Personal Watercraft Team Tips W--04--03--04 MARCH, 2004 2004 MSX 110 / 150 10-12 Hour Break -In Maintenance Interval The first 10 to 12 hours of engine operation is considered the break--in period on all 2004 MSX 110 and MSX 150 Personal Watercraft. After the initial break--in period, the engine oil and oil filter must be replaced, the valve shim clearance, or valve lash, must be inspected and adjusted, and the intake manifold fasteners must be re--torqued to specification. In addition to the three main service procedures that must be performed after the break--in period, it is recommended that the service technician perform a general maintenance overview of the watercraft and engine compartment. Service technicians should look for any loose or kinked hoses, broken wires, or loose wiring connections, and for loose or missing fasteners. Engine Oil Specifications The engine oil and oil filter must be changed after the break--in period, and then every 25 hours thereafter. ENGINE OIL SPECIFICATION: Polaris Marine PS -4 Synthetic 15W -50 OIL CAPACITY (After Oil and Filter Change): 3.4-3.7 US Quarts ( 3.3-3.5 Liters) OIL CAPACITY (Rebuilt Engine - DRY): 3.9-4.2 US Quarts (3.7-4.0 Liters) OIL PN: 2874862 / Filter PN: 0451848 / O -Ring PN: 0451937 OIL CHANGE KIT PN: 2875209 (Includes 4qts. Oil, 1 Filter, and 1 O -ring.) Currently Not Available NOTE: Mobil 1 15W--50 Type SJ Synthetic Engine Oil is the ONLY recommended oil substitute. Oil Level Check - Cold Engine Several dealers have contacted the Polaris Technical Service Department with concerns that when they remove the oil dipstick, there is no oil present on the end of the measuring stick. DO NOT be alarmed if this happens! This is a NORMAL CONDITION when the engine is cold. The only accurate method for checking the engine oil level is after the engine has been running for at least 30 seconds. 1. Verify the watercraft is level, regardless if on the trailer or moored to a dock in calm water. 2. Start the engine, and run at idle speed for at least 30 seconds, but no more than 1 minute. DO NOT REV UP THE ENGINE. 3. Stop the engine, and remove the dipstick. Wipe dipstick clean. Re--insert dipstick without re--threading into tank. 4. Remove dipstick, and read oil level. The oil level should be between the MINIMUM and MAXIMUM marks. Add oil to bring the level up to the MINIMUM mark if low, remove oil from the tank if level is above the MAXIMUM mark. 5. After running the watercraft in water for at least 30 minutes, re--check the oil level in the storage tank. The oil level MUST NOT rise above the OVERFILLED mark on the dipstick. Remove excess oil from the storage tank in the event that the oil level is above the OVERFILLED mark. 1
Oil Level Check - Cold Engine OVERFILLED RANGE Damage to engine sensors, and wastegate solenoid will occur if level is sustained. OPERATIONAL RANGE Oil level will increase as oil and engine temperature rises. OVERFILLED OIL LEVEL MAXIMUM OIL LEVEL.5 US Qt. (.5 L) MINIMUM OIL LEVEL Oil Change Procedure 1. Remove the dipstick from the oil storage tank. 2. Using a oil extraction / storage tool, insert the hose through the larger hole in the top of the tank. Verify the hose is inserted through the baffle plate located in the middle of the tank. The hose must reach the bottom of the tank. 3. Extract ALL of the oil out of the storage tank. Remove the hose, and replace the dipstick. 4. Remove the fuel injector and ignition coil wiring harness connectors. 5. Remove the upper oil supply hose from the top of the oil storage tank. 6. Locate either a 2 liter plastic bottle, or a 5 foot length of hose and a male--to--male hose coupler. REMOVE THIS HOSE 2
Oil Change Procedure - Continued 7. Insert the oil supply hose into the two--liter bottle inside the engine compartment, or, insert the coupler into both ends of the hoses, then hang the entire length of hose over the side of the watercraft. Position this hose into a oil pan or oil containment container. 8. Insert the safety lanyard into the stop switch. Press and hold the start button for no more than 15 seconds. 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. 9. 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. 10. Reinstall oil filter cover cap and torque to 24 Nm (17 ft.lbs.) 11. Clean oil tank hose fitting with brake cleaner or acetone, then reinstall the oil supply hose to the oil storage tank. Torque gear clamp to 30 in.lbs. 12. Fill to oil tank with 3.4 -- 3.7 qts. (3.3 -- 3.5 L) of Polaris PS--4 Synthetic Marine engine oil. NOTE: Never add more than 3.7 qts. (3.5 L) 13. Reconnect the fuel injector and ignition coil wiring harness connectors. 14. Start engine and idle for 30 seconds. Stop engine and re--check engine oil level. 15. Add engine oil until level is at the low mark on dipstick. ELEMENT CAP O--RING INSTALL O RING IN MIDDLE GROOVE 3
Valve Shim Clearance Inspection / Adjustment NOTE: Polaris shipped ALL PWC dealers the Valve Compression Tool, PN: PW -46991. This tool was designed to compress the valve springs and caps which would allow the technician to remove and install the valve shims. Ongoing usage of the tool revealed an issue where the improper use of the tool could cause the valve stem keepers to dislodge and fall out. When this happens, the valve may fall into the cylinder. Because of this concern, Polaris has designed a new valve compression tool that dramatically increases the ease of removing and installing valve shims without dis -lodging the valve stem keepers. The new Valve Compression - Guillotine Tool, PN: PW -47163, will be available in the coming weeks. Polaris will direct -ship the new tool to all PWC dealers. Use extreme care when using the ANY valve compression tool. DO NOT dis -lodge the valve stem keepers when extracting and installing valve shims. 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 engine. 4. Rotate the engine until the MAG cylinder is at TDC -- COMPRESSION stroke. NOTE: TDC - COMPRESSION stroke is found when the both cam lobes are pointed down, away from the rocker arms, and the piston is at TDC. 5. Verify each rocker arm is loose and not engaged by the camshaft. 6. Using a feeler gauge, measure the clearance at each of the 4 valves between the installed shim and rocker arm. Record each measurement. (Photo B) 7. If the measured clearance is within specification, no adjustment is required. 8. If the measured clearance is out of specification, the valve shim must be replaced with one that will satisfy the clearance specifications. VALVE CLEARANCE SPECIFICATION Photo A INTAKE VALVE:.08 --.15MM (.003 --.006) EXHAUST VALVE:.18 --.25MM (.007 -- 0.10) Photo B 4
Valve Shim Clearance inspection / Adjustment 9. Install the Valve Compression Tool, PN PW--46991, under the rocker arm and over the top of the valve. Push the lever down, and extract the shim using a magnet. CAUTION: Do not compress the valve into the piston face. Do not damage or move the valve keepers. 10. Measure the original shim and determine the shim, smaller or larger, that will satisfy the clearance specification. Available valve clearance shims. Part Number Shim Thickness (mm) 0451357 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, rapidly tap the start button to rotate the engine to TDC -- COMPRESSION stroke on the PTO cylinder. 12. Perform the valve adjustment procedure on the PTO cylinder valve train. 13. When completed, reinstall the valve cover. Tighten fasteners to 7 ft.lbs. (10 Nm). 14. Reinstall the phase sensor, ignition coil, and fuel injector wiring harness connectors. 5
Intake Manifold Re -Torque Procedure During the break--in period maintenance check, the fasteners that secure the intake manifold to the water--to--water heat exchanger lower bracket must be re--torqued. SA = 13 ft.lbs. (18 Nm) SB = 7 ft.lbs. (10 Nm) A B 6