Sea-Doo Challenger 5896 Manuals

Manuals and User Guides for Sea-Doo Challenger 5896. We have 1 Sea-Doo Challenger 5896 manual available for free PDF download: Shop Manual

Sea-Doo Challenger 5896 Shop Manual

Sea-Doo Challenger 5896 Shop Manual (274 pages)

Jet Boats

Brand: Sea-Doo | Category: Boat | Size: 15 MB

Table of Contents

Table of Contents

5
- Safety Notice
  7
- Introduction
  8
  - Hull Identification Number
    8
- 01 Service Tools and Products
  9
  - General Information
    12
  - Mandatory Tools
    13
    
    Propulsion System
    17
  - Recommended Tools
    18
  - Service Products
    23
Table of Contents

28
- Maintenance
  
  29
  - Periodic Inspection Chart
    29
  - Flushing and Care
    30
    
    Flushing
    30
    
    Procedure
    30
    
    Care
    32
  - Water-Flooded Engine
    33
  - Storage
    35
- Troubleshooting
  
  39
Engine

44
- Table of Contents
  
  44
- Removal and Installation
  
  45
  - Engine
    47
    
    General
    47
    
    Removal from Jet Boat
    47
    
    Cleaning
    51
    
    Installation
    51
- Top End
  
  56
  - Engine Description
    57
  - General
    57
  - Disassembly
    57
  - Cleaning
    59
  - Inspection
    59
  - Ring End Gap
    61
  - Assembly
    62
  - Rave System
    67
  - Squish Area
    69
- PTO Flywheel and Magneto
  
  71
  - 717 Engine
    71
    
    General
    73
    
    Removal
    73
    
    Magneto Flywheel
    75
    
    Cleaning
    78
    
    Installation
    78
- Bottom End
  
  80
  - 717 Engine
    80
    
    Crankshaft Misalignment and Deflection
    82
    
    Disassembly
    83
    
    General
    83
    
    Cleaning
    85
    
    Inspection
    85
    
    Assembly
    87
- Rotary Valve
  
  91
  - General
    92
    
    Disassembly
    92
    
    Cleaning
    94
    
    Inspection
    94
    
    Assembly
    96
    
    Rotary Valve Timing
    100
Cooling System

102
- Table of Contents
  
  102
- Components
  
  103
  - Sportster and Speedster
    103
    
    General
    104
    
    Water Flow Regulator Valve
    105
- Circuit
  
  107
  - General
    107
    
    717 Engine Cooling System
    110
Fuel System

112
- Table of Contents
  
  112
  - Fuel Circuit
    113
    
    Sportster and Challenger
    113
    
    Speedster
    114
    
    General
    115
- Air Intake
  
  117
- Carburetors
  
  118
  - General
    119
  - Carburetor Removal
    119
  - Cleaning
    119
  - Disassembly and Inspection
    119
  - Pump Verification
    119
  - Carburetor Assembly
    120
  - Carburetor Installation
    122
  - Adjustments
    124
  - Fuel System Pressurization
    126
Oil Injection Reservoir/Oil Injection Pump

128
- Table of Contents
  128
- Oil Injection Reservoir
  
  129
  - Sportster and Challenger
    129
    
    Speedster
    130
    
    General
    131
- Oil Injection Pump
  
  132
  - Sportster and Speedster
    134
    
    Assembly
    134
    
    Challenger
    134
    
    Cleaning
    134
    
    Disassembly
    134
    
    Adjustments
    135
    
    Checking Operation
    136
    
    Oil System Pressurization
    137
Electrical

138
- 717 Engine
  
  141
  - Magneto System
    141
  - Ignition System (Single Generator Coil)
    141
  - Mpem (Multi-Purpose Electronic Module)
    142
  - Charging System
    142
  - Starting System
    142
  - Gauges / Accessories
    142
- Overview
  
  141
- 787 Engine
  
  144
  - Magneto System
    144
  - Charging System
    144
  - Charging Circuit Schematic
    144
  - Ignition System
    145
  - Starting System and Gauges / Accessories
    145
- Magneto System
  
