Cbr900 installing cam's and timing chain. the motor will turn only 1/4 inch. im not sure where the problem is. I know the motor turns fine. its only after putting on the timing chain and the cams that the motor wont make a complete turn.

/* override srp image link color and background color */ .galleryImage { background-color: #002F56; color: rgb(0, 47, 86); } Fig. 1 Front cover pry pointsFig. 2 No. 1 piston TDC positionFig. 3 No. 1 piston TDC alignmentFig. 4 Camshaft TDC alignmentFig. 5 Timing chain alignmentFig. 6 Lefthand cam phaser alignmentFig. 7 Timing chain alignment marksFig. 8 Upper intake manifold tightening sequenceFig. 9 Valve cover tightening sequence. LefthandFig. 10 Valve cover tightening sequence. Righthand Print Options Print Text Only Print Text and images Print Timing Chain, Replace Caution: The magnetic timing wheels must not come in contact with magnets or any other strong magnetic field. This will destroy the timing wheels ability to correctly relay camshaft position to camshaft position sensor. 1. Disconnect battery ground cable. 2. Remove air cleaner housing assembly. 3. Remove upper intake manifold. 4. Remove valve covers. 5. Remove spark plugs, then raise and support vehicle. 6. Drain cooling system into suitable container. 7. Remove upper and lower oil pans. 8. Remove righthand engine mount bracket. 9. Remove bolts from front cover. 10. Carefully remove front cover by carefully prying at seven indicated points, Fig. 1. 11. Rotate crankshaft counterclockwise to place No. 1 position at TDC on exhaust stroke by aligning dimple on crankshaft with block/bearing junction, Fig. 2. Lefthand side cam phaser arrows should point toward each other and be parallel to valve cover sealing surface. 12. Mark rotation direction of following timing chains for reference during installation: a. Lefthand side cam chain. b. Righthand side cam chain. c. Oil pump chain. d. Primary chain. 13. Reset righthand cam chain tensioner by pushing back tensioner piston and installing tensioner pin tool No. 8514, or equivalent. 14. Reset lefthand cam chain tensioner by lifting pawl, pushing back piston and installing tensioner pin tool No. 8514, or equivalent. 15. Disengage oil pump chain tensioner spring from dowel pin, then remove oil pump chain tensioner. 16. Remove oil pump sprocket T45 retaining bolt, then remove oil pump sprocket and oil pump chain. 17. Install righthand camshaft phaser lock tool No. 10202, or equivalent. Minor rotation may be required to install camshaft phaser lock. 18. Loosen both intake oil control valves, then exhaust oil control valve. 19. Remove righthand camshaft phaser lock tool, then oil control valve from righthand side intake cam phaser. 20. Pull righthand side intake cam phaser off of camshaft, then remove righthand side cam chain. 21. Remove oil control valve, then pull righthand side exhaust cam phaser off camshaft. 22. Install lefthand camshaft phaser lock tool No. 10202, or equivalent. Minor rotation may be required to install camshaft phaser lock. 23. Loosen both intake oil control valve and exhaust oil control valve. 24. Remove lefthand camshaft phaser lock tool, then oil control valve from lefthand side exhaust cam phaser. 25. Pull lefthand side exhaust cam phaser off of camshaft, then remove lefthand side cam chain. 26. Remove oil control valve, then pull lefthand side intake cam phaser off of camshaft. 27. Reset primary chain tensioner by pushing back tensioner piston and installing tensioner pin tool No. 8514, or equivalent. Remove two T30 bolts, then primary chain tensioner. 28. Remove timing chain. 29. Reverse procedure to install, note following: a. Verify No. 1 piston is positioned at TDC by aligning dimple on crankshaft with block/bearing cap junction, Fig. 3. b. Verify camshafts are set at TDC by positioning alignment holes vertically, Fig. 4. c. Ensure timing chain plated link is located at 12 o'clock when dimple on crankshaft is aligned with block/bearing cap junction, Fig. 5. d. Position lefthand side cam phasers so that arrows point toward each other and are parallel to valve cover sealing surface, Fig. 6. e. Torque idler sprocket bolt to 18 ft. lbs. f. Torque oil control valve to 110 ft. lbs. g. Torque oil pump sprocket bolt to 18 ft. lbs. h. Ensure there are 12 chain pins between exhaust cam phaser triangle marking and intake cam phaser circle marking, Fig. 7. i. Torque upper intake manifold bolts to 80 inch lbs., in sequence, as illustrated in Fig. 8. j. Torque lefthand valve cover bolts in sequence, as illustrated in Fig. 9, to 106 inch lbs. k. Torque righthand valve cover bolts in sequence, as illustrated in Fig. 10, to 106 inch lbs. l. Torque timing chain tensioner to 106 inch lbs. m. Torque timing chain guide to 106 inch lbs.
Print - As Shown Print - Fit To Page / 1

