2002 Ski-Doo Shop Manual Volume Two, Page 62Get this manual
Section 03 TROUBLESHOOTING Subsection 02 (ENGINE)
5Seized piston all around the circumference (dry surface)aLack of oil, damaged oil line or defective injection pumpReplace defective part(s)6Grooves on intake side of piston onlyaOil film eliminated by water (snow infiltration in engine).This can also caused by running engine on choke for too long periodExcessive fuel will remove the oil film on the piston and make marksReplace piston(s) and check if intake system leaks7Piston color is dark due to seizure on intake and exhaust sidesaCooling system leaks and lowers coolant levelTighten clamps or replace defective partsAdd antifreeze in cooling system until appropriate level is reachedbAccumulation of foreign particles in needle valve andor main jet areaClean carburetor(s)8Cracked or broken piston(s)aCracked or broken piston(s) due to excessive pistoncylinder clearance or engine overrevingReplace piston(s)Check pistoncylinder clearance (refer to TECHNICAL DATA)Adjust drive pulley according to specifications (refer to TECHNICAL DATA) andor clean pulley sheaves if they are contaminated with greasy particles9DPM manifold air vent is obstructedaCarburetion is too leanEnsure proper air ventSYMPTOM CONDITION TestInspection PISTON RING AND CYLINDER SURFACES ARE GROOVEDNORMAL USE1Check oil qualityaPoor oil qualityUse BOMBARDIER injection oil2Check injection pump and its hosesaInadequate injection pump adjustment andor defective hosesAdjust pump according to specifications (refer to ENGINE) andor replace hoses