Ski-Doo FORMULA III, Shop Manual

Page: 104 / 356

Section 04 ENGINE
Sub-Section 03 (599 AND 779 ENGINE TYPES)
04-03-4
COMPONENT REMOVAL
Most engine components can be removed with
engine on vehicle such as :
– cylinder head
– piston(s)
– cylinder(s)
– rewind starter
– oil pump
– water pump
– magneto flywheel
– rave valve(s)
CLEANING
Discard all gaskets and O-rings.
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’’ (over an arrow
on the piston dome) must be visible after
cleaning.
Clean the piston ring groove with a groove cleaner
tool or with a piece of broken ring.
DISASSEMBLY
17,18,19,20, Piston, Piston Pin, Circlip
and Cage Bearing
Place a clean cloth over crankcase then with a
pointed tool inserted in piston notch, remove cir-
clip from piston.
Use piston pin puller (P / N 529 0210 00).
Screw in puller in order to remove it from piston.
Remove piston from connecting rod.
NOTE : 0.25 mm oversize piston and rings
are available if necessary.
RAVE System
NOTE : RAVE stands for Rotax Adjustable
Variable Exhaust.
3,4,5, Spring Clip, Cover and Spring
Remove spring clip, cover and spring.
6,7, Valve Piston and Clamp 50 mm
Cut clamp and unscrew valve piston.
8,9, Cylindrical Screw and Valve Rod
Housing
Remove cylindrical screws then valve rod housing.
10,11,12,13,14, Valve Rod, O-ring,
Washer, Distance Nut and Exhaust Valve
Pull out exhaust valve assembly.
1. Exhaust valve ass’y
Do not disassemble exhaust valve ass’y need-
lessly. Secure valve in a soft jaw vice. Remove O-
ring and washer, unscrew distance nut and re-
move washer. Unscrew valve rod from distance
nut.
INSPECTION
NOTE : See LEAK TEST AND ENGINE DI-
MENSIONS MEASUREMENT 04-04.
TOP
A06C0OA
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