Polaris 2003 MSX Owner's Manual
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Polaris 2003 MSX Owner's Manual

Polaris 2003 MSX Owner's Manual

Polaris watercraft owner's manual
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2003
2003
MSX
MSX
Owner's Manual
Owner's Manual
for Vehicle Maintenance
for Vehicle Maintenance
and Safety
and Safety

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Summary of Contents for Polaris 2003 MSX

  • Page 1 2003 2003 Owner's Manual Owner's Manual for Vehicle Maintenance for Vehicle Maintenance and Safety and Safety...
  • Page 2 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
  • Page 3 We’ve created a web site, just for YOU! Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Racing Information Check it out... www.polarisindustries.com/owner...
  • Page 4 All information in this manual is based on the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements that may affect illustrations or explanations. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.

  • Page 5: Welcome

    S Utility Task Vehiclest (UTVs) S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs) We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve...

  • Page 6: Table Of Contents

    ......MAINTENANCE and LUBRICATION ENGINE TROUBLESHOOTING POLARIS PRODUCTS ....SPECIFICATIONS .

  • Page 7: Your Responsibilities

    Store the manual in a waterproof bag in one of the storage areas on the watercraft. If the vehicle is sold, the owner’s manual and video should remain with it. If your owner’s manual is lost or missing, see a Polaris dealer for a replacement. YOUR RESPONSIBILITIES...
  • Page 8 YOUR RESPONSIBILITIES Age Restrictions This vehicle is not a toy. Polaris recommends that all operators be 16 years of age or older. Contact local authorities to find out what the legal age requirements are in your area of operation. Maintenance Requirements Follow the recommended maintenance program outlined in your owner’s manual.

  • Page 9: Identification Numbers

    If the vehicle is destroyed or stolen, you’ll have the identification numbers required by insurance and/or law enforcement. NOTE: Check with your insurance agent about obtaining insurance coverage for your watercraft, or see your Polaris dealer. Purchase Date: Vehicle Model Number: Engine ID Number: Hull ID Number:...

  • Page 10: Safety

    SAFETY Signal Words and Symbols The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.
  • Page 11 If any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needing replacement will be provided by Polaris at no charge. The warning decals summarize and highlight key safety and operational information.
  • Page 12 SAFETY Safety Decals The general safety/warning decal is located on the rear of the watercraft, just below the seat.
  • Page 13 Safety Decals The collision warning decal is located on the dash of your watercraft. Collisions result in more INJURIES AND DEATHS than any other type of accident for personal watercraft (PWC). TO AVOID COLLISIONS: SCAN CONSTANTLY for people, objects and other watercraft. Be alert for conditions that limit your visibility or block your vision of others.
  • Page 14 SAFETY Safety Decals The fuel warning decal is located near the fuel tank fill cap. The capsize warning decal is located at the rear of the watercraft, positioned upside down so the operator can read it when the boat is capsized. WARNING RIGHTING CAPSIZED BOAT S To prevent injury, do not place...
