PARTS MANUAL PN and MICROFICHE PN /03. MSX 140 Model #W045303CA MSX 140 INT L Model #W045303IA Rev. 01. E 2003 Polaris Sales Inc.

Transcription

1 PARTS MANUAL PN 0 and MICROFICHE PN 0 /0 MSX 0 Model #W00CA MSX 0 INT L Model #W00IA Rev. 0

2 TABLE OF CONTENTS Parts Manual AIR VENT A... BATTERY BOX... COMPARTMENT DOOR... COOLING SYSTEM... CRANKCASE... CRANKSHAFT and PISTON... DECALS... DRIVE SYSTEM... ELECTRICAL... ENGINE MOUNTING... ENHANCED STEERING PERFORMANCE... EXHAUST SYSTEM... B C D E F B B A B B C B B B B0 C B FUEL SYSTEM... A0 FUEL TANK... H A HULL and BODY... A- IGNITION COILS MANIFOLD I... M... OIL PUMP... OIL TANK... O P B B C A PROPULSION... R B REVERSE... A- SEAT... SHROUD and STORAGE... STARTING MOTOR... STEERING... STEERING CABLE... THROTTLE BODY... TOOL KIT... S T W WATER INLET... WATER SIPHON... A A C A A C C B B The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

3 COMPARTMENT DOOR Asm., Hinge, Front (Incl.,,,,,) - 0- Windshield, Smokin Grey (If built before 0//0) Windshield, Smoked Clear (If built after 0//0) 0 Screw Gasket, Mirror, LH Gasket, Mirror, RH Mirror, Black, LH Mirror, Black, RH 0 Washer 0 Nut, Nylok 0 Nut 00 Latch Washer, Lock 0 Screw Plunger, Latch (If built before 0//0) Plunger, Latch (If built after 0//0) A Washer, Flat (Qty. with ) Bumper, Rubber, Latch Post Washer, Flat 0 Nut, Hex, Nylok Hinge, Lower Screw Washer, Flat 0 Stud, Ball, Threaded 0 0 Rod End Pin, Dowel 00 Spring, Gas Hinge, Upper 0 Bolt Screw 000 Clip 0- Door, Compartment, Silver Metallic 0 Gauge, MFI /0

4 SHROUD and STORAGE Latch - Lid, Silver Metallic 0 0 Screw Washer, Nylon, Spacer - - Shroud, Silver Metallic, LH Shroud, Silver Metallic, RH 0 0 Mesh, Wire, Eyelet, LH Mesh, Wire, Eyelet, RH 0 Screw Washer, Flat Bumper 0 0- Asm., Shroud, Upper, Silver Metallic Seal, Bucket, Top Bucket, Storage A 0 Seal, Bucket Bottom Seal, Bucket, Bottom 0 Washer Guard, Splash Insert Insert 0 Pad 0 Box, Glove Rivet Net, Cargo (If built before /0/0) Net, Cargo (If built after /0/0) 0-00 Clip 0 Seal Plug /0

5 HULL and BODY Logo, Polaris Star 0 Screw -00 Cap, Rub Rail, Rear, Black Washer 0 Nut, Nylok - Rail, Rub, Insert 0 Screw Rivet 0 Screw 0 Plunger, Latch Nut Grip, Grab Handle Hook, Plunger Washer, Flat 0 Nut, Hex, Nylok A - - Sponson, Blade Silver, LH Sponson, Blade SIlver, RH 0 Screw Washer, Flat - Handle, Grab, Silver Metallic 0 Screw Bumper, Front - - Pad, Footwell, Front, LH Pad, Footwell, Front, RH 0- - Pad, Footwell, Center, LH Pad, Footwell, Center, RH - - Pad, Footwell, Rear, LH Pad, Footwell, Rear, RH - - Pad, Boarding, LH Pad, Boarding, RH Rail, Rub, Port Rail, Rub, Starboard /0

6 HULL and BODY 0 0 Screw 00 Asm., Bilge, Plug 0 U-Bolt 0 Nut 0 Washer, Rubber 0 Washer Washer, Lock Washer, Flat U-Bolt 0 Nut 0 Nut, Hex, Nylok A 00 Strap, Velcro Washer 0 Gasket, Strap, Bow Strap, Bow 00 Strap, Cable 00 Clamp, Hose 0 Flange 0 Rivet 0 Gasket Duct /0

