Polaris MSX 140 Owner's Manual PDF

Pages 116
Year 2004
Language(s)
English en
1 of 116
1 of 116

Summary of Content for Polaris MSX 140 Owner's Manual PDF

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Copyright 2003 Polaris Sales Inc... All information contained within this publication is based on the latest product information at the time of publication... Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication... Depictions and/or procedures in this publication are intended for reference use only... No liability can be accepted for omissions or inaccuracies... Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited... Printed in U... S... A...

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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 weve ever produced... For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owners manual... Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician... Your Polaris dealer knows your vehicle best and is interested in your total satisfaction... Be sure to return to your dealership for all of your service needs during, and after, the warranty period... Refer to page 101 for the part numbers of Polaris products for your vehicle... We take great pride in our Pure Polaris Parts Apparel and Accessories (PAA), available at your Polaris dealership or through our online store at www... purepolaris... com... Have your Pure Polaris products delivered right to your door!

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WELCOME 3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... YOUR RESPONSIBILITIES 5... ... ... ... ... ... ... ... ... ... ... ... ... IDENTIFICATION NUMBERS 7... ... ... ... ... ... ... ... ... ... ... ... SAFETY 8... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... FEATURES and CONTROLS 24... ... ... ... ... ... ... ... ... ... ... EMISSIONS 36... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... OPERATION 38... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... MAINTENANCE and LUBRICATION 74... ... ... ... ... ENGINE TROUBLESHOOTING 96... ... ... ... ... ... ... ... ... POLARIS PRODUCTS 101... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... SPECIFICATIONS 102... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... WARRANTY 104... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... CALIFORNIA EMISSIONS WARRANTY 109 INDEX 112... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

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Take Safety Training When you purchased your new Polaris watercraft, you received a watercraft safety video and an owners manual... Please review this information on a regular basis... All operators and passengers should read and understand the owners manual before riding... Store the manual in a waterproof bag in one of the storage areas on the watercraft... If the vehicle is sold, the owners manual and video should remain with it... If your owners manual is lost or missing, see a Polaris dealer for a replacement...

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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 owners manual... This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals...

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IDENTIFICATION NUMBERS Your watercrafts hull and engine identification numbers are important for model identification when registering your watercraft, when obtaining insurance, and when ordering replacement parts... The hull identification number is located on the rear right-hand boarding platform (1)... The engine identification number is located at the front of the engine near the stator cover (2)...

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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...

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SAFETY Safety Decals Important warning and instruction decals have been placed on the watercraft for your protection... Read and follow the instructions on each decal carefully... 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... Be sure to read the entire owners manual for details that affect safe operation of this watercraft...

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SAFETY Safety Decals The general safety/warning decal is located on the rear of the watercraft, just below the seat...

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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... OPERATEDEFENSIVELY at safe speeds and keep a safe distance away frompeople, objects, and other watercraft...

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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...

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SAFETY Informational Decals The Coast Guard exemption decal is located below the left-hand mirror...

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The minimum recommended age for operators of this watercraft is 16 years, but operators between 16 and 18 years of age may require close adult supervision... Obey all applicable boating rules and regulations... This watercraft does not have brakes... The watercraft is stopped by releasing the throttle... The vehicle will glide to a stop due to the natural drag of the water... Allow a minimum of 300 feet (90 m) to coast to a stop from full throttle... Jet thrust is required to steer and turn the vehicle... Never completely release the throttle and attempt to turn at more than a trolling speed... The watercraft will not turn... Practice until youre comfortable with turning and stopping, and be sure youve mastered the skills before carrying a passenger... Learn and observe all local, state, and federal boating regulations and speed limits... Boating laws and navigational rules are designed for the safety of everyone sharing the waterways...

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SAFETY 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... Observe local and state laws regarding water skiing and towing... Do not allow passengers to stand on the boarding platform while the watercraft is running or in motion... Passengers should always remain seated... Never travel over a ski jump or attempt to jump waves, wakes or other objects in the water... Doing so may severely damage the watercraft and cause personal injury due to the hard impact, a temporary loss of visibility, possible loss of control and reduced reaction time...