  • Page 15 Informational Decals The Coast Guard exemption decal is located below the left-hand mirror. Located on the upper shroud near FIRE EXTINGUISHER CONTAINER LOCATED INSIDE Located on the engine water manifold: Do Not Remove Electrical Part When Starting Or During WARNING Operation.
  • Page 16 Read and understand your owner’s manual and all warning decals before operating a Polaris watercraft. Any operator of a Polaris watercraft must know and practice the following guidelines for personal safety and the safety of passengers. Never permit a guest to operate this watercraft unless the guest has read and understands all warning decals and the owner’s...
  • Page 17 Operator Safety Your Polaris watercraft is capable of towing, but please be aware that towing can cause reduced steering control. Be extremely careful when towing other watercraft, skiers or objects behind this watercraft, as they have a significant impact on handling and steering.
  • Page 18 The operator and passenger must always wear an approved personal flotation device (PFD) at all times to prevent accidental drowning. Polaris recommends a vest-type PFD (U.S. Coast Guard type 1, 2, or 3). NOTE: The seat of the watercraft is not a PFD.
  • Page 19 Never allow more than the specified rider capacity on the watercraft. Polaris watercraft are designed to carry an operator and up to three passengers, depending on the model. Check the specifications section beginning on page 102 to determine your boat’s rider capacity.
  • Page 20 SAFETY Operator Safety Weather and Darkness Be aware of severe weather conditions. Observe weather forecasts and conditions before venturing out, and do not operate the watercraft when visibility is poor and when the water is rough. Operation of the watercraft in poor weather conditions can result in an accident and lead to severe injury, hypothermia or death.
  • Page 21 Operator Safety Obstacles and Shallow Water Always be on the lookout for dangerous obstacles above and below the water surface, especially in shallow water. Use extra caution when riding in unfamiliar areas. Never ride in water that is less than two feet (60 cm) deep, and do not operate at more than an idle speed in water that is less than six feet deep.
  • Page 22 SAFETY Operator Safety Turning and Accelerating Turning and accelerating without checking for other boats and objects in your path can cause an accident and result in severe injury or death. Always look behind the watercraft and to each side before accelerating and before making sudden turns.
  • Page 23 Operator Safety Jet Pump Water Intake Safety Contact with the jet pump or driveline components of the watercraft can result in severe injury, death or drowning. Do not allow hands, feet, ropes, straps, clothing or long hair to come in contact with the jet pump water intake (1) on the bottom of the watercraft while the engine is running.
  • Page 24 SAFETY Operator Safety Operator Awareness A collision can cause severe injury or death. Always be aware of other watercraft, swimmers and other obstacles while operating the watercraft. Always maintain a safe distance, especially if you’re an inexperienced operator. Do not exceed idle speed if any person is within 50 feet (15 m) of the rear of the watercraft.
  • Page 25 Operator Safety Vehicle Modifications Modifications to this machine could create safety hazards and reduce vehicle reliability as well as make it unsafe or illegal to operate. Do not modify this watercraft or any of its components. Any modifications to the watercraft will void your warranty. Operator Fatigue and Dehydration Long hours of boating with exposure to noise, vibration, sun, glare and wind can result in operator...