7 SEAT 0-0 Asm., Seat, Bright Silver (Incl. All) 00 Latch 0 Washer Washer, Lock 0 Bolt Seal 0/0 A

8 FUEL TANK 0 0 Nut 0 Pump,Fuel,Electric Gasket 0 Strap, Connecting Tank, Fuel w/relief Cover, Strap Asm., Strap (Incl. ) Bracket, Tank Strap Rivet 0 Pad 00 Clamp, Hose A Hose, Fuel Fill 00 Clamp, Hose 0 Gasket, Fuel Fill Inlet, Fuel Screw 0 Seal, Fuel Cap 0 Asm., Cap, Fuel, Ratchet 000 Chain, Bead 0 00 Coupling, End Rivet Nut, Fuel Inlet 0/0

9 OIL TANK 0 0 Gasket, Oil Fill Inlet, Oil 0 Rivet Cap, Oil Tank 00 Coupling, End 000 Chain Bead Screw Rivet 00 Clamp, Hose 0 0 Hose, Oil Fill Tank, Oil w/relief 0 Valve, Vacuum Check A 00 Cable Tie 0 Hose 00 Elbow, 0 Degree 0 Asm., Sender, Oil Level 00 Clamp, Hose 000- Conduit, Convoluted 00 Filter, Oil 0 00 Clip, Routing 0 Hose 000 Clamp, Hose 00-0 AR Line, Fuel 0/0

10 FUEL SYSTEM Grommet, Vent 00 Cable Tie 00 Cable Tie 00 0 Clamp, Hose 00 Valve, Relief Check 0 Fitting, Tee 0 Value, Vacuum Check 00- AR Line, Fuel 0 Asm., Connector 0 0 Fitting 00 T-Clip A0 00 T-Fitting, Large 0 L-Fitting, Large 0 O-Ring, DFI Fitting, Large 0 L-Fitting, Small O-Ring, DFI Fitting, Small Injector (See Manifold/Ignition Pg. B, Ref. ) 0 T-Fitting, Small 00 Clamp, Hose 0 0 Shrader Valve w/cap /0

11 STEERING Screw Washer, Flat Nut, Hex -00 Handle, Grab -00 Pad, Handlebar Block, Split, Throttle 0 Switch, Start/Stop -00 Asm., Handlebars/Column 00 Lanyard w/whistle 0 Screw Washer, Flat 0 Grommet, Cable 0 Bracket, Grommet Plate, Top Housing, Steering Washer, Shim 0 Arm, Steering A Screw Clamp 0 Adjuster, Mount Nut, Hex 0 T-Nut Pad, Foam Bushing, Tapered 0 Cable, Throttle 0 Ring, Retaining 0 Washer, Flat Lever, Throttle Pin, Retaining 0 00 Cable Tie Clamp Screw Washer, Lock Washer 0/0

12 STEERING CABLE Bolt Washer, Flat 000 Rod End 0 Nut 0 Seal A 0 Nut 000 Cable, Steering Seal, Rod 0 Screw 0 Nut, Nylok /0

13 REVERSE A

14 REVERSE -00 Asm., Handle, Reverse 0 Bolt Support, Handle, Reverse Screw 0 Bolt Washer, Lock Insert 00 Rivet 0 Flange, Base Gasket Plate, Base 0 0 Pinion 0 Washer 0 Nut Shaft, Cam 0 Nut, Nylok Screw Washer, Flat 0 Bolt 0 Spring, Compression Arm, Reverse Lock 0 Washer, Flat Screw 0 Bracket, Arm Lock Support 0 Screw Washer, Flat 0 Switch, Limit, Sealed 0 Bracket, Reverse, Support 00 Pin, Cotter Arm, Reverse Bushing, Flange 0 0 Spring, Compression Plunger, Detent Bracket, Reverse Plate, Forward w/stud 0 Rivet 00 Cable, Reverse Seal, Rod 00 Cable Tie Conduit, Convoluted 00 Nut Washer, Flat 0 Washer, Lock Seal, Rod 0 Seal, Rod 0 Nut 00 Rod End Washer, Flat Gate, Reverse, Directional Pin, Clevis Washer 00 Collar 0 Washer, Flat Bolt 0/0 A

