Polaris msx 110 Service Manual Download

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ENGINE DISASSEMBLY / ASSEMBLY

4.2

2004 Four Stroke PWC Service Manual

Engine Specifications -- Continued

Component

Specification

Valve Spring Free Length

INTAKE

EXHAUST

38.2mm

(1.5

″

)

38.2mm

(1.5

″

)

Valve Spring Installed Length

INTAKE

EXHAUST

32mm

(1.26

″

)

32mm

(1.26

″

)

Cylinder Head Warpage Limit

.04mm

(.001

″

)

Cylinder Specifications

BORE SIZE

TAPER LIMIT

OUT--OF--ROUND LIMIT

WEAR LIMIT

85.00 -- 85.01mm

(3.34

″

)

.008mm

(.0003

″

)

.008mm

(.0003

″

)

N/A

Camshaft Specifications

CAMSHAFT WIDTH

IN CAM LOBE HEIGHT

EX CAM LOBE HEIGHT

MAXIMUM CAMSHAFT RUNOUT

RADIAL PLAY

BEARING HOLE I.D.

CAMSHAFT AXLE O.D.

CAMSHAFT CLAMP I.D.

108.85mm -- 109.00mm

(4.28

″

-- 4.29

″

)

48.553mm

(1.911

″

)

48.209mm

(1.897

″

)

.05mm @ Sprocket / .02mm @ Base.

(.001

″

)

.020mm -- .050mm

(.001

″

)

25.972mm -- 25.988mm

(1.02

″

)

19.991mm -- 20mm

(.787

″

)

19.90mm -- 19.98mm

(.783

″

)

Rocker Arm Specifications

BEARING AXIAL PLAY

ROCKER ARM I.D.

ROCKER ARM SHAFT O.D.

ROCKER ARM HOLDER BORE I.D.

ROCKER ARM AXIAL PLAY

.013mm -- .025mm

(.0005

″

-- .0009

″

)

13.980mm -- 13.991mm

(.55

″

)

9.994mm -- 10mm

(.393

″

)

10mm -- 10.009mm

(.393

″

)

.16mm -- .26mm

(.006

″

-- .010

″

)

Crankshaft Specifications

CRANKSHAFT DEFLECTION

MAIN BEARING CLEARANCE

BEARING CODES

.02mm -- .04mm

(.0007

″

-- .0015

″

)

.03mm -- .04mm

(.0011

″

-- .0015

″

)

1.RED 2. YELLOW 3. BLUE 4. GREEN 5. BROWN

Connecting Rod Specifications

BIG END OIL CLEARANCE

SMALL END DIAMETER

BEARING CODES

.01mm -- .064mm

(.0003

″

-- .002

″

)

20.995mm -- 21.011mm

(.826

″

-- .827

″

)

1.RED 2. YELLOW 3. BLUE 4. GREEN 5. BROWN

Balance Shaft Specifications

AXIAL PLAY

RADIAL PLAY

BEARING DIAMETER

RUN OUT

.15mm -- .25mm

(.005

″

-- .009

″

)

.014mm -- .066mm

(.0005

″

-- .002

″

)

24.975mm -- 24.990mm

(.983

″

)

.014mm -- .066mm

(.0005

″

-- .002

″

)

Piston Specifications

PISTON--TO--CYL CLEARANCE

PISTON DIAMETER

WEAR LIMIT

PISTON PIN BOSS I.D.

PIN O.D.

PIN WEAR LIMIT

.041mm -- .059mm

(.0016

″

-- .0023

″

)

84.961mm -- 84.979mm (Measured 15mm from bottom, 90

from pin.

(3.34

″

-- 3.345

″

)

.04mm

(.001

″

)

21.004mm -- 21.009mm

(.826

″

-- .827

″

)

20.995mm -- 21.000mm

(.826

″

)

.05mm

(.001

″

)

Piston Ring Specifications

TOP RING INSTALLED RING GAP

TOP RING GROVE CLEARANCE

MIDDLE RING INSTALLED RING GAP

MIDDLE RING GROVE CLEARANCE

OIL RING INSTALLED END GAP

OIL RING GROVE CLEARANCE

.2mm -- .4mm

(.07

″

-- .015

″

)

.65mm -- .955mm

(.025

″

-- .037

″

)

.2mm -- .4mm

(.007

″

-- .015

″

)

.50mm -- .805mm

(.019

″

-- .031

″

)

.2mm -- .7mm

(.007

″

-- .027

″

)

.50mm -- .910mm

(.019

″

-- .035

″

)

Oil Pump Specifications

OIL PUMP TYPES

ROTOR TIP CLEARANCE (PRESSURE)

OIL PRESSURE RELIEF VALVE

OIL PRESSURE

Trochoid

N/A

SPRING FREE LENGTH =

2.7

″

(69mm) / PISTON O.D. =

.43

″

(10.9mm) /

PISTON LENGTH =

1.10

″

(27.7 -- 28mm)

21 @ IDLE -- 80 @ MAX PSI (1.5 -- 5.5 BAR)

Summary of Contents for msx 110

Page 1: ...msx 110 msx 150 Four Stroke Personal Watercraft Service Manual ...

Page 2: ...Specifications Components Teardown and Rebuilding Inspection Engine Removal and Installation Specifications Removal and Installation Engine Disassembly Inspection and Re Assembly Specifications Components Testing Troubleshooting Teardown Fuel Ignition Exhaust Systems Specifications Components Testing Troubleshooting 1 2 3 4 5 6 7 8 Electrical System Specifications NGI Gauge System Interface Box St...

Page 3: ... 2004 PWC Publication Part Numbers 1 2 Service Guidelines Safety Warnings 1 3 MSX 110 General Information 1 4 1 5 MSX 150 General information 1 6 1 7 Standard Torque Specifications 1 8 Decimal Equivalent Chart 1 9 Conversion Chart 1 10 Tap Drill Sizes 1 11 Service Tools 1 12 1 13 ...

Page 4: ...RIAL NUMBER DECAL GENERAL INFORMATION 1 3 2004 Four Stroke PWC Service Manual 2004 PWC Identification Numbers The engine I D number and hull I D number are used to register the watercraft They are unique numbers that distinguish each watercraft from others of the same model If the watercraft is ever stolen these numbers will help identify it The owner should keep a record of these num bers in a pl...

Page 5: ...W045305CA MSX 150 A International W045305IA 9918972 9919173 MSX 150 B W045305CB MSX 150 B International W045305IB 9919057 9919058 MSX 150 C W045305CC 9919057 9919058 MSX 150 International W045305IC MSX 150 D W045305CD MSX 150 D International W045305ID S C 50 State Domestic CARB Exemption S A B C D Color Option S I International Model 2004 PWC Service Manual Part Numbers Book Part Number 2004 Carbu...

Page 6: ...attery attach the red positive cable first then the black negative cable S Wear appropriate clothing eye protection and rubber gloves when working with batteries Battery acid contains sulfuric acid and is extremely poisonous Serious burns can result when in contact with skin clothing eyes or internal body compo nents S If battery acid is ingested drink large quantities of water or milk Follow with...

Page 7: ...tar label identifies engines that meet the California Air Resources Board CARB 2004 exhaust emis sion standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines These engines are equivalent to the U S EPA s 2006 standards for marine engines Emission Control Information Decals The emission control information decal is located on the flywheel cover 2004 MSX ...

Page 8: ...aust System Exhaust pipe w water jacket and water injector Sound Reduction Turbo PLANETt Engine Management System Fuel Delivery Bosch Multi Point Fuel Injection Recommended Fuel Premium Unleaded Fuel 91 92 93 Octane Idle Speed In Water 1550 50 RPM Ignition System EMS Bosch ME 7 4 4 Timing Degrees BTDC 22 Degrees BTDC Spark Plug Champion RC7PYCB Spark Plug Gap 6 7mm 025 030 in Electrical Magneto Ge...

Page 9: ... Star label identifies engines that meet the California Air Resources Board CARB 2004 exhaust emis sion standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines These engines are equivalent to the U S EPA s 2006 standards for marine engines Emission Control Information Decals The emission control information decal is located on the flywheel cover 2004 MS...

Page 10: ...stem Exhaust pipe w water jacket and water injector Sound Reduction Turbo PLANETt Engine Management System Fuel Delivery Bosch Multi Point Fuel Injection Recommended Fuel Premium Unleaded Fuel 91 92 93 Octane Idle Speed In Water 1550 50 RPM Ignition System EMS Bosch ME 7 4 4 Timing Degrees BTDC 22 Degrees BTDC Spark Plug Champion RC7PYCB Spark Plug Gap 6 7mm 025 030 in Electrical Magneto Generator...

Page 11: ...steners and use of locking agent When fastener replacement is required use only genuine Polaris fasteners RECOMMENDED TORQUE SPECIFICATION STAINLESS STEEL FASTENERS SAE Bolt Size Threads Inch Torque 8 18 32 28 in lbs 10 24 32 40 in lbs 1 4 20 28 8 ft lbs 5 16 18 24 14 ft lbs 3 8 16 25 ft lbs 3 8 24 28 ft lbs 7 16 14 40 ft lbs 1 2 13 58 ft lbs 1 2 20 70 ft lbs RECOMMENDED TORQUE SPECIFICATION STAIN...

Page 12: ...3594 3 8 375 25 64 3906 10 mm 3937 13 32 4063 27 64 4219 11 mm 4331 7 16 4375 29 64 4531 15 32 4688 12 mm 4724 31 64 4844 1 2 5 13 mm 5118 33 64 5156 17 32 5313 35 64 5469 14 mm 5512 9 16 5625 37 64 5781 15 mm 5906 19 32 5938 39 64 6094 5 8 625 16 mm 6299 41 64 6406 21 32 6563 17 mm 6693 43 64 6719 11 16 6875 45 64 7031 18 mm 7087 23 32 7188 47 64 7344 19 mm 7480 3 4 75 49 64 7656 25 32 7813 20 mm...

Page 13: ...meters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l Liters l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Liters l Liters l x 0 88 Imperial quarts Imp qt Imperial quarts Imp qt x 1 201 US quarts US qt US quarts US qt x 0 833 Imperial quarts Imp qt US quarts US qt x 0 946 Liters l Liters l x 1 057 US quarts US qt US gallons US gal x 3 785 Liters l Liters l x 0...

Page 14: ...2 59 64 1 1 8 7 63 64 1 1 8 12 1 3 64 1 1 4 7 1 7 64 1 1 4 12 1 11 64 1 1 2 6 1 11 32 1 1 2 12 1 27 64 1 3 4 5 1 9 16 1 3 4 12 1 43 64 2 4 1 2 1 25 32 2 12 1 59 64 2 1 4 4 1 2 2 1 32 2 1 2 4 2 1 4 2 3 4 4 2 1 2 3 4 2 3 4 Metric Tap Drill Sizes Tap Size Drill Size Decimal Equivalent Nearest Fraction 3 x 50 3 x 60 4 x 70 4 x 75 5 x 80 5 x 90 6 x 1 00 7 x 1 00 8 x 1 00 8 x 1 25 9 x 1 00 9 x 1 25 10 x...

Page 15: ... TO ROTATE ENGINE DURING DISASSEMBLY AND RE ASSEMBLY ADAPTER SLEEVE EXPANDS MOUNTING OPTIONS WHEN USING DIFFERENT ENGINE STANDS PW 46989 REQUIRED TOOL MAGNET ROTOR GEAR REMOVER BOLT USED TO REMOVE MAGNET ROTOR AND BALANCE SHAFT GEAR WHEN USED WITH PW 46982 PW 46991 REQUIRED TOOL VALVE COMPRESSOR TOOL USED TO COMPRESS VALVE SPRINGS WITH ENGINE EITHER INSTALLED OR REMOVED FROM WATERCRAFT HULL PW 470...

Page 16: ...ALLATION TOOL USED IN REMOVING AND RE INSTALLING TIMING CHAIN PU 46219 OPTIONAL TOOL MANUAL OIL PUMP CONTAINER USED TO REMOVE OIL FROM OIL TANK PW 43070 OPTIONAL TOOL ROLLING ENGINE STAND ACCEPTS PW 46984 ENGINE STAND ADAPTER PLATE DIGITAL WRENCH DIAGNOSTIC SOFTWARE REQUIRED TOOLS COMPLETE KIT PU 47063 UPDATE SOFTWARE ONLY PU 47052 PU 47102 REQUIRED TOOL MSX 110 150 COMM CABLE ADAPTER CONNECTS LAP...

Page 17: ...e Oil Level Check 2 10 Oil Change Procedure 2 10 2 11 Engine Coolant Inspection Change Procedure 2 12 Cooling System Pressure Test 2 13 Engine Compression Fuel System Pressure Tests 2 14 Battery Safety and Maintenance 2 15 2 17 Spark Plug 2 18 Fuses 2 18 Exhaust Cooling Injector Maintenance 2 19 Throttle Cable Adjustment 2 19 Gasoline Safety Fuel System Maintenance Fuel Filter 2 20 Bilge System Si...

Page 18: ...st Gap Clean n n R n Flame Arrestor Inspect n n Engine Oil Inspect Level n n n nR Engine Oil Filter Replace nR nR nR Engine Coolant Inspect n n n n Engine Coolant Replace J Compression Inspect J J Valve Clearance Inspect Adjust J J Cooling Oil Air Hoses Inspect n n n n Engine Mounts Inspect J J Engine Fasteners Inspect J J Intake Manifold Adjust Torque n n Chassis Fasteners Inspect J J Freshwater ...