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2 - Eye Protection Wear adequate eye protection to protect against water spray, sun, insects and other objects... To protect prescription eyewear and sunglasses against loss or damage, wear goggles that fit securely over them... 3 - Suit/Shoes/Gloves We recommend that all riders wear a wet/dry suit and watercraft shoes to protect against the force of the water, as well as exposure and unknown hazards in the water, such as debris and hidden objects... Riding gloves may also be considered... NOTE: A helmet may provide increased personal injury protection in some situations, such as impact with the watercraft or during a collision with other watercraft or an obstacle... However, a helmet may not provide adequate protection against all foreseeable impacts and may aggravate some injuries... For example, if a rider falls off a moving watercraft while wearing a helmet, the helmet could catch the water and cause choking, severe and permanent injuries or death... A helmet may also increase the possibility of an accident if it reduces your visibility or ability to hear or if its weight contributes to fatigue...

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Fire Safety Federal regulation requires that all watercraft carry an approved fire extinguisher... The operator is responsible for providing and maintaining the fully charged fire extinguisher in the watercraft... Do not operate the watercraft without a fire extinguisher on board... Stow your fire extinguisher under the front storage compartment in the cut-out area of the flotation foam... Know how to reach the extinguisher quickly in case of fire, and know how to use it before you operate the personal watercraft... If you have any doubts about your ability to extinguish a fire, swim away from the craft as quickly as possible... Immediately seek help from other boaters or people on shore...

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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... Never operate the watercraft after sunset, before sunrise or in any condition of darkness... The vehicle is not equipped with lights, which makes it unsafe and illegal to operate in darkness... Consult local regulations concerning allowed hours of operation... Always ride with another watercraft when operating in remote areas or in large areas of open water... Carry a flare gun on board to signal for help if necessary...

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SAFETY 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... Colliding with an underwater object could result in severe injury or death... Ingesting sand into the cooling system will also cause the engine to overheat, which could lead to serious mechanical damage...

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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... Always be aware of obstacles, swimmers and other watercraft... Quick turns or abrupt changes in speed can cause passengers to lose their balance and be ejected from the vehicle, which could result in injury... The operator should always alert any passengers before making sudden turns or changes in speed...

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SAFETY 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... Never insert any object into the intake or outlet (2) of the jet pump, and never start or operate the watercraft with the inlet grate, ride plate (3), or any guards or shields removed... To prevent serious injury due to accidental starter engagement, be sure the engine is off and the safety lanyard is disconnected before removing weeds or debris that may have collected in or around the jet pump intake...

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Operator Fitness Safe operation of this rider-active craft requires good judgement and physical skills... Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control, which could result in serious injury or death... Riding personal watercraft is strenuous... All riders should be in good physical condition... Pregnant women should consult their physicians before riding any watercraft... Reboarding the watercraft in deep water can also be strenuous... Operators and passengers should be physically fit enough to reboard the watercraft in deep water... Practice boarding in chest-deep water to be sure you are physically able to reboard if the need arises...

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Operator Fatigue and Dehydration Long hours of boating with exposure to noise, vibration, sun, glare and wind can result in operator fatigue and dehydration... These conditions can affect your balance, vision, judgment and reaction time... Fatigue and dehydration can increase your risk of an accident resulting in bodily injury or death... Combining alcohol consumption with this condition greatly increases your risk of causing an accident... Learn to recognize the early symptoms of fatigue, and allow your body to recover by taking a break from operating the watercraft... Drink plenty of non-alcoholic beverages to prevent dehydration, and wear protective riding gear to protect against exposure to weather elements...

