MSX 140

Model #W035303CA
Model #W035303CB
INT’L MSX 140
Model #W035303IA
Model #W035303IB

E 2002 Polaris Sales Inc. PARTS MANUAL PN 9918106 and MICROFICHE PN 9918107 11/02
This page left intentionally blank.

2
 TABLE OF CONTENTS
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB
Parts Manual

A M
AIR VENT . . . . . . . . . . . . . . . . . . . . . . . . . . B4 MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . B13
B O
BATTERY BOX . . . . . . . . . . . . . . . . . . . . . . . B9
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . C2
C OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
COMPARTMENT DOOR . . . . . . . . . . . . . . . . A3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . B7
P
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . B12 PROPULSION . . . . . . . . . . . . . . . . . . . . . . . B2
CRANKSHAFT and PISTON . . . . . . . . . . . . . C1 R
D REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . A13-14
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . B11
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . B1 S
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7
E
SHROUD and STORAGE . . . . . . . . . . . . . . . A4
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . B8
STARTING MOTOR . . . . . . . . . . . . . . . . . . . C3
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . B10
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . B6 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . A11
STEERING CABLE . . . . . . . . . . . . . . . . . . . . A12
F
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . A10 T
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . A8 THROTTLE BODY . . . . . . . . . . . . . . . . . . . . B14
H TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . C4
HULL and BODY . . . . . . . . . . . . . . . . . . . . . A5-6 W
I WATER INLET . . . . . . . . . . . . . . . . . . . . . . . B3
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . B13 WATER SIPHON . . . . . . . . . . . . . . . . . . . . . B5

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
 COMPARTMENT DOOR
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

2 1
4

3 3
4 5
28 6
5

6
27
26

5 5
8 25
9 24
22 5
10 5 6
23
11 21
18
12 20 19
13
16 17 18
13
15
5
12 14
13

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5434974-412 1 Windshield, Smoked Grey 14 5434830 1 Hinge, Lower
2 7518042 4 Screw 15 7518119 4 Screw
3 5412344 1 Gasket, Mirror, LH 16 7555835 2 Washer, Flat
5412345 1 Gasket, Mirror, RH 17 5133640 2 Stud
4 2632518-307 1 Mirror, LH (CA)(IA) 18 7061114 2 Rod End
2632519-307 1 Mirror, RH (CA)(IA)
2632518-342 1 Mirror, LH (CB)(IB) 19 5133641 1 Pin, Dowel
2632519-342 1 Mirror, RH (CB)(IB) 20 7042260 1 Spring, Gas
5 7556094 26 Washer 21 2874377 1 Asm., Hinge (Incl. 13,14,16,17,20,22)
6 7546704 14 Nut, Nylok 22 5434829 1 Hinge, Upper
7 7081088 1 Latch 23 7516807 4 Screw
8 7517528 2 Screw 24 7518187 4 Screw
9 5133945 1 Plunger 25 7552613 6 Washer, Lock
10 7555841 1 Washer, Flat 26 7080703 3 Clip
11 5412299 2 Bumper, Rubber, Latch Post 27 5434520-307 1 Door, Compartment (CA)(IA)
12 7556249 5 Washer, Flat 5434520-444 1 Door, Compartment (CB)(IB)
13 7546804 7 Nut, Nylok 28 3280399 1 Gauge, MFI
11/02

A3
 SHROUD and STORAGE
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

2
1
3 4 3
5

23 4

22 7 6
24
10
21
3 8
9 3
20
11
19

18
17
12

13
14

15

16

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5434626 1 Latch 11 5434678 1 Bucket, Storage
2 5434521-307 1 Lid, Glove Box (CA)(IA) 12 5521661 1 Seal, Bucket, Bottom
5434521-444 1 Lid, Glove Box (CB)(IB) 13 7518042 4 Screw
3 7518042 16 Screw 14 7556094 4 Washer
4 5434518-307 1 Shroud, Left (CA)(IA) 15 5434513 1 Guard, Splash
5434518-444 1 Shroud, Left (CB)(IB)
5434519-307 1 Shroud, Right (CA)(IA) 16 7547244 4 Insert
5434519-444 1 Shroud, Right (CB)(IB) 17 7547245 7 Insert
5 5247054 1 Mesh, Wire, Eyelet, LH 18 5830234 1 Pad, Glove Box
5247055 1 Mesh, Wire, Eyelet, RH 19 5434666 1 Box, Glove
6 7518130 4 Screw 20 7621336 4 Rivet
7 7556252 4 Washer, Flat 21 2683156 1 Net, Cargo
8 5224854 4 Bumper 22 5434770-070 2 Clip
9 1014182-307 1 Shroud, Upper CA)(IA) 23 5830235 1 Seal
1014182-444 1 Shroud, Upper CB)(IB)
24 5434726 1 Plug
10 5521658 1 Seal, Bucket, Top
11/02

