Yeah I realize this is an old thread, but maybe what I have to say has some value. I blew my 94 stage 2 KA climbing Sherwin summit north of Bishop California in the eastern sierras. Anyway, #3 conrod had a meltdown and it cracked my crank and sent the piston smashing into the head and the motor hadda be replaced.
So, I have this worn out old used 95 KA now and I'm in the middle of a partial tear down having just installed a new timing set for the 2nd time. In following the directions specific to the FSM for this task I find that it does matter if your @ TDC and marks are lined up perfectly @ install, but do not expect to cycle the motor after install and have your chain marks align on the first go, they wont! But if you look at the marks on the sprocket, crank and the cam gears, they DO line up at the end of each engine cycle precisely where they should be @ TDC to begin the next cycle. After the motor has been rotated with the timing chain in place, it will not line up with the marks on the chain. I'm not 100 percent sure I'm doing this right, but Im pretty sure I didn't do it wrong twice in a row. This is what I think I know so far, but I'm a long way from putting my Dizzy in and cranking her over to prove it to myself. Having cycled the motor several times though Im confident that there is no interference and that what I think I know as stated here, is correct.
