95 XP hard starting, rotary valve issues

[sretooh]

Hello, I've recently purchased a 95 XP and don't know much about it's history.
It's had hard starting problems so I replaced all the fuel components and lines as well as rebuilt the carbs.
It still continued to have hard starting problems, so I took apart the carbs and double checked everything.
Upon inspecting the rotary valve, I discover that the clearance is way off, greater than .5mm for sure.
But what I'm really concerned about is the damage that the case appears to have, scratches/score marks and some damage to the intake port on the MAG cylinder.

Could someone let me know if this damage is something that I should be concerned with?
Cylinder compression was 145 at the MAG, and 150 at the PTO.

 

[mikidymac]

Unfortunately if you can feel those grooves you need new cases. The good news is good used ones are cheap and it’s a good time to put in new crank seals.

 

[sretooh]

Thanks so much, I've sourced a good replacement crankcase.
The crank seals you talking about, are you referring to the forward and rear seals?
What else should I be thinking about since its all torn apart? Should I lookin into new bearings and rings, etc. etc.?

 

[mikidymac]

If compression is good I wouldn’t.

Crank and rotary gear seals and gaskets. Don’t forget no piston clips too but that’s about it.

I like WSM complete gasket kits for budget builds and hfgreg fro PWC Muscle can hook you up.

 

[sretooh]

what do you mean by "Don’t forget no piston clips too"
Thanks!

 

[mikidymac]

Sorry, new clips as you have to pull the piston pins and pistons to split the cases and should never reuse piston pin clips.