  • Page 26: Features And Controls

    NOTE: The throttle lever installed on your MSX is finger-operated, but Polaris also offers an accessory thumb-operated lever. See your Polaris dealer for more information. 6. Instrumentation - Instrumentation is New Gen- eration Instrument (NGI). See page 30 for a detailed explanation of the NGI display.
  • Page 27 FEATURES AND CONTROLS...
  • Page 28 FEATURES AND CONTROLS 1. Front Compartment Door- The door provides access to the fire extinguisher, oil tank, fuel fill, oil fill and main storage space. 2. Fire Extinguisher Compartment - Located under the front compartment door and under the storage bucket in the left side flotation foam, this compartment provides secure storage for the fire extinguisher.
  • Page 29 FEATURES AND CONTROLS...
  • Page 30 FEATURES AND CONTROLS Engine Components (under seat) 1. Battery 2. Engine Management Module (EMM) 3. Spark plugs 4. Air intake cover 5. Starter solenoid 6. Exhaust silencer 7. Exhaust pipe 8. Exhaust cooling water hose 9. Cooling water manifold 10. Thermostat assembly (under end of water manifold) 11.
  • Page 31 FEATURES AND CONTROLS Engine Components 4,11...
  • Page 32 FEATURES AND CONTROLS New Generation Instrument (NGI) Primary Functions S Speedometer S Clock S Tachometer S Engine Hourmeter S Trip Odometer S Oil Level S Fuel Level S Low Oil/Pressure/Fuel/ Battery Voltage Warnings S High Engine Temperature Warning S Check Engine Warning Accessible Functions S Tachometer S Engine Hourmeter...
  • Page 33 New Generation Instrument (NGI) Function Overview Speedometer The large numeric speedometer displays vehicle speed. The NGI receives signals via a paddle wheel located on the ride plate. The gauge interprets these signals and computes actual vehicle speed. Tachometer The NGI has the ability to display between 0 and 9950 RPM.
  • Page 34 FEATURES AND CONTROLS New Generation Instrument (NGI) Instrument Operation DISPLAY MODE There are three different display modes the gauge uses to display information to the operator. The three modes are: MAIN MODE, SPEED/TACHOMETER MODE and NAVIGATION MODE. Press and release the MODE button on the left handlebar control to advance through the three modes.
  • Page 35 New Generation Instrument (NGI) Display Warnings The NGI will alert the operator to the following conditions: S LOW FUEL (Fuel level reaches 1/8 level.) S LOW OIL (Oil level reaches 1/7 level.) S LOW BATTERY VOLTAGE (Battery voltage is at or below 10.9 vDC) S HIGH TEMPERATURE (Temperature is monitored by EMM) S CHECK ENGINE...
  • Page 36 Always keep the intake and/or impeller free of debris and weeds. Your Polaris watercraft is equipped with a device that will limit engine revolutions per minute (RPM) if the engine overheats. This feature is designed to help prevent engine damage caused by engine overheating.
  • Page 37 FEATURES AND CONTROLS Optional Equipment See page 101 for a list of Polaris products for servicing your watercraft. S U.S. Coast Guard-approved fire extinguisher (UL 5-B:C Rating) PN 2871012 S Registration numbers (see your Polaris watercraft...

