msx150 part diag

MSX 150Model #W045305CAMSX 150 INT’L

Model #W045305IAMSX 150

Model #W045305CBMSX 150 INT’L

Model #W045305IBMSX 150 INT’L

Model #W045305IEE 2004 Polaris Sales Inc.

PARTS MANUAL PN 9919057 and MICROFICHE PN 9919058 2/04

MSX 150Model #W045305CCMSX 150 INT’L

Model #W045305ICMSX 150

Model #W045305CDMSX 150 INT’L

Model #W045305IDMSX 150 INT’L

Model #W045305IF

TABLE OF CONTENTSMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150

INT’L W045305IC and MSX 150 INT’L W045305IE and MSX 150 W045305CD and MSX 150 INT’L W045305ID and MSX 150 INT’L W045305IF

Parts Manual

AAIRBOX D1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

BBATTERY BOX B6. . . . . . . . . . . . . . . . . . . . . . .

CCHAIN TENSIONER C5. . . . . . . . . . . . . . . . . . .COMPARTMENT DOOR A3. . . . . . . . . . . . . . . .COOLANT BOTTLE D7. . . . . . . . . . . . . . . . . . .COOLANT ELBOW D8. . . . . . . . . . . . . . . . . . . .COOLANT RAIL B10. . . . . . . . . . . . . . . . . . . . . .COOLING SYSTEM B4. . . . . . . . . . . . . . . . . . .CRANKSHAFT and BALANCE SHAFT B12. . . . . .CYLINDER C7. . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS B8. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE SYSTEM A12. . . . . . . . . . . . . . . . . . . . . .

EECU MOUNTING D14. . . . . . . . . . . . . . . . . . . . .ELECTRICAL B5. . . . . . . . . . . . . . . . . . . . . . . .ENGINE BEDPLATE D2. . . . . . . . . . . . . . . . . . .ENGINE MOUNTING B7. . . . . . . . . . . . . . . . . .ENHANCED STEERING PERFORMANCE D12. . .EXHAUST GASKETS and HARDWARE C10. . . . .EXHAUST SYSTEM B3. . . . . . . . . . . . . . . . . . .

FFLYWHEEL C2. . . . . . . . . . . . . . . . . . . . . . . . .FUEL RAIL C9. . . . . . . . . . . . . . . . . . . . . . . . . .FUEL SYSTEM A9. . . . . . . . . . . . . . . . . . . . . . .FUEL TANK A8. . . . . . . . . . . . . . . . . . . . . . . . .

HHEAT EXCHANGER D5. . . . . . . . . . . . . . . . . . .HULL and BODY A5-6. . . . . . . . . . . . . . . . . . . . .

IIGNITION COILS C11. . . . . . . . . . . . . . . . . . . . .INTAKE D4. . . . . . . . . . . . . . . . . . . . . . . . . . . .INTERCOOLER D3. . . . . . . . . . . . . . . . . . . . . .

MMAGNETO C1. . . . . . . . . . . . . . . . . . . . . . . . . .

OOIL COOLER C14. . . . . . . . . . . . . . . . . . . . . . . .OIL FILTER C6. . . . . . . . . . . . . . . . . . . . . . . . .OIL LINES D6. . . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP B14. . . . . . . . . . . . . . . . . . . . . . . . . .OIL SUMP B9. . . . . . . . . . . . . . . . . . . . . . . . . .OIL TANK D6. . . . . . . . . . . . . . . . . . . . . . . . . . .

PPISTON and ROD B13. . . . . . . . . . . . . . . . . . . . .POPOFF VALVE D1. . . . . . . . . . . . . . . . . . . . . .PPU ASM. D13. . . . . . . . . . . . . . . . . . . . . . . . . .PROPULSION A14. . . . . . . . . . . . . . . . . . . . . . .

RREVERSE A13. . . . . . . . . . . . . . . . . . . . . . . . . .

SSEAT A7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SENSORS D10. . . . . . . . . . . . . . . . . . . . . . . . . .SHROUD and STORAGE A4. . . . . . . . . . . . . . .STEERING A10. . . . . . . . . . . . . . . . . . . . . . . . . .STEERING CABLE A11. . . . . . . . . . . . . . . . . . . .

TTHROTTLE BODY D4. . . . . . . . . . . . . . . . . . . .TOOL KIT D11. . . . . . . . . . . . . . . . . . . . . . . . . . .TURBOCHARGER and LINES C12-13. . . . . . . . . . . .

VVALVE COVER C8. . . . . . . . . . . . . . . . . . . . . . .VALVE TRAIN C4. . . . . . . . . . . . . . . . . . . . . . . .VALVES C3. . . . . . . . . . . . . . . . . . . . . . . . . . . .VOLTAGE REGULATOR D9. . . . . . . . . . . . . . . .

WWATER EXCHANGER D5. . . . . . . . . . . . . . . . .WATER INLET B1. . . . . . . . . . . . . . . . . . . . . . .WATER PUMP B11. . . . . . . . . . . . . . . . . . . . . . .WATER SIPHON B2. . . . . . . . . . . . . . . . . . . . .