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FEATURES AND CONTROLS 1... Starter Button - Depress and hold the starter but- ton to start the engine... Release it as soon as the engine starts... Do not depress for more than ten seconds at a time... NOTE: The lanyard and lock plate must be at- tached to the engine stop switch to start the engine 2... Stop Switch/Lanyard - Push this switch down or disconnect the lanyard plate to stop the engine quickly... 3... Safety LanyardWrist Cord - The lock plate end is attached to the stop switch... The wrist band is attached to the operators wrist or PFD... 4... Gauge Mode Button - This button operates the display change for the NGI... See page 30... 5... Throttle - Squeeze the throttle lever toward the handlebar to increase speed... Release the lever to slow the craft and return the engine to idle... 6... Instrumentation - Instrumentation is New Gen- eration Instrument (NGI)... See pages 30-33... 7... Seat Latch - The seat latch secures the seat in posi- tion... When released, it provides access to the engine compartment...

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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... 3... Handlebars - The handlebars control the orienta- tion of the jet pump outlet nozzle, which in turn con- trols the direction of craft movement... 4... Console Storage 5... Seat/Engine Compartment - Removing the seat provides access to the engine, battery, electrical box, exhaust system, and other components...

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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... Spark arrestor/air filter 12... Engine cooling water outlet hose (under thermostat assembly)

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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

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FEATURES AND CONTROLS 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 and interprets them to compute actual speed... Maximum display is 75 MPH (120 Km/H)... A higher speed will not display...

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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... MAIN MODE displays SPEED and CLOCK... SPEED/TACHOMETER MODE displays SPEED and TACHOMETER... NAVIGATION MODE displays SPEED, TRIP ODOMETER and ENGINE HOURS...

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FEATURES AND CONTROLS 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)

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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... If the high temperature indicator and warning displays, stop the engine immediately... Clean the jet pump and impeller... If the cause of overheating is identified and corrected, normal operation can be resumed by releasing and reapplying the throttle... If the engine continues to overheat after cleaning the jet pump and impeller, take the watercraft to an authorized Polaris dealer for service...

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Contact an authorized Polaris dealer for replacement parts and equipment... Provide part numbers when possible... Accessories Polaris has a wide range of watercraft accessories, from wetsuits and life vests to accessory mirrors, touring and towing gear, and performance parts... Contact your Polaris dealer or visit www... polarisindustries... com to see our full line of available products...

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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... Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine SI engine repair establishment or individual... Refer to the California Emission Control System Limited Warranty beginning on page 109...

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The one-star label identifies engines that meet the Air Resources Boards 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... EPAs 2006 standards for marine engines...

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each use, severe injury or death could result... Always inspect the vehicle as outlined in the checklist before each use to ensure its in proper and safe operating condition... See page 75 for additional inspection information... Always remove the lanyard from the engine stop switch before performing the pre-operation inspection...

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Inspect and remove any debris; ensure intake grate is secure; push rear of craft up and down in the water to flush sand out of wa- ter intake before starting...

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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...

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Refueling Carefully remove the fuel cap... NOTE: Keep the watercraft horizontal while fueling... The use of a funnel or flexible spout will help avoid gasoline spillage on the watercraft... Always wipe up any spills immediately... Wash out the footwells with water if fuel or oil spills in those areas... Use fresh, seasonal gasoline that has been stored in a clean container... For the best performance from gasoline, purchase only what is needed for a month or less of operation... NOTE: If the fuel or oil levels become low, a warning light will flash on the NGI display... Proceed to shore and refuel...

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The oil fill cap (1) is located under the front compartment door... Check the oil level before each use of the vehicle and add oil as necessary... Make sure the engine is off and the safety lanyard is removed from the engine stop switch before adding oil...

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CAUTION A clogged intake or the ingestion of sand into the cooling system will cause engine overheating and result in jet pump or engine damage... 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...

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OPERATION Pre-Operation Inspection Steering Check the handlebars for free movement throughout their full range... Make sure the jet pump outlet nozzle changes direction as the handlebars are turned from left to right and vice versa... Be sure the handlebars and handlebar grips fit snuggly... Visually inspect the control cable to ensure that its in working condition...

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Fire Extinguisher The operator of the watercraft is required by law to carry a fire extinguisher on board... Always keep a fully charged and working fire extinguisher inside the fire extinguisher holder, which is located inside the storage area under the front compartment door... 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...