  • Page 38: Emissions

    EMISSIONS EPA Emissions Regulations All direct injection equipped engines manufactured by Polaris Industries are certified to the United States Environmental Protection Agency regulations for the control of air pollution. For this reason, factory procedures for servicing must be strictly followed, and wherever practicable, returned to the original intent of the design.
  • Page 39 California Star Labels One Star - Low Emission The one-star label identifies engines that meet the Air Resources Board’s 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S.

  • Page 40: Operation

    OPERATION Pre-Operation Inspection Use the Pre-Operation checklist beginning on page 39 to verify that your vehicle is in proper operating condition before each use. Procedures are outlined in further detail on the pages following the checklist. WARNING If a proper inspection is not performed before each use, severe injury or death could result.
  • Page 41 Pre-Operation Inspection Item What To Do Bilge Drain water from the bilge before putting the craft in the water. Fuel/oil tank Check fuel/oil; add as necessary; levels inspect for presence of water. Jet pump Inspect and remove any debris; water intake ensure intake grate is secure;...
  • Page 42 OPERATION Pre-Operation Inspection Fuel WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas. WARNING Gasoline is highly flammable and explosive under certain conditions.
  • Page 43 Pre-Operation Inspection Fuel CAUTION Using a non-recommended fuel may cause serious engine damage. Polaris recommends the use of 87 octane (or higher) non-oxygenated or 89 octane (or higher) oxygenated fuel only. Your watercraft features an oil injection system, and it’s not necessary to pre-mix the gasoline and oil.
  • Page 44 Wipe up any spills immediately. 4. Visually inspect the oil for water or foreign matter. If either is present, see your Polaris dealer for service. A warning light on the NGI display will flash if oil is low (1/8 tank or less).
  • Page 45 If any obstruction cannot be removed, have an authorized Polaris dealer service it immediately. Clear the pump of sand after operating in shallow water or after beaching the watercraft.
  • Page 46 If the craft is operated in salt water, spray the inside of the hull (engine and components) with waterproof lubricant spray after every use. See page 101 for part numbers of Polaris products. The engine compartment is located beneath the seat. Be sure the seat, engine cover and front compartment door are properly positioned and securely latched before operating the watercraft.
  • Page 47 A fire extinguisher is not standard equipment with this watercraft. Contact your Polaris dealer or a fire extinguisher dealer to purchase a U.S. Coast Guard-approved fire extinguisher with a UL 5-B:C rating.
  • Page 48 Doing so will ensure a good battery at the end of the storage period and a longer life for the battery. NOTE: The Polaris Battery Tendert battery charger can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre-determined point.
  • Page 49 Pre-Operation Inspection Hull Use a non-abrasive cleaner to remove any marine growth and inspect the hull for cracks or damage. Do not operate the watercraft if the hull is damaged. Drain Plugs and Bilge Turn each bilge drain plug (1) counterclockwise and remove it.
  • Page 50 If it doesn’t, press the stop switch to stop the engine. Do not ride the watercraft. See your Polaris dealer for service before operating the watercraft. 3. If removing the lanyard lock plate successfully stopped the engine in the previous step, start the engine again and allow it to run for a few seconds.
  • Page 51 The throttle must be applied in order to turn the watercraft. Engine Break-in Procedure The break-in period for your new Polaris watercraft is defined as the time it takes to use the first full tank of gasoline. No single action on your part is as important as following the procedures for a proper break-in.
  • Page 52 OPERATION Engine Break-in Procedure CAUTION If the engine is operated while the watercraft is in very shallow water, sand, weeds and debris may be sucked into the jet intake and could cause damage to the impeller or injury to bystanders. Ingesting sand into the cooling system will cause the engine to overheat, which could lead to engine damage.
  • Page 53 Navigational Rules This watercraft must be operated in accordance with all navigational rules and regulations governing it and the waterway on which it’s operated. These rules are used and enforced internationally, as well as by the U.S. Coast Guard and local law enforcement. Any operator of this watercraft should be aware of these rules and should obey them when encountering other vessels.
  • Page 54 OPERATION Navigational Rules Rule 2 Rule 2 is “The General Prudential Rule” of the International Rule. This rule states that all operators have the responsibility of taking action to avoid a collision. All vessels involved in a potential collision become give-way vessels.
  • Page 55 Navigational Rules Overtaking Vessels If your watercraft is passing another vessel, your craft is the give-way vessel. The other vessel is expected to maintain its course and speed. You must not interfere with its course of travel. If your craft is the stand-on vessel, maintain your course and speed until the other vessel has passed you.
  • Page 56 OPERATION Navigational Rules Non-Motorized Craft Non-motorized craft (sailboats, canoes, etc.) are normally given the right-of-way, with the following exceptions: S When a non-motorized craft is overtaking a power vessel, the power vessel has the right-of-way. S Non-motorized craft should stay clear of fishing ves- sels.
