SeaDoo GSX 5620 Manual
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SeaDoo GSX 5620 Manual

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Summary of Contents for SeaDoo GSX 5620

  • Page 2 ® SHOP MANUAL SUPPLEMENT 219 100 034...
  • Page 3 Legal deposit : National Library of Quebec National Library of Canada All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 1996 Printed in Canada ®...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION SUB-SECTION PAGE SAFETY NOTICE ............................INTRODUCTION ............................ELECTRICAL SYSTEM 01 - Instruments and Accessories ...........01-01-1 PROPULSION SYSTEM 01 - Reverse System (GTX Model) ..........02-01-1 STEERING SYSTEM 01 - GSX and GTX Models............03-01-1 HULL / BODY 01 - Components ..............04-01-1 TECHNICAL DATA 01 - GSX and GTX Models............05-01-1 WIRING DIAGRAMS ........................06-00-1...

  • Page 5: Safety Notice

    SAFETY NOTICE SAFETY NOTICE This manual was primarily published to be used by watercraft technicians trained by the manufacturer who are already familiar with all service and maintenance procedures relating to Bombardier made Sea- Doo watercraft. Please note that the instructions will apply only if proper hand tools and special service tools are used. It is understood that this manual may be translated into another language.

  • Page 6: Introduction

    SHOP MANUAL SUPPLEMENT INTRODUCTION This Sea-Doo Shop Manual Supplement contains information specifically applicable to the GSX (5620) and GTX (5640) watercraft models. This manual covers the main differences of these new models. If a particular system is not covered in this manual, refer to the Sea-Doo Shop Manual (P / N 219 100 031) to obtain the required addi- tional information.

  • Page 7: Electrical System

    Section 01 ELECTRICAL SYSTEM Sub-Section 01 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES GENERAL With a garden hose, spray the speed sensor with water. The lake temperature on the Info Center It is possible to activate the Info Center gauge gauge should adjust to the water temperature. when the engine is not running.
  • Page 8 Section 01 ELECTRICAL SYSTEM Sub-Section 01 (INSTRUMENTS AND ACCESSORIES) Change the direction of the compass. There The BLACK wire is the ground. should be a change of direction on the Info Center The PURPLE / YELLOW wire is the pulse signal Gauge.
  • Page 9 Section 01 ELECTRICAL SYSTEM Sub-Section 01 (INSTRUMENTS AND ACCESSORIES) LAKE TEMPERATURE LOW FUEL RESISTANCE FUEL LEVEL Disconnect the 2-circuit connector housing of the LEVEL RED (Ω) LCD GRAPHIC LIGHT Info Center gauge which contains a BLACK / OR- ANGE and TAN / ORANGE wires. 0 + 2.2 FULL Connect potentiometer test probes to the BLACK...
  • Page 10 Section 01 ELECTRICAL SYSTEM Sub-Section 01 (INSTRUMENTS AND ACCESSORIES) NOTE : The gauge must be activated to ob- tain a reading. RESISTANCE DISPLAY (Ω) TEMPERATURE (°C) 25590.1 5 ± 2 20005.8 10 ± 2 15761.7 15 ± 2 12510.2 20 ± 2 10000.0 25 ±...

  • Page 11: Propulsion System

    Section 02 PROPULSION SYSTEM Sub-Section 01 (REVERSE SYSTEM) REVERSE SYSTEM GTX Model 3 N•m (27 lbf•in) Loctite 242 Synthetic Loctite grease 3.5 N•m (31 lbf•in) 2.5 N•m (22 lbf•in) Sealant 4 N•m 6 N•m 3 N•m (35 lbf•in) (53 lbf•in) (27 lbf•in) Loctite 7 N•m...
  • Page 12 Section 02 PROPULSION SYSTEM Sub-Section 01 (REVERSE SYSTEM) DISASSEMBLY 1, Deflector Put shift lever in reverse position. Disconnect reverse cable by loosing bolt no. 2 and lock nut no. 3 from cable lever. Loosen 2 Allen screws no. 4 and remove deflec- tor.
  • Page 13 Section 02 PROPULSION SYSTEM Sub-Section 01 (REVERSE SYSTEM) ASSEMBLY Make sure the shift lever action is smooth and precise. Forward, neutral and reverse positions Assembly is essentially the reverse of disassem- should be easy to select with a detent position be- bly procedures.
  • Page 14 Section 02 PROPULSION SYSTEM Sub-Section 01 (REVERSE SYSTEM) F07J08A 1. Bolt 2. Ball joint 3. Cable lever 4. Flat washer 5. Lock nut ADJUSTMENT Put shift lever in forward position. The pawl lock no. 7 should be engaged in the an- chor no.

