1996 Sea-Doo GSX 5620 / GTX 5640 Service Manual

Service manual for Sea-Doo GSX 5620 and GTX 5640 watercraft models from 1996. Provides detailed information and procedures for maintenance and repair. Part Number: 219 100 034

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Document Details

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Document Number / Seller:
30894 / Patrick Owens
File Size:
21.40 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Sea-Doo
Last updated / verified
Feb 20, 2025

Models Covered & Key Technical Specifications

1996 Sea-Doo GSX 5620, GTX 5640 (219 100 034) - 1996

Supplements the Sea-Doo Shop Manual with model-specific information. | Sea-Doo Watercraft Division.

  • Certified Clearance Data: 0.05 mm (.002 in) establishes the maximum cylinder head warpage Specification.
  • General End Play: For optimal operation, 0.05 mm (.002 in) defines the ring/piston groove clearance Baseline.
  • Defined Power Draw: 0.060 - 0.108 mm (.0024 - .0043 in) -- signifies the piston/cylinder wall clearance Topology.
  • Key Precision Specs: The cylinder taper requires 0.100 mm (.004 in) for maximum clearance Logic.
  • Primary Holding Capacity: Maximum throughput reaches 0.39 - 0.74 mm (.015 - .029 in) Standards.
  • Baseline Specifications: 0.003 - 0.012 mm (.00012 - .00047 in) establishes the connecting rod/piston pin radial clearance Matrix.

Professional Workshop Service Manual & Technical Specifications

OEM-Grade Troubleshooting Overhaul Manual: Sea-Doo 1996 Sea-Doo manual: GSX 5620, GTX 5640 models Field-Reference

Model-Portfolio: GSX / GTX // Engineering-Metrics: Propulsion / Ignition Logic // Model-Portfolio: 1996 Watercraft. Component Operational-Logic Calibration-Standards
Magneto System 08-01-1 08-01-1
Ignition System 08-02-1 08-02-1
Charging System 08-03-1 08-03-1
Starting System 08-04-1 08-04-1
Instruments and Accessories 08-05-1 08-05-1
Wiring Diagrams 14-00-1 14-00-1

The repository is divided into comprehensive sections covering all major systems. Methodically requiring detailed analysis of electrical and mechanical components, this manual ensures optimal performance and longevity for your Sea-Doo watercraft.

Electrical System

Diagnostic procedures are covered for the magneto, ignition, charging, and starting systems, including detailed inspection and installation guidelines for instruments and accessories, and comprehensive wiring diagrams.

Engine Mechanics

Detailed procedures cover engine removal, top end, bottom end, rotary valve, and exhaust system components, ensuring thorough understanding and execution of all engine-related tasks.

Fuel and Cooling Systems

Procedures for fuel circuit, air intake, and carburetor systems are documented, alongside comprehensive guidance on cooling system components and circuits for maintaining peak engine efficiency.

Lubrication and Propulsion

Documentation includes oil injection systems and pumps, and detailed steps for propulsion system maintenance, including jet pump and drive system procedures.

Troubleshooting

This manual provides systematic troubleshooting guides for common issues, helping to quickly diagnose and resolve problems related to engine performance, electrical systems, and other key areas. ...documents torque specifications for components to ensure proper pivot-point integrity.

FAQ

What is the **required** fluid capacity requirements? keyboard_arrow_down

56.5 L is the specified fuel tank capacity for the GSX (5620) model.

Calculate the **specified** component identification. keyboard_arrow_down

The ignition coil primary resistance is 0.33 - 0.62 Ω for proper function.

What values **essential** adjustment procedures? keyboard_arrow_down

A 165 kg (364 lb) load limit is specified for the GSX (5620) model, including passenger and 10 kg luggage.

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Reviews (4)

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Received my download link quickly and it was easy to access. Great service!
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This manual has everything you need for maintenance and repairs. The troubleshooting section is especially helpful!
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Rated 4 out of 5 stars
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New
The wiring diagrams are a lifesaver. Highly recommend for anyone working on Sea-Doo models!