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

A3

COMPARTMENT DOORMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L

W045305IC and MSX 150 INT’L W045305IE and MSX 150 W045305CD and MSX 150 INT’L W045305ID and MSX 150 INT’L W045305IF

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Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 5435307-466 1 Windshield, Smokin’ Clear2 7518042 4 Screw3 5412344

541234511

Gasket, Mirror, LHGasket, Mirror, RH

4 2632908-0702632909-0702632518-445

2632519-445

2632908-4452632909-4452632908-4412632909-4412632908-4442632909-444

111

1

111111

Asm., Mirror, Blk, LH (CD)(IF)Asm., Mirror, Blk, RH (CD)(IF)Asm., Mirror, Turbo Silver, LH(CA)(If built before 2/1/04)Asm., Mirror, Turbo Silver, RH(CA)(If built before 2/1/04)Asm., Mirror, Turbo Silver, LH (CA)Asm., Mirror, Turbo Silver, RH (CA)Asm., Mirror, Catalina Blue, LH (CC)(IE)Asm., Mirror, Catalina Blue, RH (CC)(IE)Asm., Mirror, Solar Red, LH (CB)Asm., Mirror, Solar Red, RH (CB)

5 7556094 22 Washer6 7546704 12 Nut, Nylok7 7546705 2 Nut8 7081088 1 Latch9 7552613 6 Washer, Lock10 7517528 2 Screw11 5134119 1 Plunger, Latch

12 7555841 1 Washer, Flat13 5412299 2 Bumper, Rubber, Latch Post14 7555831 5 Washer, Flat15 7546804 5 Nut, Hex, Nylok16 ------ -- -- -- -- 1 Hinge, Lower17 7518185 4 Screw18 5133641 1 Pin, Dowel19 2632863 1 Asm., Hinge, Front (Incl. 15,16,21,24)20 5435401 2 End, Gas Shock21 7042260 1 Spring, Gas22 7516807 4 Bolt23 7518187 4 Screw24 ------ -- -- -- -- 1 Hinge, Upper25 7080703 3 Clip26 5434520-1093

5434520-4455434520-4445434520-441

1111

Door, Compartment, Stealth Blk (CD)(IF)Door, Compartment, Turbo Silver (CA)Door, Compartment, Solar Red (CB)Door, Compartment, Catalina Blue(CC)(IE)

27 3280458 1 Gauge, NGI

2/04

A4

SHROUD and STORAGEMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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1 5435640 1 Latch2 5434521-1093

5434521-4455434521-4445434521-441

1111

Lid, Glove Box, Stealth Blk (CD)(IF)Lid, Glove Box, Turbo Silver (CA)Lid, Glove Box, Solar Red (CB)Lid, Glove Box, Catalina Blue (CC)(IE)

3 7518042 16 Screw4 7556286 16 Washer, Nylon, Spacer5 5434518-1093

5434519-10935434518-4455434519-4455434518-4445434519-4445434518-4415434519-441

11111111

Shroud, Left, Stealth Blk (CD)(IF)Shroud, Right, Stealth Blk (CD)(IF)Shroud, Left, Turbo Silver (CA)Shroud, Right, Turbo Silver (CA)Shroud, Left, Solar Red (CB)Shroud, Right, Solar Red (CB)Shroud, Left, Catalina Blue (CC)(IE)Shroud, Right, Catalina Blue (CC)(IE)

6 52470545247055

11

Mesh, Wire, Eyelet, LHMesh, Wire, Eyelet, RH

7 7518130 4 Screw8 7556252 4 Washer, Flat9 5224854 4 Bumper10 1014182-1093

1014182-4451014182-4441014182-441

1

111

Asm., Shroud, Upper, Stealth Blk(CD)(IF)Asm., Shroud, Upper, Turbo Silver (CA)Asm., Shroud, Upper, Solar Red (CB)Asm., Shroud, Upper, Catalina Blue(CC)(IE)

11 5521658 1 Seal, Bucket, Top12 5434678 1 Bucket, Storage13 5521660 1 Seal, Bucket, Bottom14 5521642 1 Seal, Bucket, Bottom15 7518042 4 Screw16 7556094 4 Washer17 5434513 1 Guard, Splash18 7547244 13 Insert19 7547245 7 Insert20 5830234 1 Pad21 5434666 1 Box, Glove22 7621336 4 Rivet23 2683618 1 Net, Cargo24 5434770-070 2 Clip25 5830235 1 Seal26 5434726 1 Plug

2/04

A5

HULL and BODYMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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1 7078465 1 Logo, Polaris Star2 7518201 3 Screw3 5435337-070 1 Cap, Rub Rail, Rear, Black4 7555836 3 Washer5 7546704 3 Nut, Nylok6 5521683-368 2 Rail, Rub, Insert7 7518150 4 Screw8 7621488 12 Rivet9 7518221 24 Screw10 2632897 1 Hook, Tow w/Non-Adjust Plunger11 7555831 10 Washer, Flat12 7546804 6 Nut, Hex, Nylok13 5434911-467

5434912-46711

Sponson, Slasher Metal, LHSponson, Slasher Metal, RH

14 7518205 8 Screw

15 7556293 8 Washer, Flat16 5435338-1093

5435338-4455435338-4445435338-441

1111

Handle, Grab, Stealth Blk (CD)(IF)Handle, Grab, Turbo Silver (CA)Handle, Grab, Solar Red (CB)Handle, Grab, Catalina Blue (CC)(IE)

17 7517668 6 Screw18 5434965 1 Bumper, Front19 5812653-318

5812654-31811

Pad, Footwell, Front, LHPad, Footwell, Front, RH

20 5812655-3185812656-318

11

Pad, Footwell, Center, LHPad, Footwell, Center, RH

21 5812657-3185812658-318

11

Pad, Footwell, Rear, LHPad, Footwell, Rear, RH

22 5812659-3185812660-318

11

Pad, Boarding, LHPad, Boarding, RH

23 5521671-0705521672-070

11

Rail, Rub, PortRail, Rub, Starboard

5/04

A6

HULL and BODYMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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1 7511882 4 Screw2 1060125 2 Asm., Bilge, Plug3 7518220 2 U-Bolt4 7546705 8 Nut5 7555870 4 Washer, Rubber6 7556094 4 Washer7 7552613 4 Washer, Lock8 7555874 4 Washer, Flat9 7518194 1 U-Bolt10 7547235 2 Nut11 7546804 4 Nut, Hex, Nylok12 7081140 1 Strap, Velcro