  • Page 15: Steering System

    Section 03 STEERING SYSTEM Sub-Section 01 (GSX AND GTX MODELS) GSX AND GTX MODELS 14 N•m (10 lbf•ft) 26 N•m (19 lbf•ft) Loctite 242 10 N•m (89 lbf•in) 4 N•m (35 lbf•in) 14 N•m (10 lbf•ft) Loctite 242 6 N•m (53 lbf•in) 6 N•m Loctite 242...
  • Page 16 Section 03 STEERING SYSTEM Sub-Section 01 (GSX AND GTX MODELS) DISASSEMBLY 1, Grip To remove grip, pull out cap no. 2 and remove screw no. 3. Pull out grip. 4, Cover Remove grips no. 1. Loosen set screws no. 5 of handlebar housings no.
  • Page 17 Section 03 STEERING SYSTEM Sub-Section 01 (GSX AND GTX MODELS) F07K04A 1. Boot 2. Tie rap F07K06A Disconnect the throttle and choke cables from 1. Steering stem arm 2. Steering cable carburetor levers. Loosen bolts no. 11 retaining cable support to Disconnect the wiring harnesses leading out of steering support (refer to cable support no.
  • Page 18 Section 03 STEERING SYSTEM Sub-Section 01 (GSX AND GTX MODELS) 15, 16, Steering Stem Arm and Support Loosen bolts no. 17 retaining steering stem arm to support. F07K09A 1. Keyway 2. Integrated flat key Replace lock nuts no. 18 by new ones. Torque bolts no.
  • Page 19 Section 03 STEERING SYSTEM Sub-Section 01 (GSX AND GTX MODELS) GTX Model F00J01A TYPICAL 1. Bolt 2. Flat washers 3. Lock nut. Torque to 2 N•m (18 lbf•in) ALIGNMENT To position handlebar in straight ahead position, insert a pin in the steering support and turn the handlebar until the pin locks the steering stem.

