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Oh you probably don't want to force it. If it's out of position you'd need to rectify that. As I recall there's a spline on the shaft, and all the parts need to go back on in proper order. Are you able to visually confirm that everything is where it should be?
How far is it supposed to stick out? Right now it is flush so you can't see it stick out but you can touch it.
I believe it is just the shaft stuck at the bearing's inner race. I'll try to wiggle it a little more and see if it works. Thank you again.
Update: I just reviewed your video in YouTube and looks like you had it in the same place as mine. I should be good to go. The stator cover goes on without issues (bearing not installed yet), meaning the shaft doesn't touch it when seated against the stator.
Great videos btw...thank you for making them!
Ok, everything is back together except for the carbs. Engine turns smoothly and without any weird noises. I am planning to install them in the next day or so. Looks promising so far. Thank you all!
That is awesome news!!! Happy you were able to get out of that pickle. Now bolt everything up and test everything for a good few miles not too far from home and low speed.
Thanks for reporting back and solving the problem.
Problem solved. The '96 rod with the extra indentations did the trick. Engine turns fast and smoothly. The scope is what really made it possible since without it, lining up the rod into the base of the tensioner would be extremely hard. The coat hanger method to disable the ratchet to install the stator back in worked perfectly. I also placed a socket on the threaded part of the shaft to make it easier to slide all the way through the bearing at the other end. I had removed the outer bearing, so torquing was easy. I used a torque wrench with a socket on the outer shaft nut, and a box end wrench on the other end below the starter.
Now off to replacing the cam chain tensioner. I had replaced it 26 years ago and the rattle is back. I tried cleaning it but it made no difference. If it doesn't improve with a new one I'll replace the cam chain as well, bur rather not go there.
Thank you Red Baron and Tentacleslap for all your help!
FYI group, two months into the fix and no issues. I attached a recording so you can hear how smoothly it cranks. I also just replaced the timing chain and tensioner so it is super quiet again.