  • Page 57 Navigational Rules Avoid Collisions SCAN CONSTANTLY for people, objects and other watercraft. Be alert for conditions that limit your visibility or block your vision of others. OPERATE DEFENSIVELY at safe speeds, and keep a safe distance away from people, objects and other watercraft.
  • Page 58 OPERATION Launching the Watercraft 1. Inspect the drain plugs to ensure they’re securely installed. 2. Launch the watercraft in an area free of weeds and debris. Make sure the craft is in at least two feet of water before starting the engine. 3.
  • Page 59 4. Perform the pre-operation check found on page 39. If you have any questions about the features or controls of this watercraft, see your Polaris dealer. CAUTION If the engine is run while the watercraft is in very shallow water, sand, weeds and debris may be sucked into the jet intake and could cause damage to the impeller or injury to bystanders.
  • Page 60 OPERATION Starting the Engine WARNING Starting the engine immediately generates a forward thrust, which could cause an unprepared operator to fall from the machine, causing serious injury or death. Always be seated and alert when starting the watercraft. Never hold the throttle open while starting.
  • Page 61 Boarding the Watercraft Practice boarding the watercraft in shallow water before riding in deep water. Any passengers should also practice boarding in the event they must reboard in deep water. Boarding and Starting in Deep Water (Operator Only) Make sure the watercraft engine is turned off when boarding in deep water.
  • Page 62 OPERATION Boarding the Watercraft Boarding With a Passenger A watercraft behaves differently with a passenger on board, requiring more operator skill. Practice operating skills alone, before taking a passenger on board. Make sure the watercraft engine is turned off when boarding with a passenger.
  • Page 63 Reverse Operation WARNING Activating reverse while the craft is moving forward could cause loss of control and result in damage to the watercraft or severe personal injury to the operator or passenger(s). Do not attempt to activate reverse while moving forward above planing speed.
  • Page 64 OPERATION Stopping the Watercraft WARNING Colliding with an object in the water can result in serious injury to the operator or passengers. All riders must keep feet, arms and hands inside the watercraft at all times, and especially while approaching a dock, vessel or other object. Do not turn off the engine while approaching an object.
  • Page 65 Beaching the Watercraft CAUTION Sand, pebbles, weeds and debris can enter the jet pump and cause severe damage to components. Ingestion of sand into the cooling system may cause the engine to overheat and could result in severe engine damage. Never beach the watercraft while the engine is running.
  • Page 66 OPERATION Operating in Rough Conditions If riding in rough conditions, it’s possible for the operator to hit his/her chest or face on the watercraft or handlebars and be injured. If the operator is ejected from the craft, injuries may make it difficult to reboard. Operating the craft in rough water conditions is not recommended, and it’s illegal in some states to operate the watercraft in or near the surf line.
  • Page 67 Towing a Disabled Watercraft If the watercraft becomes inoperable in the water, it can be towed by another watercraft. Before towing, use a vice grip pliers to close off the cooling water inlet hose (1) located at the bottom of the watercraft hull (the hose from the pump box to the exhaust pipe).
  • Page 68 OPERATION Righting a Capsized Watercraft Capsizing a watercraft is not recommended by Polaris and should be avoided. Overturning a watercraft is not considered the normal operation for which your vehicle is intended. WARNING This watercraft does not right itself if it has been capsized.
  • Page 69 Never exceed the load capacity for the watercraft. Polaris watercraft are designed to carry an operator and up to three passengers, depending on the model. Refer to the capacity decal on your craft and the specifications beginning on page 102 to determine your boat’s rider capacity.
  • Page 70 After the water has drained, wipe the engine compartment (bilge) dry with clean towels. 6. If the craft is used in salt water, Polaris recommends that the inside of the hull (engine and components) be sprayed with T 9 metal protectant after each use.
  • Page 71 11. Inspect the area for damage. If damage is found, see your Polaris dealer for service. NOTE: Whenever possible, avoid operating the watercraft in weedy areas. If it’s unavoidable, vary the watercraft speed, as weeds tend to accumulate more rapidly at steady and trolling speeds.
  • Page 72 OPERATION Post Operation Maintenance Temporary Storage If the watercraft will be stored temporarily (less than 30 days), perform the daily maintenance procedures beginning on page 68 and also perform the following temporary storage procedures. 1. Block the seat (engine compartment) open about 1/2″...
  • Page 73 Be sure the trailer matches the watercraft’s weight and design and that it meets trailer laws and regulations in your area. We recommend the use of a Polaris watercraft cover for protection from rocks and other debris while transporting. 1. Tie the watercraft securely to the trailer at the bow and stern.
  • Page 74 Use the procedure on page 73. All others should take the watercraft to an authorized Polaris dealer for service. If this is not possible, call your Polaris dealer for further instructions.
  • Page 75 8. Check the fuel and oil for the presence of water. If water is present, take the watercraft to an authorized Polaris dealer for immediate service. Do not run the craft if water is present in the fuel or oil.

