Choke flap stuck in engine

If it was me, I'd slap it back together and run it, but I have a few spare heads laying around.

Do you think those gouges+scratches would be an issue though? Fingernail slightly catches the longest one..the other ones seem to be surface scratches/not deep at all.

Well, got everything put back together...now running into an issue with the dreaded timing. Set the mark to T so that both 1 and 4 are at tdc, counted the pins 1 and in between 43 and 44, installed cams, evenly bolted everything down, put top cover on, put chain tensioner in, rotated by hand and at some point i meet some resistance and it wont rotate anymore. Any ideas? Is the chain not taught enough before i put the tensioner in? I don't believe valves are hitting since i put the lobes the exact way they're supposed to be facing..

Just making sure, are your spark plugs out? If not, it's probably just compression building. If they are, I'd pull the valve cover and check the clearances, maybe one's super tight. If it's not that, I'd double check the timing chain spacing - I don't know much about 550s, so here's a link to check out: gpzweb.s3-website-us-east-1.amazonaws.co...KZZXZR550500400.html

Dis you read this whole page, especially the part near the bottom about the shop manual errors concerning cam timing?

s3.amazonaws.com/gpzweb/CamsKZZXZR550500...KZZXZR550500400.html

Is there even the remotest chance that something fell down the camchain tunnel? I ask because this has happened in the past .

Are all of the valve-cover cam-end plugs accounted for? Sometimes they stick to the valve cover and fall into the motor during valve-cover removal.

Figured it out, chain was buckling due to it not being taught. Got it all together started it up and I still have a ticking noise coming from the top end only this time it’s on the right side instead of cylinder 1. I’m at a loss right now on wtf is going on. Think I’ll just bring it to my mechanic and have him deal with this headache

Yes, you shouldn't really rotate the motor without proper camchain tension, as it can also jump teeth and alter timing.

Thanks for the help, I’ll update soon

Update: she’s finally back home and running good. Mechanic said after checking it all over I mixed up the spark plug wires, and something with the carb was why it wasn’t idling after I put it all back together. Said I did a pretty good job for rebuilding it with no experience. Ticking noise is still there but I’m pretty sure it’s just a shim out of spec, I’ll save that job for winter lol but other than that she rides good and at least I’ll have some riding weather until the snow starts. Thank you everyone who’s been helpful, really appreciate you guys. For being a young guy with a classic bike it’s really rewarding working on it.

Nice job! I have a few motors that need rebuilding if you have some spare time

Ticking noise can be a loose/leaking exhaust flange.