2005 Ski Doo 500SS lost a cylinder

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snowlover

New member
My wife's 500SS finally had a major failure, the PTO side went down. It has close to 9000 miles so I figured this day would come. I have not looked into why it went, just that there is no compression on the PTO side. I have some questions on this motor...are the cylinder NiCaSil or plain old cylinders? How do you get the motor out of the chassis? Not a lot of room to work on it in the chassis. I plan on putting in 2 new pistons and am hoping the cylinders are ok. I am also going to replace both carb boots while I am at it.

I know this is going to cost me but I can not afford to get a new sled at this time and my wife and son both love this sled. I am hoping to rebuild it and get another 9000 miles out of it.
 
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raceinsnow

New member
The cylinders are nicisil and i would say yes you would need to have that re chromed.A couple of things to watch out for are the wrist pin bearings are cage-less and will fall in the motor if you are not careful.You need to look at the crank seal on the pto side and also for a cracked y pipe so this won't happen again.
 
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jimfsr

New member
You are in luck, the cyl. are not plated and can be bored out if needed. The motor comes out pretty good. You have to remove the exhaust Y-pipe from the cyl. Remove the RAVE valves. Remove the carbs from the intakes. Disconnect the oil pump lines and cable.(it will leak out, so plug the lines)
remove the recoil from the motor(torx bolts), go in through the 1" or so diam. holes in the sides of the engine bay on the bottom. There are 4 allen head bolts to remove. Disconnect the wires as needed(don't forget the temp sender on top), drain the coolant, remove hoses, pull the motor out the clutch side. Install in reverse order, bleed the oil pump and it should be good to go.

You should do the crank too, with that many miles, that will be next. Factory re-man should be fine. Probably about $1500 or less, to do it all yourself.

If you want to go cheap, you can pull the cyl w/o pulling the motor.

One more thing.... the piston pin bearings are loose, no cages, so when you pull the pistons off, make SURE you don't drop any bearing needles into the motor.
 
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raceinsnow

New member
Sorry I was wrong .Its been a long time since I have seen a iron cylinder bore.Skidoo dose offer an oversize piston.
 
S

snowlover

New member
Thanks

Thanks everyone! I already replaced the Y pipe. It went out about 500 miles ago and possibly the cause of the failure. I may take it to a shop and let them do it just because I know he will do it right. Not that I can not do it, I just rather pay to have it done right.
 
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