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Check the battery fluid level and add only distilled water if the level is low... Tap water contains minerals that are harmful to a battery... Maintain the fluid level between the upper and lower marks (1) on the battery... Keep the battery in good condition and fully charged at all times, as a weak battery can leave you stranded... Never operate the watercraft with a battery thats too weak to start the engine or shows signs of loss of power... Use a trickle charger to maintain the batterys charge during the off season... 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... See your dealer or visit our online store at www... purepolaris... com...

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Drain Plugs and Bilge Turn each bilge drain plug (1) counterclockwise and remove it... Clean the plug and plug hole of any sand and debris before reinstalling... Do not operate the watercraft if any drain plug is loose or missing... When the watercraft is out of the water, remove the drain plugs and carefully flush out the bilge with fresh water... Allow the bilge to drain completely... Wipe out the bilge with dry shop towels and reinstall the drain plugs... After launching the craft, remove the seat and check for leaks...

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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... Depress the engine stop button... If the engine doesnt stop immediately, remove the lanyard lock plate to stop the engine... Do not ride the watercraft... See your Polaris dealer for service before operating the watercraft...

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OPERATION Principles of Operation The engine is directly coupled to a driveshaft... When running, the driveshaft rotates the impeller... The impeller is positioned so that water is drawn up from beneath the watercraft... The water travels through the impeller and is accelerated, producing thrust to move the watercraft forward... Pulling or squeezing the throttle lever increases engine speed (watercraft speed)... Turning the handlebar pivots the jet pump nozzle (water outlet) which controls the watercrafts direction... The throttle must be applied in order to turn the watercraft...

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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... Whenever starting the engine, always be sure the watercraft is in water at least two feet (60 cm) deep...

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OPERATION Navigational Rules This watercraft must be operated in accordance with all navigational rules and regulations governing it and the waterway on which its 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... The following rules are condensed and are provided only for your convenience... Consult a U... S... Coast Guard Auxiliary or Department of Motor Vehicles for a complete set of rules governing the waters where youll be riding... You may also obtain this information when registering your watercraft...

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Meeting Vessels When meeting another power vessel head-on and a collision appears likely, neither vessel has the right-of-way... Both vessels are obligated to alter course to avoid an accident... Keep the other vessel to your port (left) side and take evasive action to the starboard (right) side (1)... This rule does not apply if youll be clear of the other vessel by maintaining your course and speed (2)...

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Crossing Paths When two power vessels are crossing each others path close enough to run the risk of collision, the vessel having the other on the starboard (right) side must give way... For example, if the other vessel (4) is on your vessels (3) starboard (right) side, you must give way... If the other vessel is on your port (left) side, your vessel is the stand-on vessel and should maintain its course and direction... The other vessel must give way... However, always drive defensively in case the give-way vessel fails to give your vessel the proper right-of-way... Always be prepared to stop quickly or take evasive action...

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Fishing Vessel Right-of-Way All vessels that are fishing with nets, lines or trawls are considered fishing vessels under International Rules... Vessels with trolling lines are not considered fishing vessels... Fishing vessels have the right-of-way, regardless of position... However, they must not interfere with the passage of other vessels in narrow channels...

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OPERATION 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... S Do not follow directly behind PWCs or other boats... S Do not go near others to spray or splash water... S Avoid sharp turns or other maneuvers that make it hard for others to avoid you or understand your course of travel...

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1... Release the throttle lever... When the engine has slowed to an idle and the craft has stopped moving, push in the stop button... The engine should stop immediately... You may also stop the engine by pulling the lanyard lock plate off the engine stop switch...

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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... Ingesting sand into the cooling system will cause the engine to overheat, which could lead to engine damage... Whenever starting the engine, always be sure the watercraft is in water at least two feet (60 cm) deep...

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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...

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OPERATION 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...

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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...

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Turning the Watercraft Engine thrust is required to steer and turn the vehicle... If you release the throttle, the watercrafts ability to turn is reduced... Your MSX watercraft is equipped with Polaris Enhanced Steering Performance (ESP) technology, a system that provides enhanced maneuverability if the operator releases the throttle but still needs steering control... See page 34 for more information... High thrust makes the watercraft turn more sharply... Lower thrust makes the watercraft turn less sharply... Making sharp turns at high speeds may cause the watercraft to spin out and may cause rider(s) to be ejected from the watercraft... Make gradual turns when operating at higher speeds... Always look behind the craft before turning to avoid collisions...

