Sea-doo GTX DI 5563 2002 Jet Ski Manuals

Manuals and User Guides for Sea-doo GTX DI 5563 2002 Jet Ski. We have 1 Sea-doo GTX DI 5563 2002 Jet Ski manual available for free PDF download: Shop Manual

Sea-doo GTX DI 5563 2002 Shop Manual

Sea-doo GTX DI 5563 2002 Shop Manual (505 pages)

Brand: Sea-doo | Category: Boat | Size: 34 MB

Table of Contents

Table of Contents

4
- Service Tools
  6
  - Hull Identification Number
    7
- Maintenance
  8
- Management
  11
  - General Information
    12
  - Engine Emissions Information
    12
  - Tightening Torques
    17
Table of Contents

19
- Mandatory Service Tools
  
  20
  - Engine
    20
  - Cooling/Fuel/Oil Systems
    23
  - Propulsion System
    24
  - Steering System
    26
- Optional Service Tools
  
  27
  - Engine
    27
  - Cooling/Fuel/Oil Systems
    30
  - Propulsion System
    31
  - Watercraft Handling
    31
- Service Products
  
  32
Table of Contents

37
- Periodic Inspection Chart
  
  38
- Flushing and Lubrication
  
  42
  - General
    42
  - Procedure
    42
- Water-Flooded Engine
  
  45
  - General
    45
  - Procedure
    45
- Storage
  
  49
  - Engine Draining
    49
  - Propulsion System
    49
  - Fuel System
    49
  - Engine Oil Change and Filter
    50
  - Cooling System Flushing and Engine Internal Lubrication
    50
  - Engine Lubrication
    50
  - Battery
    51
  - Watercraft Cleaning
    51
  - Additional Recommended Protection
    51
  - Anticorrosion Treatment
    53
  - Checklist
    54
  - Troubleshooting Chart
    55
  - Engine (DI
    59
  - Engine
    60
  - Engine
    61
  - Cooling System
    62
Table of Contents

65
- Leak Test
  
  66
  - General
    66
  - Preparation
    66
  - Testing Procedure
    66
  - Fuel System
    66
  - Engine Leakage Diagnostic Flow Chart
    69
- Removal and Installation
  
  70
  - General
    70
  - Engine Removal
    70
  - Cleaning
    72
  - Installation
    73
- Magneto System
  
  76
  - Disassembly
    77
  - Cleaning
    78
  - Assembly
    78
- Top End
  
  82
  - General
    83
  - Disassembly
    84
  - Cleaning
    87
  - Inspection
    88
  - Used Piston Measurement
    89
  - Ring End Gap
    90
  - Assembly
    91
- Bottom End
  
  97
  - Disassembly
    98
  - Cleaning
    101
  - Inspection
    102
  - Lubrication
    102
  - Assembly
    106
- Exhaust System
  
  110
  - Removal
    111
  - Tuned Pipe Repair
    115
  - Installation
    115
Table of Contents

119
- Leak Test Procedure
  
  121
  - Preparation
    121
  - Procedure
    122
  - Installation
    123
- Leak Test
  
  121
- Intake System
  
  124
  - Removal
    125
  - Assembly
    129
- Exhaust System
  
  131
  - Exhaust Pipe
    132
  - Exhaust Manifold
    135
  - Muffler (Lh)
    136
  - Muffler (Rh)
    137
  - Exhaust Outlet
    137
- Removal and Installation
  
  139
  - General
    139
  - Engine Removal
    139
  - Cleaning
    140
  - Installation
    140
- Pto Housing/Magneto
  
  144
  - General
    145
  - Pto Housing
    145
  - Pto Seal
    148
  - Coupling
    148
  - Stator
    149
  - Rotor and Encoder Wheel
    150
  - Ring Gear
    150
  - Starter Drive Ass'y
    151
- Lubrication System
  
  153
  - General
    155
  - Oil Level Verification
    155
  - Engine Pressure Test
    156
  - Oil Filter
    158
  - Oil Strainers
    159
  - Engine Oil Pressure Regulator
    161
  - Oil Pressure Pump
    162
  - Oil Suction Pump
    165
  - Oil Filter Bypass
    168
  - Oil Cooler
    168
  - Oil Separator
    169
- Cylinder Head and Valves
  
