Ski-Doo Formula S 1998, Shop Manual

Page: 92 / 338

Section 04 ENGINE
Subsection 03 (377, 443 AND 503 ENGINE TYPES)
04-03-7
– Remove piston pin puller and expansion
sleeve.
– Install circlips as described below.
– When installing new needle bearing, insert
needles with thrust washers. Instead of expan-
sion sleeve, needles are held in place by 2 inner
plastic cage halves.
– Use piston pin puller (P/N 529 0290 00) to insert
piston pin. Plastic halves should come off pis-
ton. If not, pull them out using long nose pliers.
– Install circlips as described below.
At assembly, place the pistons over the connect-
ing rods with the letters “AUS” (over an arrow on
the piston dome) facing in the direction of the ex-
haust port.
1. Exhaust
All Engines Except 503
To center the piston pin with the connecting rod
bearing, use centering tool (P/N 529 0091 00).
NOTE: The circlip on the opposite side can be in-
stalled before pin installation, the tool will easily
go out.
All Models
To minimize the effect of acceleration forces on
circlip, install each circlip so the circlip break is at
6 o’clock as illustrated. Use piston circlip installer
(P/N 529 0169 00).
1. Place circlip in
2. Restrain
3. Oil
A21C01A
A21C01A
A01C01A
AUS
1
A01B1SA
529 0091 00
A01B1QA
1
2
3
529 0169 00