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The operator of the watercraft should practice stopping to become familiar with the procedure... Stopping is affected by gross weight (watercraft and rider), vehicle speed, wind direction and water surface conditions... The watercraft is not equipped with a brake system... When the throttle is released, the natural drag of the water slows and stops the watercraft... Always keep a safe distance from other vessels, swimmers, objects in the water and the shoreline... Refer to local regulations about safe operating distances for the body of water you operate on...

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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... Shut off the engine when entering water less than two feet (60 cm) deep...

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OPERATION Operating in Rough Conditions If riding in rough conditions, its 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 its illegal in some states to operate the watercraft in or near the surf line...

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OPERATION 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)... Clamp it off as near to the T-fitting as possible... Do not clamp off the hose beyond the T-fitting, as water will be able to enter the exhaust system through the fitting...

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CAUTION Failure to right a capsized craft promptly and correctly may result in severe engine damage if the engine is operated with air or water in the lines... A capsized watercraft must be uprighted in a clockwise direction as viewed from the rear... If the watercraft has remained in a 180 (capsized) position for more than two minutes, all fuel and oil lines must be inspected for water and/or air...

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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 boats rider capacity... Never exceed the stated capacity for your vehicle... When more than one person is riding, the watercraft handles differently, which means that the operator must have enough prior riding experience to handle the watercraft with one or more passengers aboard... The operator should be skilled in operation and maneuvers before carrying any passenger... Passengers should sit behind the operator and face toward the bow of the watercraft... A passenger riding as a spotter in towing situations should face the rear of the craft and hold on to the rear grab handle...

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starting the engine and revving it repeatedly at partial throttle for about ten seconds until water no longer comes out... NOTE: If the craft is towed up or down a steep hill after removing it from the water, this procedure may be repeated...

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WARNING Serious injury and damage to the watercraft will result if the jet pump and impeller are cleaned while the engine is running... Always stop the engine, remove the lanyard lock plate and disconnect the battery before servicing the jet pump and impeller...

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WARNING Serious injury and damage to the watercraft will result if the jet pump and impeller are cleaned while the engine is running... Always stop the engine, remove the lanyard lock plate and disconnect the battery before servicing the jet pump and impeller...

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OPERATION Post Operation Maintenance Transporting The Watercraft Do not route ropes or tie downs over the seat as they could cause permanent damage to the seat... Protect the watercraft body by placing padding or similar material between the ropes or cables and the watercraft body... Be sure the trailer matches the watercrafts 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...

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NOTE: Only mechanically experienced individuals should attempt to remove water from a waterlogged engine... 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...

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OPERATION Post Operation Maintenance Engine Water Removal Procedure Use the following procedure for removing water from a submerged engine... Attempt this procedure only if you are mechanically experienced and have adequate assistance for lifting and supporting the watercraft...

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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... Do not use flammable sprays or protectants in the engine compartment... Do not use petroleum based protectants or lubricants in the engine compartment, as most are flammable and may also deteriorate rubber components...

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MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule NOTE: Maintenance intervals are based upon average operating conditions... 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...

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ENGINE Engine corrosion protection/fogging(daily-if used in salt water) L** L L Cooling system flushing (daily after use in salt water) I** I Exhaust cooling hose screen I/C I/C Exhaust hose condition I I Engine mounts (replace if removed for engine service) I I Thermostat/popoff valve assembly/spring I/C I/C* R Water inlet and outlet hoses and clamps I I I R Spark plugs/Compression test I I Spark Plugs (replace every 100 hours) R I R Engine fastener re-torque (cyl head/cyl base, exhaust) I I Oil pump adjustment I I

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I - Inspect, adjust, service, replace if necessary A - Adjust C - Clean R - Replace L - Lubricate with recommended lubricant

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Inspect and tighten all fasteners, including throttle body mounts, en- gine mounts, exhaust system, all hose clamps; inspect muffler, bat- tery, oil and fuel tank fastening devices, pump, steering fasteners... Aggressive riding requires more frequent service...