A4
 HULL and BODY
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

6 7
27 5
4

1
2 26
3 4
5 25
6
7
8
20
24

17 21
9 22
23
16 18
11 10
15
19
14
10
12

13

6
5

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5521652-305 1 Rail, Rub, Insert 15 7518258 6 Screw
2 5521653-070 1 Rail, Rub, Base, Back 16 7547261 2 Nut
3 7518150 6 Screw 17 5812342-318 1 Pad, Footwell, Rear, LH
4 5434523-070 2 Cap, Rub Rail 5812343-318 1 Pad, Footwell, Rear, RH
5 7556293 10 Washer, Flat 18 5812340-318 1 Pad, Footwell, Center, LH
5812341-318 1 Pad, Footwell, Center, RH
6 7518205 10 Screw
19 5812338-318 1 Pad, Footwell, Front, LH
7 7078465 2 Logo, Polaris Star 5812339-318 1 Pad, Footwell, Front, RH
8 5812425-318 1 Pad, Boarding, LH 20 7621488 10 Rivet
5812344-318 1 Pad, Boarding, RH
21 7546704 2 Nut, Nylok
9 5134037 1 Plunger
22 5434965 1 Bumper, Front
10 7556249 14 Washer, Flat
23 7518201 2 Screw
11 2632654 1 Hook, Tow
24 7556094 2 Washer
12 7546804 9 Nut, Nylok
25 5521652-224 2 Rail, Rub, Insert
13 5434911-413 1 Sponson, LH
5434912-413 1 Sponson, RH 26 5521650-070 1 Rail, Rub, Base, LH
5521651-070 1 Rail, Rub, Base, RH
14 5434522-307 1 Handle, Grab (CA)(IA)
5434522-444 1 Handle, Grab (CB)(IB) 27 7518221 48 Screw
11/02

A5
 HULL and BODY
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

1 2
3
4
5 6
7 12
9

8
10
11

11
13
21
14
20 15
19
16
17
18

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7511882 4 Screw 12 7081140 1 Strap, Velcro
2 1060125 2 Asm., Bilge, Plug 13 7555834 2 Washer
3 7518220 2 U-Bolt 14 5812021 1 Gasket
4 7546705 4 Nut 15 2632213 1 Strap, Bow
5 7555870 4 Washer, Rubber Dish 16 7080492 2 Cable Tie
6 7556094 4 Washer 17 7080439 2 Clamp, Hose
7 7546704 4 Nut, Nylok 18 5433220 2 Flange
8 7555874 4 Washer, Flat 19 7661042 6 Rivet
9 7518194 1 U-Bolt 20 5411545 2 Gasket
10 7547235 2 Nut 21 5433082 2 Duct
11 7546804 4 Nut, Nylok
11/02

A6
 SEAT
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

3
4
5

7
6

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2683013-404 1 Asm., Seat (Incl. All) 4 7552613 2 Washer, Lock
2683145-404 1 Cover, Seat 5 7516806 2 Screw
2 7081088 1 Latch 6 5521647 1 Seal
3 7556094 2 Washer 7 5521659 1 Bumper, Seat
11/02

A7
 FUEL TANK
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB
20

21 19
22 18
17
23
16
24
1
15

5 3

4
14

13
6
8
7
7 9
10

11 10
10 12
5
9

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5433259 1 Nut 13 7080451 1 Clamp, Hose
2 2410129 1 Pump, Fuel 14 5412441 1 Hose, Fuel Fill
3 5411636 1 Gasket 15 7080766 1 Clamp, Hose
4 5412305 2 Strap, Connecting 16 5812421 1 Gasket, Fuel Fill
5 5812444 4 Pad 17 5433553 1 Inlet, Fuel
6 5434872 1 Tank, Fuel 18 7511873 1 Screw
7 5521615 4 Cover, Strap 19 5411305 1 Seal, Fuel Cap
8 5434786 4 Strap, Fuel Tank 20 2520177 1 Cap, Fuel, Ratchet
9 5247183 4 Bracket, Tank Strap 21 7080710 1 Chain
10 7621485 12 Rivet 22 7080442 2 Coupling, End, Fuel Cap Chain
11 5812152 2 Pad 23 7621229 1 Rivet
12 7555837 4 Washer, Flat 24 5433621 1 Nut, Fuel Inlet
11/02