13 7555834 2 Washer14 5812021 1 Gasket, Strap, Bow15 2632213 1 Strap, Bow16 7080492 1 Cable Tie, 11 Inch17 7080598 2 Cable Tie, 21.25 Inch18 7080439 2 Clamp, Hose19 5433220 2 Flange20 7661042 6 Rivet21 5411545 2 Gasket22 5430016

543456311

Duct, Inlet, Air 76 Inch (RH)Duct, Inlet, Air 38 Inch (LH)

11/03

A7

SEATMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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1 2683420-404 1 Asm., Seat (Incl. All)2 7081088 1 Latch3 7556094 2 Washer

4 7552613 2 Washer, Lock5 7516806 2 Bolt6 5521668 1 Seal

2/04

A8

FUEL TANKMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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1 5433259 1 Nut2 2410374 1 Pump, Fuel3 5412305 2 Strap, Connecting4 5411636 1 Gasket5 5434874 1 Tank, Fuel6 5521615 4 Cover, Strap7 2632743 4 Asm., Strap (Incl. 6)8 5247361 4 Bracket, Tank Strap9 7621485 8 Rivet10 5812564 1 Pad11 7080451 1 Clamp, Hose

12 5412441 1 Hose, Fuel Fill13 7080766 1 Clamp, Hose14 5812560 1 Gasket, Fuel Fill15 5433553 1 Inlet, Fuel16 7511873 1 Screw17 5411305 1 Seal, Fuel Cap18 2520177 1 Asm., Cap, Fuel, Ratchet19 7080710 1 Chain, Bead20 7080442 2 Coupling, End21 7621229 1 Rivet22 5433621 1 Nut, Fuel Inlet

1/04

A9

FUEL SYSTEMMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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1 7052358 2 Connector, Quick Fuel Return2 7080476 12 Clamp, Hose3 5410682 1 Grommet, Vent4 7080483 1 Cable Tie, 4 Inch5 7080138 2 Cable Tie6 7052118 1 Value, Vacuum Check7 8450104-250 AR Line, Fuel8 7052111 1 Fitting, Tee9 7051015 1 Valve, Relief Check

10 7052253 1 Asm., Connector11 7052355 1 Fitting, Reducer12 8450107-250 AR Line, Fuel13 7080482 1 T-Clip14 2520387 1 Filter, Fuel15 7080598 1 Cable Tie, 21.25 Inch16 7621485 3 Rivet17 5247983 1 Bracket, Fuel Filter

3/04

A10

STEERINGMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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1 7517520 4 Screw2 7555837 2 Washer, Flat3 7541931 4 Nut, Hex4 5433355-070 1 Handle, Grab5 5434516-070 1 Pad, Handlebar6 5432729 1 Block, Split, Throttle7 2410381 1 Switch, Start/Stop8 1821342-070 1 Asm., Handlebar/Column9 7080675 1 Lanyard w/Whistle10 7518247 3 Screw11 7555831 3 Washer, Flat12 5410836 1 Grommet, Cable13 5246810 1 Bracket, Grommet14 5246438 1 Plate, Top15 5434771 1 Housing, Steering16 7556262 2 Washer, Shim17 5631307 1 Arm, Steering

18 7517528 3 Screw19 5434772 1 Clamp20 5434773 1 Adjuster, Mount21 7542335 1 Nut, Hex22 7547250 3 T-Nut23 7080138 3 Cable Tie24 5812485 1 Pad, Foam25 5434915 2 Bushing, Tapered26 7081186 1 Cable, Throttle27 7710426 1 Ring, Retaining28 7555840 1 Washer, Flat29 5434913 1 Lever, Throttle30 7661628 1 Pin, Retaining31 5432728 1 Clamp, Split, Throttle32 7518151

75526137555836

666

ScrewWasher, LockWasher

11/03

A11

STEERING CABLEMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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1 7515120 1 Bolt2 7555839 2 Washer, Flat3 7060170 2 Rod End4 7542150 2 Nut5 5412206 1 Seal, Rod6 1860114 1 Nut

7 7081080 1 Cable, Steering8 7080138 1 Cable Tie9 5411818 1 Seal, Rod10 7518026 1 Screw11 7542133 2 Nut, Nylok

2/04

A12

DRIVE SYSTEMMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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1 5410663 1 Bumper2 1591388 1 Driveshaft3 5812538 1 Cover, Coupler4 1350091 1 Asm., Bearing Support5 5133826 1 Washer, Thrust6 5248082 AR Shim7 5631450 1 Coupler, Drive Pump

8 5412559 1 Coupler, Drive9 5631451 1 Coupler, Drive, Engine10 7518119 4 Bolt11 7556055 4 Washer, Lock12 7516603 2 Bolt13 5812495 1 Gasket, Base, Bearing Support

1/04

A13

REVERSEMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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1 5435313 1 Gate, Reverse2 7555839 2 Washer, Flat3 7661010 1 Pin, Cotter4 7061062 1 Rod, End5 7661117 1 Pin, Clevis6 7542150 1 Nut7 5412206 1 Seal, Rod8 5411818 1 Seal, Rod9 7081089 1 Cable, Reverse10 4010051-100 1 Conduit, Convoluted11 7080138 2 Cable Tie12 5435282 1 Plate, Base, Reverse13 7710556 4 Retainer14 2632646-070 1 Asm., Handle, Reverse15 5812529 1 Gasket, Base, Reverse16 7546704 3 Nut, Nylok17 7556094 3 Washer18 7516807 3 Bolt19 5435279 1 Plate, Cable Alignment

