So I pulled the valve cover off today planning to remove the cylinder to check the piston clearance and ring gap. When I went to put it back on it wouldn't sit flush again. I spent an hour and a half but no matter what, it wouldn't go back. The front right corner is sitting about 1/8" off the top of the cylinder and won't go farther. Any sugestions?

 

valve cover-- not the head, correct?

make sure you have it rotated the right way-- ie try it 180 degrees from how it is now.

Will it sit flat on a level surface-- like a counter?

 

Yeah the valve cover. It's sitting flat on my work bench. I tried rotating it 90 degrees 4 times and it still wouldn't sit correctly. Everything is lined up, it doesn't make sense.

 

did you check to see if anything was up out of the engine it self..any thing sticking out ..maybe somthin poped out of place..

 

Found it. The bearing on the end of the cam has a pin that has to slide down into a slot to sit level.

Next question:
I have the cdi cover off and the pulse generator removed, now the the spark advancer won't budge. I have removed the bolt and the main part slid off the shaft, but the internals won't slide off the cam. I can't remove the cylinder until it's done!