Ski-Doo FORMULA 500 1997, Shop Manual

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Section 03 ENGINE
Sub-Section 02 (443 AND 503 ENGINE TYPES)
03-02-7
1. Pusher 21 mm (.826 in)
Use a locking tie to fasten all needles and thrust
washers along with sleeves.
NOTE: The PTO cylinder or fan housing have
to be removed to give access to MAG piston
pin with the puller.
NOTE: 0.25 and 0.5 mm oversized piston
and rings are available if necessary.
503 Engine
Place a clean cloth over crankcase to prevent cir-
clips
no. 15 from falling into crankcase. Then with
a pointed tool inserted in piston notch, remove cir-
clip from piston
no. 13 .
To remove piston pin no. 14 , use piston pin puller
(P/N 529 0210 00) as follows:
– Fully screw puller handle.
– Insert puller end into piston pin.
– Screw (LH threads) extracting nut.
– Hold puller firmly and rotate puller handle coun-
terclockwise to pull piston pin.
NOTE: The PTO cylinder or fan housing have
to be removed to give access to MAG piston
pin with the puller.
NOTE: 0.25 and 0.5 mm oversized piston
and rings are available if necessary.
INSPECTION
Refer to ENGINE DIMENSIONS MEASUREMENT
03-04.
ASSEMBLY
443 Engine
When reinstalling original needle bearings, make
sure that 31 needles are inserted between expan-
sion sleeve and locating sleeve.
1. Expansion sleeve
2. 31 needles
3. Locating sleeve
– Grease thrust washers and install them on each
end of needles.
– Using a 21 mm (.826 in) diameter pusher, insert
needles into connecting rod.
A21C04A
1
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A01B1AA
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A21C03A
1
2 3