20 7512049 2 Screw21 7555837 1 Washer, Flat22 7661010 1 Pin, Cotter23 7518298 1 Screw24 7556299 1 Washer, Flat25 5435281 1 Arm, Reverse26 7661159 2 Rivet27 2410417 1 Sensor, Reed, Magnet28 7516817 1 Screw29 5435280 1 Track, Reverse Driver30 2410442 1 Sensor, Reed, Switch, Reverse31 7547001 2 Nut32 7555856 2 Washer, Flat33 7556269 1 Washer, Lock34 7515368 2 Bolt35 7555874 2 Washer, Flat36 5020683 2 Collar37 7555866 2 Washer

1/04

A14

PROPULSIONMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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1 7542455 4 Nut, Hex2 7555966 2 Washer3 5132111 4 Stud, Mounting, Pump, Long4 5131573 1 Housing, Pump w/o Ring5 5410735 2 O-Ring6 5432269 1 Pipe, Water, Engine7 5132088 1 Stator8 5010294 1 Spacer9 3514008 2 Bearing10 3610043 2 Seal, Stator Bearing11 5134505 1 Spacer, Impeller12 5134338 1 Impeller13 5410731 1 O-Ring14 5131196 1 Extension, Pump15 7522019 1 Screw16 5630598 1 Anode, Zinc17 5244556 1 Bracket, Steering Cable Nut

18 5410817 1 O-Ring19 5410819 1 O-Ring20 5431523 1 Screen, Engine Inlet21 5130999 1 Nozzle, Steering22 7515366 2 Bolt23 5431518 2 Bearing, Steering Nozzle24 5130938 2 Collar25 7552610 4 Washer, Lock26 7555835 4 Washer, Flat27 7515389 4 Bolt28 1350097 1 Asm., Nozzle29 5432841 1 Wedge, Pump30 7512064 3 Screw31 5431519 1 Cone, Pump32 5811984 1 Seal, Tail Cone33 5132674 1 Shaft, Stub34 5410818 1 O-Ring

1/04

B1

WATER INLETMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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1 7517897 2 Screw2 7556270 2 Washer, Lock3 7556271 2 Washer, Flat4 2410344 1 Asm., Wheel, Paddle5 4010051-10 1 Conduit, Convoluted6 7080138 3 Cable Tie

7 5631598-329 1 Plate, Ride8 5631330 1 Scoop, Inlet9 5631328-067 1 Grate, Inlet10 7556293 1 Washer, Flat11 7518119 9 Bolt

3/04

B2

WATER SIPHONMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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1 7080138 8 Cable Tie2 5431409 2 Elbow, Siphon Hose3 8450051-600 4 Line, Fuel4 7670116 2 Clip, Routing

5 5432036 2 Pickup, Siphon w/Strainer6 5431990 2 Pipe, Water, Bilge7 8450054-33 2 Hose, Water

11/03

B3

EXHAUST SYSTEMMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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4E 2003 Polaris Sales Inc.

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1 7518026 2 Screw2 7555838 4 Washer, Lock3 7555857 4 Washer, Flat4 5631414-329 1 Cover, Exhaust, Outlet5 5132446 1 Fitting, Exhaust6 5247008 1 Bracket, Pump Face, Silencer Mount7 5430621 1 Strap8 5243775 2 Hook, Strap, Narrow9 7621485 2 Rivet10 5240134 1 Clip, Strap11 7080907 4 Clamp, Hose12 5412523 1 Hose, Exhaust13 7080439 2 Clamp, Hose

14 7517538 5 Screw15 7556055 5 Washer, Lock16 5020747 1 Fitting, Injector17 1202743-329 1 Pipe, Exhaust (Incl. 16,19)18 5812528 1 Gasket, Exhaust19 7052071 1 Fitting, Pipe20 1261341-067 1 Asm., Silencer Exhaust21 5412525 1 Hose, Exhaust, Silencer/Resonator22 5812558-318 2 Pad, Resonator23 5433811 1 Resonator, Exhaust24 5412524 1 Hose, Exhaust, Resonator/Outlet25 7518259 2 Screw

2/04

B4

COOLING SYSTEMMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


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13

11


1 5811317 1 Gasket2 5431444-133 1 Fitting, Thru-Hull3 7080475 6 Clamp, Hose4 7080138 6 Cable Tie5 5521287-76 1 Conduit, Flex6 5412502 1 Hose, Water7 5412565 1 Hose, Water Main to Intercooler8 5521287-90 1 Conduit, Flex

9 7080476 3 Clamp, Hose10 8450054-23 1 Hose, Water11 7080474 1 Clamp12 5521398-37 1 Conduit, Flex13 8450054-46 1 Hose, Water14 5431784 1 Fitting, Tee15 5412510 1 Hose, Water

3/04

B5

ELECTRICALMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


4

10

12

6

16

78

11

9

5

2 3


1

131415

17


1 2434016 1 Fuse, 10 Amp.2 4010859 2 Fuse, 15 Amp.3 4010752 1 Fuse, 2 Amp.4 2461024 1 Harness, Wire, Door5 2461238 1 Harness, Chassis6 5410346 3 Insulator, Cable, Solenoid7 7546705 2 Nut8 7552613 2 Washer, Lock9 ------ -- -- -- -- 1 Cable (See Battery Box Pg. B6, Ref. 9)

10 4011057 1 Solenoid, Starter11 7556261 2 Washer, Lock, External12 4010237 1 Cable, Solenoid/Starter13 2410532 1 Harness, Engine14 7080464 1 Anchor, Cable Tie15 5521286-2.5 9 Conduit, Wire16 7080138 5 Cable Tie17 7080492 1 Cable Tie, 11 Inch

