Engine Rotation Locking

  • Buffalo515
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Engine Rotation Locking

05 Jul 2026 13:22 - 05 Jul 2026 16:25
#925529
Been rebuilding this 1985 zx550A. The entire engine has been taken apart and put back together. When i try to rotate the engine with the cams in it stops at 2 places. Heres some troubleshooting ive done so far.

-No bent valves. I pulled the head after this condition to make sure again after this. 
-Timed the cams according to service manual and louds graphics. 
-engine rotates freely with cams removed so i think bottom end is fine
-Checked valve clearances for each valve. All meet the minimum clearance so its not a lack of clearance. 
-Ive removed the tensioner and still experience this condition while rotating with hand pressure keep the chain on the sprockets. 
-Everything is oiled with a light coat of oil and the caps are torqued to spec in order of service manual
-It stops at the same two spots every time. (Intake 1 and Exhaust 2 depressed / Intake 3 and Exhaust 1 depressed). 

Ive included pictures of my cam timing and of the positions of everything in these two spots. Let me know what you think im kindve lost. 
Travis
Maryland
1981 GPZ 550 -gone
1984 GPZ 550
1985 GPZ 550
Last edit: 05 Jul 2026 16:25 by Street Fighter LTD.

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  • StreetfighterKz
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Re: Engine Rotation Locking

05 Jul 2026 14:15
#925530
You show multiple “timing mark” pics as far as I can tell.  The cam lobes for #1 are typically facing directly toward each other when 1&4 are at TDC. It’s really hard to tell from your pics is that’s the case.

Later, Doug
1978 z1000 Streetfighter
1976 z900 ‘Stripfighter
1978 z1000 w/RC Turbo
1979 z650 Resto-Mod
1983 Gpz750 Resto-Mod
2018 Z900RS

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  • StreetfighterKz
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Re: Engine Rotation Locking

05 Jul 2026 14:22
#925531
The lobes on #1 can also face away, as that would be the compression stroke as the exhaust lobe would be close to opening the valve.

Later, Doug
1978 z1000 Streetfighter
1976 z900 ‘Stripfighter
1978 z1000 w/RC Turbo
1979 z650 Resto-Mod
1983 Gpz750 Resto-Mod
2018 Z900RS

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  • Wookie58
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Re: Engine Rotation Locking

05 Jul 2026 15:25 - 05 Jul 2026 15:34
#925532
As well as the timing marks have you confirmed correct pin count between the sprockets ?
you say it locks in two places, have you forced it past the first one to find there is a second?
rotating the motor while trying to tension the chain with your hand is a recipe for disaster. Reset the marks with the tensioner removed and the correct pin count, refit the cam cover, reset the tensioner then try to rotate the motor 
Last edit: 05 Jul 2026 15:34 by Wookie58.

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  • hugo
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Re: Engine Rotation Locking

06 Jul 2026 03:17
#925539
Assuming sprockets markings align with head, with crank is at TDC and cyl 1 and 4 are high, and pin number between sprocket marks is correct,.....is it really locking up solid???,

........ or are you simply overreacting to compression resistance-no-resistance fluctuation as valves open and close?? 

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  • Wookie58
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Re: Engine Rotation Locking

06 Jul 2026 04:56
#925541
According to the pic with the blue text your pin count is wrong (1 tooth out on inlet cam)

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  • Buffalo515
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Re: Engine Rotation Locking

06 Jul 2026 08:49 - 06 Jul 2026 08:55
#925546
Thank you for the replies so far. In order...

Streetfighter, the order of the pictures came out alphabetical instead of sequential of upload i think. So picture 1 shows the cam position i set them at with the timing plate showing TDC "T" lined up with timing mark. Picture 5 the position of the timing plate when i set the cams (TDC). The other pictures show the cam lobe conditions when it locks up. 

Wookie, confirmed pin count. The z4/in line is between pins 43/44 as seen in picture 1 i posted.

Hugo, no its locked at those points. Plugs are removed and it moves quite freely before those points. I have rebuilt this same model of engine before but im unsure where to look next. Guessing this has to be a timing issue. 

I have rebuilt this same model of engine before but im unsure where to look next. Streetfighter do the lobes look at normal position in picture 1 for TDC? 
Travis
Maryland
1981 GPZ 550 -gone
1984 GPZ 550
1985 GPZ 550
Last edit: 06 Jul 2026 08:55 by Buffalo515.

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Re: Engine Rotation Locking

Yesterday 05:00
#925572
I found the issue. Figured id post in case someone runs into same issue. When i said timing plate before i was referring to the Rotor, Pulsing Coil (21007-1104). Well, the 4x8mm tension pin (555A0408)
that connects the crankshaft to the Rotor, Pulsing Coil broke off, so I was setting cam timing while the lower end was oriented correctly. Retrospectively I should have probably looked inside the cylinder to confirm top dead center. I found a drill bit that fit snuggly into the hole and cut it to 8mm, rotating fine now. 
Travis
Maryland
1981 GPZ 550 -gone
1984 GPZ 550
1985 GPZ 550
The following user(s) said Thank You: StreetfighterKz, slmjim+Z1BEBE, TexasKZ, sf4t7, Wookie58

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