Need engine help . . .

[Mandres]

Ok, so I've finally gotten my engine back together (for the most part).  New rings, valves, valve guide, and seals all around.  I set the timing according to the procedure in the Haynes manual, and everything went back together fine.  Here's my problem:  I cannot rotate the crank through a complete rotation.  After about 270 degrees of rotation it hits some kind of positive mechanical stop and won't go any further.  Anybody have any ideas?  I'm guessing maybe the cam chain is binding on the crank or maybe one of the buckets in the head is stuck.  I guess my next step is to remove the cams again and see if the crank will rotate freely then.  Anybody seen this before?  Am I making sense? 

Thanks,

-M

[tf1075]

Are you sure the cam timing is right? it could be the piston hitting on a valve.

[KYGS500E]

double check that there are 18 link points (not one whole link = 2 points) between the two arrows (Numbers 2 & 3) and that number 1 arrow is completely level with the head.  To make it completely level you will have to screw the cam caps down on the front left valve (exuast) and push it into the cylinder... i messed mine up cause i didn't know that.  If that didn't work... make sure the bike is in neutral... if its not on its side stand the wheel can't turn if its in gear...

After that... yeah... take the cams off.... pull up on the cam chain and maybe shake it some... also... like you said... see if it will turn without the chain hooked in (but keep some tension on the chain with your hand so it doesn't bind... aka pull up)

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[Mandres]

Thanks for the input fellas.  I quadruple-checked the 18 pins so I know I'm good there.  I'll have to double check the '#1 = level with the head' thing.  I know it was close to level, does it need to be exact?   I was very, very careful when rotating the crank so I doubt any further damage was done even if something was off. 

[Mandres]

ok, I took the cams out and then reinstalled them and now it's all good.  I don't know if maybe the timing was off a bit or if the chain was just binding.  If the timing was off I really, really hope that no damage was done.  I was turning the crank very slowly so I don't think anything could have gotten bent.  I guess I won't know for sure until I get the engine back in the frame and check the compression.

-M