5/04

B6

BATTERY BOXMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


1

7

23

4

98

5


6


1 5432413 1 Cover, Battery2 5410682 1 Grommet, Vent3 7052356 1 Fitting, Elbow4 5432121 1 Tube, Vent5 7080138 3 Cable Tie

6 2520338 1 Asm., Velcro Strap, Battery7 4140009 1 Battery, 19 Amp.8 2200619 2 Kit, Battery Bolt9 4011076 1 Cable, Ground, Battery

1/04

B7

ENGINE MOUNTINGMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


1112

8

9


4

7

10

5

2

13

3

6

1


1 7172701 1 Decal, Oil Maintenance2 7172442 1 Decal, Spark Plug Rec 150/1103 7172426 1 Decal, Emission Control Information4 7547001 4 Nut5 7552612 4 Washer, Lock6 7547235 1 Nut7 7556302 4 Washer, Flat

8 5211727 AR Shim9 3021253 4 Mount, Engine10 5435343 4 Block, Motor Mount, Spacer11 7555831 8 Washer, Flat12 7556055 8 Washer, Lock13 7518258 8 Screw

5/04

B8

DECALSMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


179

8

15

6

18

114

14

2122

123

23

2019

5

7

10

2E 2003 Polaris Sales Inc.

16

131

24

25


220268022027172202679

111

Decal, Kit, ’04 MSX 150 (CA)(CD)(IF)Decal, Kit ’04 MSX 150 (CB)Decal, Kit ’04 MSX 150 (CC)(IE)

1 7171381 1 Decal, NGI2 7170887 1 Decal, Lens Cover, Gauge3 7171063 1 Decal, Low Emissions4 7170794 1 Decal, Coast Guard Exemption5 7172528 1 Decal, Warning, Collision6 7172389 1 Decal, 3 Capacity7 7172604 1 Decal, Warning, Op Protect8 7079171 1 Logo, Planet9 7079125 1 Decal, Spark Ignition Comp w/Canada10 7171396 1 Decal, Fire Extinguisher11 7172603 1 Decal, Warning Fuel12 7171853

717185411

Decal, Air Intake, LHDecal, Air, Intake, RH

13 7171867 1 Decal, “MSX”, Hood, RH (CD)(IF)14 7170886 1 Decal, Medallion15 7170787 1 Decal, Reverse

16 7170895 1 Decal, “LIBERTY MARINE”17 7078465 1 Logo, Polaris Star18 7172602 1 Decal, Warning, Capsized Boat19 7170818 2 Decal, Hull, “POLARIS”20 7171865

71718667170804717080571718777171878

111111

Decal, Deck, Rear, LH (CA)(CD)(IF)Decal, Deck, Rear, RH (CA)(CD)(IF)Decal, Deck, Rear, LH (CB)Decal, Deck, Rear, RH (CB)Decal, Deck, Rear, LH (CC)(IE)Decal, Deck, Rear, RH (CC)(IE)

21 7172433 1 Decal, Patent22 7171898 2 Decal, “POLARIS”, Brush Aluminum23 7171863

71718647170802717080371718757171876

111111

Decal, Deck, Front, LH (CA)(CD)(IF)Decal, Deck, Front, RH (CA)(CD)(IF)Decal, Deck, Front, LH (CB)Decal, Deck, Front, RH (CB)Decal, Deck, Front, LH (CC)(IE)Decal, Deck, Front, RH (CC)(IE)

24 7172443 1 Decal, Fuel Req25 7172605 1 Decal, Warning, Under Seat

2/04

B9

OIL SUMPMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


1

8

2

3

11

14

12

9

7

13

10


6

1

5

9

4


1 0451543 4 Bolt2 0451513 2 Washer3 0451561 1 Screen, Oil4 0451542 9 Bolt5 0451447 4 Sleeve, Centering6 0451544 3 Bolt7 0451901 1 Asm., Gear

8 0451545 1 Bolt9 0451538 4 O-Ring10 0451986 1 Elbow, Connection11 0451546 2 Screw12 0451985 1 Plug13 0451984 1 Cover, Sump, Dry14 0451548 1 Pump, Suction

2/04

B10

COOLANT RAILMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


6

10

2

5

3

1

8

4

E 2003 Polaris Sales Inc. 9

7


1 0451350 1 Sensor, Water Temperature2 0451553 2 O-Ring3 0451542 2 Bolt4 0451987 1 Asm., Coolant Rail5 0451849 1 Asm., Thermostat

6 0451552 1 O-Ring7 0451943 1 Nipple, 90 Degrees8 0451453 1 Circlip9 0451915 1 O-Ring10 0451556 1 Fitting

2/04

B11

WATER PUMPMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


3

4

12

8

117


10

2

9

5 6

1

1


1 0451528 2 Clamp2 0451520 1 Hose3 0451951 1 Housing, Water Pump4 0451875 1 O-Ring5 0451854 1 Seal, Slide Ring6 0451898 1 Ring, Counter

7 0451900 1 Shaft, Waterpump8 0451899 1 Gear, Intermediate9 0451942 1 Impeller10 0451542 2 Bolt11 0451544 1 Bolt12 0451555 1 Bolt

2/04

B12

CRANKSHAFT and BALANCE SHAFTMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


3

2

67

1


45


1 0451454 1 Asm., Crankshaft2 0451522 1 Key3 0451435 1 Shaft, Balance, Gear Drive4 0451347 4 Shell, Bearing, Balance Shaft