Page 19: ...llow gasoline see your doctor immediately Never try to syphon gasoline using mouth suction S If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time The engine exhaust from this product cont...

Page 20: ...TO ENGINE MOUNT 50 Loctitet 262 STEERING CABLE JAM NUTS 40 in lbs 4 5Nm STEERING CABLE ADJUSTER CLAMP 8 11 Loctitet 242 REVERSE CABLE JAM NUTS 40 in lbs 4 5Nm STEERING CLAMP 8 11 Loctitet 242 SACRIFICIAL ANODE 25 in lbs 2 8Nm PTO DRIVE COUPLER HAND TIGHTEN Flush Kit A flush kit will allow the operator to clean the freshwater cooling circuit after riding in saltwater or for performing routing maint...

Page 21: ... 100 Propylene Glycol 2875063 1 Gallon Container 100 Propylene Glycol Used to boost cold weather protection freeze temperature in cold weather states Polaris Environmentally Safe Engine Coolant 50 50 Pre Mix 2875041 6 1 Gallon Case 2875042 55 Gallon Drum Polaris Premium All Season Grease 2871312 Grease Gun Kit 2871322 3 oz 4 Pack 2871423 14 oz Tube Nyogel Di Electric Grease 2871329 Champion Spark ...

Page 22: ... 1 Expose inner linkage and apply grease Steering Nozzle 1 Apply light film of grease to exposed steering linkage and pivot points Reverse System 1 Generously lubricate reverse cable Polaris Premium Grease PN 2871423 Polaris Premium Grease PN 2871423 Polaris Premium Grease PN 2871423 ...

Page 23: ...shim between bushing and strike plate Repeat step 3 If plate continues to hit washer install second and final shim 5 Apply lithium based grease to the inside bore of the lower tapered bushing and install into steering housing 6 The number of shims installed on the lower section of the post is determined by the number installed on top The total number of shims used to install the entire steering po...

Page 24: ... measurements equal 5 Tighten adjuster block screws to specification Reverse Cable Adjustment Under normal operation the reverse cable should not require adjustment If the reverse linkage does not func tion properly inspect the cable for damage Inspect all linkage fasteners brackets and pivots for wear ordam age When a new cable is installed the cable must be adjusted 1 Place reverse shift lever i...

Page 25: ...rform procedure when the engine is cold Adjusting the valve clearance can be accomplished while the engine is inside the engine compartment 1 Remove the ignition coils spark plugs fuel injector wiring harness and cam phase sensor harness connector from the valve cover 2 Remove the valve cover from the engine 3 Insert the lanyard into the stop switch Rapidly tap the start button to rotate the engin...

Page 26: ... 2 50 0451358 2 55 0451359 2 60 0451360 2 65 0451361 2 70 0451362 2 75 0451363 2 80 0451364 2 85 0451365 2 90 0451366 2 95 0451367 3 00 0452023 3 05 0451368 3 10 0451369 3 15 0451370 3 20 0451371 3 25 0451372 3 30 0451373 3 35 0451374 3 40 0451375 3 45 0451376 3 50 0451377 3 55 0451378 3 60 0451379 3 65 0451380 3 70 11 After performing the valve adjustment procedure on the MAG cylinder valves rapi...

Page 27: ...e as the engine warms up to operating temperature but SHOULD NEVER RISE PAST THE OVERFILLED MARK Remove oil from tank if level is above MAX mark after warming engine to operating tem perature Warming the engine up can be accomplished by installing a flush kit Never exceed 2000 RPM when connected to a flush kit CAUTION Never allow the oil level to exceed the OVERFILLED OIL LEVEL mark on the top of ...

Page 28: ...Release the start button for at least 30 seconds Repeat this process three to four times or until little or no oil is pumped out of the sump and into the container 8 Locate the oil filter cover cap Remove the cap and remove the o ring and filter element Replace filter element and o ring with new parts 9 Reinstall oil filter cover cap and torque to 24 Nm 17 ft lbs 10 Clean oil tank fitting with bra...

Page 29: ...pump housing 1 The coolant level must be maintained between the MIN and MAX marks on the side of the coolant expansion tank Never overfill the expansion tank Engine Coolant Change Procedure 1 Remove the hose that connects the coolant expansion tank the water pump cover The engine coolant will drain into the engine compartment bilge 2 Re attach the hose Open the two hull bilge plugs Place two conta...

Page 30: ...o the coolant outlet manifold on the intake side of the engine 2 Insert a small bolt or plastic plug into the end of the bleed hose and secure with small gear clamp 3 Attach a Mity Vact hand pump to the expansion tank air bleed nipple Pressurize the expansion tank to 10 15 psi 7 1 bar The internal engine cooling circuit should maintain the pressure 4 A drop in pressure may indicate a worn or damag...

Page 31: ...move both spark plugs 2 Remove both fuel injector harness connectors 3 Install the compression gauge into one of the cylinders 4 Insert the lanyard and push the starter button for no more than 15 seconds Obtain reading from gauge then release gauge pressure 5 Measure remaining cylinder 6 Reassemble in reverse order Tighten fasteners to specification Fuel System Pressure Test WARNING Wear safety gl...

Page 32: ...could cause personal injury When re installing battery connect black nega tive cable last Whenever installing batteries care should be taken to avoid the possibility of explosion resulting in serious burns Always connect the positive red cable first and the negative black cable last When working with batteries always wear safety glasses or a face shield and protective gloves Battery electrolyte co...

Page 33: ...ve cable last WARNING Keep the battery away from sparks and open flames during charging because the battery gives off gases which are explosive If you smell fuel do not attempt to charge the battery When using a battery charger connect the battery to the charger before turning on the charger This reduces the possibility of sparks at the terminals which could ignite the battery gases Do not connect...

Page 34: ...n black negative cable 6 Apply dielectric grease to each cable end and to terminal post area 7 Reinstall battery cover and electrical box over battery and reconnect straps 8 Verify that cables are properly routed 9 Verify that vent hose is not kinked Battery Storage 1 Remove battery Clean casing and terminals with baking soda and water one tablespoon of baking soda to one cup water Apply dielectri...

Page 35: ...r to specifications Adjust if necessary by bending the side electrode carefully 4 Coat spark plug threads with a small amount of anti seize compound 5 Install spark plug and torque to 18ft lbs 6 Make sure spark plug caps are screwed completely onto end of plug wire 7 Apply a small amount of Nyogelt grease to inside of plug caps and install 8 Push cap onto plug until cap snaps into place Torque ign...

Page 36: ...re hoses are not restricted kinked or collapsed internally CAUTION 1 Loosen clamp connecting hose to fitting and remove hose 2 Inspect and clean orifice 3 Reinstall cooling hose Throttle Cable Adjustment The throttle cable connects the throttle flipper with the Pedal Position Unit PPU The cable is located underneath the steering helm 1 Turn adjuster clockwise to loosen the throttle flipper freepla...

Page 37: ...un in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time Shut off fuel valve if applicable whenever the watercraft is stored parked or transported Fuel Lines Vent Lines 1 Check fuel lines and vent lines for signs of wear deterioration damage or leakage Replace if necessary Ensure that clamps are tight 2 Be sure all lin...

Page 38: ...in position Bilge Drain Plugs 1 Inspect bilge plug for cracks or damage from over tightening 2 Periodically inspect sealing O ring and replace if worn or damaged Inspect drain plug gasket keeper strap and tightness of screws 3 Inspect bilge drain plug mounting bolts for proper torque Torque mounting bolts to 8 10 in lbs View From Inside Hull Screen To pump fitting 040 hole must be clear to prevent...

Page 39: ...spect the scoop sealing area for signs of black exhaust trails which indicate a leak in the sealant around the scoop Even a small leak will ventilate the pump area creating cavita tion of the pump and reducing performance If a leak is evident remove the scoop and re seal Refer to Final Drive Jet Pump section for procedures Excess silicone sealant can be trimmed until flush with edges Impeller Clea...

Page 40: ...unting surfaces must be clean and the mounting bolt tight to maintain a good con nection between the pump and anode 1 Periodically inspect anode for excessive wear If wear exceeds 50 of original size replace anode 2 Check bolt to be sure it is tight If the bolt is loose the anode is useless Remove anode and clean mounting surfaces on pump and anode 3 Apply dielectric grease to bolt threads and con...

Page 41: ...cessive steering arm can be re adjusted on handlebar shaft Reference chapter six for further information Fasteners Parts Hoses Inspect the watercraft for any loose nuts bolts fasteners and hoses Be sure that all hose clamps are tight Re place cracked damaged or deteriorating hoses Intake Manifold Fastener Re Torque During the 12 hour break in and first 25 hour maintenance check the intake manifold...

Page 42: ...one to threads when reinstalling Hand tighten 1 Intake manifold drain plug Apply marine grade silicone to threads when reinstalling Hand tighten The drain plugs are designed to allow any water inside of the intercooler or air intake to escape in the event where the watercraft has rolled over and taken on water NOTE Never operate the watercraft without the drain plugs installed Severe engine damage...

Page 43: ...oughout the year and where the air temperature drops below 26_F 4 Top off the fuel tank with fresh fuel S A full fuel tank will prevent the formation of moisture and mold inside the tank 5 Add Polaris Premium Fuel Stabilizer PN 2870652 to the fuel tank Follow the mixing instruction outlined on the bottle s label S Fuel begins to break down and form varnish after 30 days Adding stabilizer will prev...

Page 44: ...3 MSX 110 150 Service Manual Engine Removal Installation Engine Subassembly Removal 3 1 3 8 Engine Mount Removal 3 9 3 10 Engine Installation 3 10 ...

Page 45: ...ositive RED and negative BLACK battery cables from the battery after removing the engine oil and prior to performing any engine work Failure to do so may cause severe injury or death NOTE The use of an engine hoist is strongly recommended for working on and removing the en gine from the engine compartment Place masking tape around the engine compartment seat mat ing surface Doing so will prevent n...

Page 46: ... oil storage tank Photo B Identify each hose and its location during removal 7 Un latch the TOP worm gear clamp that secures the oil storage tank to the rear of the engine NOTE Do not loosen or tighten the lower worm gear clamp 8 Lift the oil storage tank up and out of the cradle 9 Remove the two lower tank hose connections Identify each hose and its location during removal Photo C 10 Remove the c...

Page 47: ...e intercooler Photo D 13 Remove the fasteners and slide the intercooler forward towards the fuel tank NOTE The intercooler cannot be removed until an engine hoist is connected to the engine and the en gine assembly is moved rearward FRONT ENGINE MOUNT REGULATOR RECTIFIER INTERCOOLER FASTENERS x2 MOUNTING PINS x2 FRESHWATER INLET OUTLET REAR ENGINE MOUNT ...

Page 48: ...h hose during removal Photo E 15 Remove the freshwater and engine coolant hose from the heat exchanger 16 Locate the engine coolant outlet elbow located next to the intake manifold Rotate the elbow down and towards the engine Photo F 17 Remove the intake pipe pop off valve fuel rail w fuel injectors and associated hoses Photo G 18 Remove the intake manifold fasteners Reference illustration on next...

Page 49: ...ar of the engine compartment and out of the watercraft 20 Slide the heat exchanger towards the rear then remove from engine compartment Photo H 21 Remove the two fasteners that secure the lower bracket to the engine Remove the lower bracket UPPER TO LOWER BRACKET FASTENERS x3 WATER TO WATER HEAT EXCHANGER INTAKE MANIFOLD LOWER BRACKET UPPER BRACKET MANIFOLD FASTENERS x4 LOWER BRACKET FASTENERS x2 ...

Page 50: ... 3 6 2004 Four Stroke PWC Service Manual Engine Removal and Installation Continued 22 Locate and remove the four engine mounting nuts and washers Photo J Front Left Mount Shown BOW STERN REAR ENGINE MOUNT FRONT ENGINE MOUNT LIFTING HOOKS ...

Page 51: ...upwards Move the engine rearward once the engine straps clear the engine mount studs With engine pushed back remove the intercooler assembly 25 Reposition the engine in the middle of the compartment Carefully rotate the engine on to the intake side Photo L NOTE An assistant may have to lift the engine up while the engine is rotated on to its intake 26 Lay the engine on to the intake side NOTE The ...

Page 52: ...tion Continued 28 Illustration of exhaust manifold to engine assembly 29 Reposition the core engine assembly into the center of the engine compartment 30 Carefully lift the engine straight up and out of the compartment Photo N MANIFOLD MOUNTING NUTS AND WASHERS x8 MANIFOLD TURBO UNIT WASTEGATE BOW STERN ...

Page 53: ...mbly 1 The engine must remain suspended by the hoist chains 2 Remove the front engine mounting strap 3 Insert a ratchet extension or metal dowel into the balance plate hole Rotate the engine until dowel prevents engine from rotating counterclockwise Photo O 4 Place a pry bar or large open end wrench across the coupler fingers Rotate counter clockwise to remove coupler from PTO shaft NOTE Wrapping ...

Page 54: ...everse of their removal During engine installation several important notes must be made S Always verify the correct number of engine mounting strap shims are installed on each engine mount ing post The correct number of shims is written next to each mounting post S The engine core is the first component that is installed into the engine compartment Locate the in tercooler underneath the top deck a...