A8
 OIL TANK
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

4
5

7
6
3 5

2
1 8

22
9
24
21 23

19 10
20
17
9

18 17

16
15
11

14
13
12

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5812420 1 Gasket, Oil Inlet 13 7080138 4 Cable Tie
2 5433914 1 Inlet, Oil 14 5521608 1 Hose
3 7661042 4 Rivet 15 7052130 1 Elbow, 90 Degree
4 5432843 1 Cap, Oil Tank 16 2410131 1 Sender, Oil Level
5 7080442 2 Coupling 17 7080474 2 Clamp, Hose
6 7080710 1 Coupling, End, Fuel Cap Chain 18 4010051-36 1 Conduit, Convoluted
7 7517241 1 Screw 19 2530015 1 Filter, Oil
8 7621229 1 Rivet 20 7670109 1 Clip, Routing
9 7080481 2 Clamp, Hose 21 5521609 1 Hose
10 5412440 1 Hose, Oil Fill 22 7080307 2 Clamp, Hose
11 5434871 1 Tank, Oil 23 8450059-150 AR Line, Fuel
12 7052118 1 Valve, Vacuum Check 24 7080138 2 Cable Tie
11/02

A9
 FUEL SYSTEM
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

1
2
3
4
9
5
6
5
9 4
7 8

9
12 5 5

18
18 21 10
18 20 5
19 5
19 11
5 9
5 9 17
17

17 5
5 15
16 15
15 12
9 5 13 5
9 5 13 5
14 5

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5410682 1 Grommet, Vent 12 7080482 2 T-Clip
2 7080483 1 Cable Tie 13 7052230 2 T-Fitting, Large
3 7052078 1 Connector, 1/4-3/16 14 7052229 1 L-Fitting, Large
4 7080138 2 Cable Tie 15 5411601 6 O-Ring, DFI Fitting, Large
5 7080476 20 Clamp, Hose 16 7052227 1 L-Fitting, Small
6 7051015 1 Valve, Relief Check 17 5411599 6 O-Ring, DFI Fitting, Small
7 7052111 1 Fitting, Tee 18 ------- 3 Injector (See Manifold/Ignition Pg.
8 7052118 1 Value, Vacuum Check B13, Ref. 17)
9 8450104-1525 AR Line, Fuel 19 7052228 2 T-Fitting, Small
10 7052253 1 Connector 20 7080948 2 Clamp, Hose
11 7052329 1 Fitting 21 2872602 1 Ficht w/Cap, Shrader Valve
11/02

A10
 STEERING
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

4
3
5
2
1 7 12
8 10 11
3
6
13
14
32

31 1 15
23
30 29
28 22
27 21 16
26 17
20
19
18
18
25 24

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517520 4 Screw 18 7517528 3 Screw
2 7555837 2 Washer, Flat 19 5434772 1 Clamp
3 7541931 4 Nut, Lock 20 5434773 1 Adjuster
4 5433355-070 1 Handle, Grab 21 7542335 1 Nut, Nylok
5 5434516-070 1 Pad, Handlebar 22 7547250 3 T-Nut
6 5432729 1 Block, Throttle 23 5812485 1 Pad, Foam, Handlebar
7 2410343 1 Switch, Start/Stop 24 5434915 2 Bushing, Tapered
8 1821342-070 1 Asm., Steering Column 25 7081136 1 Cable, Throttle
9 7080675 1 Lanyard w/Whistle 26 7710426 1 Ring, Retaining
10 7517538 3 Screw 27 7555840 1 Washer, Flat
11 7556249 5 Washer, Flat 28 5434913 1 Lever, Throttle
12 5410836 1 Grommet 29 7661628 1 Pin, Retaining
13 5246810 1 Bracket, Grommet 30 7080483 1 Cable Tie
14 5246438 1 Plate, Top 31 5432728 1 Clamp
15 5434771 1 Housing, Steering 32 7518151 6 Screw
16 7556262 2 Washer, Shim 7552613 6 Washer, Lock
7555836 6 Washer, Flat
17 5631307 1 Arm, Steering
11/02

