Ski-Doo FORMULA S 1997, Shop Manual

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Section 03 ENGINE
Sub-Section 02 (443 AND 503 ENGINE TYPES)
03-02-12
NOTE: Engine must be removed from chas-
sis to perform the following procedures.
Remove engine from chassis.
Remove fan guard, rewind starter, starting pulley,
trigger coil wire from 4-connector housing, mag-
neto flywheel then fan housing.
Remove stator plate.
CLEANING
Discard all seals, gaskets and O-rings.
Clean all metal components in a non-ferrous met-
al cleaner. Use gasket remover (P/N 413 7085 00)
accordingly.
Remove all trace of Loctite 242 from crankshaft
taper.
Remove old sealant from crankcase mating sur-
faces with Bombardier gasket remover (P/N 413
7085 00).
DISASSEMBLY
To remove bearings nos. 3 and 4 from crankshaft,
use a protective cap and a special puller, as illus-
trated.
1. PTO side
2. MAG side
INSPECTION
Refer to ENGINE DIMENSIONS MEASUREMENT
03-04.
ASSEMBLY
Smear anti-seize lubricant (P/N 413 7010 00) on
part of crankshaft where bearing fits.
To check proper clearance between bearing no. 3
and counterweight, use feeler gauge (P/N 420
8766 20).
Mount second bearing with distance gauge (P/N
420 8768 22) for 443 engine and (P/N 420 8768
24) for 503 engine for proper positioning.
1. Feeler gauge
2. Distance gauge
Prior to installation, place bearings into an oil con-
tainer filled with oil heated to 75°C (167°F).
This will expand bearings and ease installation. In-
stall bearings with groove as per exploded view.
Bearings are pressed on crankshaft until they rest
against radius. These radius maintain the gap
needed for bearings lubrication.
When installing crankshaft, position drive pins
no. 10 as illustrated.
1. Drive pins
At seal no. 2 assembly, apply a light coat of lithi-
um grease on seal lip.
-
CAUTION
Never use a sharp object to scrape away old
sealant as score marks incurred are detri-
mental to crankcase sealing.
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