Ski-Doo FORMULA III, Shop Manual

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Section 04 ENGINE
Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)
04-04-10
TYPICAL
The gap can be measured with the engine in-
stalled on vehicle. Use 45° bent blade feeler
gauge (Snap-On FB300A) inserted through intake
socket of valve cover.
If gap is under tolerances, rotary valve cover can
be refaced to increase clearance.
If gap is over tolerances, cover replacement may
be necessary. Check if surfaces on crankcase
halves are damaged, replacement wear plate is
available.
Second Method
Remove rotary valve cover and its O-ring.
Use the following type of solder :
– rosin core
– diameter : 0.5 mm (0.020 in)
– electronic application (available at electronic
stores)
Install 2 short pieces (13 mm (1/2 in) long) of sol-
der directly on rotary valve, one above and one be-
low rotary valve gear. Apply grease to hold solder
in position.
Reinstall cover in place WITHOUT its O-ring and
torque screws to 20 N•m (15 lbf•ft).
Remove cover then clean and measure com-
pressed solder thickness, it must be within the
specified tolerance.
TYPICAL
1. Solder
CHECKING SURFACE FLATNESS
Intake manifold, intake manifold cover, rotary
valve cover can be checked for perfectly mating
surfaces.
Lay part on a surface plate (marble, mirror or thick
glass plate).
Holding down one end of part, try pushing down
the other end.
If any play is felt, part must be rectified.
RECTIFYING SURFACES
Stick a fine sand paper sheet on the surface plate
then lightly oil the sand paper.
Rub manifold mating surface on sand paper using
8-figure movements.
Sand until mating surface is perfectly straight.
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