Ski-Doo 800 Engine Rebuild
This 800 had the Mag side bearing go bad, seized the engine necessitating a rebuild.
Please note that this page is only to give you more pictures and more confidence to tackle this yourself along with some tips that you may find useful.
It is not replacing the Ski-Doo manual.
PTO side of the rebuilt crankshaft with ISO-Flex Grease applied per manual.
Mag side of the rebuilt crankshaft with the ISO-Flex Grease applied per manual.
ISOFLEX grease. This is a must on the PTO and Mag side bearings and seals.
Crankshaft Case bottom cleaned up and ready to go.
After removing original gasket material, I lightly go over it with 400 grit sand paper to remove nicks, imperfections etc.
Crankshaft Case top cleaned up and ready to go.
Showing the crankshaft being installed in the crankshaft upper case.
I am using the cans to hold the case up giving room for the rods.
Gasket surfaces cleaned of any excess grease. This is extremely important.
I run a die over all fasteners to clean up the threads so a accurate torque reading may be obtained.
Bolts lined up after cleaning of the threads. This saves time.
The lower crankcase half with gasket material applied.
2 stroke oil applied to oil pump gear.
Bottom case installed.
Mag end.
PTO end.
All fasteners were now torque to factory specifications.
Now we are ready for the top end.
Please note that Ski-Doo's of this vintage come with "cageless" bearings. We are installing "Caged" bearings.
The pistons are shown installed on the rods. These pistons only have 800 miles on them, so they are being reused.
Ring Compressor tool in place.
Cylinder being slid over the piston. Once the cylinder is over the ring, the ring compressor is removed from the piston.
Both Cylinders in place, and the exhaust manifold bolted on. The Exhaust manifold should be loosely installed BEFORE you torque the cylinder bolts.
Heads on the engine.
Ready to rock and roll!