  • Page 76: Maintenance And Lubrication

    MAINTENANCE AND LUBRICATION General Maintenance Replace the pop-off valve, spring and seals every 100 hours. Replace inlet and outlet hoses and clamps every 100 hours. After washing the engine compartment of the watercraft, protect the metal components with a T9 Metal Protectant or another non-flammable metal protectant.
  • Page 77 Watercraft operated in saltwater require daily corrosion protection and engine flushing, and more frequent maintenance and lubrication. Fogging kits should be added to all Polaris watercraft. The engine should be fogged if the watercraft will not be used for more than 48 hours.
  • Page 78 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule DESCRIPTION ENGINE Engine corrosion protection/fogging(daily-if used in salt water) Cooling system flushing (daily after use in salt water) Exhaust cooling hose screen Exhaust hose condition Engine mounts (replace if removed for engine service) Thermostat/popoff valve assembly/spring Water inlet and outlet hoses and clamps Spark plugs/Compression test Spark Plugs (replace every 100 hours)
  • Page 79 Periodic Maintenance Schedule DESCRIPTION FUEL SYSTEM Fuel filter and oil filter Throttle cable Fuel cap/oil cap gaskets Fuel lines, oil lines, related hose clamps, check valves and hose inspection, fuel system pressurization Vent system (oil and fuel) check-valves; hose routing Fuel system pressure/vacuum test Air intake silencer JET PUMP...
  • Page 80 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule DESCRIPTION HULL / DECK / STEERING / CONTROLS Steering support hub bushings/fasteners/handgrips Steering cable Steering Nozzle Bushings Reverse cable inspection, lubrication Handlebar/steering operation (turns fully/freely/fasteners) Hull, clean and inspect for cracks, damage, or leaks Drain Plug Condition Bilge system inspection, should not leak Seat and compartment seals (condition of seal)
  • Page 81 Inspect the rubber spider coupler (1) monthly. See your Polaris dealer for replacement if wear or damage is found. Inspect the bearing carrier (2) for water leaks through or around the drive shaft. See your Polaris dealer for replacement if a leak is detected.
  • Page 82 MAINTENANCE AND LUBRICATION Lubrication Seat Latch And Hooks Grease the locking mechanism of the seat latch at the rear of the seat opening. Throttle Body And Oil Injection Pump Grease springs, exposed portions of cable and shafts at the throttle bodies. Grease often if used in salt water. Electrical Connections Apply dielectric grease to battery posts and exposed cable connections.
  • Page 83 Spark Plugs Always use the recommended spark plugs for your Polaris watercraft and make sure the spark plug gap is within specification. Measure gap (1) with a wire thickness gauge. S Use NGK PZFR6H spark plugs. S Proper electrode gap is .028″ +/- .002″...
  • Page 84 MAINTENANCE AND LUBRICATION Spark Plugs A spark plug with cracked porcelain or damaged threads should be changed immediately. If the electrodes are badly worn or burned the plug should also be replaced. If the spark plug is in good condition, clean it with a clean shop cloth and/or wire brush.
  • Page 85 The use of non-recommended cleaning or polishing products could seriously damage the appearance and/or integrity of your watercraft’s gelcoat surface. We recommend the use of the Polaris products listed on page 101. See your Polaris dealer for additional information about the care of your watercraft.
  • Page 86 MAINTENANCE AND LUBRICATION Polaris synthetic 2-cycle oils are formulated specifically to work with your Polaris Liberty marine engine. They’ve been thoroughly tested and provide the ultimate in performance and protection for your engine. In addition, our biodegradable oil is environmentally friendly. See page 101 for the part numbers of Polaris products.
  • Page 87 1. Depress and release the throttle lever. It should return to its initial position smoothly. If it doesn’t, see your authorized Polaris dealer for service. 2. Throttle lever free-play should not exceed .020″-.060″ (.5-1.5 mm). If it does, see your authorized Polaris dealer for service.
  • Page 88 MAINTENANCE AND LUBRICATION Battery Battery Maintenance and Charging WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
  • Page 89 Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1.
  • Page 90 MAINTENANCE AND LUBRICATION Battery Battery Charging WARNING Batteries produce explosive gases. Any sparks in the area could result in an explosion and cause serious injury or death. Keep sparks, flame, cigarettes, etc. away. Never charge a battery while it’s in the watercraft. Always remove the battery and charge in a safe area.
  • Page 91 2. Top off the battery with distilled water and charge it to a specific gravity of 1.26. 3. Recharge the battery monthly to prevent battery discharge and sulfating or use a Polaris Battery Tendert battery charger or similar trickle charger to maintain the charge during the storage period.
  • Page 92 After using the watercraft, visually inspect the screen for buildup of contaminants. Clean as required by flushing engine and/or screen with fresh water. See flushing procedure on page 91. If the screen cannot be cleaned by flushing, see your Polaris dealer for additional cleaning.
  • Page 93 Always flush the cooling system any time the watercraft has been beached. MAINTENANCE AND LUBRICATION Polaris recommends the use of Flush Kit PN 2873623 when flushing the cooling system. 1. Attach a garden hose to the female coupler/hose attachment.
  • Page 94 Perform all of the procedures outlined in this section of your owner’s manual before storing the watercraft. Refer to page 101 for part numbers of Polaris products. Clean the cooling system according to instructions on page 91.
  • Page 95 The fogging oil coats all internal parts for prevention of rust and corrosion, which in turn will extend the life of the engine. See page 101 for part numbers of Polaris products. 1. Remove the...
  • Page 96 5. Spray the exterior of the engine with T9 metal protectant. 6. Cover the watercraft with an opaque tarp or Polaris watercraft cover and store the craft in a clean, dry place. NOTE: Make sure the nose is positioned upward at a 10_ angle to allow water drainage during storage.
  • Page 97 Extended Storage Lubrication 1. Remove the spark plugs and pour about one tablespoon of a recommended 2-cycle oil into each cylinder. 2. Inspect the spark plugs and apply dielectric grease to the threads. Install new plugs if necessary. 3. Lubricate the throttle and steering cables as outlined on page 79.

