KZ900 A4 FRUSTRATED- Can't get valve timing right

Very frustrating, what am I doing wrong? 5 times and I can't get all the marks to line up

I've followed all the steps and read all the books and looked at numerous postings.

Set engine at TDC
I count the 28 chain links and mark them.
I mark the sprockets and line the marks up to the top of the head.
I keep the chain taught.
The cam lobes at the #4 end point at each other.
I installed the tensioner
I turn the crank clockwise and bring it back to TDC
All the marks line up - turns over smoothly
BUT, THE 28 AND THE LINK DOESNT LINE UP - EVERYTHING ELSE IS LINED UP EXCEPT THE 28 AND THE 28 LINK IT SEEMS TO COME UP 2 OR 3 LINKS OFF every time.
Please help, it's getting crazy!

Are you going to TDC once or twice? Was it running before? You set the exhaust cam with the little arrow just at or below the edge of the valve cover surface. Count the from next pin up and go to 28. 28 is marked on the intake cam sprocket. Bolt the idler between the cams then the tensioner. Go around twice and it should line up.
Steve

swest wrote: Are you going to TDC once or twice? Was it running before? You set the exhaust cam with the little arrow just at or below the edge of the valve cover surface. Count the from next pin up and go to 28. 28 is marked on the intake cam sprocket. Bolt the idler between the cams then the tensioner. Go around twice and it should line up.
Steve

Dont make an ass u and me.
I'm assuming you have the proper factory service manual, right?
As Steve says, that little > mark on the exhaust cam sprocket, has to be very close to pointing right at the edge of the cam cover to head surface. Start counting from the first pin up from the > mark, with the cam chain pulled tight in front from the crank sprocket and over the top of the exhaust cam sprocket.
Then get the link count going and put that last pin right on the intake cam sprocket tooth gullet with the number ... leave the intake cam where ever it is and push it into the cam bearing. ....put the bearing caps on.
Don't be afraid to put a dab of white paint on the cam link's pin count to make sure you are getting it right.

Thanks for your thoughts. I have both the factory shop manual and the Clymer.

When i rotate the crank, there seems to be a slight variance in the chain tension at the cam idler sprocket. The marks at the cam sprockets are dead on the head surface when # 4 piston is TDC.

The #28 on the intake sprocket does not return to the setting (the pin) even though all other indicators are dead on balls.

I am thinking that somehow i'm not getting the chain taught when I slip the cams in, but like I said, 5 times and still not confident it's properly timed, even though the cams and TDC marks are dead on. But I also doubt the timing chain should vary in tension.

Should the 28th pin return to the 28 mark on the intake sprocket each and every time TDC is confirmed?? This is the key question I have and the manual is ambitious regarding the 28 pin issue.

I appreciate the good will found on this site. Thanks again in advance.

Have you checked your valve clearances? If the cams are that far out you could have bent a valve or two. (I doubt it) When you turn the crank past the 2/3 T mark and go back to 1/4 the timing will show 180* out from the cylinder you just set the timing for. You will go one more full revolution and be back where you started. All should be the same. Ignore the lines on the cam sprockets. I asked it it was running before. No answer. If this is a fresh build, it's possible the crank is a 16 tooth not a 15. Pics always helps when asking for advice. I ask questions for a reason, that was one of them.
Steve

Any chance engine was apart? Different parts switched? Like a 124 pin, Mark II cam chain?

Thanks for your help. I

Okay, thanks for staying with me. The machine was not running and sat for 15 years.

I understand that it needs to be rotated 2 revolutions to get back to TDC, and when I do that the cams seem to line up with marks, but the 28th pin doesn't return to the 28 sprocket mark. Its off a couple of links.

I turned the crank carefully so I doubt the valves contacted the piston.

My guess is that it has been apart years ago.

When I got it I did a cold compression check and found 1 bent exhaust valve and replaced it. #1,2,and 3 had good even compression, #4 had the bent valve.

Just can't get everything to sync regarding timing marks and the 28th pin wont return to its location.

Have not checked valve clearances yet. It's really weird.

But the little > lines up with the valve cover surface?
Steve

Yes, the > line up on both the exhaust and intake side when the TDC mark is lined up. The cam lobes on #4 are level and pointing at each other. Except for the 28 pin misalignment, everything else seems and feels right.