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Drive Line The drive line consists of a drive shaft spider coupler and a bearing carrier with a sealed bearing inside... It does not require routine greasing... However, grease is required during reassembly of the system when its been disassembled for service... Grease must be applied to the drive shaft before its installed through the bearing carrier... NOTE: We recommend that all drive line service be performed by your Polaris dealer...

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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...

Page 83

NOTE: If the spark plug tip is black or grey, have the watercraft serviced by an authorized Polaris dealer as soon as possible... S A black tip indicates several potential problems: the wrong spark plug (wrong heat range) is being used; excessive idling occurs; the carburetor idle speed mixture or high speed mixture is too rich or the RPM limiter is malfunctioning...

Page 84

Wipe any water from the spark plug and the inside of the cap... Install the spark plug and torque to 18 ft... lbs... (24 Nm)... If a torque wrench is not available, 1/4 to 1/2 turn beyond finger-tight is close to the correct torque... Push the cap down on the plug until it clicks... NOTE: Apply dielectric grease to the inside of the spark plug cap to prevent corrosion... Before installing a used plug, wipe off the threads and apply dielectric grease... Also clean the gasket surface...

Page 85

MAINTENANCE AND LUBRICATION Fuel System To prevent carbon buildup behind the piston ring, the fuel systems of direct injection models must be treated every 25-30 hours, or seasonally if accumulated hours are less than 25... Add Carbon Clean Plus to the fuel tank at a ratio of two ounces per gallon of fuel... For the best performance and extended life of your watercraft, Polaris recommends the use of Nature Oil Biodegradable 2-Cycle Oil in Polaris watercraft engines... See page 101 for the part numbers of Polaris products...

Page 86

MAINTENANCE AND LUBRICATION Oil Nature Oil Biodegradable 2-Cycle Oil S A new, cleaner burning formula for improved ex- haust valve performance while maintaining lubricity in heat soaked engines

Page 87

Fuses The NGI is protected by a 2 amp fuse... There are also two 15 amp inline fuses on the chassis harness for the fuel pump and any battery powered accessories... After changing a fuse, always reinstall the weathertight cover to keep the fuses dry...

Page 88

Antidote: External: Flush with water... Internal: Drink large quantities of water or milk... Follow with milk of magnesia, beaten egg, or vegetable oil... Call physician immediately... Eyes: Flush with water for 15 minutes and get prompt medical attention... Batteries produce explosive gases... Keep sparks, flame, cigarettes, etc... away... Ventilate when charging or using in an enclosed space... Always shield eyes when working near batteries... KEEP OUT OF REACH OF CHILDREN...

Page 89

Battery Removal 1... Release the battery by loosening the straps (1)... 2... Remove the battery vent tube from the battery... 3... Disconnect the black (negative) battery cable first... 4... Disconnect the red (positive) battery cable next... 5... Lift the battery out of the watercraft, being careful

Page 90

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 its in the watercraft... Always remove the battery and charge in a safe area... Make sure the battery charger is turned off and unplugged before connecting the cables to a battery... Ventilate when charging or using in an enclosed space... Always shield eyes when working near batteries...

Page 91

vent tube... NOTE: It must be free of obstructions and securely installed... If not, battery gases could accumulate and cause an explosion... The tube should be routed away from the frame and body to prevent corrosion... Avoid skin contact with electrolyte, which can cause severe burns...

Page 92

MAINTENANCE AND LUBRICATION Salt Water and Unclean Water Care When the watercraft is operated in salt water or water with impurities like silt, sand and other particulates, additional cleaning and maintenance is mandatory after each use... Clean the jet pump water inlet screen and all other affected areas of the watercraft... Flush the cooling system...

Page 93

MAINTENANCE AND LUBRICATION Cooling System Flushing The watercraft uses water for propulsion and for cooling... Flushing the cooling system with fresh water (never anti-freeze) will neutralize the corroding effects of salt water or water with impurities like silt, sand, alkali and other particles... Flushing will also clean out other residue left in the water passages of the watercraft cooling system... Flush the water passages every day the watercraft is used, any time the craft has been beached and before storing the craft for an extended time...