• Fig. 1 Front cover pry points
• Fig. 2 No. 1 piston TDC position
• Fig. 3 No. 1 piston TDC alignment
• Fig. 4 Camshaft TDC alignment
• Fig. 5 Timing chain alignment
• Fig. 6 Lefthand cam phaser alignment
• Fig. 7 Timing chain alignment marks
• Fig. 8 Upper intake manifold tightening sequence
• Fig. 9 Valve cover tightening sequence. Lefthand
• Fig. 10 Valve cover tightening sequence. Righthand

wow no job stated.
04 (2.3L) ill take a wild guess and say, you might be fiddling the cam
and doing something there, new cam, new lifters, new chain, new head, ? what?
FSM means factory service manual, ever heard of one?

the FSM is just lousy 4 bucks why not read that first. and not mess it up.

https://suzukipitstopplus.com/Products/1004-2004-aerio-service-manual.aspx

you said SET, so i can only assume its all apart. right then
you want to Instal the chain and time it, right so here are the fsm steps
no photos. log in and read the FSM for that.

1. Check that match mark on crankshaft timing sprocket is in match with timing mark on lower crankcase.
2. Install crankshaft timing sprocket as shown in figure.
3. Apply oil to bush of idler sprocket and install idler sprocket and sprocket shaft.
4. Install first timing chain by aligning dark blue plate of first timing chain and match mark on idler sprocket.
5. Bring yellow plate of first timing chain into match with match mark on crankshaft timing sprocket.
6. Apply engine oil to sliding surface of timing chain tensioner and then install it as shown in figure. Tighten tensioner nut to 18 ft. lbs. (25 Nm).
7. With latch of tensioner adjuster No.1 returned and plunger pushed back into body, insert stopper into latch and body. After inserting it, check to make sure that plunger will not come out.
8. Install timing chain tensioner adjuster No.1. Tighten the timing chain tensioner adjuster No. 1 bolt to 8 ft. lbs. (11 Nm).
9. Pull out stopper from adjuster No.1.
10. Apply engine oil to sliding surface of timing chain guide No.1 and then install it. Tighten guide bolts to 6.5 ft. lbs. (9 Nm).
11. Check that dark blue and yellow plates of first timing chain are in match with match marks on sprockets respectively.
12. Install second timing chain as follows:
    • Check that match mark on crank timing sprocket is in match with timing mark on lower crankcase.
    • Check that arrow mark on idler sprocket faces upward.
    • Check that knock pins of intake and exhaust camshafts are aligned with timing marks on cylinder head.
    • Install second timing chain by aligning yellow plate of second timing chain and match marks on idler sprocket.
    • Install sprockets to intake and exhaust camshafts by aligning dark blue plate of second timing chain, match marks on intake sprocket and exhaust sprocket respectively. NOTE As an arrow mark is provided on both sides, camshaft timing sprocket has no specific installation direction.
      
