Sea-doo GTI 5641 Jet Ski Parts Manuals

Manuals and User Guides for Sea-doo GTI 5641 Jet Ski Parts. We have 1 Sea-doo GTI 5641 Jet Ski Parts manual available for free PDF download: Shop Manual

Sea-doo GTI 5641 Shop Manual

Sea-doo GTI 5641 Shop Manual (372 pages)

1997 SeaDoo

Brand: Sea-doo | Category: Boat | Size: 53 MB

Table of Contents

Table of Contents

4
- Section
  
  5
- Table of Contents
  
  5
  - Safety Notice
    5
    
    Hull Identification Number
    6
    
    General Information
    10
Table of Contents

11
- Periodic Inspection Chart
  
  12
  - Flushing and Lubrication
    
    13
    
    General
    13
    
    Procedure
    13
  - 04
    
    19
    
    General
    17
    
    Procedure
    17
    
    Water-Flooded Engine
    17
    
    Fuel System
    19
  - 05
    
    20
  - 06
    
    20
  - 07
    
    20
    
    Storage
    19
    
    Propulsion System
    20
    
    Troubleshooting Chart
    23
Table of Contents

26
- Leak Test
  
  28
  - General
    28
  - Preparation
    28
  - Testing Procedure
    28
  - Engine Leakage Diagnostic Flow Chart
    33
  - Engine Removal
    34
  - General
    34
  - Removal and Installation
    34
  - Cleaning
    37
  - Installation
    37
  - Magneto System
    
    40
    
    General
    42
    
    Removal
    42
    
    Cleaning
    45
    
    Disassembly
    45
    
    Assembly
    47
    
    Installation
    48
  - 01
    
    69
  - 02
    
    69
  - 03
    
    69
    
    Top End
    50
    
    General
    52
    
    Disassembly
    54
    
    Cleaning
    56
    
    Inspection
    57
    
    Assembly
    60
    
    Cylinder Head
    66
    
    Adjustment
    67
    
    Combustion Chamber Volume Measurement
    67
    
    Bottom End
    69
    
    Crankshaft Misalignment and Deflection
    71
    
    Disassembly
    72
    
    Cleaning
    75
    
    Inspection
    75
    
    Assembly
    77
    
    Rotary Valve
    82
    
    General
    83
    
    Inspection on Watercraft
    83
    
    Rotary Valve Timing
    91
    
    Exhaust System
    93
    
    Tuned Pipe Removal
    96
    
    Exhaust Manifold Removal
    98
    
    Muffler Removal
    98
    
    Tuned Pipe Repair
    98
    
    Installation
    99
    
    Engine Cooling System
    115
Table of Contents

117
- Fuel Circuit
  118
  - General
    123
  - Fuel Filter
    124
  - Removal
    124
  - Inspection
    126
  - Assembly
    127
  - Fuel System Pressurization
    127
  - Air Intake
    
    129
    
    Assembly
    130
    
    Removal
    130
  - Carburetors
    
    132
    
    General
    134
    
    Removal
    134
    
    Cleaning
    135
    
    Disassembly and Inspection
    135
    
    Assembly
    136
    
    Installation
    139
    
    Adjustments
    140
    
    Throttle Cable
    140
Table of Contents

143
- Oil Injection System
  144
  - General
    147
  - Oil System Pressurization
    147
  - Oil Injection Pump
    
    148
    
    Assembly
    150
    
    Cleaning
    150
    
    Disassembly
    150
    
    Removal
    150
    
    Adjustments
    151
    
    Checking Operation
    153
Table of Contents

154
- Ignition System
  155
  - General
    155
  - Ignition Timing Procedure
    158
  - Bombardier Ignition Tester
    165
  - Ignition System Testing Procedure
    165
  - Spark Plugs
    170
  - Charging System
    
    173
    
    General
    173
    
    Testing Procedure
    173
    
    Battery
    176
  - Starting System
    
    182
    
    General
    184
    
    Starting System Troubleshooting
    185
    
    Cleaning
    186
    
    Starter Disassembly
    186
    
    Starter Removal
    186
    
    Parts Inspection
    187
    
    Starter Assembly
    187
    
    Starter Installation
    189
    
    Starter Specification
    190
  - Instruments and Accessories
    
    191
    
    General
    191
    
    Inspection
    191
  - Digitally Encoded Security System
    
    200
    
    General
    200
Table of Contents

203
- Jet Pump
  204
  - General
    205
  - Jet Pump Inspection on Watercraft
    205
  - Removal
    207
  - Disassembly
    209
  - Cleaning
    211
  - Parts Inspection
    212
  - Assembly
    214
  - Installation
    221
  - Pump Pressurization
    221
  - Steering Cable
    223
  - Drive System
    
    224
    
    General
    227
    
    Removal
    227
    
    Disassembly
    231
    
    Parts Inspection
    231
    
    Assembly
    232
    
    Lubrication
    237
  - Reverse System
    
    238
    
    Disassembly
    239
    
    General
    239
    
    Assembly
    240
    
    Reverse Gate
    240
    
    Shift Lever
    241
    
    Adjustments
    242
    
    Disassembly
    245
    
    Inspection
    245
    
    Assembly
    246
    
    Adjustment
    247
  - Variable Trim System
    
    248
  - Manual Trim
    
    248
    
    Assembly and Installation
    249
    
    Disassembly
    249
    
    Removal
    249
  - Electric Trim
    
    250
    
    Disassembly
    251
    
    General
    251
    
    Inspection
    251
    
    Removal
    251
    
    Assembly
    252
    
    Installation
    252
    
    Adjustment
    253
Table of Contents

254
- Sp and Spx Models
  255
  - Removal and Installation
    256
  - Steering Alignment
    259
  - Gts Model
    
    260
    
    Removal and Installation
    261
    
    Steering Alignment
    264
  - Gs, Gsi, Gsx, Gti and Gtx Models
    
    265
    
    Disassembly
    266
    
    Assembly
    268
    
    Steering Alignment
    269
  - Hx and Xp Models
    
    270
    
    Removal
    271
    
    Assembly and Installation
    272
    
    Disassembly
    272
    
    Steering Alignment
    274
Table of Contents

277
Adjustment and Repair/Adjustment and Repair

281
- 08
  
  340
- 09
  
  340
- 10
  
  340
- 11
  
  340
- 12
  
  340
  - Alignment
    
    275
    
    Direct Action Suspension
    278
    
    Disassembly
    279
    
    Assembly
    280
    
    Inspection
    280
    
    Adjustment and Repair
    282
    
    Seat Adjustment
    296
    
    Access Panel Adjustment
    298
    
    Storage Compartment Cover Adjustment
    298
    
    Inlet Grate Removal
    299
    
    Riding Plate
    299
    
    Jet Pump Support
    300
    
    Deflector
    302
    
    Drain Plug Installation
    302
    
    Seat Removal
    302
    
    Seat Cover Replacement
    303
    
    Bumper Replacement
    304
    
    Sponson Replacement
    304
    
    Baffle Sealing (Gts Model)
    305
    
    Decals Replacement
    305
    
    Hood Removal
    305
    
    Hull and Body Repair
    306
    
    Tools and Materials List
    308
    
    Hull Insert Repair
    309
    
    Wire Color Codes
    340
    
    Wiring Diagrams
    340

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