A11
 STEERING CABLE
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

2
3
4
5
6

9
8 4
3
10 2
10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7515120 1 Screw 6 1860114 1 Nut
2 7555839 2 Washer, Flat 7 7081080 1 Cable, Steering
3 7060170 2 Rod End 8 5411818 1 Seal
4 7542150 2 Nut 9 7518026 1 Screw
5 5412206 1 Seal 10 7542133 2 Nut, Nylok
11/02

A12
 REVERSE
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB
5
3 6
4 7 8 9
1 2 10 13
14 15
19
20
21
11 12
16 17 18 22
33

32
23
14
14
29
31
30
4 25 24
34
28
35
23 26
20
27
36

38
39
37
38
41
42 39 40
34

43

44
52

27 45

46 45 48
47

49
50
51

A13
 REVERSE
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2632646-070 1 Handle, Reverse 27 7661010 2 Pin, Cotter
2 7516809 5 Screw 28 5433871 1 Arm, Reverse
3 5434514 1 Support, Handle 29 5433647 1 Bushing
4 7517669 6 Screw 30 7041995 1 Spring, Compression
5 7516805 2 Screw 31 5433673 1 Plunger
6 7661040 8 Rivet 32 5245635 1 Bracket, Reverse Plate, Forward
7 5434066 1 Flange 33 7661041 2 Rivet
8 5811982 1 Gasket 34 7081089 1 Cable, Reverse
9 5434973 1 Plate, Base 35 5411819 1 Seal
10 5434067 1 Pinion 36 7080138 2 Cable Tie
11 7556094 2 Washer 37 4010051-100 1 Conduit, Convoluted
12 7546705 3 Nut 38 7547001 2 Nut
13 5434967 1 Shaft, Cam 39 7555856 2 Washer, Flat
14 7546704 1 Nut, Nylok 40 7556269 1 Washer, Lock
15 7516816 1 Screw 41 5411818 1 Seal, Rod
16 7555856 1 Washer, Flat 42 5412206 1 Seal, Rod
17 7516806 1 Screw 43 7542150 2 Nut
18 7041888 1 Spring, Compression 44 7061062 1 Rod End
19 5433676 1 Arm, Reverse Lock 45 7555839 2 Washer, Flat
20 7555837 2 Washer, Flat 46 5434049 1 Gate, Reverse, Directional
21 7511882 1 Screw 47 7661117 1 Pin, Clevis
22 5412058 1 Bracket, Arm Lock 48 7555866 2 Washer
23 7512049 4 Screw 49 5020683 2 Collar
24 7555857 2 Washer, Flat 50 7555874 2 Washer, Flat
25 2410241 1 Switch, Limit 51 7515368 2 Screw
26 5245180 1 Bracket, Reverse, Support 52 5434272 1 Bracket, Reverse Stop
11/02

A14
 DRIVE SYSTEM
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

1
2
4
3 5
6

7
8
9
10
12
11

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5133826 1 Washer, Thrust 7 1350091 1 Asm., Bearing Support
2 5410663 1 Bumper, Drive Shaft 3610040 4 Seal
3 1590349 1 Driveshaft 8 5631451 1 Coupler, Pump
4 7518186 3 Screw 9 5412363 1 Coupler, Spider, Rubber
5 755837 3 Washer 10 5631450 1 Coupler, Engine
6 5246907 1 Cover 11 7518119 4 Screw
12 7556055 4 Washer, Lock
11/02

