Section 04
ENGINE
Subsection 07
(ROTARY VALVE)
04-07-2
SMR2002-026_04_07A.FM
GENERAL
The following verification procedures such as clear-
ance of rotary valve cover or rotary valve shaft gear
backlash can be performed without removing en-
gine from watercraft.
However engine must be removed from water-
craft to work on rotary valve shaft/components.
Refer to REMOVAL AND INSTALLATION for en-
gine removal procedure.
Bottom end must be opened to remove rotary
valve shaft. Refer to BOTTOM END.
INSPECTION ON WATERCRAFT
Remove carburetor(s). Refer to CARBURETOR.
Rotary Valve Cover
Unscrew 4 screws
no. 2
and withdraw rotary valve
cover
no. 1
.
Remove rotary valve
no. 13
.
Rotary Valve/Cover Clearance
The clearance between the rotary valve and the
cover must be 0.30 ± 0.05 mm (.012 ± .002 in).
NOTE:
If the clearance is below 0.25 mm (.010 in)
this could create an overheating situation and if
the clearance is over 0.35 mm (.014 in) this could
create a hard starting situation.
There are 2 methods to verify rotary valve/cover
clearance:
– the 45° feeler gauge method
– the soldering wire method.
45° FEELER GAUGE METHOD
Remove O-ring
no. 12
from rotary valve cover
no. 1
.
Remove intake manifold from rotary valve cover
(except
787 engine
).
Reinstall cover
no. 1
in place WITHOUT its O-ring
and torque screws to 20 N•m (15 lbf•ft).
Insert feeler gauge blade through cover inlet ports
to verify clearance. At least verify clearance at two
different places in each port.
Feeler gauge blade from 0.25 mm (.010 in) to
0.35 mm (.014 in) thickness should fit between ro-
tary valve and cover.
1. 45
°
feeler gauge
If rotary valve cover clearance is out of specifica-
tions, machine rotary valve cover seating surface
or replace the cover.
SOLDERING WIRE METHOD
Remove O-ring from rotary valve cover.
Use the following type of solder:
– resin core
– diameter:
0.8 mm (.032 in)
– electronic application (available at electronic
stores).
Install 2 soldering wire pieces of 13 mm (1/2 in)
long directly on rotary valve, one above and one
below rotary valve gear. Apply grease to hold sol-
der in position.
Refer to the following illustration for proper posi-
tion or rotary valve and pieces of soldering wire.
TYPICAL
1. Soldering wire
Reinstall cover in place WITHOUT its O-ring and
torque screws to 20 N•m (15 lbf•ft).
F01D53A
1
F01D3PA
1
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