5 045134204513440451345

444

Bearing, Main, YellowBearing, Main, BlueBearing, Main, Green

6 0451394 1 Gear, Balance, Shaft, Drive7 0451413 1 Nut

2/04

B13

PISTON and RODMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


2

1

4

3


1


1 0451999 2 Kit, Asm., Piston2 0451903 2 Asm., Rod, Connecting

3 0451853 4 Bolt, Connecting Rod4 0451338 4 Bearing, Red

2/04

B14

OIL PUMPMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


2

1

4

6

53



1 0451452 1 Key2 0451857 1 Pump, Oil3 0451506 2 O-Ring

4 0451983 1 Cover, Pump5 0451453 1 Circlip6 0451403 1 Asm., Insert

2/04

C1

MAGNETOMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



11

12

13

10

5

23

26

2221

20

1

24

25

4

17

2

79

6

19

8

18

3

1

4

16

14

15


1 0451447 2 Sleeve, Centering2 0451892 1 Key3 0451982 1 Cover, Front4 0451542 16 Bolt5 ---- -- -- -- -- -- 1 Gear, Starter, Wheel6 0451494 6 Bolt7 ---- -- -- -- -- -- 1 Wheel, Speed Sensor8 ------ -- -- -- -- 1 Wheel9 ------ -- -- -- -- 1 Clutch, Starter10 0451579 1 Bearing, Needle11 0451931 1 Asm., Starter Gear Wheel12 0451411 1 Motor, Starter13 0451568 2 Bolt

14 0451904 1 Lead, Starter15 0451868 1 Gromment, Rubber16 0451906 1 Nut17 0451961 1 Rotor, Alternator (Incl. 5-9)18 0451932 1 Washer19 0451417 1 Bolt20 0451544 3 Bolt21 0451486 1 Stator, Alternator22 0451494 1 Bolt23 0451988 1 Cover, Alternator24 0451570 4 Bolt25 0451543 1 Bolt26 0451493 1 Clamp, Cable

2/04

C2

FLYWHEELMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



2

4

5

1

3


1 0451953 1 Shaft, Stub2 0451952 1 Flywheel3 0451956 6 Washer

4 0451950 6 Bolt5 0451946 1 Seal

2/04

C3

VALVESMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



7

5

4

3

2

1

6


1 0452014045201504520160452017045201804520190452020045202104520220452000045200104520230452002045200304520040452005045202404520060452007045200804520090452010045201104520120452013

8888888888888888888888888

Shim, Valve, 2.50Shim, Valve, 2.55Shim, Valve, 2.60Shim, Valve, 2.65Shim, Valve, 2.70Shim, Valve, 2.75Shim, Valve, 2.80Shim, Valve, 2.85Shim, Valve, 2.90Shim, Valve, 2.95Shim, Valve, 3.00Shim, Valve, 3.05Shim, Valve, 3.10Shim, Valve, 3.15Shim, Valve, 3.20Shim, Valve, 3.25Shim, Valve, 3.30Shim, Valve, 3.35Shim, Valve, 3.40Shim, Valve, 3.45Shim, Valve, 3.50Shim, Valve, 3.55Shim, Valve, 3.60Shim, Valve, 3.65Shim, Valve, 3.70

2 0451402 16 Collet, Valve

3 0451852 8 Cup, Spring4 0451384 8 Spring, Valve5 0451439 8 Pad, Spring6 0451914 4 Valve, Exhaust7 0451388 4 Valve, Intake

2/04

C4

VALVE TRAINMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



11

76

3

2

4

8

8

12

10

9

567


1 0451576 1 Asm., Cam Shaft2 -------------- 8 Shim, Valve

(See Valves Pg. C3 for Details)3 ---- -- -- -- -- -- 8 Spring, Valve

(See Valves Pg. C3, Ref. 4)4 0451598 8 Seal, Valve Stem5 0451594 8 Screw6 0451972 2 Asm., Rocker Arm, Long

7 0451971 2 Asm., Rocker Arm, Short8 0451846 4 Shaft, Rocker Arm9 0451855 2 Support, Rocker Arm 110 0451428 8 Sleeve, Centering11 0451997 1 Asm., Head, Cylinder12 0451856 2 Support, Rocker Arm 2

2/04

C5

CHAIN TENSIONERMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



3

6

8

7

1

2

9

4

5


1 0451543 1 Bolt2 0451381 1 Guide, Rail Chain3 0451845 1 Element, Tensioner4 0451872 1 Seal, Ring5 0451861 1 Plug, Tensioner

6 0451965 1 Guide, Chain7 0451905 1 Screw8 0451841 1 Rail, Chain9 0451397

045157711

Chain, TimingLink, Timing Chain

2/04

C6

OIL FILTERMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


E 2003 Polaris Sales Inc. 1

2

3

4


1 0451430 1 Cover, Oil Filter2 0451842 1 Filter, Oil

3 0451848 1 Insert, Oil Filter4 0451937 1 Seal, Ring, Oil Filter

2/04

C7

CYLINDERMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



4

15

2

20 3

101213

11

21 18

19

14

1

16

17

6

7

8

9

5


1 0451447 2 Sleeve, Centering2 0451382 8 Tie Rod3 0451426 4 Sleeve, Tie Rod4 1202457 1 Asm., Engine Block5 0451941 2 Pin6 0451843 1 Piston7 0451859 1 Guide, Sleeve8 0451860 1 Spring9 0451858 1 Plate, Clamp10 0451527 4 Washer11 0451526 1 Bolt12 0451523 2 Bolt

13 0451525 1 Bolt14 0451940 1 Gasket, Head15 ------ -- -- -- -- 1 Head, Cylinder

(See Valve Train Pg. C4, Ref. 11)16 ------ -- -- -- -- 8 Sleeve

(See Valve Train Pg. C4, Ref. 12)17 0451450 2 Nozzle, Oil, Block18 ------ -- -- -- -- 2 Support, Rocker Arm

(See Valve Train Pg. C4, Ref. 9)19 0451594 8 Screw20 0451870 8 Nut21 ------ -- -- -- -- 2 Support, Rocker Arm