  171
  - General
    172
  - Spark Plug
    172
  - Valve Cover
    172
  - Rocker Arm
    173
  - Camshaft Timing Gear
    176
  - Timing Chain
    178
  - Cylinder Head
    178
  - Camshaft
    180
  - Valve Spring
    181
  - Valve
    182
- Engine Block
  
  186
  - General
    188
  - Crankshaft Locking
    188
  - Crankshaft
    188
  - Timing Chain
    193
  - Chain Tensioner
    193
  - Balancer Shaft
    194
  - Engine Block
    196
  - Piston/Connecting Rod
    202
  - Piston Rings
    207
Table of Contents

209
- Overview
  
  211
- Operating Principle
  
  212
- Fuel Delivery System
  
  212
  - Basic Operation
    212
  - Air/Fuel Rail Assembly
    212
  - Fuel Pump Module
    213
- Air Compressor System
  
  212
- Air Induction
  
  212
- Electronic Management
  
  214
  - MPEM (Multi-Purpose Electronic Module)
    214
  - Ignition System
    218
- General
  
  219
  - Fuel System
    219
  - Electrical System
    220
  - Amp Connector Pin-Out
    221
- Component Inspection and Adjustment
  
  219
- Quick Fuel Pressure Test
  
  222
- Air Induction System
  
  223
  - Throttle Body
    223
- Air Compressor
  
  226
  - Pressure Test
    226
  - Repair
    227
- Fuel Delivery
  
  230
  - Fuel Pressure Regulator
    230
  - Fuel Injector
    232
  - Air/Fuel Rail
    233
  - Direct Injector
    234
  - Fuel Pump
    235
- Electronic Management
  
  239
  - Mpem Replacement
    239
  - Throttle Position Sensor (Tps)
    240
  - Crankshaft Position Sensor (Cps)
    242
  - Manifold Air Temperature Sensor (Mats)
    244
  - Water Temperature Sensor (Wts)
    244
  - Manifold Air Pressure Sensor (Maps)
    245
  - Exhaust Gas Temperature Sensor (Egt)
    246
  - Knock Sensor (Ks)
    246
  - Rave Solenoid
    247
  - Ignition Coil
    248
  - Tdc Setting
    250
  - Spark Plugs
    253
  - Cranking System
    254
  - DI System Test Summary
    254
- Diagnostic Procedures
  
  257
- Dess System
  
  257
- General
  
  257
- Fault Detection and Compensatory Actions
  
  259
  - Component Failure Warning System
    259
- Vck (Vehicle Communication Kit)
  
  261
- DI System Fault Codes
  
  262
Table of Contents

268
- Overview
  
  270
- Complete Electrical System Overview
  
  271
- Magneto System and Power Supply
  
  272
- Operating Principle of Engine Management
  
  272
- Fuel Delivery System
  
  273
  - Basic Operation
    273
  - Intake Manifold
    273
  - Fuel Pump Module
    274
- Air Induction
  
  273
- Electronic Management
  
  274
  - EMS (Engine Management System)
    274
  - Ems - General Functions
    275
  - Ems - Engine Management Functions
    277
  - Mpem - Multi-Purpose Electronic Module
    280
- Component Inspection and Adjustment
  
  281
- General
  
  281
  - Fuel System
    281
  - Electrical System
    282
  - Engine Connector Pin-Out
    283
  - Connectors on Engine
    284
- Air Induction System
  
  285
  - Throttle Body
    285
- Fuel Delivery
  
  288
  - Fuel Pump
    289
  - Fuel Rail
    291
  - Fuel Injector
    291
- Electronic Management
  
  293
  - Ems Ecu and Mpem Replacement
    293
  - Engine Wiring Harness
    294
  - Throttle Position Sensor (Tps)
    296
  - Idle Bypass Valve
    298
  - Crankshaft Position Sensor (Cps)
    299
  - Camshaft Position Sensor (Caps)
    300
  - Manifold Air Temperature Sensor (Mats)
    301
  - Coolant Temperature Sensor (Cts)
    302
  - Manifold Air Pressure Sensor (Maps)
    303
  - Exhaust Gas Temperature Sensor (Egt)
    303
  - Knock Sensor (Ks)
    304
  - Oil Pressure Switch (Ops)
    305
  - Oil Separator Pressure Switch (Osps)
    305
  - Tops Valve (Blow-By)
    307
  - Ignition Coils
    309
  - Tdc Setting (Top Dead Center)
    310
  - Engine Start/Stop Switch Verification
    310
  - Safety Lanyard Switch Verification
    310
  - Spark Plugs
    311
  - Cranking System
    311
- General
  
