2003 Ski-Doo ZX Series Factory Shop Manual, Page 122Get this manual
Section 04 ENGINE Subsection 02 (377, 503 AND 552 ENGINE TYPES)
NOTE: Engine must be removed from chassis to perform the following proceduresRemove engine from chassisRemove fan guard, rewind starter, starting pulley, trigger coil wire from 4-connector housing, magneto flywheel then fan housingRemove stator plate
INSPECTION
Refer to ENGINE DIMENSIONS MEASUREMENT
ASSEMBLY
Smear anti-seize lubricant (PN 413 701 000) on part of crankshaft where bearing fitsTo check proper clearance between bearing no3 and counterweight, use feeler gauge (PN 420 876 620)Mount second bearing with distance gauge (PN 420 876 822) for 377 and (PN 420 876 824) for 503 for proper positioning1 2
CLEANING
Discard all seals, gaskets and O-ringsClean all metal components in non-ferrous metal cleanerUse gasket remover (PN 413 708 500) accordinglyRemove all trace of Loctite 243 from crankshaft taperRemove old sealant from crankcase mating surfaces with Bombardier gasket remover (PN 413 708 500)CAUTION: Never use sharp object to scrape away old sealant as score marks incurred are detrimental to crankcase sealing