15 DRIVE SYSTEM 0 0 Bumper, Drive Shaft 0 Driveshaft Screw Washer, Flat 0 Cover, Coupler 00 Asm., Bearing Support Washer, Thrust 0 Coupler, Drive, Engine Coupler, Drive, Spider, Rubber 0 Coupler, Drive, Pump Bolt 0 Washer, Lock Gasket, Base, Bearing Support /0 B

16 PROPULSION Nut, Hex Washer Stud, Mounting, Pump, Long Housing, Pump 0 O-Ring Pipe, Water, Engine Fitting 0 Stator 00 Spacer 0 00 Bearing 00 Seal, Stator Bearing 00 0 Spacer, Impeller (If built before //0) Spacer, Impeller (If built after //0) 0 Impeller Seal, Impeller/Shaft Extension, Pump 0 Screw 0 Anode, Zinc Bracket, Steering Cable Nut B 0 O-Ring 0 0 O-Ring Screen, Engine Inlet 0 Nozzle, Steering Bolt 0 Collar 0 Washer, Lock Washer, Flat Bearing, Steering Nozzle Bolt 00 Asm., Nozzle, Pump 0 Wedge, Pump 0 Screw (If built before //0) Screw (If built after //0) Cone, Pump Seal, Tail Cone Shaft, Stub 0 O-Ring /0

17 WATER INLET 0 0 Screw 0 Washer, Lock Washer, Flat 0 Asm., Paddle, Wheel Conduit, Convoluted 00 Cable Tie - - Plate, Ride, Black (If built before 0/0/0) Plate, Ride, Black (If built after 0/0/0) 0 Scoop, Inlet Grate, Inlet, Black (If built before 0//0) Grate, Inlet, Black (If built after 0//0) 0 Bolt /0 B

18 AIR VENT 0 Bolt 0 Washer, Lock Washer, Flat Spacer 0 Decal, Liberty Marine HO DI 0 B -00 Plug, Intake Silencer 0 O-Ring -00 Cover, Air In 0 Decal, DFI Fuel Injection Filter, Intake Silencer /0

19 WATER SIPHON 00 Cable Tie 0 Elbow, Siphon Hose Line, Fuel 00 Cable Tie 0 Clip, Routing 0 Pickup, Siphon w/strainer 0 Pipe, Water, Bilge /0 B

20 EXHAUST SYSTEM Screw Washer, Lock - Cover, Exhaust Outlet 0 Seal, Exhaust Fitting Fitting, Exhaust -0 Asm., Silencer, Exhaust 000 Clamp, Hose 0 Hose, Exhaust 0 Clamp, Hose 0 Bumper Hose, Exhaust, Pipe/Silencer 00 Clamp, Hose 00 Bolt Washer, Lock 00 Bolt Washer, Flat 0 Screw 00 Gasket, Exhaust Pipe Bolt 0 Bolt 0- Asm., Exhaust Manifold 00 Fitting, Drain, Exhaust Manifold B Screw 0 Fitting, Screen, Exhaust 0- Asm., Exhaust Pipe (Incl.,,) 00 Fitting, Inlet, Water Fitting, 0 Degree Hose, Pipe Drain Rivet 0 0 Clip, Strap Hook, Strap, Narrow 00 Bracket, Pump Face, Silencer 0 Strap Washer, Flat 0 Bolt 0 Hose, Silencer to Resonator (If built to 0//0) Hose, Silencer to Resonator (If built from 0//0) 0 Nut, Nylok Resonator, Exhaust Bracket, Resonator/Grab Handle 0 Hose, Resonator to Outlet Screw 0/0