      
      

• Install intake and exhaust camshaft timing sprocket bolts. To install it, fit a spanner to hexagonal part at the center of camshaft to hold it stationary. Tighten the camshaft timing sprocket bolt to 57.5 ft. lbs. (80 Nm).
• Push back plunger into tensioner body and hold it at the position by inserting stopper into body.
• Install timing chain tensioner adjuster No.2 with new gasket. Tighten the timing chain tensioner adjuster No. 2 bolts to 8 ft. lbs. (11 Nm) and No. 2 nut to 33 ft. lbs. (45 Nm).
• Pull out stopper from timing chain tensioner adjuster No.2.
• Turn crankshaft two rotations clockwise then align timing mark on crankshaft and timing mark on cylinder block.
• Check that timing marks of cylinder head and cylinder block are in match with match marks on sprockets respectively.
• Apply oil to timing chains, tensioner, tensioner adjusters, sprockets, and guides.
• Install timing chain cover. Reverse removal sequence to install timing chain cover noting the following points:
  
  • Apply sealant "A" and "B" to area as shown.
    
    • "A": Sealant 99000-31250
    • "B": Sealant 99000-31140
  • Apply sealant amount to the following areas.
    
    • "a": 0.12 inches (3mm)
    • "b": 0.08 inches (2mm)
    • "c": 0.24 inches (6mm)
    • "d": 0.63 inches (16mm)
    • "e": 0.55 inches (14mm)
    • "f": 2.56 inches (65mm)
    • "g": 2.87 inches (73mm)
    • "h": 0.16 inches (4mm)
  • Apply engine oil to oil seal lip, then install timing chain cover. Tighten bolts and nut to 8 ft. lbs. (11 Nm).
    NOTE Before installing timing chain cover, check that pin is securely fitted.
• • Before installing timing chain cover, check that pin is securely fitted.
• Install alternator belt idler pulley. Tighten nut to 30.5 ft. lbs. (42 Nm).
• Install alternator belt tensioner. Tighten bolts to 18.5 ft. lbs. (25 Nm).
• Install water pump pulley.
• Install A/C compressor bracket (if equipped). Tighten bracket bolts to 40 ft. lbs. (55 Nm).
• Install cylinder head cover with new gaskets and seal washers and tighten nuts to 8 ft. lbs. (11 Nm).
• Install oil pan.
• Install crankshaft pulley using pulley holder tool. Tighten the crankshaft pulley bolt to 108.5 ft. lbs. (150 Nm).
• Install engine assembly.
• Install all remaining components in the reverse order of the removal procedure.

did that cover it, surely not.
but if you get the FSM and read it or log in , you will not miss the photos and the complex sealing bs on this motor.

Procedure is pasted below. Please let me know if you have questions.
Removal & Installation2.2L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Drain the engine oil.
4. Remove or disconnect the following:
   NOTE The timing chain has 2 matching colored links and 1 uniquely colored link.
   Negative battery cable, PCV hose, Fuel line bracket, Ignition coil and module assembly Ground strap from camshaft cover, Camshaft cover, Front fender liner, Accessory drive belt Crankshaft balancer pulley, Accessory drive belt tensioner, Front cover-to-water pump bolt Remaining front cover bolts, Front cover
   
5. Rotate the engine until the crankshaft sprocket mark aligns with the matching colored link (2) at the 5 o-clock position.
6. Confirm that the INT diamond on the intake camshaft sprocket is aligned with the uniquely colored link at (1) the 2 o-clock position.
7. Confirm that the EXH triangle on the exhaust camshaft sprocket is aligned with the matching colored link (3).
8. Remove or disconnect the following:
   NOTE Use a 24 mm wrench to hold the camshafts to prevent them from turning.
   Timing chain tensioner, Fixed timing chain guide access plug, Fixed timing chain guide Upper timing chain guide, Exhaust camshaft sprocket, Timing chain tensioner guide Intake camshaft sprocket, Timing chain through the top of the cylinder head Crankshaft sprocket
   
   
   

   Fig. Lining up the crankshaft sprocket mark with the colored link in the 5 o-clock position (2).
   
   
   
   

   Fig. Aligning the intake camshaft sprocket mark with the colored link in the 2 o-clock position (1).
   