(See Valve Train Pg. C4, Ref. 12)2/04

C8

VALVE COVERMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



3

5

4

1

2


1 0451416 10 Bolt2 0451513 10 Washer3 0451960 1 Cover, Valve

4 0451433 2 Seal 2, Valve Cover5 0451432 1 Seal 1, Valve Cover

2/04

C9

FUEL RAILMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



4

7

6

5

1

2

3


1 0451471 1 Clip, Locking2 0451512 2 Bolt3 0451513 2 Washer4 0451938 1 Rail, Fuel

5 0451351 1 Valve, Pressure Regulator6 0451864 2 Injector7 0451507 2 Clip, Locking

2/04

C10

EXHAUST GASKETS and HARDWAREMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



12

2

34


1 0451515 2 Gasket, Exhaust2 0451504 4 Screw

3 0451505 4 Screw4 0451503 8 Nut

6/03

C11

IGNITION COILSMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



3

4

1

2


1 0451512 4 Bolt2 0451513 4 Washer

3 0451978 2 Coil, Ignition4 0451967 2 Plug, Spark

2/04

C12

TURBOCHARGER and LINESMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



24

12

1110

4

5

1819

17

13

9

7

27

25

226

3

68

232220

21

16

1514

3 4

20


1 0451353 1 Sensor2 0451514 1 Seal3 0451529 2 Clamp4 0451929 1 Hose5 0451530 2 Clamp6 0451349 1 Valve7 0451583 1 Bolt, Banjo8 0451588 2 Seal9 0451878 1 Fitting, Banjo10 0451883 1 Bolt11 0451876 2 Bolt12 0451996 1 Mount, Turbocharger13 0451866 1 Hose14 0451516 1 Seal

15 0451524 1 Fitting16 0451533 2 Clamp17 0451546 2 Bolt18 0451862 1 Return19 0451874 1 O-Ring20 0451532 1 Clamp21 0451479 1 Hose22 0451886 1 Fitting23 0451560 1 Seal24 0451991 1 Asm.,Turbocharger25 0451945 1 Switch, Thermo26 0451915 1 Seal27 0451865 1 Hose

2/04

C13

TURBOCHARGER and LINESMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



18

12

17

20

14

19

21

1110

1516

7 9

5 641

64

13

1

2

2

2

3

8 13


1 0451889 1 Hose2 0451531 4 Clamp3 0451893 1 Fitting4 0451546 2 Bolt5 0451461 1 Y-Connection6 0451908 2 O-Ring7 0451890 1 Hose8 0451531 2 Clamp9 0451462 1 Elbow, Water10 0451927 1 Conduit11 0451948 2 Panduit

12 0451499 1 Hose, Formed13 0451533 4 Clamp, Hose14 0451562 1 Connector, Hose15 0451897 1 Mount, Pulse Valve16 0451546 2 Bolt17 0451529 2 Clamp, Hose18 0451498 1 Hose, Formed19 0451551 1 Bolt, Banjo20 0451564 1 Bolt, Banjo21 0451560 2 Washer

2/04

C14

OIL COOLERMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



8

61 2

18

3

11

4

9

10

17

16

8

5

7

5

12

13

15

15

14

13

14


1 0451995 1 Bracket, Intercooler2 0451464 2 Pin, Straight3 0451559 2 Screw4 0451912 2 Pad, Rubber5 0451528 4 Clamp6 0451502 1 Hose7 0451558 1 Connector, Straight8 0451465 2 Hose9 0451591 2 Strap, Clamp

10 0451542 4 Bolt11 0451396 1 Exchanger, Heat, Oil12 0451537 2 Clamp13 0451948 4 Panduit14 0451928 2 Conduit15 0451533 4 Clamp16 0451484 1 Hose, Oil17 0451478 1 Hose, Oil18 0451543 2 Bolt

2/04

D1

AIRBOX and POPOFF VALVEMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



6

5

8

10

11

1

2

43

3

799


1 0451948 2 Panduit2 0451926 1 Conduit3 0451533 2 Clamp4 0451474 1 Hose5 0451542 1 Bolt6 0451422 1 Airbox

7 0451513 1 Washer8 0451407 1 Valve, Popoff9 0451948 2 Cable Tie10 0451891 1 Hose, Air11 0451528 1 Clamp, Hose

2/04

D2

ENGINE BEDPLATEMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



8

7

9 5

1

2 3

5

14

4

6


1 0451575 4 Screw2 0451543 3 Bolt3 0451994 1 Bracket, Oil Tank4 0451871 2 Bracket5 0451428 2 Sleeve

6 0451542 1 Screw7 0451910 2 Bolt8 0451989 1 Bracket, Engine, Front9 0451990 1 Bracket, Engine, Rear

2/04

D3

INTERCOOLERMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



11

5

3

1

2

15414

7

10

16

9

18

6

6

8

19

20

17

17

1213


0451958 1 Asm., Intercooler1 0451542 10 Bolt2 0451513 8 Washer3 0451421 1 Cover, Intercooler4 0451578 1 O-Ring5 0451408 1 Insert, Intercooler6 0451472 2 Foam, Rubber, Intercooler7 0451468 2 Rubber, Intercooler8 0451966 2 Clamp9 0451475 1 Hose10 0451902 2 Bolt

11 0452025 1 Housing, Intercooler12 0451569 1 Plug13 0451915 1 Seal14 0451574 1 O-Ring15 0451567 1 O-Ring16 ------ -- -- -- -- 2 Rubber17 0451533 2 Clamp18 0451458 1 Hose19 0451962 1 Conduit20 0451948 2 Panduit