Page 94

MAINTENANCE AND LUBRICATION Extended Storage When the watercraft will not be used for a month or more, preventative maintenance is required to keep components from deteriorating... An authorized Polaris dealer can do the required preventative maintenance or you can do it yourself with a minimum of tools... Perform all of the procedures outlined in this section of your owners 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

Watercraft Engine Fogging Procedure Polaris recommends the use of fogging oil to prevent rust and corrosion on internal engine parts (i... e... crankshaft, bearings, pistons, rings, cylinder walls)... 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...

Page 96

CAUTION Never clean the watercraft with strong detergents, abrasives, degreasers, paint thinner, acetone, window cleaners, ammonia or products containing alcohol... They can damage finishes, decals, vinyl and plastics and accelerate UV breakdown, which could cause color change and premature deterioration of parts...

Page 97

2... Inspect the spark plugs and apply dielectric grease to the threads... Install new plugs if necessary...

Page 98

Loose battery connections or ground Check all connections and tighten as needed

Page 99

Fouled or defective spark plugs Inspect, clean and/or replace spark plugs

Page 100

Weak spark from spark plugs Inspect, clean and/or replace spark plugs

Page 101

Clogged exhaust and/or cooling system Clean exhaust, flush cooling system

Page 102

ENGINE TROUBLESHOOTING Engine RPM is Too High With Limited Speed

Page 103

Fuel System Maintenance Products Carbon Clean Plus 2871326

Page 104

Fuel Tank 17... 8 gal... (67... 4 l) Oil Reservoir 6 qt... (5... 68 l) Rider Capacity 1-3 people Rider Weight Limit (total) 500 lbs... (227 kg) Total Weight Capacity 565 lbs... (256 kg) Length 126 in... (320 cm) Width 48... 3 in... (122... 6 cm) Height 42... 5 in... (108 cm) Dry Weight 685 lbs... (311 kg) Hull Material Fiberglass Reinforced

Page 105

(NGI) Ski Tow Hook, Stainless Steel Standard Throttle Finger Trigger Mirrors Standard Bilge Pump Siphon Sponsons Matrix Blade Footwell Pads Hydro-Turft Seat Single Child Grab Handle Standard Accessories MSX Knee Pads, Tow Pylon

Page 106

REGISTRATION At the time of sale, theWarranty Registration Formmust 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 theWarranty Registration Formwill be thewarranty entitlement... If you have not signed the original registration and received the customer copy, please contact your dealer immediately... NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR PERSONAL WATERCRAFT IS REGISTERED WITH POLARIS AND YOU HAVE CONFIRMED THAT YOU HAVE WATCHED THE SAFE- TY AND OPERATION VIDEO AND REVIEWED THE SUMMA- RY TRAINING POINTS...

Page 107

Warranty Policy Thiswarranty does not cover accidental damage, normalwear and tear, abuse or improper handling... Thiswarranty also does not cover any per- sonal watercraft that has been altered structurally, modified, neglected, improperlymaintained, used for racing, or used for purposes other than for which itwasmanufactured, or for any damageswhich occur during trailer transit or as a result ofunauthorized serviceor theuse ofunautho- rized parts... In addition, this warranty does not cover physical damage to paint or finish, gel coat stress cracks, tearing or puncturing of uphol- stery material, corrosion, or defects in parts, components or personal watercraft due to fire, explosions or any other cause beyond Polaris control...

Page 108

Polaris warrants to the ultimate purchaser and each subsequent pur- chaser that this engine is designed,built, and equipped to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act... Polaris warrants that this engine is free from defects inmateri- als and workmanship that would cause the engine to fail to conform with applicable regulations for theU... S... EPA emissionwarranty period, which is one (1) year from the date of purchase for the emission-related components in this engine...