  • Page 20: Hull / Body

    Section 04 HULL / BODY Sub-Section 01 (COMPONENTS) COMPONENTS GSX Model 5 N•m (44 lbf•in) Loctite 5 N•m (44 lbf•in) Loctite 5 N•m (44 lbf•in) Loctite 5 N•m 5 N•m (44 lbf•in) (44 lbf•in) 5 N•m Loctite (44 lbf•in) Loctite 5 N•m (44 lbf•in) 8 N•m...
  • Page 21 Section 04 HULL / BODY Sub-Section 01 (COMPONENTS) Loctite Loctite 8 N•m (71 lbf•in) 15 N•m (11 lbf•ft) Sealant Loctite Sealant 2.5 N•m (22 lbf•in) Sealant F06L02S 04-01-2 PARTS...
  • Page 22 Section 04 HULL / BODY Sub-Section 01 (COMPONENTS) GTX Model Loctite Loctite 5 N•m 5 N•m (44 lbf•in) (44 lbf•in) Loctite 8 N•m (71 lbf•in) Loctite Loctite 5 N•m (44 lbf•in) 8 N•m (71 lbf•in) Loctite Loctite Sealant 5 N•m (44 lbf•in) Body Loctite...
  • Page 23 Section 04 HULL / BODY Sub-Section 01 (COMPONENTS) Loctite Loctite 8 N•m (71 lbf•in) 15 N•m (11 lbf•ft) Loctite Loctite 8 N•m Sealant (71 lbf•in) Sealant 1.5 N•m (13 lbf•ft) Sealant F07L04S 04-01-4 PARTS...
  • Page 24 Section 04 HULL / BODY Sub-Section 01 (COMPONENTS) 8 N•m (71 lbf•in) 1.4 N•m (12 lbf•in) 0.8 N•m (7 lbf•in) Loctite Loctite 5 N•m (44 lbf•in) 5 N•m (44 lbf•in) 8 N•m (71 lbf•in) Loctite 3 N•m (26 lbf•in) Loctite 242 5 N•m (44 lbf•in) F07L05S...
  • Page 25 Section 04 HULL / BODY Sub-Section 01 (COMPONENTS) Loctite 242 4 N•m (35 lbf•in) 5 N•m (44 lbf•in) Loctite 242 Loctite 242 4 N•m (35 lbf•in) Loctite 242 5 N•m (44 lbf•in) Loctite 242 5 N•m (44 lbf•in) F07L06S 04-01-6 PARTS...
  • Page 26 Section 04 HULL / BODY Sub-Section 01 (COMPONENTS) Sealant Body 31 N•m Loctite (23 lbf•ft) Loctite Ultra Black Loctite 8 N•m (71 lbf•in) Loctite 598 Ultra Black Sealant Body Loctite Ultra Black Loctite 598 Ultra Black 8 N•m (71 lbf•in) Loctite 4 N•m (35 lbf•in)
  • Page 27 Section 04 HULL / BODY Sub-Section 01 (COMPONENTS) ADJUSTMENT 2, Lock Pin Adjust seat lock pin as per following specifica- 1, Front Hook tions : Adjust front hook as per following specifications : F06L03A F02L24A GSX MODEL 1. Lock pin GSX MODEL 2.
  • Page 28 Section 04 HULL / BODY Sub-Section 01 (COMPONENTS) The flat washer no. 10 should be installed with its sharp edge opposite to the steering support. F06L03A GTX MODEL - REAR SEAT 1. Lock pin F07L09A 2. Adjustment nut (apply Loctite 271) A.
  • Page 29 Section 04 HULL / BODY Sub-Section 01 (COMPONENTS) 9, Shoe F07L0BA F07L0AA 1. Nuts 8, Support Using a heat gun, heat jet pump support until it is possible to pull it. NOTE : Shims may have been installed be- tween support and body. Do not remove these shims, otherwise jet pump alignment will be altered.

  • Page 30: Technical Data

    Section 05 TECHNICAL DATA Sub-Section 01 (GSX AND GTX MODELS) GSX AND GTX MODELS ENGINE GSX (5620) GTX (5640) Engine type Bombardier-Rotax 787 Induction type Rotary valve Exhaust system Type Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm (.139 in) Water injection fitting (cone)
  • Page 31 Section 05 TECHNICAL DATA Sub-Section 01 (GSX AND GTX MODELS) ELECTRICAL GSX (5620) GTX (5640) Magneto generator output 180 W @ 6000 RPM or 5.0 A @ 2000 RPM Ignition system type DC-CDI Spark plug Make and type NGK BR8ES 0.5 - 0.6 mm (.020 - .024 in) mm (in) 3.38 (.133)
  • Page 32 Section 05 TECHNICAL DATA Sub-Section 01 (GSX AND GTX MODELS) PROPULSION GSX (5620) GTX (5640) Propulsion system Bombardier Formula Pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines Oil type SEA-DOO JET PUMP SYNTHETIC POLYOLESTER OIL 75W90 GL5...
  • Page 33 Section 05 TECHNICAL DATA Sub-Section 01 (GSX AND GTX MODELS) MATERIALS GSX (5620) GTX (5640) Hull Composite Inlet grate Aluminum Impeller housing / venturi / nozzle Plastic / Plastic / Aluminum Plastic / Plastic / Plastic Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Exhaust muffler...
  • Page 34 Section 05 TECHNICAL DATA Sub-Section 01 (GSX AND GTX MODELS) TIGHTENING TORQUES GSX (5620) GTX (5640) Exhaust manifold screw 40 N•m (30 lbf•ft) (3) (4) Magneto flywheel nut 105 N•m (77 lbf•ft) Flywheel (PTO side) 110 N•m (81 lbf•ft) Crankcase screws 24 N•m (17 lbf•ft) (3) (4)

This manual is also suitable for:

Gtx 5640

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