2/04

D4

INTAKE and THROTTLE BODYMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



5

1

20

11

15

14

17

1213

18

10

7

19

6

4 3

9

2

43

221

8

16

16

1


1 0451476 1 Hose2 0451966 4 Clamp3 0451880 2 Screw4 0451352 2 Sensor5 0451959 1 Tube, Connection6 0451877 4 Bolt7 0451405 1 Body, Throttle8 0451981 1 Flange9 0451957 1 Manifold, Intake10 0451555 4 Bolt11 0451894 1 Fitting, Banjo

12 0451385 1 Screw13 0451915 2 O-Ring14 0451431 1 Hose15 0451425 1 Connector, Hose16 0451948 1 Panduit17 0451593 1 Hose18 0451863 2 O-Ring19 0451873 1 Clamp20 0451896 1 Hose, Air21 0451528 1 Clamp

2/04

D5

WATER/HEAT EXCHANGERMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



8

119

2

6

5

4

12

13

7

1

3

10

10


1 0451543 2 Screw2 0451480 1 Hose3 0451533 2 Clamp4 0451459 1 Hose5 0451883 2 Screw6 0451992 1 Bracket, Intake Manifold7 0451913 2 Rubber

8 0451420 1 T-Hose9 0451473 1 Hose10 0451528 6 Clamp11 0451481 1 Hose12 0451993 1 Exchanger, Heat, Water13 0451911 2 Rubber

2/04

D6

OIL TANK/LINESMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



11

17

318

16

20

14

6

7

1

21

2

2

45

19

612

8

9

10

15

13

9


1 0451590 1 Dipstick, Oil2 0451529 2 Clamp, Hose3 0451482 1 Hose4 0451524 1 Fitting5 0451516 1 Seal6 0451385 1 Screw7 0451947 1 Hose8 0451879 1 Bolt9 0451915 4 Seal10 0451912 2 Seal11 0451939 1 Clamp, Hose

12 0451468 1 Rubber13 0451530 1 Clamp14 0451930 1 Hose15 0451532 1 Clamp16 0451936 1 Screw17 0451963 1 Asm., Oil Tank18 0451446 1 Cyclon19 0451533 2 Clamp, Hose20 0451477 1 Hose, Oil21 0451496 1 Sheet, Splash, Oil Tank

2/04

D7

COOLANT BOTTLEMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



8

7

5

4

3

12

6


1 0451542 2 Bolt2 0451513 2 Washer3 0451571 1 Cap, Expansion Tank4 0451964 1 Tank, Expansion

5 0451955 1 Hose6 0451530 2 Clamp, Hose7 0451533 2 Clamp, Hose8 0451497 1 Hose, Formed

2/04

D8

COOLANT ELBOWMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



1

23


1 0451489 1 Plug2 0451514 1 Seal3 0451436 1 Elbow, Connection

6/03

D9

VOLTAGE REGULATORMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



3

4

1

2


1 0451555 2 Bolt2 0451513 2 Washer

3 0451485 1 Regulator, Voltage4 0451888 1 Mount

2/04

D10

SENSORSMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



12

5

4

3

67


1 0451565 1 Screw2 0451509 1 Sensor, Knock3 0451880 1 Screw4 0451355 1 Sensor, Speed

5 0451887 1 Switch, Oil Pressure6 0451354 1 Sensor, Phase7 0451998 1 Screw

2/04

D11

TOOL KITMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



1

2

3 5

7

6

4


2874830 1 Kit, Tool1 2874832 1 Socket, Spark Plug2 2872383 1 Wrench, Open End, 10mm-13mm3 2874517 1 Screwdriver

4 2874831 1 Wrench, 5mm Allen5 2871109 1 Wrench, Allen, Plated6 2683516 1 Pouch, Tool Kit7 9918972 1 Manual, Owners, ’04 MSX 150

11/03

D12

ENHANCED STEERING PERFORMANCEMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L


1

7

45

8

9

10

3


6

2

2


1 7080483 1 Cable Tie, 4 Inch2 7621229 6 Rivet3 2410416 1 Sensor, Switch, Reed4 5247548 1 Bracket, Reed, Switch5 7546704 2 Nut, Nylok

6 7555836 2 Washer7 7516805 2 Screw8 7517717 2 Screw9 5247547 1 Bracket, Reed, Magnet10 2410417 2 Sensor, Reed, Magnet

1/04

D13

PPU ASM.MSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



78 9

3

3

4

4

5

5

6

6

1

2


1 7518042 2 Screw2 7556286 2 Washer, Nylon3 7081186 1 Cable, Throttle4 5248071 1 Retainer, Cable5 7555831 1 Washer, Flat

6 7080483 1 Cable Tie, 4 Inch7 2410446 1 Asm., PPU/Bracket8 2410451 1 Interface, PPU to ECU9 2410507 1 Interface, Power Down Control

1/04

D14

ECU MOUNTINGMSX 150 W045305CA and MSX 150 INT’L W045305IA and MSX 150 W045305CB and MSX 150 INT’L W045305IB and MSX 150 W045305CC and MSX 150 INT’L



3

58 7

94

2

6

6

1

10


1 ------ -- -- -- -- 1 Screw(See Hull and Body Pg. A5 for Details)

2 7518259 4 Screw3 0451492 1 ECU4 7510002 2 Screw, Flange5 3021533 4 Mount

6 7547245 3 Insert, 6mm7 7555838 4 Washer, Lock8 7542140 4 Nut9 5247898 1 Bracket, ECU/Relay/Solenoid10 ------ -- -- -- -- 1 Nut

(See Hull and Body Pg. A5 for Details)1/04

PRINTED IN THE USA PARTS MANUAL PN 9919057 AND MICROFICHE PN 9919058 11/03

Ch

ang

edp

ages

in99

1905

71

23

45

67

89

1011

1213

14

Aco

ver

toc

x

Bx

x

C D E F G

12

34

56

78

910

1112

1314

msx150 part diag

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