Checking timing / Rotary Valve 787 2003 GTI LE RFI

[aaajaws]

I bougha used 2003 GTI LE RFI that I suspect Rotary valve is off timing. It wont start and has blow by on the hull. Is there a step by step method to get to the valve and check it while in the hull. Also is the a kit for new gaskets needed?
Thanks

 

[racerxxx]

Has the rotary valve or cover ever been off? Unless the brass gear stripped (something usually would have jammed the valve), the only other way the time of the valve could have changed is by physically removing it and retiming it improperly.

 

[aaajaws]

last owner said he set the rotary valve with the dial. He has never owned a PWC before this one. He not a PWC tech just a tinkerer like me but I don't know what to believe what else would cause this blow back ? I saw a video that said if the valve or cover was scorned it would cause it ..?

 

[racerxxx]

Not sure where to tell you to go. If you're suspect you can dig in and tear it apart and check it. You could luck out. Google for the service manual it will give you the tear down for the RFI. But there is a lot more with these RFI skis.

 

[etemplet]

Pull the rotary valve. It's pretty easy providing the bolts cooperate. Pull the air box, disconnect the 3 plugs on the Throttle body, leave the 4 bolts on the throttle body in place after loosening them. I put nuts on the end of each bolt to hold the assembly together. Then just set the throttle body out of the way towards the front of the ski. Try not to kink any of the cables. Remove the 4 bolts on the rotary valve cover and pull it off. Make sure the rotary valve does not come off when you remove the cover. You are troubleshooting and you want to know the postion of the valve. Clean it up a bit.. find top dead center on the mag cylinder and set the valve correctly.

If you haven't done it, it will likely be an adventure.... Roughly 147 degrees and 67 degrees. but check the numbers. Make sure you are AT TCD on the mag. Good Luck !!

This picture is me taking clearance readings on the rotary valve. I use .-32" solder as a gauge then I mic it. The position you see the vale in, is accurate for Top Dead Center but you'll need the degree tool to get it spot on. Sometimes you flip the valve over to get the readings where you want them. Good Luck again.

 

[etemplet]

I made a little video of rotary valve timing. Hope it is spot on. Just trying to help people. If you see anything wrong let me know but... I think it will help anyone setting the timing to do a decent job or at least understand the procedure. Not bad for a one handed video, LOL Touchdowns everyone !!

Gene's Rotary Valve Timing

 

[nibroc]

thanks for that vid.....

 

[etemplet]

Hope it helps ya bro ! Good Luck !