discovery The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days It is recommended that any replacement part s u...

Page 111: ... 7 Engine components with damage proximately caused by a failure un der warranty of any warranted emission related part EXCLUSIONS This limited warranty is void if the direct cause of the need to repair or replace a warranted part is due to owner operator abuse neglect im proper maintenance tampering modification misuse alteration or improper adjustment Use of parts that are not equivalent to Pola...

Page 112: ...MISSIONS 36 37 Encountering Vessels 52 Engine and Exhaust System Draining 92 Engine Compartment 44 Engine Components 28 29 Engine Doesn t Start 58 Engine Fogging Procedure 93 Engine Oil 106 ENGINE TROUBLESHOOTING 96 100 Engine Water Removal Procedure 73 EPA Emissions Regulations 36 106 Extended Storage 92 95 F FEATURES AND CONTROLS 24 35 Fire Extinguisher 45 Fire Safety 17 Fishing Vessel Right of ...

Page 113: ...2 S Safe Riding Gear 16 Safe Riding Position 21 SAFETY 8 23 Safety Decals 9 12 Safety Training 5 Salt Water and Unclean Water Care 90 Seat 45 Service and Maintenance 20 Signal Words and Symbols 8 Signal words and symbols 8 Spark Plugs 81 82 SPECIFICATIONS 102 103 Stand on Vessel 51 Starting In Deep Water 59 Starting the Engine 57 58 Steering Cable 79 Steering Cable Inspection 85 Steering Inspectio...

Page 114: ...his watercraft unless the guest has read and understands all warning labels and the Owner s Manual THIS MANUAL SHOULD REMAIN WITH THE WATERCRAFT IN ITS STORAGE BAG AT ALL TIMES For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 542 0500 Fax 763 542 0599 Part No 9918124 Printed in USA Pantone 307 ...

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Polaris 2003 MSX, Owner'S Manual

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