B1
 PROPULSION
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB
9

8 6

10
6 11
12
13 24
5 23
4 14
15
3
2 16 25
1
3
28
17 22 26
1 18 27

29

3 21 30
19
1 32 31
2 33
1
20 34
35
36
11

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7542455 4 Nut, Nylok 19 5244556 1 Bracket, Steering Cable Nut
2 7555966 2 Washer, Flat 20 5410817 1 O-Ring
3 5132111 4 Stud, Mounting, Pump, Long 21 5410819 1 O-Ring
4 5411107 1 Seal, Water Pipe 22 5431523 1 Screen, Engine Inlet
5 5131573 1 Housing, Pump 23 5130999 1 Nozzle, Steering
6 5410735 2 O-Ring 24 7515366 2 Screw
7 5432269 1 Pipe, Water, Engine 25 5130938 2 Collar
8 5133977 1 Fitting 26 7552610 4 Washer, Lock
9 5132088 1 Stator 27 7555835 4 Washer, Flat
10 5010294 1 Spacer, Bearing 28 5431518 2 Bearing, Steering Nozzle
11 3514008 2 Bearing 29 7515389 4 Bolt
12 3610043 2 Seal, Stator Bearing 30 1350013 1 Nozzle
13 5010295 1 Spacer, Impeller 31 5432841 1 Wedge, Pump
14 5132707 1 Impeller 32 7512064 3 Screw
15 5410731 1 O-Ring 33 5431519 1 Cone, Pump
16 5131196 1 Extension, Pump 34 5811984 1 Seal, Tail Cone
17 7522019 1 Screw 35 5132674 1 Shaft, Stub
18 5630598 1 Anode, Zinc 36 5410818 1 O-Ring
11/02

B2
 WATER INLET
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

1
2
3
4

6
8

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517897 2 Screw 5 5631257-329 1 Plate, Ride
2 7556270 2 Washer, Lock 6 5631330 1 Scoop, Inlet
3 7556271 2 Washer, Flat 7 5631328-067 1 Grate, Inlet
4 2410344 1 Wheel, Paddle 8 7518119 9 Screw
11/02

B3
 AIR VENT
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

1
E 2002 Polaris Sales Inc.

3 6

4 7
5

10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7516725 2 Screw 6 5432138-070 3 Plug, Intake Silencer
2 7552610 2 Washer, Lock 7 5410589 3 O-Ring
3 7555831 2 Washer, Flat 8 5434248-070 1 Cover, Air In
4 5333474 2 Spacer 9 7078778 1 Decal, DFI Fuel Injection
5 7170894 1 Urocal, Liberty Marine HO Direct In- 10 7080601 1 Filter, Intake Silencer
jection 140
11/02

B4
 WATER SIPHON
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

2
2 1
1

5
1

1 3

1 1
6
6 1

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7080138 12 Cable Tie 4 7080492 1 Cable Tie
2 5431409 2 Elbow, Siphon Hose 5 7670116 2 Clip, Routing
3 8450051-600 4 Line, Fuel 6 5432036 2 Pickup, Siphon w/Strainer
11/02

B5
 EXHAUST SYSTEM
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB
11 12
10
9
13
1
7
2 4 7 8
3 7
5
6
40 14
10
15 16
15
39 29 17 17
38

7
28
18
37 35 27
7 26 17 15

30 25
19
34 31 20
36 21
17
32 15
33
24 23
22

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5631414 1 Cover, Outlet 21 7516725 5 Screw
2 7515116 4 Screw 22 1261220-329 1 Asm., Exhaust Manifold
3 7555837 4 Washer, Flat 23 5020746 1 Fitting, Drain
4 5810529 1 Seal 24 7518195 1 Screw
5 5132457 1 Fitting, Exhaust 25 7052327 1 Fitting, Screen
6 1261297-067 1 Silencer 26 1202352-399 1 Asm., Exhaust Pipe (Incl. 25,28,27)
7 7080907 8 Clamp, Hose 27 5020668 2 Fitting, Inlet, Water
8 5412407 2 Hose, Exhaust 28 5133884 1 Fitting, 90 Degree
9 7516809 1 Screw 29 5412439 1 Hose, Pipe Drain
10 7555857 5 Washer, Flat 30 7621485 2 Rivet
11 5247146 1 Bracket, Exhaust Hose 31 5240134 1 Clip, Strap
12 7546704 1 Nut 32 5243775 2 Hook, Strap, Narrow
13 5434977 1 Hose, Pipe to Silencer 33 5247008 1 Bracket, Silencer
14 7517005 2 Screw 34 5430621 1 Strap, Rubber
15 7552611 6 Washer, Lock 35 5412437 1 Hose, Silencer to Resonator
16 7517004 2 Screw 36 5434966 1 Resonator
17 7555856 6 Washer, Flat 37 5246535 1 Bracket, Resonator
18 7517309 1 Screw 38 5412438 1 Hose, Resonator to Outlet
19 5830051 1 Gasket 39 7080445 1 Clamp, Hose
20 7516727 4 Screw 40 7552613 4 Washer, Lock
11/02