  312
- Diagnostic Procedures
  
  312
- Self-Diagnostic Mode
  
  314
- VCK (Vehicle Communication Kit)
  
  315
- 4-Tec System Fault Codes
  
  315
Table of Contents

318
- Circuit, Components and Care
  319
- Circuit
  324
- Components
  326
- Care
  330
- Circuit
  331
- Cooling System Leak Test
  331
- Coolant Replacement
  333
- Draining the System
  333
- Inspection
  333
- Coolant Pump Housing
  335
- Coolant Pump Impeller
  336
- Thermostat
  336
- Rotary Seal
  337
- Care
  339
Table of Contents

341
- Fuel Circuit
  
  342
  - General
    344
  - Removal
    344
  - Inspection
    346
  - Assembly
    347
  - Fuel System Pressurization
    347
- Air Intake
  
  349
  - Removal
    351
  - Assembly
    352
Table of Contents

353
- Oil Injection System
  
  354
  - General
    355
  - Oil System Pressurization
    355
- Oil Injection Pump
  
  356
  - Oil Pump Identification
    357
  - Removal
    357
  - Disassembly
    357
  - Cleaning
    357
  - Assembly
    357
  - Adjustment
    358
  - Checking Operation
    359
Table of Contents

361
- Charging System
  
  362
  - General
    362
  - Testing Procedure
    362
  - Battery
    364
- Starting System
  
  369
  - General
    370
  - Starting System Troubleshooting
    371
  - Starter Removal
    372
  - Starter Disassembly
    372
  - Cleaning
    375
  - Parts Inspection
    376
  - Starter Assembly
    377
  - Starter Installation
    377
  - Starter Specification
    379
- Instruments and Accessories
  
  380
  - General
    380
  - Addition of Accessories
    385
  - Inspection
    385
Table of Contents

389
- Jet Pump
  
  390
  - General
    391
  - Jet Pump Inspection on Watercraft
    391
  - Removal
    393
  - Disassembly
    395
  - Cleaning
    398
  - Parts Inspection
    398
  - Assembly
    400
  - Pump Pressurization
    408
  - Installation
    409
  - General
    412
  - Jet Pump Inspection on Watercraft
    412
  - Removal
    413
  - Pump Assembly
    413
  - Disassembly
    416
  - Cleaning
    419
  - Parts Inspection
    419
  - Assembly
    420
  - Pump Pressurization
    425
  - Installation
    425
- Drive System
  
  427
  - General
    429
  - Removal
    429
  - Inspection
    433
  - Installation
    435
  - Lubrication
    440
- Reverse System
  
  441
  - Disassembly
    442
  - Inspection
    443
  - Assembly
    443
  - Adjustment
    444
Table of Contents

445
- Steering System
  
  446
  - Disassembly
    447
  - Assembly
    450
- Off-Power Assisted Steering System (O.p.a.s.)
  
  452
  - General
    453
  - Side Vane
    453
  - Cylinder Support Assembly
    454
  - Tie Rod
    455
  - Sealed Tube
    456
  - Filter
    456
  - Valve
    456
  - Water Hose
    457
  - Cross Support Plate
    457
- Alignment
  
  459
Table of Contents

460
- Adjustment and Repair
  461
- Front Seat Adjustment
  465
- Glove Box
  465
- Storage Compartment Inner Shell
  465
- Storage Cover Shock
  468
- Storage Compartment Cover Adjustment
  469
- Deflector And/Or Upper Grill
  470
- Info Center (Lcd Gauges)
  470
- Mirror
  470
- Finition Plate
  471
- Inlet Grate
  471
- Riding Plate
  471
- Jet Pump Support
  472
- Drain Plug Installation
  473
- Seat Cover Replacement
  473
- Bumper Replacement
  474
- Sponson Replacement
  474
- Decals Replacement
  475
- Hull and Body Repair
  475
- Tools and Materials List
  478
  - Wiring Diagrams
    489

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