Cleaning; Assembly - Sea-doo GTX DI 5563 2002 Shop Manual

CAUTION: Ensure to completely screw the puller
until it bottoms. Otherwise, not enough threads
would be engaged and damage may occur.
1. Puller
Tighten puller screw and at the same time, tap on
screw head using a hammer to release magneto
rotor from its taper.
CAUTION: Be careful after ring gear removal
not to bend the encoder wheel teeth. Also pay
attention when putting away. If you suspect a
bent tooth, refer to ENGINE MANAGEMENT for
inspection procedure.
Stator and Trigger Coil/CPS
(Crankshaft Position Sensor)
Loosen screws no. 20 and no. 21 to remove the
stator no. 9 and trigger coil no. 10 from the engine
magneto cover.
1. Remove screws
SMR2002-061_04_04A.FM
Subsection 04 (MAGNETO SYSTEM)

CLEANING

Clean all metal components in a solvent.
CAUTION: Clean coils and magnets using only
a clean cloth.
Clean crankshaft taper and threads using acetone.
Apply the acetone on a rag first then clean the
crankshaft.

ASSEMBLY

Battery Charging Coil
Position new coil, crimp and solder all wires.
Prior to assembly, apply Loctite 243 (blue).
Use magneto coil centering tool (P/N 420 876 922)
and install it so that it fits around armature plate
before tightening screws no. 23.
F00D0AA
1. Magneto coil centering tool (P/N 420 876 922)
Magneto Flywheel and Ring Gear
Apply Loctite 648 (green) to magneto flywheel
mating surface. Lay ring gear on a steel plate, then
heat with a propane torch in order to install it on
magneto flywheel.
www.SeaDooManuals.net
Section 04 ENGINE (DI)
1
04-04-3