21 COOLING SYSTEM 0 0 Gasket - Fitting, Thru-Hull Fitting, 0 Degree Hose, Water Hose, Water Hose, Water Hose, Water Hose, Water Hose, Water 00 Clamp, Hose Fitting, Tee 00 0 Clamp, Hose Hose, Water, T-Fitting/Pipe Thermostat, Degrees F. Valve, Pop-Off 0 Gasket, Thermostat 0 Spring, Compression Washer 00 Seal, O-Ring Thermostat Fitting Cover, Thermostat 0 Fitting 00 Anchor, Cable Tie 00 Cable Tie 0 00 Cable Tie -0 Conduit, Flex -. 0 Conduit, Wire 00- Tubing, Convoluted 00 Cable Tie -0 - Conduit, Flex Conduit, Flex 00 T-Fitting Hose, Water /0 B

22 ELECTRICAL Fuse, Amp. 00 Fuse, Amp. 0 Harness, Wire, Door Harness, Engine NOTE: Harness on Enhance Steering Performance Pg. C, Ref. to be removed when replacing Engine Harness. has features of included in it. Boot 00 Capacitor 0 Insulator, Cable 0 Nut Washer, Lock 0 00 Cable, Solenoid/Starter Washer, Lock, External 00 Solenoid, Starter 00 Cable, Solenoid/Starter Rivet Washer, Flat 00 Cable Tie - Conduit, Flex 0 Asm., Velcro Strap, EMM 0 Decal, DFI Fuel Injection 0 00 EMM, Programmed /0 B

23 BATTERY BOX 0 Cover, Battery 0 Grommet, Vent 0 Fitting, Elbow AR Tube, Vent 00 Cable Tie B 0 Asm., Velcro Strap, Battery 000 Battery, Amp 00 Kit, Battery Bolt 0 Insulator, Cable Cable, Ground, Battery/Engine 0/0

24 ENGINE MOUNTING 0 0 Clip, Retainer 0 O-Ring Bumper, Temp Sensor 0 Screw Spacer Washer, Flat 0 Sensor, Water Temperature 00 Decal, Spark Plug 0 Kit, Short Block, NOTE: The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston and crankshaft assembly. 0 Bolt 0 Washer, Lock - Plate, Mount, Front B0 0 Washer, Lock Screw Shim, Slotted 0 Nut, Hex, Nylok Washer, Flat 0 Mount, Engine Plate, Motor Mount 0 0 Screw Washer, Flat Bolt 0 Screw Washer, Flat Nut, Nylok 0- Plate, Mount, Rear /0

25 DECALS Kit, 0 MSX 0, Decals Decal, NGI 0 Decal, Lens Cover, Gauge 00 Decal, Low Emissions 0 Decal, Coast Guard Exemption Decal, Warning (If built before /0/0) Decal, Warning, Collision (If built after /0/0) Decal, Capacity, Passenger (If built before 0//0) Decal, Capacity, (If built after 0//0) Decal, Warning, Rear (If built before /0/0) Decal, Warning, OP, Protect (If built after /0/0) 0 Logo, Planet 0 Decal, Spark Ignition Comp w/canada 0 Decal, Fire Extinguisher 00 0 Decal, Refueling, Warning (If built before //0) Decal, Warning, Fuel (If built after //0) B Decal, Air Intake, LH Decal, Air Intake, RH 0 Decal, Medallion 0 Decal, Reverse 0 Logo, Polaris Star 0 0 Decal, Caution, Capsize (If built before //0) Decal, Caution, Capsized Boat (If built after //0) Decal, Deck, Rear, LH Decal, Deck, Rear, RH 0 Decal, Patent (If built before //0) Decal, Patent Update (If built after //0) 0 Decal, POLARIS Hull 0 Decal, POLARIS 0 Decal, Deck, Front, LH Decal, Deck, Front, RH /0

26 CRANKCASE Stud, Cylinder Stud, Cylinder Flange 0 Kit, Crankcase, 00 (Incl. -) 00 Pin, Dowel Bolt Screw Screw 00 Retainer 0 Sensor, Crank Position 0 O-Ring Screw Clamp, Stator Wires 00 Flywheel Housing (Incl.,) 00 Pin, Dowel Bushing Bolt 0 Plate, Stator Mount 0 Screw 000 Stator, Ignition B 0 0 Screw 00 Flywheel 0 Bushing Bushing 0 Spring 0 Asm., Cover, Flywheel 0 Washer 0 Plug, Timing Hole - Cover, Water Jacket 0 Bolt 0 0 Fitting, 0 Degree 0 Bolt Screw Gasket, Water Jacket Cover 0 Plug 0 Gasket, Flywheel Cover Asm., Bendix (See Starting Motor Pg. C for Details) /0