   
   
   

   Fig. Aligning the exhaust camshaft sprocket (3).
   

To install:

1. Install the crankshaft sprocket with the timing mark in the 5 o-clock position.
2. Assemble the intake camshaft sprocket to the timing chain with the timing mark lined up with the uniquely colored link (1). Hand tighten a new intake camshaft sprocket bolt.
3. Lower the timing chain through the opening in the cylinder head.
4. Route the timing chain around the crankshaft sprocket and line up the first marching colored link (2) with the timing mark on the crankshaft sprocket.
5. Install the exhaust camshaft sprocket with a new bolt loosely onto the exhaust camshaft.
6. Align the timing mark on the sprocket with the last matching colored (3).
7. If necessary, align the camshaft as follows:
   1. Using a 24 mm wrench, first turn the intake camshaft until the alignment feature on the back of the camshaft sprocket seats in the notch in the front of the intake camshaft.
   2. Turn the crankshaft 45 degrees in either direction.
   3. Turn the intake camshaft to the appropriate location.
   4. Turn the crankshaft back to top dead center (TDC).
8. When the sprocket seats in on the camshaft, tighten the sprocket bolt hand tight.
9. Verify all of the colored links and the appropriate timing marks are still aligned.
10. Install the fixed timing chain guide. Tighten the bolts to 133 inch lbs. (15 Nm).
11. Install the upper timing chain guide. Tighten the bolts to 89 inch lbs. (10 Nm).
12. Using a 24 mm wrench to hold the camshafts, tighten the camshaft sprocket bolts 63 ft. lbs. (85 Nm) plus 30 degrees.
13. Measure the timing chain tensioner from end to end. A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 2.83 inches (72 mm) front end to end. A tensioner in the active state will measure 3.35 inches (85 mm) from end to end.
14. If the timing chain tensioner is not in the compressed state, perform the following steps:
    1. Remove the piston assembly from the body of the timing chain tensioner by pulling it out.
    2. Install the bottom half of the Tensioner tool J-45027-2 into a vise.
    3. Install the notch end of the piston assembly into the bottom half of the tensioner tool.
    4. Using the top half of the Tensioner tool J-45027-1, turn the ratchet cylinder into the piston.
    5. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore.
    
    
15. Install the timing chain tensioner assembly. Tighten to 66 ft. lbs. (75 Nm).
16. Release the timing chain tensioner by compressing it approximately 0.08 inches (2mm). Feed a rubber-tipped tool down through the cam drive chest to reset on the cam chain. Give the tool a sharp jolt diagonally downwards to release the tensioner.
17. Install the timing chain oiling nozzle.
18. Install the timing chain guide bolt access hold plug with silicone sealant on the threads. Tighten the plug to 59 ft. lbs. (90 Nm).
19. Install or connect the following:
    
    Camshaft cover. Tighten the bolts to 89 inch lbs. (10 Nm). Front cover with new gasket. Tighten the bolts to 18 ft. lbs. (25 Nm). Accessory drive belt tensioner. Tighten the bolts to 33 ft. lbs. (45 Nm). Crankshaft balancer pulley using a new bolt. Tighten the bolt to 74 ft. lbs. (100 Nm) plus 75 degrees. Accessory drive belt, Front fender liner, Ground strap to camshaft cover Ignition coil and module assembly, Fuel line bracket, Air intake assembly, Negative battery cable
20. Refill the cooling system to the correct level.
21. Refill the engine with oil to the correct level.
22. Start the engine and check for leaks.
    
    
    

    Fig. Compressing the timing chain tensioner-2.2L engine.
    