Page 55: ...5 4 16 Piston Assembly 4 17 Valve Assembly 4 18 Balance Plate PTO Assembly 4 19 Crankshaft Balance Shaft Assembly 4 20 Engine Disassembly 4 21 4 28 Engine Inspection 4 29 4 42 Engine Assembly 4 43 4 57 Timing Chain Installation Timing Procedure 4 49 4 52 Freshwater Internal Engine Cooling Systems 4 58 Thermostat Water Pump Seal Removal Installation 4 59 Freshwater Cooling Circuit Illustrations 4 6...

Page 56: ...oling System Requirement 50 50 Distilled Water and Propolyne Glycol Warm Weather States 60 40 Propolyne Glycol To Distilled Water Cold Weather States Cooling System Capacity Thermostat Opening Temperature System Pressure 3 5 US Quarts 3 3 Liter 180_ F 82_ C 14 6 PSI 1 Bar 17 PSI 1 2 Bar Maximum System Pressure Valve Timing 1mm Valve Lift EV OPENS EV CLOSES IV OPENS IV CLOSES 52_ BBDC 2_ ATDC 14_ B...

Page 57: ... CLEARANCE BEARING CODES 02mm 04mm 0007 0015 03mm 04mm 0011 0015 1 RED 2 YELLOW 3 BLUE 4 GREEN 5 BROWN Connecting Rod Specifications BIG END OIL CLEARANCE SMALL END DIAMETER BEARING CODES 01mm 064mm 0003 002 20 995mm 21 011mm 826 827 1 RED 2 YELLOW 3 BLUE 4 GREEN 5 BROWN Balance Shaft Specifications AXIAL PLAY RADIAL PLAY BEARING DIAMETER RUN OUT 15mm 25mm 005 009 014mm 066mm 0005 002 24 975mm 24 ...

Page 58: ...lug Elbow Connector 11 15 M12 x 1 5 Hose Connector in Lower Crankcase 30 40 Loctite 577 M18 x 1 5 Oil Filter Cover Cap 17 24 Dry Sump Oil Filter Screen 7 10 Loctite 243 M6 x 20 Dry Sump Cover to Lower Crankcase 7 10 M6 x 20 M6 x 35 M6 x 60 Dry Sump Pump Gear 28 38 Loctite 272 M8 x 25 Dry Sump Pump to Cover 7 10 M6 x 20 M6 x 25 Dry Sump Hose Connector 7 10 M6 x 16 Balance Shaft Drive Gear Nut 51 70...

Page 59: ...rbocharger Bracket to Manifold 17 24 M8 x 50 Wastegate Actuator Locknut 7 10 Wastegate Bracket to Manifold 7 10 Torx E8 Wastegate to Bracket 7 10 M6 Actuator Arm to Lever 7 10 M6 x 20 Intercooler Cover 6 9 M6 x 20 Intercooler Mounting Fasteners 7 10 M6 x 35 Intake Manifold Specific Fastener Torque Specifications Component FT LBS Nm Notes Fastener s Airbox Screen Arrestor Fastener 6 9 M6 x 20 Manif...

Page 60: ... Sensor 7 10 M6 x 10 Oil Pressure Switch 7 10 M10 x 1 Coolant Manifold Temp Sensor 13 18 Ignition Coil Fasteners 7 10 M6 x 20 Spark Plugs 20 27 Dielectric Grease Starter Motor Fasteners 7 10 Nyogel M6 x 20 Balance Plate PTO Specific Fastener Torque Specifications Component FT LBS Nm Notes Fastener s Balance Plate to Crankshaft 51 70 Loctite 577 M10 x 1 X 45 Engine Mounts Specific Fastener Torque S...

Page 61: ...Hand Tighten K80 x30 Separator Oil Return Fitting 7 10 Banjo Bolt Oil Cooler to Intercooler Bracket 7 10 M6 x 20 Oil Storage Tank Rollover Valve 7 10 Banjo Bolt Oil Storage Tank Pullover Gear Clamp 2 3 High Pressure Oil Hose Connections Turbocharger Rollover Valve 7 10 M10 x 1 Banjo Bolt Gear Clamp Torque Specifications 8 16mm 2 Nm Over 16mm 2 4 Nm NOTE Some or all clamps may be Oetikert clamps ...

Page 62: ...TIMING CHAIN LINK REMOVAL INSTALLATION TOOL USED IN REMOVING AND RE INSTALLING TIMING CHAIN PW 46989 REQUIRED TOOL MAGNET ROTOR GEAR REMOVER BOLT USED TO REMOVE MAGNET ROTOR AND BALANCE SHAFT GEAR WHEN USED WITH PW 46982 PW 46991 REQUIRED TOOL VALVE COMPRESSOR TOOL USED TO COMPRESS VALVE SPRINGS WITH ENGINE EITHER INSTALLED OR REMOVED FROM WATERCRAFT HULL PW 47077 REQUIRED TOOL CAMSHAFT ALIGNMENT ...

Page 63: ...Y EXHAUST SIDE OF ENGINE SEALING O RING FILTER CARTRIDGE FILTER CAP ASSEMBLY NOTES Filter Cap Torque 18 ft lbs 25 Nm Apply a light film of engine oil to sealing o ring and filter cap threads during installation OIL FILTER CHANGE INTERVAL BREAK IN 10 TO 12 HOURS EVERY 25 HOURS THEREAFTER ...

Page 64: ... Torque 7 ft lbs 10 Nm Cam Phase Sensor Fastener Torque 6 6 ft lbs 9 Nm Always use new gaskets and o rings when removing or replacing parts Torque valve cover fasteners in a criss cross pattern beginning with the four inside fasteners Cam phase sensor port faces exhaust side of engine Verify valve cover sealing surface is dry and clean from containments VALVE COVER FASTENERS M6 X 45 ...

Page 65: ...IN 08 0 15MM 003 006IN EX 18 25MM 007 010IN Verify camshaft orientation during installation Hole in camshaft is located on the PTO side of engine Always replace camshaft sprocket and timing chain together CAMSHAFT SPROCKET BEARING AXLE AXLE CAPS VALVE SHIMS ROCKER ARM PINS VALVE STEM SEAL SHORT ROCKER ARM LONG ROCKER ARM LONG ROCKER ARM SHORT ROCKER ARM CENTERING SLEEVES SPRINGS SPRING BASE AND RE...

Page 66: ... 272 to threads Plug Fastener Torque 11 ft lbs 15 Nm Oil Supply Elbow Fastener Torque 7 ft lbs 10 Nm Bedplate Fastener Torque 7 ft lbs 10 Nm Clean bedplate and lower crankcase mating surfaces prior to apply silicone Verify surfaces are free from any oil residue Apply a thin bead of Three Bondt 1215 to mating surfaces of bedplate and lower crankcase Dry sump oil pump is not serviceable Replace comp...

Page 67: ... PIPE BLEED HOSE FITTING INTAKE SIDE OF ENGINE COOLANT FLOW WHEN THERMOSTAT OPENS ASSEMBLY NOTES Water Pipe Fastener Torque 7 ft lbs 10 Nm Thermostat Opening Temperature 180_F 82_C Snap ring chamfer faces outward towards rear of engine Always use new o rings during installation and reassembly Elbow pipe points down and toward the heat exchanger WATER PIPE FASTENERS M6 X 20 ...

Page 68: ...st face outwards towards rear of engine when installed Verify retaining cap does not move when snap ring is installed An audible click must be heard and alignment pin must be inserted properly into engine case when installing the timing rotor into the oil pump bore Verify balance shaft timing key is oriented properly inside shaft keyway SNAP RING CHAMFER FACES OUT RETAINING CAP O RINGS OUTER ROTOR...

Page 69: ...maged or unevenly worn Press tensioner into housing until flush with plug to set tensioner Tensioner should remain in locked position Activate tensioner by pushing tensioner in and past flush Tensioner should activate and extend outwards Replace if function is incorrect UPPER CHAIN GUIDE INSTALLED FROM TOP OF CRANKCASE TIMING CHAIN MUST USE CHAIN BREAKER TO DISASSEMBLE AND REASSEMBLE TENSIONER CHA...

Page 70: ...D ASSEMBLY COMPONENT LAYOUT CYLINDER HEAD NUTS ROCKER ARM TOWER FASTENERS M6 X 20 ROCKER ARM TOWERS CYLINDER HEAD HEAD GASKET UPPER CRANKCASE LOWER CRANKCASE CENTERING SLEEVES M8 X 50 M8 X 70 M8 X 90 LONG BOLT OIL PUMP COVER WASHERS PRESSURE RELIEF PISTON RELIEF SPRING RELIEF VALVE COVER PLATE ...

Page 71: ...UE SEQUENCE SPECIFICATIONS Apply engine oil to bolt threads 1st STEP Torque cylinder head nuts in sequence 15 ft lbs 20 Nm Torque crankcase fasteners in sequence 12 ft lbs 16 Nm 2nd STEP Torque cylinder head nuts in sequence 30 ft lbs 40 Nm 3rd STEP Torque cylinder head nuts in sequence 180_ Torque crankcase fasteners in sequence 18 ft lbs 24 25 Nm 9 10 11 12 MAG PTO MAG PTO ...

Page 72: ...EN 0789 0791IN 2 005 2 010mm 5 BROWN 0791 0793IN 2 010 2 015mm Rod Cap Fastener Torque 1st Step 7 ft lbs 10 Nm 2nd Step 14 ft lbs 20 Nm 3rd Step Turn 90_ APPLY ENGINE OIL TO FASTENER THREADS PRIOR TO INSTALLATION Connecting rod caps feature a cracked mating surface Cap must be marked during removal and installed correctly OIL CONTROL RING UPPER RINGS PISTON PIN CONNECTING ROD BEARINGS CONNECTING R...

Page 73: ...ENGINE DISASSEMBLY ASSEMBLY 4 18 2004 Four Stroke PWC Service Manual VALVE ASSEMBLIES COMPONENT LAYOUT VALVE SHIM VALVE KEEPER VALVE SPRING BUCKET SPRING RETAINER SPRING ...

Page 74: ...ke PWC Service Manual BALANCE PLATE PTO ASSEMBLY COMPONENT LAYOUT ASSEMBLY NOTES Balance Plate Fastener Torque 51 ft lbs 70 Nm Apply Loctitet 577 to threads CRANKSHAFT BALANCE PLATE FASTENERS M10 X 1 X 45 LOCTITEt 577 STUB SHAFT WASHERS FLANGE SEAL ...

Page 75: ...LY ASSEMBLY 4 20 2004 Four Stroke PWC Service Manual CRANKSHAFT COUNTER BALANCER ASSEMBLIES COMPONENT LAYOUT CRANKSHAFT PLAIN BEARINGS CRANKSHAFT BALANCE SHAFT GEAR TIMING KEY BALANCE SHAFT PLAIN BEARINGS BALANCE SHAFT ...

Page 76: ...move the coolant outlet manifold oil filter cover and electric starter motor from engine case Photo B 3 Remove the two high pressure oil feed hose banjo bolts from the cylinder head exhaust side rear mounting location Photo C NOTE The two high pressure oil feed hoses supply oil to the turbocharger bearing house and oil supply shutoff valve located on the top of the oil supply tank ...

Page 77: ...the flywheel housing Photo D NOTE The stator is attached to the inside of the cover Note the two alignment dowels as circled in photo 5 Photo of stator inside of cover Photo E 6 Remove the water pump cover and impeller Photo F NOTE The impeller can be removed by turning the nut counter clockwise Hold the flywheel stationary while removing the impeller ...

Page 78: ...the PTO coupler bolts into the PTO end of the crankshaft Have an assistant place a pry bar across these two bolts to prevent the crankshaft from rotating Photo H 9 Remove the flywheel bolt and washer from the front of the engine Install flywheel puller bolt into flywheel PN PW 46989 Carefully tighten puller bolt until flywheel comes off of crankshaft nose Photo I 10 Remove the flywheel timing key ...

Page 79: ...not required Only remove if damaged or re placement of balance shaft is required 12 Remove lock pin and rotate engine 180_ Remove the sump cover Photo K NOTE The sump oil pump is attached to the inside of the sump cover 13 Install crankshaft hand crank PN PW 46981 into nose of crankshaft Tighten lock nut against crankshaft 14 The high pressure oil pump is located on the PTO side of the engine It i...

Page 80: ...r clockwise Perform steps 15 and 16 on the MAG cylinder valve train NOTE A piston is at TDC on the compression stroke when the piston is up and there is axial free play in each of the rocker arms 18 Place rocker arm assemblies and rocker arm pins on a clean towel or piece of paper Identify each part for use during assembly Photo M NOTE The MAG exhaust side rocker arm features a cam phase sensor pi...

Page 81: ... crank crank the timing chain out of the engine 25 With the timing chain removed from the engine the crankcase can be split in two To begin loosen and remove the four case bolts located in the oil sump gallery Photo O 26 The lower case bolt located on the PTO side also holds the oil pump relief piston cover in place Photo P 27 Once the plate is removed use a magnet to remove the spring and piston ...

Page 82: ...he cylinder head nuts Photo R 29 Carefully pull the cylinder head assembly up and off of the crankcase 30 Remove the chain guide fastener and chain guide Photo S 31 Rotate the engine assembly 180_ Remove the tensioner chain guide from the crankcase 32 Using a soft faced hammer carefully tap the lower section of the crankcase loose from upper crankcase Once loose pull the lower crankcase up and awa...