27 MANIFOLD 0 0 Screw 0 Plug, Pipe 0 Decal, Warning 0 Bolt 00 Gasket, Water, Manifold Screw 0 Bolt Washer, Flat Cap 0 O-Ring Injector B Gasket, Cylinder Base 0 Cylinder 0 Nut Rivet O-Ring O-Ring 00 Restrictor, Cylinder Head 0- Head, Cylinder 0 0- Asm., Manifold, Water Washer 00 Plug, Spark, NGK, DFI 0/0

28 IGNITION COILS Asm., Wire, Spark Plug 0 Plate, Coil Mount 00 Coil, Ignition Washer Washer, Lock Screw B Wire, Ground 00 Coil, Ignition, DFI 0 Bolt 0 Spacer, DFI EMM 0 Mount, Rubber, DFI EMM 0/0

29 THROTTLE BODY 0 0 Screw 00 Base, Intake Silencer 00 Gasket, Carburetor, Upper Asm., Throttle Body 00 Gasket, Carburetor 0- Adaptor, Carburetor 0 Bolt Bolt Washer 0 00 Retainer Stuffer, Reed Block 0 Asm., Block, Triple Reed C 0 Bolt 00 Clamp, Nylon, Cable -0 Conduit 00 Strap 00 Cable Tie 0 Screw 0 Asm., Sensor, Throttle Position 0 0 Spring 0 Coupler 0 Sensor, Air Temperature Spacer /0

30 CRANKSHAFT and PISTON Kit, Crankshaft (Incl.,-) 0 Circlip, Piston Pin, Piston 0 Kit, Piston Rings, Standard 0 Kit, Piston Asm., Standard (Incl. -) 0 Kit, Connecting Rod Asm. Bearing (If built before 0//0) Bearing (If built after 0//0) 0 Nut Coupler, Pump Drive 0 Washer 0 00 Seal 0 Bushing 0 Bearing, Ball Key, Woodruff Crankweb, MAG Bearing, Ball Crankweb, Center 0 Labyrinth Crankweb, PTO 0 Seal, Flange 0 0 O-Ring Collar, Crankshaft /0 C

31 OIL PUMP 00 Cable, Oil Pump Washer 0 E-Ring, Retaining 00 Asm., Oil Pump (Incl. ) 000 Clamp Line, Fuel 0 Bolt O-Ring /0 C

32 STARTING MOTOR Brush, Complete (Incl. -) 00 Asm., Bendix (Incl. -)(If built before 0//0) 00 Asm., Bendix (Incl. -)(If built after 0//0) 00 Starter, Long Stud (Incl.,-) 0 Bolt, Through 0 Bolt 0 Nut 0 Washer, Spring 0 Washer 00 O-Ring 0 Spring, Brush 00 Ring, Rubber 00 Asm., Rear Bracket 0 0 AR Washer, Thrust 0 Washer, Thrust 00 Asm., Armature 00 Asm., Front Bracket 0 O-Ring 0 Washer 0 Ring, Snap 0 Stopper 0 Cover 0 Spring 0 Bushing 00 Asm., Gear (Incl. -0) /0 C

33 TOOL KIT Kit, Tool, Metric (Incl. -) Socket, Spark Plug Wrench, Open End (0mm-mm) Screwdriver, Standard/Phillips 00 Pouch, Tool Kit 0 Wrench, Allen, Plated Manual, Owners, 0 MSX 0 0/0 C

34 ENHANCED STEERING PERFORMANCE 0 Harness 00 Controller 0 Screw Washer 0 Nut, Nylok Cam 0 Switch, Limit Bracket, Switch Screw 0 00 Cable Tie Conduit, Convoluted 0/0 C

35 PRINTED IN THE USA PARTS MANUAL PN 0 AND MICROFICHE PN 0 /0

36 Changed pages in 0 0 A cover toc x B x C D E F G 0