B6
 COOLING SYSTEM
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

3
1 4

2
10
5 6
7
8
9

28
11
27
12
13
26
14
25
15
24 16
23
17
22 21
20
18
19

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5434149-133 1 Fitting, Thru-Hull 14 7041310 1 Spring, Compression
2 5812237 1 Gasket 15 7556174 1 Washer
3 5133884 1 Fitting, 90 Degree 16 5134022 1 Spacer
4 5412374 1 Hose, Water 17 5410860 1 Seal, Thermostat Housing
5 5411793 1 Hose, Water 18 5631136 1 Cover, Thermostat
6 7080475 14 Clamp, Hose 19 7052156 2 Fitting, 90 Degree
7 5431784 1 Fitting, Tee 20 7080138 14 Cable Tie
8 7080476 14 Clamp, Hose 21 7080492 1 Cable Tie
9 8450054-38 1 Hose, Water 22 5521398-60 1 Conduit, Flex
8450054-42 2 Hose, Water 23 5521286-2.5 7 Conduit, Wire
8450054-68 1 Hose, Water
8450054-170 1 Hose, Water 24 8360011-34 3 Tubing, Convoluted
8450054-80 1 Hose, Water 25 7080598 1 Strap, Cable
10 5410897 1 Hose, Stinger 26 5521287-18 AR Conduit, Flex
11 7051008 1 Thermostat, 143 Degrees F. 5521287-117 AR Conduit, Flex
12 5432799 1 Valve, Pop-Off 27 7052340 1 T-Fitting
13 5412014 1 Gasket, Thermostat 28 5412376 1 Hose, Water
11/02

B7
 ELECTRICAL
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

1 2 3

16
12 11
5
6
13 7

15 14 8
9
10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 4010859 1 Fuse, 15 Amp. 9 7556261 2 Washer, Lock, External
2 4010752 2 Fuse, 2 Amp. 10 4010858 1 Solenoid, Starter
3 2461024 1 Harness, Wire, Door 11 4010642 1 Cable, Solenoid/Starter
4 2461179 1 Harness, Engine 12 7621485 2 Rivet
5 5410346 3 Insulator, Cable 13 7555837 2 Washer, Flat
6 7546705 2 Nut 14 7080138 3 Cable Tie
7 7552613 2 Washer, Lock 15 5521287-18 1 Conduit, Flex
8 4010237 1 Cable, Solenoid/Starter 16 4010789 1 EMM
11/02

B8
 BATTERY BOX
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

4
3
11 5
9
10
4

6
8

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5432413 1 Cover, Battery 7 7080138 1 Cable Tie
2 7081117 2 Strap, Velcro 8 4140009 1 Battery, 19 Amp
3 5410682 1 Grommet, Vent 9 2200619 2 Kit, Battery Bolt
4 7080483 3 Cable Tie 10 5410346 2 Insulator, Cable
5 7052078 1 Connector 11 4010280 1 Cable, Ground, Battery/Engine
6 5432121 AR Tube, Battery Vent
1102

B9
 ENGINE MOUNTING
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB
2
1 3

5
6

18 19
20
21
8 7

17 22
6
8
16 10
9
11
12
12 13
15 14

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5244176 1 Clip, Retainer 12 7556293 16 Washer
2 7516603 1 Bolt 13 3021253 4 Mount, Engine
3 2410125 1 Sensor, Water Temperature 14 5246667 4 Plate, Motor Mount
4 TBA 1 Kit, Short Block, NOTE: The Short Block 15 7518104 8 Screw
assembly contains a crankcase assem- 16 7556249 8 Washer, Flat
bly, cylinder and cylinder head assembly,
and a piston and crankshaft assembly. 17 7518119 8 Screw
5 7517497 1 Screw 18 5631160-329 1 Plate, Mount, Rear
6 7556055 9 Washer, Lock 19 7518188 4 Screw
7 5631161-329 1 Plate, Mount, Front 20 7552608 4 Washer, Lock
8 7552609 6 Washer, Lock 21 7556277 4 Washer, Flat
9 7518132 4 Screw 22 7517330 2 Screw
10 5246894 8 Shim, Slotted 23 7077026 1 Decal, Spark Plug
11 7546804 8 Nut, Nylok
11/02

