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I replaced base and head gaskets on a 1999. After reassembly I turned the crank shaft by hand, it stopped with the TDC mark on the cam sprocket at about five o'clock. Does anyone have any thoughts?
 

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Were the timing marks aligned between the cam and flywheel? Could be piston to valve interference. Take the cam chain off and double-check the timing marks/re-do the timing. Good thing you didn't flick the starter




I found TDC with the slit mark on the cam sprocket and the pointer on the cylinder head. What do the marks look like, that you are talking about. Is this correct, to redo the timing, take off the cam chain so the the cam sprocket and crank shaft turn independently, align marks on both separately, reinstall cam chain?





Thanks for your help.
 

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The flywheel has a TDC mark (either a "T" or the last "I" designates TDC on the flywheel; the manual says a "T" and some have it but mine had 3 "I"s, like this I-I I, and it was the last one).

And the cam has a TDC mark.

And the head has a TDC mark.



Remove the plug from the crankcase cover to insure the flywheel is at TDC (the picture below shows what I'm talking about; center that mark in the hole). When the flywheel is at TDC, insure the cam chain is adjusted so the cam is also at TDC (cam mark/slit lines up with mark/slit on the head).





***post corrected 2/1/11*** thanks igofar
 

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Remove the spark plug and place your finger over the hole and slowly turn the crank. You'll be able to feel the pressure building against your finger. Watch the marks on the crank while you do this. The CORRECT mark that you want is the 3rd line. The first line is the timing light to be used with a timing light. Somewhere in the service manual it states this. Remove the cam chain sprocket, keeping tension on the chain so it does not slip off the bottom sprocket. I used a bungie cord hooked to the handlebars, and the chain rode against it if that makes sense. Turn the crank a few times to verify TDC with the pressure against your finger and the 3rd mark. When you finally get it correct, the weight of the magnet will want to pull it past the mark a little. I used a short section of 2x4 to rest the ratchet handle on. (3rd hand) Once the crank line is correct, place the timing sprocket on the shaft and make sure its lined up CORRECTLY with the index mark. If its off 1/2 chain link, the bike either won't start, or will run like poop! Ask me how I know?

On both of my 08's the timing mark lines up on the chain in the area thats in between two links.

hope this helps.

Igofar
 
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