Section 03 787 RFI ENGINE
Subsection 05 (ROTARY VALVE)
GENERAL
The clearance of rotary valve cover or rotary valve
shaft gear backlash can be performed without tak-
ing apart engine.
However engine must be disassembled to work
on rotary valve shaft/components.
INSPECTION (ASSEMBLED
ENGINE)
Rotary Valve/Cover Clearance
Remove air intake silencer and throttle body. Re-
fer to appropriate
VEHICLE SHOP MANUAL
.
Refer to table below to find dimension specifica-
tions. For measurement procedures, refer to EN-
GINE MEASUREMENT section.
TOLERANCES
ENGINE
MEASUREMENT
NEW PARTS
(min.)
(max.)
Rotary valve/cover
clearance
0.25 mm
(.010 in)
0.3 mm
(.014 in)
NOTE:
If the rotary valve/cover clearance is too
small, this could create an overheating situation
and if the clearance is too high, this could create a
hard starting situation.
Rotary Valve Shaft Gear Backlash
Verify rotary valve shaft gear backlash as follows:
Remove PTO flywheel guard.
Remove spark plugs, rotary valve cover and valve.
Manually feel backlash at one position, then turn
crankshaft about 1/8 turn and recheck. Continue
this way to complete one revolution.
Backlash must be even at all positions. Otherwise
overhaul engine to find which part is faulty (gear,
rotary valve shaft or crankshaft with excessive de-
flection).
DISASSEMBLY
Rotary Valve Cover
Remove air intake silencer and throttle body. Re-
fer to appropriate
VEHICLE SHOP MANUAL
.
Unscrew 4 retaining screws and withdraw rotary
valve cover
no. 1
and rotary valve
no. 13
.
Rotary Valve Shaft
To remove the rotary valve shaft assembly, the
engine must be removed from watercraft (refer to
appropriate
VEHICLE SHOP MANUAL
).
First remove snap ring
no. 4
from crankcase.
F01D22A
1
1. Removing snap ring
Open bottom end and remove crankshaft (refer to
BOTTOM END section).
To remove rotary valve shaft assembly, use the
appropriate puller (P/N 290 876 488).
290876488
Place puller over rotary valve shaft end and screw
on puller bolt into shaft. While retaining bolt with
a wrench, turn puller nut CLOCKWISE until shaft
comes out.
smr2005-084
103
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