B10
 DECALS
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

2
3 13
4 12

11
15
5 10 14

16

17
19
18
21 20
6 9
22

7 8

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7171381 1 Decal, NGI 13 7170891 1 Decal, Intake Cover, LH
2 7170887 1 Decal, Lens Cover, MSX Gauge 7170892 1 Decal, Intake Cover, RH
3 7170110 1 Decal, Low Emissions 14 7170886 1 Decal, Medallion
4 7170794 1 Decal, Coast Guard Exemption 15 7170787 1 Decal, Reverse
5 7170791 1 Decal, Warning 16 7170789 1 Decal, Caution, Capsize
6 7170788 1 Decal, Capacity, 3 Passenger 17 7170818 2 Decal, Hull, “POLARIS”
7 7170445 1 Decal, “POLARIS”, Hood Center 18 7170816 1 Decal, Deck, Rear, LH
7170817 1 Decal, Deck, Rear, RH
8 7170792 1 Decal, Warning, Rear
19 7170888 1 Decal, Patent
9 7079171 1 Logo, Planet
20 7078465 2 Logo, Polaris Star
10 7079125 1 Decal, Spark Ignition Comp
21 7170889 2 Urocal, “POLARIS”
11 7171396 1 Decal, Fire Extinguisher
22 7170814 1 Decal, Deck, Front, LH
12 7170790 1 Decal, Refueling, Warning 7170815 1 Decal, Deck, Front, RH
11/02

B11
 CRANKCASE
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

1
2
3

30
4 32
31

3 33

34
5 35
29
36
9 28
6
7
10 8
27
25
12 26
11 24
20 23
13 22
21
18
15 16 19
17

14

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5133418 6 Stud 19 4010320 1 Stator, Ignition
2 5131677 6 Stud, Cylinder Flange 20 7517602 3 Screw
3 2202423 1 Kit, Crankcase, 1200 (Incl. 4-6) 21 4010646 1 Flywheel
4 7663001 2 Pin, Dowel 22 3569806 1 Bushing
5 7516913 2 Screw 23 3574214 1 Bushing
6 7517628 6 Screw 24 7041457 1 Spring
7 7517974 1 Screw 25 1202574 1 Cover, Flywheel
8 7080654 1 Retainer 26 7555908 1 Washer, Thrust
9 2410128 1 Sensor, Crank Position 27 5433820 1 Plug, Timing Hole
10 5411564 1 O-Ring 28 5631431-329 1 Cover, Water Jacket
11 7517431 1 Screw 29 7516806 7 Screw
12 5243231 1 Clamp, Stator Wires 30 7052156 2 Fitting, 90 Degree
13 1202023 1 Asm., Flywheel Housing (Incl. 14,15) 31 7516809 4 Screw
14 7663002 3 Pin, Dowel 32 7517662 6 Screw
15 3514378 1 Bushing 33 5812474 1 Gasket, Water Jacket Cover
16 7516723 4 Screw 34 7051529 3 Plug
17 5631069 1 Plate, Stator Mount 35 5811550 1 Gasket, Flywheel Cover
18 7517620 3 Screw 36 4060119 1 Asm., Bendix
11/02

B12
 MANIFOLD / IGNITION
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB
1
2

3 21

22
4 20 23
25
24
26
5
6
19 31
30
29 28
18 27
17
16
7

9
10
11
15
12

14

13

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7051527 1 Plug 17 1253375 3 Injector
2 7075383 1 Decal, Warning 18 5412393 3 O-Ring
3 7516806 6 Screw 19 5247092-385 3 Cap
4 5830061 3 Gasket, Water, Manifold 20 1202577-329 1 Manifold, Water
5 7517832 6 Screw 21 4010810-24 3 Wire, Spark Plug
6 7555835 6 Washer, Flat 22 5247206 1 Plate, Coil Mount
7 7518031 18 Screw 23 4010184 1 Coil, Ignition
8 3021387-244 3 Head, Cylinder 24 7555836 6 Washer, Flat
9 5244008 6 Restrictor, Cylinder Head 25 7555949 6 Washer, Lock
10 5411675 3 O-Ring 26 7516817 6 Screw
11 5412232 3 O-Ring 27 2461187 1 Wire, Ground
12 7661159 6 Rivet 28 4010362 1 Coil, Ignition, DFI Twin
13 3021332 3 Cylinder 29 7516807 4 Screw
14 5811784 3 Gasket, Cylinder Base 30 5243526 4 Spacer
15 7547021 12 Nut 31 5411660 4 Mount, Rubber
16 3070189 3 Plug, Spark, NGK, DFI, PZFR6H
11/02