By :"specs" I assume you need install position? To index the gears, whne you take it apart, turn the crank pulley 'till the timing mark aligns with the "0" on the timing scale. Don't turn the crankshaft again. When you are ready to install the chain, locate the mark on the crank gear and align the mark on the cam gear so they point to each other. The mark on the crank gear should be at 12 o'clock and the cam gear mark at 6 o'clock. Make sure when you put the cam gear on the cam that the location pin fits into the gear to position it correctly. Jeep recommends that after putting the chain and gears on, you rotate the engine by hand and place the crank mark at 6 o'clock and the cam gear at 3 o'clock, then count the number of pins in the chain (pins, not links) between those two points. There should be 15 pins. If you are rebuilding the engine and have the cylinder removed, it's a good time to check the front crank pulley (some have the outer ring move on the rubber). Put a piece of flat steel across #1 cylinder with a bolt through the steel extending into the bore center. Turn the engine by hand 'till the piston contacts the bolt. Make a mark on the pulley and turn the engine in the opposite direction till contact is again made. Your timing mark on the pulley should be exactly between the two marks you made. If not, make a new mark at that point and use that as your actual TDC reference. If it is radically off, replace the pulley.
When setting up cam position I always use a degree wheel. If you are installing an aftermarket cam
its important to do that. If you're just replacing a stock chain, You will be fine with the method I've outlined.

Sukkle julle nog? Het my instruksie nie gehelp nie?. Ek die opgetel, dalk help dit?

The way I understand it is that if #1 is at TDC and the T mark is lined up with the crankcase seam - there is no offset woodruff key (i.e. ignition advancer). If you think about, what's changing (when there is an offset key, that is), is the rotational position of the flywheel in relation to any given crankshaft position (i.e. TDC). So...

IF there is no offset key, rotate the crank so that #1 (and #4 by the way) are at TDC. The T mark should line up with the seam. From there, put the exhaust cam in (taking slack out of the cam chain from the exhaust side). When you go to set the cam into the chain do it in such a way that the cam timing mark is slightly ahead (toward front of motor) of the mark on the cam cap (EDIT - Since you're not actually installing the cap yet simply place it on top of the cam in such a way that there is an even gap between IT and the head surface. This way you can eyeball the position of the marks.). Then install the intake cam in a similar manner. That is, set the cam into the chain so the cam timing mark is slightly ahead of the cap mark. EDIT - When both cams are in place, install the cams caps (follow the torqueing procedure so you don't break them OR the cams!!!). After the caps are installed, grab a dowel and stick it in the cam chain tensioner hole and push the slack out of the chain. This SHOULD rotate the cams back (toward rear of motor) so the marks DO in fact line up.

CAUTION: Keep periodically checking to make sure the T mark is STILL lined up properly while putting the cams in. The crank DOES have a tendency to move around a bit while you're trying to jimmy the cams back in.

If the cams are out it's a bit easier since they are not part of the equation yet. It sounds like you're trying to figure out why the T mark isn't lining up when the cam timing marks ARE lined up. Go once step at a time - starting without the cams - as I described above and you shouldn't have a problem.

If you DO have an offset key, you MAY need to get a stock key to get the timing right. THEN, re-install the offset once the cams are back in. This point / tip was given to me by our resident GURU Reelrazor (who I'm sure will chime in at some point).

Timing Chain & Gears Removal & Installation To Remove:
NOTE: Keep the cam chain away from magnetic fields.
Crankshaft set at TDC marks

1. Turn the crankshaft pulley so its Top Dead Center (TDC) mark (1) lines up with the pointer (2).
2. Raise and support the vehicle.
3. Remove the front tires/wheels. Front undercar splash shield
   
   
4. Remove the front undercar splash shield.
5. Remove the drive belt.
6. Remove the cylinder head cover (See section on Valve Cover).
7. Remove the crankshaft pulley (See section on Crankshaft Damper). CKP sensor and VTC solenoid electrical connectors
   
   
8. Disconnect the Crankshaft Position (CKP) sensor connector (1) and Variable Valve Timing Control (VTC) oil control solenoid valve connector (2).
9. Remove the VTC oil control solenoid valve (See section on VTC Solenoid Valve).
10. Support the engine with a jack and wood block under the oil pan. Ground cable and upper bracket removal
    
