Ski-Doo Formula 500 1998, Shop Manual

Page: 87 / 398

Section 04 ENGINE
Subsection 02 (443 AND 503 ENGINE TYPES)
04-02-6
NOTE: The following procedures can be done
without removing the engine from chassis.
CLEANING
Discard all gaskets. Use Gasket Remover (P/N
413 7085 00) to clean mating surfaces.
Clean all metal components in a non-ferrous met-
al cleaner.
Scrape off carbon formation from cylinder ex-
haust port, cylinder head and piston dome using a
wooden spatula.
NOTE: The letters AUS and arrow on the piston
dome must be visible after cleaning.
Clean the piston ring grooves with a groove clean-
er tool, or with a piece of broken ring.
DISASSEMBLY
Remove top fan cowl, intake sockets and lower
fan cowl.
Remove cylinder heads.
443 Engine
On this 443 engine, piston pin needle bearing is
mounted without a cage.
Use piston pin puller (P/N 529 0210 00) along with
expansion sleeve and locating sleeve.
– Place a clean cloth or rubber pad (P/N 529 0234
00) over crankcase to prevent circlips no. 15
from falling into crankcase. Then with a pointed
tool inserted in piston
no. 13 notch, remove
piston circlip on side where piston pin no. 14
puller will be inserted.
– Insert piston pin puller (P/N 529 0210 00) then
install expansion sleeve over puller rod.
1. Expansion sleeve
– Pull out piston pin by unscrewing puller until
first thread of puller rod aligns with 503 mark.
1. 503 mark on puller
– Screw in puller in order to remove it from pis-
ton.
– Remove piston from connecting rod.
– Install locating sleeve. Then push needle bear-
ings along with thrust washers using a 21 mm
(.826 in) diameter pusher.
A21C06A
1
529 0210 00
A21C05A
1