Page 109

How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer... If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle... Outside the Country where your vehicle was purchased: If you are traveling temporarily outside the country where your vehicle was purchased, you should take your vehicle to an authorized Polaris dealer... You must show the dealer photo identification from the country of the selling deal- ers authorized location as proof of residence... Upon residence verification, the servicing dealer will be authorized to perform the warranty repair...

Page 110

WARRANTY Exported Vehicles How to Get Service If You Move: If you move to another country, be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move... Vehicles importation rules vary considerably from country to country... You may be required to present documentation of your move to Polaris Industries in order to continue your warranty coverage... You may also be required to obtain documentation from Polaris Industries in order to register your ve- hicle in your new country... If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied...

Page 111

Select emission control parts frommodel year 2002 and laterwatercraft enginesarewarranted for4 years, or for 250 hours ofuse, or for theperi- od prior to the first scheduled replacement of the warranted part as re- quired by the maintenance schedule in the owners manual or other written instructions provided by Polaris, whichever occurs first... How- ever, warranty coverage based on the hourly period is only permitted for watercraft engines equipped with appropriate hour meters or their equivalent... 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... If any emission--related part is defective under warranty, the part will be re- paired or replaced by Polaris...

Page 112

CALIFORNIA EMISSION CONTROL SYSTEM LIMITED WARRANTY OWNERS WARRANTY RESPONSIBILITIES: As thewatercraft engine owner, you are responsible for performance of the required maintenance listed in your owners manual... Polaris rec- ommends that you retain all receipts coveringmaintenanceon yourwa- tercraft engine, but Polaris cannot deny warranty coverage solely for lack of receipts or your failure to ensure the performance of all sched- uledmaintenance... As thewatercraft engineowner, 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, impropermainte- nance, or unapproved modifications... Receipts and records pertaining to regular scheduled maintenance may be relevant in the event ques- tions arise concerningmaintenance... The receipts should be transferred to each subsequent owner of this watercraft...

Page 113

This limited warranty is void if the direct cause of the need to repair or replace a warranted part is due to owner/operator abuse, neglect, im- proper maintenance, tampering, modification, misuse, alteration, or improper adjustment... 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 invalidatingwarranty liability hereunder... In addition, the use of add--on or modified parts will be grounds for disallowing a war- ranty claim...

Page 114

B Battery 46, 72, 86-89... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Charging 88... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Fluid 86... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Installation 89... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Maintenance 86... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Removal 87... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery Storage 89... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Beaching the Watercraft 63... ... ... ... ... ... ... ... ... ... ... Before Starting the Engine 57... ... ... ... ... ... ... ... ... Boarding in Deep Water 59... ... ... ... ... ... ... ... ... ... ... Boarding the Watercraft 59-60... ... ... ... ... ... ... ... ... Boarding With a Passenger 60... ... ... ... ... ... ... ... ... Boating Under the Influence 22... ... ... ... ... ... ... ... Break-In Procedure 49-50... ... ... ... ... ... ... ... ... ... ... ... ... Buoys And Markers 55... ... ... ... ... ... ... ... ... ... ... ... ... ...

Page 115

S Safe Riding Gear 16... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Safe Riding Position 21... ... ... ... ... ... ... ... ... ... ... ... ... ... SAFETY 8-23... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Safety Decals 9-12... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Safety Training 5... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Salt Water and Unclean Water Care 90... ... ... Seat 45... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Service and Maintenance 20... ... ... ... ... ... ... ... ... ... Signal Words and Symbols 8... ... ... ... ... ... ... ... ... ... Signal words and symbols 8... ... ... ... ... ... ... ... ... ... Spark Plugs 81-82... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... SPECIFICATIONS 102-103... ... ... ... ... ... ... ... ... ... ... Stand-on Vessel 51... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Starting In Deep Water 59... ... ... ... ... ... ... ... ... ... ... ... Starting the Engine 57-58... ... ... ... ... ... ... ... ... ... ... ... ... Steering Cable 79... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Steering Cable Inspection 85... ... ... ... ... ... ... ... ... ... Steering Inspection 44... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Stopping the Watercraft 62... ... ... ... ... ... ... ... ... ... ... ...

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