    
11. Remove the ground cable (1), and remove the upper bracket (2). Side engine mount bracket removal
    
    
12. Remove the side engine mount bracket. Timing chain cover removal
    
    
13. Remove the timing chain cover bolts both from the front to the block and from the bottom to the oil pan.
14. Remove the timing chain cover.
15. Loosely install the crankshaft pulley. Compress the timing chain auto-tensioner
    
    
16. Turn the crankshaft counterclockwise to compress the auto-tensioner. Lock the timing chain auto-tensioner
    
    
17. Align the holes on the lock (1) and the auto tensioner (2), and then insert a 0.06 inch (1.5 mm) diameter pin (3) into the holes.
18. Turn the crankshaft clockwise to secure the pin. Removal of the timing chain auto-tensioner
    
    
19. Remove the auto-tensioner. Removal of the timing chain guide B
    
    
20. Remove the cam chain guide B. Removal of the timing chain guide A
    
    
21. Remove the cam chain guide A (1) and tensioner arm (2).
22. Remove the cam chain.

Timing Chain, Sprockets, Front Cover and Seal REMOVAL & INSTALLATION 2.5L and 4.0L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Accessory drive belt
   • Cooling fan and shroud
   • Crankshaft damper
   • Front crankshaft seal
   • Accessory brackets
   • Front cover
   • Oil slinger
3. Rotate the crankshaft so that the timing marks are aligned. Fig. 1: Timing chain alignment marks — 2.5L and 4.0L engines
   
   
4. Remove the timing chain and sprockets. To install:
   
5. For 2.5L engines, turn the timing chain tensioner lever to the unlock (down) position. Pull the tensioner block toward the tensioner lever to compress the spring. Hold the block and turn the tensioner lever to the lock (up) position. Fig. 2: Timing chain tensioner — 2.5L engines
   
   
6. Install the timing chain and sprockets with the timing marks aligned. Tighten the camshaft sprocket bolt to 80 ft. lbs. (108 Nm) for 2.5L engines or to 50 ft. lbs. (68 Nm) for 4.0L engines.
7. For 2.5L engines, release the timing chain tensioner.
8. Install or connect the following:
   • Oil slinger
   • New front crankshaft seal to the front cover
   • Front cover, using a new gasket
   • Timing Case Cover Alignment and Seal Installation Tool 6139 in the crankshaft opening to center the front cover Fig. 3: Timing Case Cover Alignment and Seal Installation Tool 6139 — 2.5L and 4.0L engines
     
   
   
9. Tighten the front cover bolts as follows:
   1. Step 1: Cover-to-block 1⁄4 inch bolts to 60 inch lbs. (7 Nm)
   2. Step 2: Cover-to-block 5⁄16 inch bolts to 16 ft. lbs. (22 Nm)
   3. Step 3: Oil pan-to-cover 1⁄4 inch bolts to 85 inch lbs. (9.5 Nm)
   4. Step 4: Oil pan-to-cover 5⁄16 inch bolts to 11 ft. lbs. (15 Nm)
10. Install or connect the following:
    • Accessory brackets
    • Crankshaft damper. Tighten the bolt to 80 ft. lbs. (108 Nm).
    • Cooling fan and shroud
    • Accessory drive belt
    • Negative battery cable
11. Start the engine and check for leaks.

did u hav piston @tdc power stroke-valves shud slightly clic with ur hand after ajust-mite hav performed it at exhaust stroke! let me know

your timing chain should have an automatic tensinor. look at the engine where the cooling fins are and there will be a protruding piece that looks like a 1/2 inch wide by 2 or so inch long with a little rubber plug. removing the plug will reveal a screw that if turned will retreact the tensinor and hold it. whent the screw is turned the opposit way it will release the tensionor and as it is spring loaded will push on the chain. i would remove the whole unit by takin out the two screws and than retract and release the mechanism a few times to be assured it runs free. when you install it be sure it is in the retracted position as if it is not it will shear the end off the cam. once instaled turn the screw to put tension back on the chain. if the adjuster dose not retract and release correctly must replace.

I have a similar problem. I just replaced the water pump and now the POS wont start. Like it is not getting fuel>