Page 83: ...od Photo U NOTE The connecting rod caps are cracked dur ing manufacture creating a unique mating surface between the connecting rod and cap Always verify that the lower cap matches the connecting rod 35 Always keep the connecting rod plain bearings rod caps and bolts with the piston assembly the engine was manufactured with 36 Remove the crankshaft assembly from the crankcase Remove each crankshaf...

Page 84: ...S Out of specification Replace Measure valve face width S Out of specification Replace valve Measure valve seat contact width 1 Apply light coating of Prussian Blue or similar dye compound to valve face 2 Install valve into valve guide 3 Tap valve several times to make a clear impression on the valve face Do not rotate valve 4 Remove valve and measure valve seat width S Out of specification Recond...

Page 85: ...Manual Engine Inspection Procedures Valve Inspection Measure valve margin thickness S Out of specification Replace valve Measure valve stem diameter S Out of specification Replace valve Measure valve guide inside diameter S Out of specification Replace valve guide ...

Page 86: ...ection Procedures Valve Inspection Measure valve stem runout S Out of specification Replace valve Measure valve spring free and installed length S Out of specification Replace spring Cylinder Head Inspection Measure cylinder head warpage S Out of specification Replace cylinder head ...

Page 87: ...Out of specification Replace cylinder block NOTE Cylinders are plated with NiCaSil Measure cylinder for taper and out of round limits 1 BORE Maximum diameter of Da Df 2 TAPER Maximum of Da De and Db Df 3 Out of Round Maximum of Da Db and De Df S Out of specification Replace cylinder block Camshaft Inspection Measure camshaft width S Out of specification Replace camshaft ...

Page 88: ...Procedures Camshaft Inspection Measure cam lobe height S Out of specification Replace camshaft Measure camshaft runout S Out of specification Replace camshaft Measure camshaft bearing hole inside diameter S Out of specification Replace camshaft NOTE Bearings must be removed to measure I D ...

Page 89: ...Procedures Camshaft Inspection Measure camshaft axle outside diameter S Out of specification Replace axle Measure camshaft axle clamp inside diameter S Out of specification Replace cylinder head Rocker Arm Inspection Measure rocker arm axial play S Out of specification Replace rocker arm ...

Page 90: ... Rocker Arm Inspection Measure rocker arm shaft outside diameter S Out of specification Replace rocker arm shaft Measure rocker arm post bore inside diameter S Out of specification Replace rocker arm post Crankshaft Inspection Measure crankshaft deflection S Out of specification Replace crankshaft ...

Page 91: ...ead gasket cylinder and the cylinder head nuts Torque nuts and bolts to specified torque and tightening sequence 5 Carefully remove components and measure each compressed piece of Plastigauge 6 Reference bearing replacement guide if bearing oil clearance is out of specification S Out of specification Replace main bear ings crankcase or crankshaft Crankshaft Main Bearing Replacement Guide Replaceme...

Page 92: ...pressed piece of Plastigauge 5 Reference bearing replacement guide if bearing oil clearance is out of specification S Out of specification Replace connecting rod bearings Measure small end inside diameter S Out of specification Replace connecting rod Connecting Rod Bearing Replacement Guide Replacement of the connecting rod bearings is required when the bearing oil clearance is out of specificatio...

Page 93: ...ection Procedures Balance Shaft Inspection Measure balance shaft runout at several locations S Out of specification Replace balance shaft Measure bearing diameter S Out of specification Replace balance shaft Piston Inspection Measure piston diameter S Out of specification Replace piston ...

Page 94: ...spection Measure piston pin boss inside diameter S Out of specification Replace piston Measure piston pin outside diameter S Out of specification Replace piston pin Confirm piston to cylinder clearance specification S Out of specification Replace piston pin Measure installed ring end gap S Out of specification Replace rings or cylinder block ...

Page 95: ...ice Manual Engine Inspection Procedures Piston Inspection Measure piston ring grove clearance S Out of specification Replace piston ring or piston High Pressure Oil Pump Inspection Measure relief spring free length and piston dimensions S Out of specification Replace spring and piston ...

Page 96: ...from fully extended position 2 Once locked push tensioner inward Tensioner should activate and spring outwards S Replace tensioner assembly if tensioner will not lock then engage when pushed inward from locked position Chain Tensioner Guides Visually inspect both chain guides S Replace guides if any cracking or abnor mal wear and tear is found NOTE Tensioner chain guide shown Starter Motor Clutch ...

Page 97: ...eplace timing chain if any damage obvious wear and tear or broken mis shaped plates are found Valve Removal 1 Install rocker arm shafts Install valve spring compression tool PN PW 46991 Push lever down and withdraw valve keepers 2 The valve will now fall out of the bottom of the cylinder Always keep the valve with its original location ...

Page 98: ...wer Crankcase S Cylinder Head S Bedplate S Lower Sump S Crankshaft Balance Shaft 4 After cleaning parts blow dry with compressed air 5 With the engine facing up on stand lubricate cylinders with engine oil 6 Obtain both piston assemblies Lubricate piston assemblies with engine oil 7 Install the upper and oil control rings with the markings facing upwards 8 Place ring compressor tool PN PW 46983 on...

Page 99: ... bearings and balance shaft bearings Selection is made using bearing selection process described in this chapter 13 Coat all bearings and journals with engine oil Install water pump drive gear into crankcase 14 Install the chain tensioner guide into the exhaust side of the crankcase Tighten fastener to specification 15 Install the balance shaft with the gear facing the front of the engine NOTE Ver...

Page 100: ...g rod bearings 19 Match each unique cap mating surface with the appropriate connecting rod Loosely install each fastener then tighten evenly 20 Torque connecting rod cap bolts to specification 21 Verify the lower and upper crankcase mating surfaces are free from engine oil or foreign material 22 Apply a thin even bead of Three Bond 1213t case sealant to the upper crankcase mating surface 23 Apply ...

Page 101: ...e Assembly 24 Verify the crankcase stud oil jackets are installed on the four studs as outlined in the photo NOTE Verify stud jackets are installed in the middle of each stud 25 Carefully install the lower crankcase on to the upper crankcase 26 Loosely install two of the four lower crankcase fasteners ...

Page 102: ..._ so the pistons face upwards 29 Clean the cylinder head mating surface free from oil and foreign material Install a new cylinder head gasket with the part numbers and markings facing up and the larger coolant slots located on the exhaust side of the engine NOTE Always use a new cylinder head gasket re gardless of original condition 30 Install the cylinder head over the stud bolts with the exhaust...

Page 103: ...and spring Place cover over spring and insert fastener Hand tighten fastener 34 Install the remaining lower crankcase fastener 35 Rotate the engine 180_ Cylinder Head Up 36 Tighten cylinder head nuts and lower crankcase fasteners to specification as outlined on page 4 15 37 Rotate the engine 180_ Cylinder Head Down 38 Proceed with the TIMING CHAIN INSTALLATION TDC PROCEDURE ...

Page 104: ...77 Timing Chain Installation 1 Remove the rocker arm pins and rocker arms from the cylinder head 2 Install the Crankshaft Hand Crank Tool into the nose of the crankshaft Set the jam nut so the crankshaft can be turned left or right 3 Rotate the crankshaft until double dot alignment marks on each gear face each other The engine will be set to BDC when the two sets of double dots face each other 4 I...

Page 105: ... the cylinder head CAUTION Do not drop the chain into the engine 6 Insert the stuffer end of the Timing Chain Hook Stuffer PN PW 47108 tool into the chain gallery NOTE The stuffer wedge will prevent the chain from catching on the sprocket 7 Allow three to four chain links to fall past the cylinder head parting line NOTE Verify the chain is not caught on the bal ance shaft sprocket and that the mar...

Page 106: ...in around the balance shaft sprocket and under the crankcase support member NOTE The hooked end of the Timing Chain Hook Stuffer Tool will simplify pulling the chain around the sprocket 10 Carefully drop the chain UNDERNEATH the crankshaft and around the chain guide NOTE Do not drop the chain around the OUT SIDE of the crankshaft When performed prop erly the chain should drop easily through the en...

Page 107: ...rm towers NOTE The Camshaft Alignment Tool will lock the camshaft into the correct timing position in relation to the crankshaft and balance shaft 13 Wrap chain around camshaft sprocket and secure links with new pins and plate assembly NOTE Do not use the chain crimper to as semble chain links at this time 14 Rotate the engine 180_ Cylinder Head Up 15 Carefully rotate the crankshaft until the timi...

Page 108: ...new plate Crimp the new chain pins and plates together using the Chain Breaker Tool PN PW 46985 2 Verify the chain tensioner is set in the locked position To set the chain tensioner grasp end in palm of hand and press assembly down on a hard surface The tensioner is set in the locked position when it is flush with the tensioner housing 3 Install the chain tensioner into the crankcase Tighten housi...

Page 109: ... activates 7 Once activated there should be no slack present in the timing chain 8 Install low pressure pump and screen into bedplate Clean bedplate and lower crankcase mating surfaces 9 Apply a thin bead of Three Bond 1215t to the mating surface and Install the bedplate Tighten fasteners to specification 10 Install the high pressure oil pump assembly as outlined on page 4 12 11 Rotate the engine ...

Page 110: ...r battery cable to the motor at this time 16 Press the water pump shaft into the mechanical seal 17 Apply a thin bead of Three Bond 1215t to the front gear cover mating surface 18 Install the front gear cover Tighten fasteners to specification 19 Install the water pump impeller Tighten impeller nut to specification 20 Install water pump housing and coolant hose Tighten fasteners to specification ...

Page 111: ...2 Install the roller bearing starting gear and flywheel key into end of crankshaft 23 Install the flywheel on to the crankshaft Verify flywheel fits over key 24 Apply Loctitet 262 to flywheel bolt and install 25 Install two of the PTO coupler bolts into the PTO end of the crankshaft Have an assistant place a pry bar across these two bolts to prevent the crankshaft from rotating 26 Tighten flywheel...

Page 112: ...r cut wires 29 Reinstall the two high pressure oil supply hoses and banjo bolt to the top of the cylinder head 30 Tighten banjo bolt to specification NOTE Before installing the valve cover and gaskets the valve clearance must be checked Follow the procedure outlined in chapter two Replace any valve clearance shims that are out of specifica tion or worn After completing the valve clearance adjustme...

Page 113: ...dissipated to the freshwater circuit inside of the water to water heat exchanger Freshwater Cooling Circuit JET PUMP WATER TO WATER HEAT EXCHANGER OIL STORAGE TANK EXHAUST MANIFOLD EXHAUST PIPE WATER INJECTOR TURBINE JACKET PIPE JACKET PUMP BOX OUTLET INTERCOOLER HEAT EXCHANGER DRAIN HOSE Internal Engine Cooling Circuit WATER PUMP BOTTOM OF CYLINDER HEAD INTAKE SIDE TOP OF CYLINDER HEAD INTAKE SID...

Page 114: ...emoval Installation NOTE The engine must be removed to access the water pump housing 1 The water pump cover can be removed by 4 fasteners that mount the cover to the front gear cover 2 Always replace the o ring with new during reassembly 3 The impeller can be removed by holding the crankshaft stationary while turning the impeller nut counter clockwise 4 Tighten fasteners to specified torque outlin...

Page 115: ...se Routings EXHAUST PIPE FRESHWATER INJECTOR HOSE FRESHWATER OUTLET HOSE WATER TO WATER HEAT EXCHANGER FRESHWATER INLET HOSE TO INTERCOOLER FRESHWATER INLET HOSE TO HEAT EXCHANGER FRESHWATER OUTLET HOSE FROM HEAT EXCHANGER TO OIL STORAGE TANK FRESHWATER OUTLET HOSE FROM INTERCOOLER TO HEAT EXCHANGER ...

Page 116: ...er Circuit Cooling Hose Routings FRESHWATER OUTLET HOSE FROM HEAT EXCHANGER TO OIL STORAGE TANK FRESHWATER OUTLET HOSE FROM INTERCOOLER TO HEAT EXCHANGER FRESHWATER OUTLET HOSE FROM OIL STORAGE TANK TO EXHAUST MANIFOLD WATER INJECTOR TEE FITTING TO EXHAUST COOLING WATER INJECTOR ...

Page 117: ...N TANK ENGINE COOLANT HOSE FROM WATER OUTLET RAIL TO HEAT EXCHANGER THERMOSTAT OPEN ENGINE COOLANT HOSE FROM HEAT EX CHANGER TO OIL COOLER THERMO STAT OPEN ENGINE COOLANT HOSE FROM HEAT EXCHANGER TO OIL COOLER THERMO STAT CLOSED ENGINE COOLANT HOSE FROM TURBO TO WATER PUMP ENGINE COOLANT HOSE FROM WATER PUMP TO TURBO ENGINE DISASSEMBLY ASSEMBLY 4 62 2004 Four Stroke PWC Service Manual Internal Eng...

Page 118: ... COOLANT HOSE FROM WATER OUTLET RAIL TO EXPANSION TANK ENGINE COOLANT HOSE FROM WATER PUMP TO TURBO ENGINE COOLANT HOSE FROM TURBO TO WATER PUMP ENGINE DISASSEMBLY ASSEMBLY 4 63 2004 Four Stroke PWC Service Manual Internal Engine Coolant Hose Routing Front View ...

