User Manuals: Sea-doo RX DI 5591 Personal Watercraft

Manuals and User Guides for Sea-doo RX DI 5591 Personal Watercraft. We have 1 Sea-doo RX DI 5591 Personal Watercraft manual available for free PDF download: Shop Manual

Sea-doo RX DI 5591 Shop Manual

Sea-doo RX DI 5591 Shop Manual (557 pages)

Brand: Sea-doo | Category: Boat | Size: 38 MB

Table of Contents

Table of Contents

5
- Safety Notice
  6
  - Hull Identification Number
    7
  - General Information
    12
  - Engine Emissions Information
    13
  - Tightening Torques
    17
Table of Contents

20
- Mandatory Service Tools
  
  21
  - Engine
    21
  - Cooling/Fuel/Oil Systems
    24
  - Propulsion System
    25
- Optional Service Tools
  
  27
  - Engine
    27
  - Cooling/Fuel/Oil Systems
    30
  - Propulsion System
    31
  - Watercraft Handling
    32
- Service Products
  
  33
Table of Contents

38
- Periodic Inspection Chart
  
  39
- Flushing and Lubrication
  
  41
  - General
    41
  - Procedure
    41
- Water-Flooded Engine
  
  44
  - General
    44
  - Procedure
    44
- Storage
  
  47
  - Engine Draining
    47
  - Propulsion System
    48
  - Fuel System
    49
  - Cooling System Flushing and Engine Internal Lubrication
    49
  - Battery
    49
  - Watercraft Cleaning
    49
  - Additional Recommended Protection
    49
  - Anticorrosion Treatment
    55
  - Checklist
    55
- Troubleshooting Chart
  
  56
Table of Contents

65
- Leak Test
  
  67
  - General
    67
  - Preparation
    67
  - Testing Procedure
    67
  - Engine Leakage Diagnostic Flow Chart
    73
- Removal and Installation
  
  75
  - General
    75
  - Engine Removal
    75
  - Cleaning
    79
  - Installation
    80
- Magneto System
  
  85
  - Disassembly
    89
  - Cleaning
    95
  - Assembly
    96
  - Magneto Flywheel
    97
- Top End
  
  100
  - General
    104
  - Disassembly
    106
  - Cleaning
    115
  - Inspection
    115
  - Used Piston Measurement
    116
  - Ring End Gap
    118
  - Assembly
    119
  - Adjustment
    128
- Bottom End
  
  130
  - Disassembly
    134
  - Cleaning
    142
  - Inspection
    143
  - Assembly
    147
- Rotary Valve
  
  155
  - Rotary Valve Timing
    163
- Exhaust System
  
  165
  - Removal
    171
  - Tuned Pipe Repair
    176
  - Installation
    177
Table of Contents

184
- Overview
  
  186
- Air Induction
  
  187
- Fuel Delivery
  
  187
  - Fuel Pump
    187
  - Fuel Pressure Regulator
    187
  - Fuel Filters
    188
  - Fuel Pump Module
    188
  - Fuel Injectors
    188
- Electronic Management
  
  189
  - Electronic Control Unit (Ecu)
    189
  - Mpem (Multi-Purpose Electronic Module)
    189
- Diagnostic Procedures
  
  191
  - Diagnostic Option Example
    191
- Fault Code Tables
  
  192
  - Ecu Faults
    192
  - Input Signal Faults
    192
  - Output Signal Faults
    193
- Component Inspection
  
  194
- General
  
  194
- Fuel Delivery
  
  196
  - Fuel Filter
    196
  - Fuel Pump
    196
  - Regulator
    196
  - Fuel Injector
    197
  - Leak Test (Supply and Ventilation Circuits)
    198
  - High Pressure Test (Fuel Pump Circuit)
    198
- Air Induction System
  
  196
  - Throttle Body
    196
- Electronic Management
  
  199
- Engine Cannot Reach Maximum Revolutions
  
  205
  - Throttle Position Sensor (Tps)
    206
  - Throttle Cable Adjustment
    206
  - Crankshaft Position Sensor (Cps)
    207
  - Air Temperature Sensor (Ats)
    207
  - Water Temperature Sensor (Wts)
    207
  - Air Pressure Sensor (Aps)
    207
- Flooded Engine Feature
  
  205
- Spark Plug Inspection
  
  205
- Engine Starts but Runs Poorly
  
  205
- Ecu Fault Codes
  
  205
- Troubleshooting Summary
  
  205
- Engine Does Not Start
  
  205
- Fuel Pump Assembly
  
  207
Table of Contents

209
- Overview
  
  211
- Operating Principle
  
  212
- Air Compressor System
  
  212
- Air Induction
  
  212
- Fuel Delivery System
  
  212
  - Basic Operation
    212
  - Air/Fuel Rail Assembly
    212
  - Fuel Pump Module
    213
- Electronic Management
  
