[gerard jones]

Savoy1 here, had to register again as gerard when I lost my password info.

I did find what looks like rubber O ring in the top of the cyl.
Hopefully they will be included in a gasket kit.

I've found lots of used cyls online, could always do that.
A retired neighbor who ran sleds for years here (northern Maine) said he honed his and it was good, he thinks we should try it. if it doesn't hone up ok I'll not bother reinstalling it.

 

[gerard jones]

You can reset your password if you have that email handy.

Yeh, tried that.,
It sends reset to an old email I got rid of 3 years ago,
autofill must have entered the old email address when I registered .

 

[gerard jones]

Again go to the swap meets and find the parts you need

I don't even know anyone who rides a snowmobile, how do I go about finding swap meets,
I tried google, most seem to be 1000 miles from northern Maine.

 

[gerard jones]

I found a cyl and piston on ebay for $139, does it matter which side of the engine?
the listing doesn't say fan or clutch side and I thought there is a difference but don't know enough about these things,
The clutch side cylinder is what went on mine.
Heres the listing.
Also it says 380f
Mine is a 1996 e380, is there a difference?

96 97 98 99 Skidoo Formula 380 377 Deluxe Fan Cylinder Bore Jug Piston Touring E | eBay

<p>Comes exactly as pictured. Decent used shape Ski-doo Formula 380f Deluxe Fan Engine Motor Cylinder Bore Jug. Condition is "Used".</p>

www.ebay.com

 

[gerard jones]

If your jug is bad just have it replated, I send mine to US Chrome in Wi.

Is it plated? nikasil?
I'll look it up.
Would I go back with original size piston, 62mm, or I guess it depends if they bore it over.?

 

[gerard jones]

I have sent them over sized pistons and they can bore it and replate it over sized!
I have had a 580 bored out to 625? or so
Comes back even better than new!

I would too but social security doesn't leave enough money at the end of the month.
If they give us another stimulus check, then I'm all in for rebore on both side .

For now, we're gonna try clean with muriatic and hone it, if it won't hone i'll get a used one.
I only have a decent caliper for measuring but both cyl seem to be 62mm.
Fan side is all original, AUS mark on piston , it just needs rings.
The damaged side has a replacement piston with STD marking.

I flipped the block upside down and spun the crank, nothing fell out.

 

[gerard jones]

meanwhile, 5 months later...

Found a 377 salvage engine, stuck from sitting, for $50 .
I might just grab it and see if the piston/sleeve are ok for me to use.

 

[gerard jones]

Do NOT just replace rings!
Always replace piston as it comes with rings!
The Piston is what is worn!

I plan on swapping cyl and piston as a set if they fit the crankcase.
I see a number 1693 on the cyl, is that what I need to match.?

 

[gerard jones]

Ok , so i found 2 cyls with heads for my sled for $150 locally.
I still need 2 pistons.
My question is how to remove the clutch, it isn't coming off using water and teflon tape, tried with breaker bar and impact gun, it isn't moving.
I wanted to buy the tool but don't know which one to get, the clutch I am dealing with isn't the original clutch.
I'd like to change the crankcase seals in case that was the cause of the scorched cyl/piston.
I looked at the clutch removal tools but theres dozens of them.
Anyone have any ideas for me?

 

[gerard jones]

heres a pic.

 

[gerard jones]

There are two different TRA clutch pullers. One is for etecs and large motors. The other is for everything from 1992-2006. That clutch probably came off a 500 (check the spring), but it could have also come off an older 440 or larger machine.

can you give me a link to the clutch puller suited for 92 to 2006.

 

[gerard jones]

TRA clutch. Definitely not the original as Skidoo was using Comet Bell clutches on the 380s.

It is actually a better clutch.

TRA clutch puller will work just fine. Typically they are about $25.

What you can do is stand the engine up so you can spray some WD-40 or equivalent in the hole and let it sit for a few hours. If you notice the liquid coming out from behind the clutch, chances are the taper is wrong for the motor, but I really don't think that is an issue. With the WD-40 in there, after a few hours try doing the water trick, but with WD-40 instead. Even if it doesn't work, you would have forced WD-40 into the taper. Then let it sit for an hour again.

I've done all that, tried with 5-30 motor oil too with engine standing on end.
Been trying off and on since June.

 

[gerard jones]

yeh I tried mapp gas, didn't do it for me.

 

[gerard jones]

cant remove clutch, can't find the right tool so I've decided to pass on the crank seals and keep going,
found a cyl and piston on ebay, bought it... its on the way .
I'll need to helicoil the sparkplug thread .
Question, should I order a gasket kit.

 

[gerard jones]

Yes order a complete gasket kit. Will have everything you need in it for assembly including seals. Also I would take it to a shop that can press that clutch off and do the seals so you know it is all done and done right. They shouldn't charge much for doing something like that.

yeh good idea, I know place that I can take it to for the clutch.

Do you suggest ebay for gasket set, I've read the cyl head O ring seal is a problem in these kits.

 

[gerard jones]

mfgsupply or dennis kirk. You can look up the kit on parts unlimited and find the part numbers to search around on those two sites or amazon. eBay I would only order if it is a name brand.

Parts Unlimited Snow 2021

Help your customers get their sleds and themselves ready for a season of winter fun with the 2021 Parts Unlimited Snow catalog.

assets-static.lemansnet.com

Thanks, the dennis kirk site was exactly what I was looking for.
Got the seal kit and piston pin retainer clips.

 

[gerard jones]

A local powersport shop said theres a couple of different clutch pullers for the TRA clutch and he's not sure which one to order, instead he said he will pop it off for me if I bring it in.
All the parts are in transit , it looks like I might actually get to ride this year. !

 

[gerard jones]

Waiting on the shop to pop my clutch off, I have all parts except a set of piston rings which I'll get from the same shop, he stocks parts. Meantime I started to swap the ski's to a newer pair the seller gave me. But the axle bolts are too short, ordered new ones to find the originals are not M10 but M12. !
Oh well, bit by bit.
No real snow here in northern maine yet.

 

[gerard jones]

Got my engine back, only $10 to pull the clutch off.
I think I have all parts needed now.
The shop looked at my ring gear and said I need a bigger one 8 1/2 inch dia.
I have a question, whilst the clutch is off the crankshaft, is it possible for me to determine which puller tool I need to order by looking inside it?
I cannot visualize how they function.
The end of the crank is threaded , what about the clutch part that slips over the crankshaft... should that have threads inside it also to engage a puller? I don't recall seeing threads inside when I looked.
If it has no threads to push it off the crank then I'm baffled.
It's out in the garage, dark freezing cold right now.

 

[gerard jones]

Most clutch pullers push on the end of the crankshaft. As you tighten the puller, it pushes hard enough to pop the clutch off. The outside of the primary should have threads that the puller engages.

OK, maybe I missed the threads in the primary, I'll take a look.
I want to be able to pull the clutch myself at a later date if I can find a ring gear for the starter.