Page 119: ...NG TO HEAT EXCHANGER THER MOSTAT OPEN ENGINE COOLANT HOSE FROM HEAT EXCHANGER TO OIL COOLER THERMOSTAT OPEN ENGINE COOLANT HOSE FROM WATER OUTLET RAIL TO OIL TANK THERMOSTAT CLOSED ENGINE DISASSEMBLY ASSEMBLY 4 64 2004 Four Stroke PWC Service Manual Internal Engine Coolant Hose Routing Right View ...

Page 120: ...unt of oil to the oil storage tank than what the high pressure pump requires This ensures a constant supply of oil A small amount of pressurized oil is supplied to the turbocharger bearing house and oil storage tank anti siphon valve The anti siphon valve is located on top of the oil storage tank The valve works by preventing oil from the tank to back feed into the engine in the even that oil pres...

Page 121: ...y are drawn into the intake air stream and burned Crankcase Ventilation Circuit OIL STORAGE TANK OIL SEPARATOR CRANKCASE SUMP FLAME ARRESTOR Low Pressure Pump Removal Installation NOTE The engine must be removed to access the low pressure pump 1 Remove the crankcase bedplate from the lower crankcase 2 Remove the fasteners securing the screen to the bedplate and pump 3 Remove the pump from the bedp...

Page 122: ...ATOR RETURN HOSE OIL TURBO TO SUMP SUPPLY HOSE OIL SUMP TO OIL COOLER SUPPLY HOSE OIL OIL COOLER TO OIL TANK RETURN HOSE OIL OIL SEPARATOR TO SUMP SUPPLY HOSE BLOW BY OIL SEPARATOR TO AIR INTAKE SUPPLY HOSE BLOW BY OIL TANK TO OIL SEPARATOR SUPPLY HOSE OIL OIL TANK TO OIL PRESSURE PUMP LEFT SIDE RIGHT SIDE BOW STERN ...

Page 123: ...HIGH PRESSURE HOSE TO ANTI SIPHON VALVE HIGH PRESSURE HOSE TO TURBOCHARGER ENGINE DISASSEMBLY ASSEMBLY 4 68 2004 Four Stroke PWC Service Manual High Pressure Oil Supply ...

Page 124: ...GREEN LOW PRESSURE PRE FILTRATION BLUE HIGH PRESSURE PRE FILTRATION RED HIGH PRESSURE POST FILTRATION ENGINE DISASSEMBLY ASSEMBLY 4 69 2004 Four Stroke PWC Service Manual High Pressure Oil Supply ...

Page 125: ...Wiring Harness Connector Illustrations 5 12 5 14 Engine Management Sensor Circuit Drawings w Trouble Codes 5 15 5 27 ECU Connectors 5 28 ECU Trouble Codes 5 29 Electronic Throttle Body PPU Troubleshooting 5 30 Exhaust System Illustration 5 31 Turbocharger Wastegate Overview 5 32 5 33 Charge Air Cooler Overview Turbocharger Troubleshooting 5 34 RPM Limiting Modes 5 35 Troubleshooting Engine Will No...

Page 126: ...o this demand by translating the throttle flipper travel into a specified engine output The Engine Control Unit ECU is responsible for controlling and monitoring the density of each cylinders air charges the mass of injected fuel and ignition timing In order to accomplish these tasks the ECU relies on the following sensors and feedback systems Throttle Flipper Position PPU Electronic Throttle Body...

Page 127: ... Bosch ZS K 1 Primary Coil Resistance 73Ω 10 Secondary Coil Resistance N A Diode Protected Fuel Injector Type Bosch EV 6E Fuel Injector Resistance 12Ω Engine Speed Sensor Resistance 860Ω 10 68_F 20_C Engine Speed Sensor Gap 8mm 5mm 03 in 02 in Cam Phase Sensor Resistance Tested Using Diagnostic Software Cam Phase Sensor Gap 8 mm 03 in TURBOCHARGER Type 3K Warner Intercooler Type Freshwater Cooled ...

Page 128: ...ASSEMBLY NOTES Each air intake hose must be positioned as outlined in illustration FUEL INJECTION IGNITION EXHAUST SYSTEMS 5 3 2004 Four Stroke PWC Service Manual Air Inlet Hose Routings ...

Page 129: ...el filter is connected to supply hose Both hoses are routed underneath steering cable at helm location Both hoses are routed over the steering cable at engine compartment location FUEL FILTER FUEL SUPPLY FUEL RETURN STEERING CABLE FUEL INJECTION IGNITION EXHAUST SYSTEMS 5 4 2004 Four Stroke PWC Service Manual Fuel Hose Routing ...

Page 130: ...MBLY NOTES Vent hose is connected to V nozzle on fuel pump Hose routed between reverse assembly and top deck FUEL INJECTION IGNITION EXHAUST SYSTEMS 5 5 2004 Four Stroke PWC Service Manual Vent Hose Routing ...

Page 131: ...amp Torque 35 in lbs 4 Nm Verify tank pad is installed Replace tank hold down straps if worn or damaged FUEL PUMP LOCKING NUT FUEL PUMP O RING HOLD DOWN STRAPS FUEL TANK PROTECTIVE PAD FUEL CAP CAP RETAINER FUEL CAP LOCKNUT FUEL INJECTION IGNITION EXHAUST SYSTEMS 5 6 2004 Four Stroke PWC Service Manual Fuel Tank Assembly ...

Page 132: ...ds and kinks Never locate hoses near sharp objects Check valve opening pressure 1 5 PSI Vacuum Relief Valve will allow air flow to pass when differential vacuum is equal to or less than 3 HG FUEL FILTER FUEL PUMP FUEL SUPPLY HOSE FUEL RETURN HOSE VACUUM RELIEF VALVE CHECK VALVE QUICK CONNECT FITTING FUEL INJECTION IGNITION EXHAUST SYSTEMS 5 7 2004 Four Stroke PWC Service Manual Fuel Supply Vent Ho...

Page 133: ... injectors in clean dry place Never allow foreign material to enter fuel injector screens Clean fuel injector nozzles and screens with clean fuel FUEL PRESSURE REGULATOR REGULATOR CIRCLIP FUEL SUPPLY FUEL INJECTORS INJECTOR RETAINING CLIPS FUEL RETURN FUEL INJECTION IGNITION EXHAUST SYSTEMS 5 8 2004 Four Stroke PWC Service Manual Fuel Rail Fuel injectors ...

Page 134: ...ankcase Fastener Torque 22 ft lbs 30 Nm High Pressure Air Banjo Fitting Torque 7 ft lbs 10 Nm Never re use o rings or gaskets Verify heat exchanger mount pads are installed ELECTRONIC THROTTLE BODY ETB BOOST AIR TEMP SENSOR MANIFOLD PRESSURE SENSOR LOWER BRACKET HEAT EXCHANGER MOUNTING PADS AIR INTAKE PIPE PURGE VALVE HOSE HIGH PRESSURE AIR HOSE HIGH PRESSURE AIR BANJO FITTING INTAKE MANIFOLD FUEL...

Page 135: ... 10 Nm Ignition Coil Fastener Torque 7 ft lbs 10 Nm Apply Nyogelt to inside of spark plug cap during installation VALVE COVER IGNITION COIL SPARK PLUG FUEL INJECTION IGNITION EXHAUST SYSTEMS 5 10 2004 Four Stroke PWC Service Manual Spark Plugs Ignition Coils ...

Page 136: ... in lbs 3 Nm ECU w insulators To Mounting Bracket 6 ft lbs 8Nm Starter Solenoid Relay Fastener Torque 6 ft lbs 8 Nm DO NOT APPLY NYOGELt TO THE STARTER SOLENOID CONNECTOR OR INSIDE OF CONNECTOR HOUSING FUEL INJECTION IGNITION EXHAUST SYSTEMS 5 11 2004 Four Stroke PWC Service Manual ECU Mounting ...

Page 137: ...1 H2 BLK OR Fuel Injector Output Signal PTO Fuel Injector 2 G2 BLK OR Fuel Injector Output Signal MAG Fuel Injector 2 C2 BLK WHT Sensor Reference Ground Splice 4 Manifold Pressure Sensor 1 Boost Pressure Intake Temp Sensor 1 B2 BLU BLK Engine Speed Sensor Signal Engine Speed Sensor 2 A2 BLK WHT Sensor Reference Ground Cam Phase Sensor 1 F3 BLK GRN Fuel Pump Relay Signal Main Relay 7 C3 RED GRN 5 V...

Page 138: ...nsor Ground Engine Speed Sensor 3 E3 PUR WHT ESP Signal Input Engine Chassis Connector B K3 GRN YEL Engine High Temp MIL Output Engine Chassis Connector H A2 BLU RED Pedal Position 2 Input PPU Interface Box A E2 GRN YEL Reverse Switch Signal Input System Interface Box B H2 BLU YEL Diagnostic K Line Diagnostic Connector A J2 GREY Engine Speed Signal TACH Output Splice 12 System Interface Box G Engi...

Page 139: ...e 6 Ignition Coils 2 B3 BLK WHT Knock Sensor Ground Knock Sensor 2 C3 BLU RED Knock Sensor Signal Knock Sensor 1 F3 BLU RED Cam Phase Sensor Signal Cam Phase Sensor 2 G3 GREEN Ignition Driver 1 PTO Ignition Primary 1 H3 ORANGE Ignition Driver 2 MAG Ignition Primary 1 A2 BLU YEL Intake Air Temp Signal Boost Pressure Intake Temp Sensor 2 E2 BROWN O2 Heating Supply Lambda Sensor 2 F2 BLK GRN Main Rel...

Page 140: ...gnal circuits P1601 Throttle Valve Learning Position Out of Range Indicates the low mechanical position during learning was out of range P1602 Throttle Valve Learning Conditions Not Met Indicates environmental conditions during learning were out of range P1603 Throttle Valve Learning Signal Error Indicates the throttle valve was not able to move far enough to complete the learning process P1604 Th...

Page 141: ... not agree P0222 Pedal Position Sensor 1 Short to Ground Pedal position sensor 1 signal is too low Can be caused by a short to ground in the pedal position sensor 1 circuit P0223 Pedal Position Sensor 1 Open or Short to Bat tery Pedal position sensor 1 signal is too high Can be caused by a open circuit or short to battery voltage P0225 Pedal Position Sensor 2 Plausibility Error Indicates the signa...

Page 142: ...ry P0261 Injector 1 Short to Ground Fuel injector 1 driver circuit is shorted to ground Operating the engine with this code can cause serious engine damage P0262 Injector 1 Short to Battery Fuel injector 1 circuit is shorted to battery voltage P0264 Injector 2 Short to Ground Fuel injector 2 driver circuit is shorted to ground Operating the engine with this code can cause serious engine damage P02...

Page 143: ...anual Ignition Coil Circuit Circuit Trouble Codes P Code Description Summary P0351 Ignition Coil 1 Plausibility Error Both ignition coil circuits are shorted to ground P0352 Ignition Coil 2 Plausibility Error Both ignition coil circuits are shorted to ground P1351 Ignition Coil 2 Short to Ground Ignition coil 2 circuit is shorted to ground P1352 Ignition Coil 1 Short to Ground Ignition coil 1 circ...

Page 144: ...sibility Error Indicates the O2 sensor signal is outside an acceptable range P0132 Oxygen Sensor Circuit Short to Battery Indicates the O2 sensor signal is too high P0133 Oxygen Sensor Circuit Slow Response The O2 sensor signal is slow to respond to fuel mixture changes P0134 Oxygen Sensor Circuit Low Output The O2 sensor signal has not changed for a long period of time P0135 Heated Oxygen Sensor ...

Page 145: ...PWC Service Manual Boost Air Temperature Circuit Circuit Trouble Codes P Code Description Summary P0112 Intake Air Temperature Short to Ground The intake air temp signal is shorted to ground or open P0113 Intake Air Temperature Short to Battery The intake air temp signal is shorted to battery voltage P0237 Boost Pressure Sensor Open or Short to Ground The boost pressure signal is shorted to ground...

Page 146: ...Circuit Trouble Codes P Code Description Summary P0105 Intake Manifold Pressure Plausibility Error The measured intake manifold pressure is outside an acceptable range P0106 Intake Manifold Pressure Signal Error the intake manifold pressure is outside an acceptable range but not shorted to ground or battery voltage P0107 Intake Manifold Pressure Short to Ground The intake manifold pressure signal ...

Page 147: ...Stroke PWC Service Manual Engine Coolant Temperature Sensor Circuit Circuit Trouble Codes P Code Description Summary P0116 Engine Temperature Signal Error Indicates the engine temp signal is outside an acceptable range but not shorted to ground or battery voltage P0117 Engine Temperature Short to Ground The engine temp signal is shorted to ground P0118 Engine Temperature Open or Short to Battery T...

Page 148: ...ne Crankshaft Position Engine Speed Sensor Circuit Circuit Trouble Codes P Code Description Summary P0335 Loss of Synchronization The number of pulses or teeth on the timing rotor are not cor rect P0336 Engine Speed Sensor Signal Error The engine speed sensor signal is not valid P0337 Engine Speed Sensor Low Limit The engine speed signal voltage is outside the acceptable range P0338 Engine Speed S...

