cams reassembly, problems detected

[Venom67]

so im finally ready to reinstall my motor after a tear down to clean out all the rust from the motor sitting full of rainwater after a deployment. i am having troubles reinstalling the cams. when i tourqe down the cam holders the motor wont turn a full revolution. when they are just loosly on it all seems to work fine. also it appears as tho my timing has slipped, when the 1.4 mark is in line with the window on the points, the pistons ARE NOT at TDC. Is it possible for this to occur and if so how do i 'reset' it?

the bike is an 82 gs650G. also can anyone confirm that it is 20 pins between indicator 2 and 3 on the cam sprockets?

[Steve]

the bike is an 82 gs650G. also can anyone confirm that it is 20 pins between indicator 2 and 3 on the cam sprockets?

Yes, I can confirm that, but please be aware that the pins directly over the 2 and 3 are also counted.
Technically-speaking that is only 18 between the marks, but 20, including the marks.

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[Venom67]

Yes, I can confirm that, but please be aware that the pins directly over the 2 and 3 are also counted.
Technically-speaking that is only 18 between the marks, but 20, including the marks.

.

rogg, thx now just to figure out the 'reset' for TDC

[Nessism]

If you align the 1-4 "T" mark with the notch on the crankcase then you will be at 1-4 TDC. Once you achieve this you must make sure crank does not turn while you install the cams.

Next you pull up on the cam chain in the front to remove slack, while making sure the crank does not move, and install the exhaust cam. Last step is install the intake cam and the cam chain tensioner.

[Venom67]

If you align the 1-4 "T" mark with the notch on the crankcase then you will be at 1-4 TDC. Once you achieve this you must make sure crank does not turn while you install the cams.

Next you pull up on the cam chain in the front to remove slack, while making sure the crank does not move, and install the exhaust cam. Last step is install the intake cam and the cam chain tensioner.

the problem is that when the T mark is in lince with notch in crankcase, the 1 & 4 cyclinders are not actually at TDC, they are a bout half a crank away from that, i checked by placing a bamboo stick in cylinder during rotations

[Sunburn]

Did you have the block opened up and the crank shaft out? If not then you might be over thinking it. Did u have the crank on the "T" after the 1-4 mark? Or the mark on the 1-4?

[Nessism]

Some times the positioning can fool you. Try turning over the crank with that bamboo stalk poking out the 1 or 4 spark plug hole while watching the bamboo move up and down. You will have to hold up the cam chain with your hand to do this. When the bamboo shows you are approaching TDC, watch the indicator mark to see where the 1-4 T mark is. Once you go though this process you will hopefully, be able to find the proper TDC position.

[tom203]

Venom67 said....
"when i tourqe down the cam holders the motor wont turn a full revolution"

Make sure the "cam holders" (cam bearing caps) are in right spot- they are marked for position as a set and not interchangeable as they were bored in place during manufacturing. "A" is left front. "B" is right front, etc.

[Venom67]

Yes the holders are in the correct spot. I have gotten the cams lined up and installed and it all seems good, but now once thr clutch hub nut is installed.......the motor wont fully turn again. Im about ready to have a bon fire with this bike

[Nessism]

We are here to help but you must provide more information.

Please read this tutorial and post up some photos of the following http://members.dslextreme.com/users/...t_pictures.pdf

1) - Close up photo of the crank position showing how you are lining up 1-4 T

2) Photo showing how the 1-- mark on the exhaust camshaft is pointing at the gasket surface

3) Photo showing both intake cam and exhaust. We need to be able to see the cam chain and the pins between the 2 mark on the exhaust cam and the 3 mark on the intake cam

Please use real camera, not a phone. And use the macro for the crank shot so we can see the marks.

[Venom67]

Yes the holders are in the correct spot. I have gotten the cams lined up and installed and it all seems good, but now once thr clutch hub nut is installed.......the motor wont fully turn again. Im about ready to have a bon fire with this bike

[Steve]

Im about ready to have a bon fire with this bike

No location listed, how do we know where to bring the marshmallows?

.

[Venom67]

Im up in alberta

[platinum2]

if you have washers in the clutch make sure there in the right spot

[Venom67]

What do you mean the 'right' spot?