Ski-Doo FORMULA S 1997, Shop Manual

Page: 703 / 926

Section 03 ENGINE
Sub-Section 02 (599, 699 AND 809 ENGINE TYPES)
03-02-6
1,2,11, Cylinder Head Cover, Cylinder
Head and Cylinder
Check flatness of part sealing surfaces.
Refer to LEAK TEST AND ENGINE DIMENSION
MEASUREMENT 03-03 and look for
Checking
Surface Flatness .
– Mount piston over connecting rod with the let-
ters “AUS” (over an arrow on the piston dome)
facing in the direction of exhaust port (see illus-
tration below).
1. Exhaust
599 and 699 Engines
– Install piston pin puller (P/N 529 0210 00) and
turn handle until piston pin is correctly posi-
tioned in piston.
– Remove piston pin puller.
809 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 sleeves
– Grease thrust washers and install them on each
end of needles.
– Using a 21 mm (.826 in) diameter pusher, insert
needles into connecting rod.
Mount piston over connecting rod with the letters
“AUS” (over an arrow on the piston dome) facing
in the direction of exhaust port.
1. Exhaust
A01C01A
AUS
1
A21C01A
A21C03A
1
2 3
A21C02A
A01C01A
AUS
1