Page 149: ...uit Circuit Trouble Codes P Code Description Summary P0340 Camshaft Sensor Circuit Plausibility Error The camshaft sensor signal level is outside an acceptable range P0341 Camshaft Sensor Circuit Signal Error Indicates a problem with the camshaft sensor signal switch from high to low P0342 Camshaft Sensor Circuit Short to Ground The camshaft sensor signal is shorted to ground P0343 Camshaft Sensor...

Page 150: ...L INJECTION IGNITION EXHAUST SYSTEMS 5 25 2004 Four Stroke PWC Service Manual Knock Sensor Circuit Circuit Trouble Codes P Code Description Summary P0324 Knock Control Signal Failure Indicates a failure with the knock control sensor P0327 Knock Sensor Signal Low The knock sensor signal is too low P0328 Knock Sensor Signal High The knock sensor signal is too high ...

Page 151: ... FUEL INJECTION IGNITION EXHAUST SYSTEMS 5 26 2004 Four Stroke PWC Service Manual Wastegate Solenoid Circuit Circuit Trouble Codes P Code Description Summary P0243 Wastegate Solenoid Open Circuit Indicates an open circuit within the control circuit P0245 Wastegate Solenoid Short to Ground Indicates the control circuit is shorted to ground P0246 Wastegate Solenoid Short to Battery Indicates the con...

Page 152: ...de Description Summary P0230 Fuel Pump Open Load Indicates the fuel pump relay circuit is open Can be caused by a faulty relay damaged wiring damaged fuel pump or ECU failure P0231 Fuel Pump Short to Ground Indicates the fuel pump relay is shorted to ground Can be caused by a faulty relay damaged wiring damaged fuel pump or ECU failure P0232 Fuel Pump Short to Battery Indicates the fuel pump relay...

Page 153: ...iguration between idle speed and 4000 RPM when not under accelera tion During the closed loop configuration the lambda sensor relays the amount of oxygen within the exhaust stream to the ECU The ECU adjusts the fuel supply to achieve lambda 1 The ECU operates in the open loop mode whenever the engine is accelerating or engine RPM exceeds 4000 RPM In this mode the ECU delivers the exact amount of f...

Page 154: ...tem is its use of a Fly By Wire or Electronic Throttle Control ETC system In this system the throttle flipper is not directly connected to the the throttle plate but rather a pedal position unit or PPU Four components make up the ETC system S Pedal Position Unit PPU S Engine Control Unit ECU S Electronic Throttle Body ETB S PPU Interface Box IFB The PPU and ETB use two position sensors each to rel...

Page 155: ...UE CANNOT BE ATTRIBUTED TO PPU OR ETB COMPONENTS OR FUNCTIONS TROUBLESHOOTING ENDED TROUBLESHOOT START STOP SWITCH MAIN RELAY ECU AND ASSOCIATED WIRING HARNESSESS AND CONNEC TIONS VERIFY SIFB IS NOT IN SLEEP MODE PERFORM ETB LEARNING PROCEDURE PROCESS CHECK ALL PPU AND ETB WIRING HARNESSESS AND CONNECTIONS CONNECT DIGITAL WRENCHt SOFTWARE TO ECU VERIFY ETB LEARNING PROCEDURE DISPLAYS TRUE VERIFY E...

Page 156: ...er Torque 22 ft lbs 30 Nm Apply anti seize lubricant to threads Large Gear Clamp Torque 35 in lbs 4 Nm Tighten exhaust pipe fasteners in sequence shown in illustration EXHAUST SILENCER PLANETt RESONATOR OUTLET PIPE EXHAUST PIPE 1 2 3 4 5 TORQUE SEQUENCE FUEL INJECTION IGNITION EXHAUST SYSTEMS 5 31 2004 Four Stroke PWC Service Manual Exhaust System ...

Page 157: ...aft can reach speeds in excess of 130 000 RPM The turbocharger bearing house is lubricated by the engine oil circuit and cooled by the engine coolant circuit The exhaust manifold and turbine housing are cooled by the freshwater cooling circuit A loss or failure in any one of the circuits will cause severe turbocharger and engine damage Wastegate The amount of pre compressed intake air generated by...

Page 158: ...YSTEMS 5 33 2004 Four Stroke PWC Service Manual Turbocharger FRESH AIR COMPRESSED AIR EXHAUST GASES COMPRESSED AIR TO WASTEGATE EXHAUST GASES BLED THROUGH WASTEGATE DOOR COMPRESSOR TURBINE WASTEGATE WASTEGATE SOLENOID EXHAUST MANIFOLD ...

Page 159: ...e air cooler removes most of the heat by transferring it to the freshwater cooling circuit The cooler the air the more lbs min of air the compressor will pump into the engine Turbocharger Charge Air Cooler Troubleshooting A basic understanding of the turbocharger and charge air cooler must be obtained prior to troubleshooting each component It is important to realize the engine WILL NOT achieve ma...

Page 160: ...ting range Indicates a TORQUE REDUCTION running mode The ECU limits engine RPM by limiting the amount of torque generated by the engine Stated RPM limit is an approximation and changes with current engine operating conditions The throttle plate opening aperture ignition timing and fuel supply are controlled by the ECU to limit engine RPM in all modes except in the LIMP HOME MODE Ignition timing is...

Page 161: ...spect the propulsion driveline Verify im peller driveshaft and drive couplers rotate freely without binding Mechanical driveline failure or propulsion system jammed by foreign material Start Button Circuit Inspect Tether attachment Battery and harness connection and LH control assembly Solenoid Connections Solenoid Operation Engine electrical grounding Start switch function Electrical harness betw...

Page 162: ...mal operation the ECU grounds PINS 7 and 10 to close the main ECU power relay and fuel pump driver relay The fuel pump driver relay also supplies battery voltage to the lambda sensor igni tion coils fuel injectors and wastegate sole noid ECU Engine Management System Use the Digital Wrencht diagnostic soft ware to review current data values and download any trouble codes Repair any problems that ar...

Page 163: ...t engine Voltage at battery terminals should be at least 14 vDC Faulty alternator or voltage regulator Poor battery condition Battery cannot take or hold charge Air Intake System Inspect for blockage in intake hoses Look for signs of water intrusion Fuel System Inspect Fuel Filter Fuel Level Fuel Pump Fuel Pressure Fuel Hoses Fuel Tank Vent Hose Fuel Pump Wiring Connections and Con nectors ECU Eng...

Page 164: ...ct oil level Inspect oil hoses for kinks leaks or loose clamps Inspect oil cooler Look for engine coolant in oil or freshwater in the engine oil Lack of lubrication engine seizure Main Relay Check function of relay when lanyard is installed in STOP switch Air Intake System Check intake hoses for blockage Check for signs of water intrusion Fuel Management and Ignition System ECU Check all component...

Page 165: ... FOR MORE THAN 30 SECONDS Check all freshwater hose connections Verify there are no kinks or cuts on any of the hoses Check pump assembly for weeds or foreign material Flush the freshwater cooling circuit using flush kit Engine RPM limited to 2000 200 and WA TER TEMPERATURE WARNING indicator is ON after watercraft has re started after sitting off of five to ten minutes Will only occur on models wi...

Page 166: ...a auto ignition condition exists Pis ton Knock ECU will retard engine timing up to 9 de grees BTDC when knock sensor fails or de tects auto ignition If condition persists ECU will open wastegate solenoid and drop boost pressure Use PREMIUM GRADE fuel to obtain maxi mum engine performance 91 92 or 93 oc tane recommended Check for foreign material or water within fuel system Check boost control hose...

Page 167: ...Verify all connectors are clean and tight PPU and ETB Operation Follow troubleshooting procedures outlined within this chapter Exhaust System Inspect system of blockage Inspect system for exhaust leaks Fuel Delivery System Inspect fuel level and fuel quality Verify fuel pressure meets specification Inspect all fuel and vent hose connections and routings Inspect for leaks ECU Engine Management Syst...

Page 168: ...nded Inconsistent Performance Inspect Condition of wastegate control hoses Condition of wastegate solenoid and waste gate Perform electrical diagnostics on wastegate solenoid using Digital Wrencht diagnostic software Check for oil intrusion into wastegate control hoses Wastegate Boost Control No Diagnostic Communication Verify system wakes up after inserting the lanyard into the STOP switch Push S...

Page 169: ...y Illustration 6 5 Driveshaft Assembly Illustration 6 6 Pump Induction Assembly Illustration 6 7 Pump Removal and Assembly 6 8 Bearing Carrier Removal and Installation 6 9 Driveshaft Shim Procedure 6 10 Driveline Inspections 6 11 Stator Disassembly and Assembly 6 12 6 14 Driveshaft Alignment Procedure 6 15 6 19 Sacrificial Anode 6 20 Intake Scoop Ride Plate Removal and Installation 6 21 6 22 ...

Page 170: ...8Nm Apply Loctitet 242 to threads Final Drive Propulsion Quick Reference Guide Topic Service Recommendations Drive Couplers Inspect at preseason and at year end Driveshaft Bearing Carrier Inspect at preseason and at year end Impeller Wear Inspect at preseason every six months and at year end Inspect stator cone at preseason and at year end Steering Reverse Trim Pivot Bushings Service Limit 335in I...

Page 171: ...eller rotates freely three times Tail Cone 40 In Lbs 4 5 Steering Nozzle 14 19 Apply Loctitet 242 Reverse Nozzle 14 19 Apply Loctitet 242 Pump Assembly To Pump Housing Bolts 1st Step 2ft lbs 2nd Step 14ft lbs 1st Step 2 7 2nd Step 19 Apply Loctitet 242 Tighten in criss cross pat tern Pump Housing Bolts 28 38 Tighten in correct order Top Right Bottom Left Bottom Right Top Left Ride Plate Inlet Grat...

Page 172: ...may be drawn into the pump from the engine compartment Also inspect the through hull fitting The entire circumference of the fitting must be sealed to prevent water from entering the hull and air from entering the pump 4 Incorrectly mounted pump This can be caused by an improperly installed intake scoop or a misaligned pump there should be no detectable gap between pump housing and hull Cavitation...

Page 173: ... 19 Nm Apply Loctitet 242 Reverse Nozzle Fastener Torque 14 ft lbs 19 Nm Apply Loctitet 242 Thru hull lock plate must be installed with flat against steering cable thru hull nut Apply anti seize to pump component mating surfaces Apply premium grease to o rings prior to assembly Pump assembly must be flush against hull to prevent leakage or ventilation Apply liberal amount of marine grade silicone ...

Page 174: ... 43 94mm Service Limit Apply light film of Premium grease to seal lips o rings and stubshaft during installation Bearing spacer length is critical to driveline operation Replace if length is smaller than service limit Seal springs and or seal lips must not be folded over stretched torn etc by impeller spacer during stubshaft installation 100 ft lbs 138 Nm PROPULSION 6 5 2004 Four Stroke PWC Servic...

Page 175: ... over driveshaft taper Bumper MUST be installed between impeller and driveshaft Use light film of premium grease on carrier seals and shaft to assist in driveshaft installation Apply small amount of Premium grease to tapered spacer inside diameter During assembly perform the driveshaft shim procedure as outlined on page 6 10 14 ft lbs 19 Nm SHIM WASHERS PROPULSION 6 6 2004 Four Stroke PWC Service ...

Page 176: ...e to all mating surfaces of the hull inlet scoop front and sides of ride plate and front and rear sections of inlet grate Ventilation will occur if gaps are present at mating surfaces CAUTION DO NOT ALLOW SILICONE TO ENTER WATER HOSE OR PIPE ORIFICES SERIOUS ENGINE DAMAGE MAY OCCUR Install paddle wheel with harness end to front of boat Route harness along ride plate 30 in lbs 3 Nm 8 ft lbs 11 Nm 8...

Page 177: ...on Follow torque specifications listed on page 6 2 NOTE Always install new Nylock nuts and cotter pins Pump Housing Removal 1 Remove the pump components as described above 2 Access the pump housing mounting bolts from inside the engine compartment Remove the nuts washers and steering cable locking plate 3 Attempt to remove the housing from the hull using a small prybar Do not damage the pump housi...

Page 178: ...oosen and remove the four 4 bearing carrier mounting bolts Remove bearing carrier Bearing Carrier Installation Installation is the reverse of removal with the following exceptions 1 Begin the installation process by installing the aft Rear drive coupler Press coupler firmly into rubber dampener 2 Mount the bearing carrier to the hull loosely DO NOT torque the mounting bolts at this time 3 Carefull...

Page 179: ...led edge is flush with driveshaft bevel 2 Install two shims then hand thread coupler on to driveshaft 3 Push couplers together with rubber dampener installed 4 Measure X as outlined in illustration below 5 Reference specification table and remove or add shims Pump Housing To End of Driveshaft INCHES Number of Shims From NOMINAL Total Number of Shims X 2 110 2 4 2 110 X 2 195 1 3 2 195 X 2 280 0 2 ...

Page 180: ...cks as shown C Measure runout by rotating shaft and observing dial indicator at point B Replace if runout exceeds the service limit NOTE Excessive driveshaft runout can cause vibra tion bearing and spline failure See Pump Final Drive Troubleshooting at the end of chapter 2 2 Inspect driveshaft splines and threads inside engine drive coupler and impeller carefully for wear or damage Replace worn pa...

Page 181: ...removing tail cone hold stator with cone pointed down Twist cone off This will allow any water from enter ing the impeller assembly It is normal for a small amount of water to be inside the cone during operation 2 Mount stub shaft flat surfaces in a vise to prevent the impeller and stator from rotating 3 Install impeller removal tool and turn counterclockwise to remove The impeller removal tool ca...