B13
 THROTTLE BODY
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

3
16

14 15
13
12
4
11

6 7
8

10
9

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7516816 6 Screw 9 5432162 3 Stuffer, Reed Block
2 5630907 1 Base, Intake Silencer 10 1201595 3 Block, Triple Reed
3 5830062 3 Gasket, Carburetor, Upper 11 7516606 2 Screw
4 1253497 1 Asm., Throttle Body 12 2410379 1 Sensor
5 5830043 3 Gasket, Carburetor 13 7042067 1 Spring
6 5630582-329 1 Adaptor, Carburetor 14 5434096 1 Coupler
7 7516807 12 Screw 15 7516603 2 Bolt
8 7516814 6 Screw 16 2410299 1 Sensor, Air Temperature
11/02

B14
 CRANKSHAFT and PISTON
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

1 2 4
7
6 6
5
8
9
10

11
14 12
13

15
16
17
11
12 21
19 18
20

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3021179 3 Circlip, Piston 10 3610044 1 Seal
2 3023030 3 Pin, Piston 11 7555905 2 Bushing
3 2201631 1 Kit, Piston Rings (Standard) 12 3585503 8 Bearing, Ball, Deep Groove
TBA 1 Kit, Piston Rings (.25 mm O/S) 13 7721117 1 Key, Woodruff
TBA 1 Kit, Piston Rings (.50 mm O/S)
14 5131744 1 Crankweb, MAG, 70 mm
4 2202337 1 Kit, Piston Asm. (Std.)(Incl.1,2,3)
TBA 1 Kit, Piston Asm. (.25 mm O/S)(Incl.1,2,3) 15 5131745 4 Crankweb, Center, 70 mm
TBA 1 Kit, Piston Asm. (.50 mm O/S)(Incl. 1,2,3) 16 5131086 2 Labyrinth
5 2201445 1 Kit, Connecting Rod Asm. 17 5131746 1 Crankweb, PTO, 70 mm
6 3552112 3 Bearing 18 5412091 2 Seal
7 7546909 1 Nut 19 5410613 1 O-Ring
8 5432576 1 Coupler, Pump Drive 20 5131195 1 Collar, Crankshaft
9 7555907 1 Washer 21 2202422 1 Kit, Crankshaft (Incl. 6,11-17)
11/02

C1
 OIL PUMP
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

3
2

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7081024 1 Cable, Oil Pump 5 7080603 8 Clamp
2 7555944 1 Washer, Nylon 6 8450061-600 2 Line, Oil
3 7710427 1 E-Ring, Retaining 7 7516605 2 Screw
4 2540104 1 Asm., Oil Pump (Incl. 8) 8 5411293 1 O-Ring
11/02

C2
 STARTING MOTOR
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB
1
2

8 7
6 5
4

10
9

11 24
12

13

16

22
14 15

20
16 19
21 18
23 17
16

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3240113 2 Bolt, Through 13 3240205 1 Asm., Armature
2 7516807 2 Screw 14 3240206 1 Asm., Front Bracket
3 3240115 1 Brush (Incl. 4-8) 15 3240114 1 O-Ring
4 3240116 1 Nut 16 7555908 1 Washer, Thrust
5 3240117 1 Washer, Spring 17 3240126 1 Ring, Snap
6 3240119 1 Washer 18 3240125 1 Stopper
7 3084408 1 O-Ring 19 3240123 1 Cover
8 3240111 4 Spring, Brush 20 7041457 1 Spring
9 3084405 2 Ring, Rubber 21 3574214 1 Bushing, Flange
10 3240207 1 Asm., Rear Bracket 22 3240120 1 Asm., Gear (Incl. 16-21)
11 3240118 AR Washer, Thrust 23 4060119 1 Asm., Bendix (Incl. 16-22)
12 3240112 1 Washer, Thrust 24 4010675 1 Starter, Long Stud (Incl. 1,3-15)
8/01

C3
 TOOL KIT
MSX 140 W035303CA and MSX 140 W035303CB and INT’L MSX 140 W035303IA and INT’L MSX 140 W035303IB

4
5

2
1 3

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 ------- 1 Wrench, Spark Plug 5 2871109 1 Wrench, 3/16 Allen, Plated
2 2872383 1 Wrench, Open End (10mm-13mm) 6 2874515 1 Kit, Tool, Metric (Incl. 1-3,4,5)
3 ------- 1 Screwdriver 7 9918124 1 Manual, Owners, ’03 MSX, PWC
4 2690016 1 Pouch, Tool Kit
11/02

C4
PRINTED IN THE USA PARTS MANUAL PN 9918106 AND MICROFICHE PN 9918107 11/02