I have a 2003 KLX 110 and just installed a TB 143 big bore kit in it with the TB V2 Race head, and TB race cam.
When I go to set the timing, and have the Timing chain tensioner taught, it will bring the cam sprocket either about a half tooth off of the center mark on the head. I’ve tried cheating the sprocket both ways. It will either be a half tooth above or below the mark, no in between. See the pictures labeled numbers 1 and 2, you’ll get the idea.
The chain is seated correctly on the crank sprocket. And I’ve verified that the piston is truly at TDC with a small screwdriver poking through the spark plug hole.
I used new gaskets between the cylinder, and crank shaft, and the cylinder and the cylinder head. So I assume that spacing should be right.
I installed the cam in the cylinder head with the lobes pointing down (facing the crankshaft)
The tension on the timing chain is taught.
I rotated the crank clockwise twice as it states in the service manual and it still comes out as this.
I’ve seen a couple people had issues with this on some forums, but that was back in like ‘04 and they never posted a remedy, so I have no idea what they ended up finding.
Any help would be appreciated View attachment 271249 View attachment 271250 View attachment 271251 View attachment 271252