Page 182: ...cratches or damage Install new o rings upon reassembly 6 Using a brass hammer or aluminum drift tap bearing spacer to one side of the stator housing Drive out bearings by taping on inner races 7 Measure spacer with a Vernier caliper Replace if worn beyond service limit If the spacer is too short the bearings will be side loaded and premature wear will result Bearing Spacer Length Service Limit 1 7...

Page 183: ...ont bearing 3 Apply marine grease to seal lips and also between the two seals Install two new oil seals over impeller spacer with lips up and visible toward impeller Press seals to bottom of chamfer on sealbore about 1 8 32 cm beyond end of bore WARNING Never allow the impeller spacerto push up through the two seals when inserting the stub shaft If spacer pushes though seals the seal lips will be ...

Page 184: ...mount the pump sections to the pump housing Remove the pump sections 4 Back up the drive couplers using a large pipe wrench or strap wrench and remove the driveshaft using the DRIVESHAFT REMOVAL INSTALLATION TOOL PN PW 46593 Remove the driveshaft from the watercraft NOTE Do not damage the drive coupler fingers 5 Remove the bearing carrier from the pump box Illustration 2 6 Install a small dowel or...

Page 185: ...ket and o ring NOTE Steps 11 12 and 13 are only required if you do not have an extra Polaris pump stator already setup with bearings available If you already have a stator setup to perform align ment checks proceed with STEP 15 11 Mount the stub shaft flats in a vice Using the IMPELLER REMOVAL TOOL PN 2871036 remove the impeller from the pump stator assembly Photo C 12 Carefully lift the pump stat...

Page 186: ... Photo E If the Driveshaft Alignment Tool slides in and out of the Driveshaft Alignment Coupler Tool as outlined in STEP 16 adjustments to the engine strap mounting shims ARE NOT REQUIRED In this case remove the tools and proceed with the REASSEMBLY PROCEDURES In the case where the Driveshaft Alignment Tool DOES NOT fit into the Driveshaft Alignment Coupler Tool as outlined in STEP 16 proceed with...

Page 187: ...GHER FRONT RESULTING EFFECT ENGINE PITCHES DOWN FROM FRONT TO REAR SIDE VIEW BAR HITS HIGH WEDGES HIGH IN DRIVESHAFT ALIGNMENT COUPLER TOOL FRONT ENGINE MOUNT REAR ENGINE MOUNT REMOVING SHIMS FROM FRONT LOWER FRONT ADDING SHIMS TO REAR HIGHER REAR RESULTING EFFECT ENGINE PITCHES UP FROM REAR TO FRONT SIDE VIEW BAR HITS LEFT WEDGES LEFT IN DRIVESHAFT ALIGNMENT COUPLER TOOL RESULTING EFFECT ENGINE R...

Page 188: ... the coupler 9 Perform the DRIVESHAFT SHIM PROCEDURE outlined on page 6 10 10 Once driveshaft is screwed into coupler push the bearing carrier back against the pump wall Do not install the mounting screws at this time 11 If the impeller was removed from the pump stator the assembly will have to be re built with new seals and o rings 12 Reassemble the pump sections to the pump housing Apply a light...

Page 189: ... good connection between the pump and anode 1 Periodically inspect anode for excessive wear 2 Check bolt to be sure it is tight If the bolt is loose remove anode and clean mounting surfaces on pump and anode 3 Apply dielectric grease to bolt threads and contact surfaces 4 Tighten bolt securely NOTE During preventative maintenance verify that the anode is tightened securely to the pump housing Repl...

Page 190: ...ion 1 Begin the installation process by removing all silicone from the ride plate inlet scoop pump mount assembly and inlet grate mating surfaces 2 Prepare mating surfaces by wiping surfaces down with isopropyl alcohol or acetone WARNING All silicone residue and must be removed prior to reassembly All mating surfaces must be cleaned with isopropyl alcohol or acetone One the installation has begun ...

Page 191: ...hread the inlet grate mounting bolt 5 Apply a layer of silicone to the inlet grate tab that fits into the ride plate 6 Attach the ride plate to the hull Loosely thread mounting bolts from from to back in a criss cross pattern NOTE Wipe off all excess silicone away from compo nents Allow 24 hours before operating watercraft to allow silicone to cure Apply Silicone Marine Grade Silicone PN 8560054 A...

Page 192: ...sembly Illustration 7 5 7 6 Compartment Door Assembly 7 7 Shroud and Storage Assemblies 7 8 Seat Assembly 7 9 Steering Control Assembly 7 10 E S P Switch Assembly 7 11 PPU Assembly 7 12 Reverse System Assembly 7 13 Handlebar Steering Post Removal 7 14 Steering Cable Removal and Installation 7 15 7 16 Steering Reverse Cable Adjustment 7 17 Top Deck Hull Repair 7 18 ...

Page 193: ...70 Footwell Pads P318 Polaris paints can only be ordered through the an authorized Polaris dealership S P070 BLACK S P207 WHITE S P292 HAVASU RED S P318 CHARCOAL S P403 MATRIX SILVER ALLOY S P441 CATALINA BLUE C EAR METALLIC S P443 SARASOTA YELLOW CLEAR METALLIC S P444 SOLAR RED CLEAR METALLIC S P445 TURBO SILVER CLEAR METALLIC S P464 STEALTH BLACK S P465 BIONIC COPPER CLEAR METALLIC CAUTION Prior...

Page 194: ...4 In Lbs 1 5 Seat Post Latch 41 57 In Lbs 4 5 6 Rear Seat Plunger Nut 18 11 Apply Loctitet 262 Seat U Bolt Nuts 8 11 Apply Loctitet 262 Mirrors 22 In Lbs 2 5 STEERING SYSTEM HANDLEBAR ASSEMBLY Handlebar Cover Pad 20 In Lbs 2 Steering Housing To Top Deck 14 19 Steering Cable Adjuster Clamp 8 11 Apply Loctitet 242 Steering Arm Clamp 8 11 Apply Loctitet 242 Throttle Block 20 In Lbs 2 Rod End To Nozzl...

Page 195: ...Reverse Cable Routing CABLE PROTECTION COVER CABLE PROTECTION COVER HULL AND BODY 7 3 2004 Four Stroke PWC Service Manual Steering Cable Routing ...

Page 196: ...SECURE WITH ZIP TIES HULL AND BODY 7 4 2004 Four Stroke PWC Service Manual Siphon Hose Routings ...

Page 197: ...Torque 25 in lbs 2 8 Nm Bumper Fastener Torque 25 in lbs 2 8 Nm Grab Handle Bolt Torque 10 ft lbs 4 Nm Seat Post Plunger Nut Torque 18 ft lbs 25 Nm Sponson Fastener Torque 70 in lbs 6 Nm Apply marine grade silicone to holes SEAT POST SEAT POST AND TOW HOOK MAY BE ONE PIECE DESIGN HULL AND BODY 7 5 2004 Four Stroke PWC Service Manual Hull Assembly ...

Page 198: ... Fastener Torque 8 10 in lbs 1 Nm Tie Down Loop Torque 8 ft lbs 11 Nm Bow Loop Nuts 8 ft lbs 11 Nm Seat U Bolt Nuts 8 ft lbs 11 Nm Worm Gear Clamp Torque 25 In lbs 2 8 Nm Apply Loctite 242t to all threaded fasteners THIS PAGE ONLY Ref A 1 02 1 09 HULL AND BODY 7 6 2004 Four Stroke PWC Service Manual Hull Assembly Continued ...

Page 199: ...ror Nut Torque 22 in lbs 2 5 Nm Windscreen Bolt Torque 22 in lbs 2 5 Nm NGI Gauge Bolt Torque 14 in lbs 1 5 Nm Plunger Latch Fastener Torque 8 ft lbs 11 Nm Compartment Door To Fasteners 8 ft lbs 11 Nm Hinge Base To Top Deck Fasteners 14 ft lbs 19 Nm HULL AND BODY 7 7 2004 Four Stroke PWC Service Manual Compartment Door Assembly ...

Page 200: ... Nm Side Shrouds To Upper Shroud Fasteners 23 ft lbs 31 Nm Mesh Screen Fastener Torque 10 in lbs 1 Nm Shroud Assembly To Deck Fastener Torque 5 ft lbs 7 Nm MESH SCREENS x2 SIDE SHROUDS GLOVE BOX UPPER SHROUD HULL AND BODY 7 8 2004 Four Stroke PWC Service Manual Shroud and Storage Assemblies ...

Page 201: ...1 57 in lbs 4 6 6 4Nm Seat Post Nut Torque 18 ft lbs 24Nm Apply Loctitet 262 to nut threads Seat post height is fixed SEAT SEAL SEAT ASSEMBLY PLUNGER LATCH 41 57 IN LBS 4 6 6 4Nm HULL AND BODY 7 9 2004 Four Stroke PWC Service Manual Seat Assembly ...

Page 202: ...m Steering Cable Adjuster Clamp 8 ft lbs 11 Nm Apply Loctite 242t Steering Arm Clamp 8 ft lbs 11 Nm Apply Loctite 242t Throttle Block 20 in lbs 2 Nm Rod Ends 8 ft lbs 11 Nm Apply Loctite 242t Handlebar Grab Handle 35 in lbs 4 Nm ESP Cam To Steering Clamp 5 ft lbs 7 Nm Apply Loctite 242t REFERENCE HANDLEBAR REMOVAL AND INSTALLATION PROCEDURES ON PAGE 7 14 FOR STEERING POST SHIM LOCATIONS AND INSTAL...

Page 203: ...SEMBLY NOTES Magnet Bracket Fastener Torque 35 in lbs 4 Nm Apply Loctitet 262 to threads Reed Switch Bracket Nut Torque 8 ft lbs 11 Nm 35 in lbs 4 Nm APPLY LOCTITEt 262 8 ft lbs 11 Nm HULL AND BODY 7 11 2004 Four Stroke PWC Service Manual ESP Switch Assembly ...

Page 204: ...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 ...

Page 205: ...6 ft lbs 21 Nm Apply Loctitet 242 to threads Reverse Cable Jam Nut Torque 40 in lbs 4 5 Nm Reverse Gate Pivot Fastener Torque 14 ft lbs 19 Nm Apply Loctitet 242 to threads Apply Premium All Season Grease to exposed parts of reverse cable Apply Lithium based grease to reverse assembly moving parts 22 in lbs 2 5 Nm 40 in lbs 4 5 Nm 6 ft lbs 8 Nm 22 in lbs 2 5 Nm 14 ft lbs 19 Nm 16 ft lbs 21 Nm APPLY...

Page 206: ...ove post and install shim between bushing and strike plate Repeat step 3 If plate continues to hit washer install second and final shim 5 Apply lithium based grease to the outside taper of the lower tapered bushing and install into steering housing 6 The number of shims installed on the lower section of the post is determined by the number installed on top The total number of shims used to install...

Page 207: ...m the steering nozzle Discard the nylock nut 4 Prior to removing the thru hull nut loosen but do not remove the lockplate nut With the lockplate loose use an adjustable locking wrench to remove the thru hull nut 5 Locate and disconnect the rod end that is bolted to the steering arm underneath the shroud and top deck Discard the nylock nut 6 Remove the jam nut and rod end from the steering cable Re...

Page 208: ...3 Apply marine grade silicone to the thru hull fitting threads 4 Tighten the thru hull fitting nut to 52 in lbs 6 Nm 5 Turn locking plate flat towards thru hull nut face Tighten nut to 28 ft lbs 39 Nm 6 Lightly grease the upper steering linkage 7 Thread steering cable into adjusting nut Loosely fit adjusting nut bracket onto steering column base 8 Install steering cable rod end on top side of stee...

Page 209: ...tion Reverse Cable Adjustment Under normal operation the reverse cable should not require adjustment If the reverse linkage does not func tion properly inspect the cable for damage Inspect all linkage fasteners brackets and pivots for wear ordam age When a new cable is installed the cable must be adjusted 1 Place reverse shift lever in reverse position 2 Loosen cable adjuster nuts 3 Verify that th...

Page 210: ... more than a second Waiving the heat gun back and forth once is sufficient to soften the adhesive Prolonged heating will permanently damage the hull 2 With the footwell pad removed apply Goo Gonet and remove all old adhesive from the hull If scraping is required only use a soft plastic material 3 Remove Goo Gonet with mild detergent soap Wipe surface with acetone Allow Acetone to completely dry Fo...

Page 211: ... 1 NGI Gauge 8 2 8 3 NGI Gauge Wiring Illustration MIL Indicators 8 4 Battery Testing Maintenance 8 5 8 7 Alternator Assembly 8 8 Charging System Illustration 8 9 Start Stop Electrical System Illustration 8 10 System Interface Box Overview 8 11 8 12 Starter Motor Illustration 8 13 Starter Motor Disassembly Assembly Troubleshooting 8 14 8 18 ...

Page 212: ...e 19 AH Filling Specific Gravity 1 265 010 77 F 25 C Fully Charged Specific Gravity 1 280 010 77 F 25 C CCA 0 F 18 C 240 AMPS Recommended Charging Current 1 9 AMPS Electrolyte Volume 41 0 oz Reserve Capacity 25 minutes Charging System 3 Phase Alternator w external voltage regulator Alternator Output Voltage No Load 1200 RPM 2500 RPM 5000 RPM 21 3 Vac 43 5 Vac 87 0 Vac Alternator Coil Resistance 87...

