This is my second time, setting timing on a 900 but my first motor build. new crank new balancer new pistons etc. with the magneto line set to the rear split of the crank case the pto drivers side piston is not at tdc. I assumed I might have the wrong flywheel so I replaced it w a parts motor flywheel still no luck. set everything up like manual says and rotated by hand and it wont make a full revolution. remove the cams and it will so it obviously in the top end anyone have any insight?
1fastmofo
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When the PTO is at TDC, where is the flywheel timing mark? Is it at the case split or is it in the 12:00 position where the crank sensor hole is?
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The mark has to be dead center in the sensor hole or you'll be off.
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Thats not TDC. When the PTO cylinder is at TDC and the flywheel mark is lined up, the PTO cam lobes on bot cams should be pointed outward (intake pointed out to the back and exh pointed out towards the front. How are you checking for TDC on the PTO piston? Also looks like you have 1 cam 180deg out. When everything is aligned, the letters on both sprockets should be on the top of the horizontal hash marks. Looks like you have one on top and one on bottom. There is definitly something not right there...
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I just zoomed in on that pic. You have the cams on the wrong side it looks like from the pic. The cam with the "EX" scribed on it goes on the exhaust side and "IN" on the intake.
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