  214
  - MPEM (Multi-Purpose Electronic Module)
    214
  - Ignition System
    218
- Component Inspection and Adjustment
  
  219
- General
  
  219
  - Fuel System
    219
  - Electrical System
    220
  - Amp Connector Pin-Out
    221
- 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
- General
  
  257
- Dess System
  
  258
- Fault Detection and Compensatory Actions
  
  260
  - Component Failure Warning System
    260
- Vck (Vehicle Communication Kit)
  
  262
- DI System Fault Codes
  
  263
Circuit, Components and Care/Circuit, Components and Care

269
- Circuit, Components and Care
  270
  - Circuit
    279
  - Components
    283
  - Care
    286
Table of Contents

289
- Fuel Circuit
  
  290
  - General
    296
  - Removal
    296
  - Inspection
    298
  - Assembly
    299
  - Fuel System Pressurization
    300
- Air Intake
  
  301
  - Removal
    305
  - Assembly
    306
- Carburetor
  
  308
  - General
    309
  - Removal
    309
  - Cleaning
    310
  - Disassembly and Inspection
    310
  - Assembly
    312
  - Installation
    314
  - Adjustments
    314
Table of Contents

320
- Oil Injection System
  
  321
  - General
    326
  - Oil System Pressurization
    326
- Oil Injection Pump
  
  327
  - Oil Pump Identification
    331
  - Removal
    331
  - Disassembly
    331
  - Cleaning
    331
  - Assembly
    332
  - Adjustment
    333
  - Checking Operation
    336
Table of Contents

338
- Ignition System
  
  339
  - General
    339
  - Multi-Purpose Electronic Module (Mpem)
    341
  - Throttle Cable
    344
  - Ignition Timing
    345
  - Ignition System Testing Procedure
    352
  - Spark Plugs
    356
- Charging System
  
  360
  - General
    360
  - Testing Procedure
    360
  - Battery
    364
  - Battery Storage
    366
- Starting System
  
  370
  - General
    373
  - Starting System Troubleshooting
    374
  - Starter Removal
    375
  - Starter Disassembly
    375
  - Cleaning
    377
  - Parts Inspection
    378
  - Starter Assembly
    378
  - Starter Installation
    380
  - Starter Specification
    382
- Instruments and Accessories
  
  383
  - General
    383
  - Other Functions
    385
  - Inspection
    386
- Digitally Encoded Security System
  
  394
  - General
    394
Table of Contents

397
- Jet Pump
  
  398
  - General
    400
  - Jet Pump Inspection on Watercraft
    400
  - Removal
    403
  - Disassembly
    405
  - Cleaning
    408
  - Parts Inspection
    408
  - Assembly
    410
  - Pump Pressurization
    418
  - Installation
    418
- Drive System
  
  420
  - General
    422
  - Removal
    422
  - Inspection
    426
  - Assembly
    427
  - Installation
    429
  - Lubrication
    431
- Reverse System
  
  433
  - Disassembly
    434
  - Inspection
    435
  - Assembly
    435
  - Adjustment
    436
  - Disassembly
    440
  - Inspection
    441
  - Assembly
    441
  - Adjustment
    441
- Variable Trim System
  
  442
  - General
    444
  - Removal
    444
  - Disassembly
    445
  - Inspection
    445
  - Assembly
    445
  - Installation
    446
  - Adjustment
    447
Table of Contents

448
- Steering System
  
  449
  - Disassembly
    450
  - Assembly
    452
  - Disassembly
    455
  - Assembly
    458
- Off-Power Assisted Steering System (O.p.a.s.)
  
  460
  - General
    461
  - Side Vane
    461
  - Cylinder Support Assembly
    462
  - Tie Rod
    463
  - Sealed Tube
    464
  - Filter
    464
  - Valve
    464
  - Water Hose
    465
  - Cross Support Plate
    465
- Alignment
  
  467
  - Direct Action Suspension
    470
Adjustment and Repair

473
- Adjustment and Repair
  474
- Glove Box
  492
- Seat Adjustment
  493
- Storage Compartment Cover Adjustment
  494
- Storage Compartment Inner Shell
  494
- Access Panel Adjustment
  495
- Inlet Grate
  496
- Mirror
  496
- Riding Plate
  496
- Jet Pump Support
  498
- Deflector
  499
- Drain Plug Installation
  500
- Seat Removal
  500
- Bumper Replacement
  502
- Seat Cover Replacement
  502
- Sponson Replacement
  502
- Decals Replacement
  503
- Engine Compartment Cover Removal
  503
- Hull and Body Repair
  504
- Thru-Hull Fitting Installation
  507
- Tools and Materials List
  507
- Gti and Gti Le Models
  
  509
  - Gtx Rfi Model
    513
  - Xp Model
    517
  - Rx DI Model
    521
  - Gtx and Rx Models
    531
- Wiring Diagrams
  
  535

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