Page 213: ... below 3 MPH 5 Km H will be displayed as 0 MPH 0 Km H Tachometer Engine RPM is displayed on the gauge The gauge has the ability to display between 0 and 9990 RPM Thegauge receives the tachometer signal from the ECU Display tolerance is 100 RPM Fuel Level Current fuel level is displayed via a 8 bar LCD graphic Levels are displayed in 1 8th increments When the fuel level displayed is 1 8 or less a L...

Page 214: ...to the trip odometer while a third will return to the clock display CLOCK SET In the main mode press and hold the RESET button until the hour digits flash Approximately 6 seconds Press RESET button to advance hour digits Press the MODE button to stop hour digits flash and begin minute digits flash Press RESET button to advance 1 minute Press MODE button to set clock and exit clock set mode TRIP OD...

Page 215: ...T SWITCH MIL WARNING LAMP Rev A 1 12 2004 A B C F E E D B C A A B D E K J H G F NGI GAUGE CONNECTOR ENGINE CHASSIS CONNECTOR OIL PRESSURE SWITCH Located beneath water pump above engine mounting strap on exhaust side of engine A B D E K J H G F ENGINE CHASSIS CONNECTOR ECU ECU 200 C4 K3 GRN RED GRN YEL LT BLUE LT BLUE GRN RED GRN YEL ELECTRICAL SYSTEMS 8 4 2004 Four Stroke PWC Service Manual NGI Ga...

Page 216: ...ery with electrolyte to upper level marks on case S Set battery aside and allow it to cool and stabilize for 1 2 hour S Add electrolyte to bring level back to upper level mark on case NOTE This is the last time that electrolyte should be added If the level becomes low after this point add only distilled water S Charge battery at 1 3 of its amp hr rating for up to 2 hrs NOTE This charge rate is to ...

Page 217: ...ACID YUMICRON TYPE 100 Charged 75 Charged 50 Charged 25 Charged 0 Charged 1 270 1 210 1 160 1 120 less than 1 100 1 275 1 225 1 175 1 135 less than 1 115 At 80_F NOTE Subtract 01 from the specific gravity reading at 40_ F Load Test A battery may indicate a full charge condition in the OCV test and the specific gravity test but still not have the storage capacity necessary to properly function in t...

Page 218: ...f necessary S Charge at a rate no greater than 1 10 of the battery s amp hr capacity until the electro lyte s specific gravity reaches 1 270 or greater S Store battery either in machine with cables disconnected or store in a cool dry place NOTE Stored batteries lose their charge at the rate of 1 per day They should be recharged to a full charge every 60 to 90 days during a non use period If stored...

Page 219: ...ctitet 272 to threads Magnet Rotor Bolt Torque 73 ft lbs 100 Nm Apply engine oil to bolt threads Alternator Fastener Torque 7 ft lbs 10 Nm Alternator Cover Fastener Torque 7 ft lbs 10 Nm STARTER MOTOR STARTER GEAR FRONT COVER ALTERNATOR ALTERNATOR COVER NEEDLE BEARING STARTER GEAR SPEED SENSOR WHEEL SPRAGUE CLUTCH MAGNET ROTOR ELECTRICAL SYSTEMS 8 8 2004 Four Stroke PWC Service Manual Alternator A...

Page 220: ...OUND RED PUR FUSE PROTECTED SWITCHED BATTERY VOLTAGE YEL RED STARTER RELAY SIGNAL PURPLE SWITCHED ECU VOLTAGE D D D VOLTAGE REGULATOR D D D A B A B C D E F 30A SPARE SPARE RED YEL RED STARTER RELAY A B RED ELECTRICAL SYSTEMS 8 9 2004 Four Stroke PWC Service Manual Charging System ...

Page 221: ... BLK RED RED PUR START STOP CIRCUITS LEGEND RED 12V BATTERY VOLTAGE BLACK GROUND RED PUR FUSE PROTECTED SWITCHED BATTERY VOLTAGE YEL RED STARTER RELAY SIGNAL RED YEL STARTER RELAY SIGNAL PURPLE SWITCHED ECU VOLTAGE BLU WHT SWITCHED ECU VOLTAGE Rev B 1 19 2004 L4 BLK H C BLU WHT SYSTEM INTERFACE BOX F F A RED YEL YEL RED PURPLE ELECTRICAL SYSTEMS 8 10 2004 Four Stroke PWC Service Manual Start Stop ...

Page 222: ...power up im mediately when the lanyard is installed if the opera tor s last action was removing the lanyard to kill the engine Conversely if the operator s last action was leaving the lanyard in the stop switch for more than two minutes or stopping the engine by pushing the stop button the ECU will not power up until the SIFB sees a start signal generated by the operator pushing the start button S...

Page 223: ... HARNESS CONNECTOR GRN YEL BLU WHT GRY RED PUR GRY PURPLE YEL GRN YEL GRN BLACK SYSTEM INTERFACE BOX SIFB LEGEND RED PUR 12V BATTERY VOLTAGE BLACK GROUND GRN YEL REVERSE SWITCH SIGNAL FROM IFB BLU WHT IGNITION SWITCHED VOLTAGE FROM IFB GRY TACHOMETER SIGNAL RED YEL IGNITION SWITCHED VOLTAGE FROM START BUTTON YEL GRN REVERSE SWITCH SIGNAL FROM REVERSE SWITCH PURPLE IGNITION SWITCHED VOLTAGE FROM TE...

Page 224: ...AR HOUSING PHENOLIC WASHER BRUSH PLATE COMMUTATOR ASSEMBLY NOTES Through Bolt Torque 36 in lbs 4 Nm Brush Length Service Limit 5 16 8mm Verify all parts are clean thoroughly prior to assembly Always use new o rings during reassembly ELECTRICAL SYSTEMS 8 13 2004 Four Stroke PWC Service Manual Starter Motor ...

Page 225: ...semble Mark end covers and housing for proper reassembly 2 Remove housing through bolts 3 Remove brush end bushing dust cover and armature thrust washers Keep washers in order for reassembly 4 Remove drive end cover and armature Remove thrust washer phenolic washer and shim washers Keep washers in order for reassembly ...

Page 226: ...tance between insulated brush and starter housing Reading should be infinite OL Inspect insulation on brush wires for damage and repair or replace as necessary 7 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Slide brush end frame off end of starter NOTE The electrical input post must stay with the field coil housing 8 Measure resistance between gr...

Page 227: ...ectrical contact cleaner Armature Testing 1 Using a digital multitester measure resistance between each of the segments of thecommutator The reading should indicate 3 ohms or less 2 Measure resistance between commutator and armature shaft Reading should be infinite OL Inspect surface of commutator wear or discoloration Replace if excessively worn or damaged 3 Place armature in a growler With growl...

Page 228: ...e Replace drive end cap if necessary 6 Be sure wire insulation is in place around positive brush wire and pushed completely into slot on phenolic plate 7 Using a non petroleum grease lubricate brush end bushing and install shims 8 Align brush plate and install cover and screws 9 Reinstall bolts and tighten evenly and securely 10 Lightly grease pinion shaft and install pinion spring stopper and sna...

Page 229: ...e solenoid Connect the tester black lead to the battery positive terminal and the red tester lead to the solenoid end of the battery to solenoid cable Push the start button The reading must be less than 1 Vdc Is it No Yes Clean the battery to solenoid cable ends or replace the cable Connect the black tester lead to the solenoid end of the battery to solenoid cable and the red tester lead to the so...

Page 230: ...WIRING DIAGRAMS MSX 110 150 Chassis Harness 62456_Foldouts 3 5 04 8 34 PM Page 1 ...

Page 231: ...WIRING DIAGRAMS MSX 110 150 Engine Harness 62456_Foldouts 3 5 04 8 34 PM Page 2 ...

Page 232: ...WIRING DIAGRAMS MSX 110 150 Engine Harness 62456_Foldouts 3 5 04 8 34 PM Page 3 ...

Page 233: ... NGI MODE SWITCH SIGNAL Y GRN REVERSE SWITCH SIGNAL PUR YEL PADDLEWHEEL SIGNAL GRAY TACHOMETER SIGNAL 2 PULSE LT BLUE OIL PRESSURE SWITCH SIGNAL PINK FUEL LEVEL SIGNAL GRN YEL ENGINE TEMPERATURE SWITCH GRN RED CHECK ENGINE MIL LAMP SIGNAL Rev A 11 05 2003 PINK PINK PUR YEL BLACK BLACK BLACK RED RED BLACK RED PUR PUR WHT PUR WHT GRAY GRAY OR BLK Y GRN YEL RED YEL RED PURPLE GRN RED GRN RED LT BLUE ...

Page 234: ... F B 15A 15A 15A STARTER RELAY ECU BATTERY ENGINE HARNESS FUSE SPLICE BLOCK MAIN RELAY ECU 100 ECU 300 MAG FUEL INJECTOR PTO FUEL INJECTOR WASTEGATE SOLENOID MAG IGNITION COIL PTO IGNITION COIL A B D E K J H G ENGINE CHASSIS HARNESS CONNECTOR LAMBDA SENSOR RED RED RED RED RED PUR RED PUR RED PUR RED PUR RED PUR RED PUR RED PUR RED PUR RED PUR RED PUR RED PUR RED PUR BLK GRN BLK GRN BLK GRN RED PUR...

Page 235: ...BLK RED WASTEGATE SOLENOID REFERENCE GROUND Rev B 1 12 2004 R1 R2 7 4 5 6 13 10 2 ECU MAIN RELAY ECU 100 ECU 300 PTO FUEL INJECTOR RED PUR SPLICE 1 SPLICE 2 H2 G3 MAG FUEL INJECTOR WASTEGATE SOLENOID RED PUR G2 PTO IGNITION COIL MAG IGNITION COIL SPLICE 1 SPLICE 1 SPLICE 2 SPARK PLUG SPARK PLUG G2 G4 F2 H3 BLK OR BLK OR BLK OR BLK OR BLK GRN RED PUR GREEN BLK RED ORANGE GREEN ORANGE BLK RED SPLICE...

Page 236: ...NDER TEMP SW BLU OR BOOST PRESSURE SIGNAL BROWN LAMBDA SUPPLY VOLTAGE Rev A 11 05 2003 ECU ECU 100 ECU 300 C3 C3 A2 A2 B3 F3 E4 SPLICE 4 SPLICE 4 SPLICE 5 SPLICE 5 SPLICE 5 BLK WHT RED GRN C2 BLK WHT BLU RED MANIFOLD PRESSURE BOOST PRESSURE AIR TEMP CAM PHASE SENSOR C1 F4 BLU OR BLU YEL BLU WHT BLK WHT BLU RED B1 B2 A3 ECU 200 BLU WHT BLU BLK BLK WHT D4 TEMP SENDER BLU RED BLK WHT C4 TEMP SWITCH B...

Page 237: ...URN SIGNAL RED WHT E T B THROTTLE PLATE POSITIVE VOLTAGE BLK RED E T B THROTTLE PLATE NEGATIVE VOLTAGE Rev A 11 05 2003 ECU ECU 300 C1 B4 G1 H1 BLK WHT A1 A1 ECU 200 B1 PEDAL POSITION UNIT P P U ELECTRONIC THROTTLEBODY E T B 1 2 3 4 A2 B1 K1 1 2 3 4 5 6 BLK RED BLK WHT RED GRN RED WHT BLU GRN BLU OR RED GRN BLU RED GRY RED P P U INTERFACE BOX F E B A 5 6 C D SPLICE 10 SPLICE 11 SPLICE 11 SPLICE 10...

Page 238: ...ompression Test 2 14 Engine Coolant Change Procedure 2 12 Engine Coolant Inspection 2 12 Engine Disassembly 4 21 4 28 Engine Inspection Procedures 4 29 4 42 Engine Management Circuit Diagrams Boost Air Temperature 5 20 Camshaft Position Sensor 5 24 Electronic Throttle Body 5 15 Engine Coolant Temperature Sensor 5 22 Engine Speed Sensor 5 23 Fuel Injectors 5 17 Fuel Pump Relay 5 27 Ignition Coils 5...

Page 239: ...Door Assembly 7 7 Hull Assembly MSX 7 5 7 6 Hull Repair 7 18 Hull Specifications 7 1 I Impeller Clearance 6 11 Intake Manifold Fastener Re Torque Procedure 2 24 Intake Scoop Ride Plate Removal and Installa tion 6 21 6 22 M Maintenance Bilge Drain Plug 2 21 Maintenance Safety Warnings 2 2 Maintenance Service Products 2 4 Maintenance Specific Tools 2 3 MSX 110 Emission Information 1 6 MSX 110 Genera...

Page 240: ...15 7 16 Steering Control Assembly 7 10 Steering Post Removal and Installation 2 6 System Interface Box 8 11 Diagnostics Mode 8 11 T Tap Drill Sizes 1 13 Throttle Cable Adjustment 2 19 Trouble Codes Boost Air Temp Sensor 5 20 Camshaft Position Sensor 5 24 ECU Engine Management System 5 29 Engine Coolant Temp Sensor 5 22 Engine Speed Sensor 5 23 ETB Electronic Throttle Body 5 15 Fuel Injectors 5 17 ...

Page 241: ...Part Number 9919062 Printed in U S A ...

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