77 KZ1000 Engine Rebuild Question

Howdy All!

I am currently in the process of rebuilding the engine out of my ltd after flood damage.

I just completed putting the cams back in and counting off the 28 pins with the crank on TDC for the number one and four cyclinders and have hit what I think could be a "split the cases" snag.

I completed putting both the top tensioner and back side tensioner on and rotated the crank for the first time. There was no problems from valve/piston contact or miss timing, but I did notice a tight spot in the chain, where with the valve cover off, I can see the chain get tight and then "pop" on the top tensioner when the tight spot is passed.

This is my first time rebuilding a 4 stroke engine and I just wanted to get some second opinions on this situation.

-Jarrett

Do you have a manual? Pics of the cam timing?
Steve

some pics or a sort video would help.

Yessir, used the clymer manual and followed that step by step. That video is hilarious btw, when you cuss at the carbs being too big I was rolling over laughing:laugh:

Here's the steps I took:
1. Engine on TDC based on T marking on advance mechanism on crankshaft
2. Put in exhaust cam and align timing mark parallel with and just above mating surface of the head.
3. Count 28 pins from the pin right about the mark on the exhaust cam, mark with sharpie
4. Install intake cam, lining up marked pin with "28" stamped on intake cam
5. Check that engine is still on TDC and the install cam caps/tensioners.
6. rotate slowly

I did notice in the video you are lining the exhaust cam up on the mark behind a bolt? On mine I have it lined up on the mark between the two bolts. Damn pictures in that manual . Could that be the problem?

I will take pictures and post them later when I am home.

The only time I ever heard that pop sound after a cam swap or reinstall is when the cams were off and the intake and the exhaust vale lip would hit each other and one snap over the other, bending one of the valves.

That's what it is.... Just looked at this video on youtube and I have lined up the exhaust cam on the wrong mark.
Looks like the head is coming off to check for bent valves.

The tiny arrow on the exhaust sprocket must be at or just below the head. You then count starting one pin above going to 28. Easy mistake to do. I hope you didn't bend any valves.
Steve

Before you pull the head take the cams out and blow about 40 psi air pressure in each cylinder.

Update: Pulled head apart last night and did see visible signs of the valves contacting each other (small scrapes) but did not see any signs of any valves being bent,all of them still seat flatly. Thank goodness!

Got everything back together today and now it's turning over smoothly, no popping or binding! Go figure, actually put it together the right way and it works like it should....

Thanks for the help!

-Jarrett