  146
  - 717 Engine
    146
    
    Disassembly
    147
    
    Removal
    147
    
    Assembly
    148
    
    Installation
    148
    
    787 Engine
    149
    
    Assembly
    150
    
    Magneto Rotor and Engine Flywheel Removal
    150
- Ignition System
  
  151
- Electrical System
  
  151
  - Sportster
    151
- Electrical Box
  
  152
  - Sportster
    152
- Electrical System
  
  153
  - Speedster
    153
- Electrical Box
  
  154
  - Speedster
    154
- Ignition System Testing Procedure, 717 Engine
  
  155
  - Ignition Timing, 717 Engine
    158
  - Ignition Timing Adjustment, 717 Engine
    161
- Ignition System Testing Procedure, 787 Engine
  
  162
  - Ignition Timing, 787 Engine
    165
- Spark Plug Symbol Explanation
  
  168
  - Disassembly
    169
  - Heat Range
    169
  - Fouling
    169
  - Spark Plug Analysis
    169
  - Spark Plug Installation
    169
  - Spark Plug Chart
    170
  - 05 -The DESS (Digitally Encoded Security System)
    171
- Spark Plugs
  
  168
- The Dess (Digitally Encoded Security System)
  
  171
  - Features of the Dess
    171
  - Programming of Safety Lanyard(S)
    171
  - Safety Lanyard
    171
  - Monitoring System
    173
- Mpem (Multi-Purpose Electronic Module)
  
  175
  - Operation of Mpem
    175
  - Electrical Tests for the Mpem
    176
  - 07 -Charging System
    180
- Charging System
  
  180
  - Testing Procedure 717 Engine
    180
  - 08 -Starting System
    183
- Electric Starter
  
  183
  - Starting System Troubleshooting
    185
  - Cleaning
    186
  - Disassembly
    186
  - Inspection
    186
  - Removal
    186
  - Assembly
    187
  - Starter Installation
    189
  - Starter Specification
    190
- Starting System
  
  183
- Battery
  
  191
  - Cleaning
    191
  - Inspection
    191
  - Removal
    191
  - Troubleshooting
    191
  - Activation of New Battery
    192
  - Battery Storage
    192
  - Hydrometer Test
    192
  - Battery Charging Equipment
    195
  - Servicing
    195
  - Tips for Charging a Used Battery
    195
  - Installation of Battery
    196
  - 09 -Instruments and Accessories
    197
    
    Fuel / Oil Gauge
    199
  - 10 -Wiring Diagram
    202
    
    Fuses Location
    202
    
    Wire Color
    202
Variable Trim System (Vts)

203
- Propulsion and
  204
  - Jet Pump Inspection on Jet Boat
    206
  - Jet Pump Removal
    207
  - Cleaning
    214
  - Parts Inspection
    214
  - Jet Pump Assembly
    218
  - Pump Pressurization
    223
  - Jet Pump Installation
    225
  - All Models
    228
  - 1,2,3,4,5, Screw, Sleeve, Bushing and Nozzle
    228
  - Reverse System
    230
    
    Assembly
    231
    
    Disassembly
    231
    
    Inspection
    231
  - Variable Trim System (VTS)
    233
    
    Challenger
    233
    
    Adjustments
    234
Steering System

236
- Table of Contents
  
  236
- Steering System
  
  237
  - Sportster
    237
    
    Speedster
    238
    
    Steering Cable Replacement
    239
    
    Steering Helm Replacement
    239
    
    Steering System Inspection
    239
- Alignment
  
  241
- Throttle / Shifter / VTS Controller
  
  243
  - Removal
    243
    
    Adjustments
    243
    
    Inspection
    243
    
    Lubrication
    243
    
    Assembly
    245
Repair/Painting

246
- Hull / Deck
  
  247
  - Components
    247
    
    Bumper Replacement
    252
    
    Decal Replacement
    252
    
    Drain / Cooling Outlet(S) Location
    253
    
    Latch Adjustment
    253
    
    Rear Storage Compartment Cover Gas Shocks
    253
    
    Drain Replacement
    254
    
    Seat Removal / Installation
    254
- Hull and Deck Repair
  
  255
  - General
    255
  - Air Bubbles
    255
  - Blisters
    256
  - Minor Gelcoat Fractures
    256
  - Compound Fractures
    256
  - Tools and Materials List
    258
- Repair
  
  255
- Painting
  
  259
  - Parts that Can be Painted
    260
- Concepttm Painting Procedure
  
  262
  - Surface Preparation
    262
  - Full Panel and Overall Repairs
    262
  - Spot / Panel Repairs
    262
- Deltatm Painting Procedure
  
  263
  - Surface Preparation
    263
  - Deltatm 2800, Color
    263
  - Recommended Spray Equipment
    263
- Technical Data
  
  264
- All Models
  
  264

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