  • Page 98: Engine Troubleshooting

    Low battery voltage Mechanical failure Solution Replace the fuse Recharge battery to 12.5 VDC Check all connections and tighten as needed See your Polaris dealer Check all connections and tighten Install lock plate under shut-off switch Solution Refuel Replace with new fuel...
  • Page 99 Possible Rich Fuel Mixture Cause Fuel is very high octane ENGINE TROUBLESHOOTING Solution Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Replace with new fuel Clean screen fitting Drain exhaust Recharge battery to 12.5 VDC...
  • Page 100 Inspect and clean cooling system Clean screen fitting Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer See your Polaris dealer...
  • Page 101 Hydrolock Too much load/weight on craft Mechanical failure ENGINE TROUBLESHOOTING Solution Replace with recommended fuel See your Polaris dealer Set gap to specs or replace plugs Solution Replace spark plugs and/or wires Replace with recommended fuel Replace with recommended fluids...
  • Page 102 Cavitation, impeller damaged or worn Unusual Noise or Vibration From Propulsion System Possible Cause Weeds or debris lodged in impeller Damaged driveshaft Damaged pump bearings Solution Clean intake See your Polaris dealer Solution Clean the impeller See your Polaris dealer See your Polaris dealer...

  • Page 103: Polaris Products

    Battery Tendert Battery Charger 2870652 Retaining / Sealing Products Loctitet Products 2871312 Threadlock 242 Threadlock 262 2871322 Threadlock 271 2871423 Loctitet 518 2871460 Marine-Grade Silicone 2871329 POLARIS PRODUCTS 2870791 2871517 2872890 2872891 2872892 2872893 2871589 2871966 2871965 2871964 2871064 2873261 2871950...

  • Page 104: Specifications

    (.71 mm +/- .05 mm) Electric Starter Fuel Type 12V, 19A Fuel Delivery Intake Type ENGINE Polaris Marine 1200 HO DI Case Reed New Tuned Pipe/Water Cooled Oil Injected PLANETt TC-W3 or Synthetic 2-Cycle Oil 85 mm x 70 mm...
  • Page 105 PROPULSION Impeller, Stainless Steel Progressive Pitch, Radial Blade Propulsion Jet Pump Type Single Stage Axial Flow, Six Vane Stainless Steel Stator Transmission Reverse System Impeller Diameter Instrumentation 3 Blade, Ski Tow Hook, Stainless Steel Jet Drive Throttle Dominator, Mirrors Bilge Pump Direct Drive Sponsons Standard...

  • Page 106: Warranty

    REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement.
  • Page 107 The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 108 213 of the Clean Air Act. Polaris warrants that this engine is free from defects in materi- als and workmanship that would cause the engine to fail to conform with applicable regulations for the U.S.

  • Page 109: California Emissions Warranty

    The electronic engine management module in your water- craft engine contains a very accurate clock (i.e., hour meter) that accu- mulates engine run time. This clock will be used by Polaris to limit warranty coverage to 250 hours of use, within the first 4 years. Warran- ty coverage expires after 4 years, regardless of the hours of use.
  • Page 110 As the watercraft engine owner, you should however be aware that Polaris may deny you warranty coverage if your water- craft engine or a part has failed due to abuse, neglect, improper mainte- nance, or unapproved modifications.
  • Page 111 Use of parts that are not equivalent to Polaris parts, improper service, or lack of required maintenance which causes the warranted part(s) to fail may constitute abuse and/or improper ser- vice, thereby invalidating warranty liability hereunder.

  • Page 112: Index

    INDEX Accessories ..... Age Restrictions ....Anti-corrosion Treatment .
  • Page 113 ....Periodic Maintenance Schedule . . . 75-78 POLARIS PRODUCTS ..Post Operation Maintenance ..
  • Page 114 THIS MANUAL SHOULD REMAIN WITH THE WATERCRAFT, IN ITS STORAGE BAG, AT ALL TIMES. For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone (763) 542-0500 Fax (763) 542-0599 Part No. 9918124 Printed in USA...

This manual is also suitable for:

Msx 2003

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