Hey there, new to the forum and appreciate the add.

I have a 01 warrior that I just completely rebuilt. New crank, rod, piston and head was checked with valve grind and new seals put in. Got it all put back together and in the frame. Put timing chain on and followed manual. Get the "T" in the window and line cam gear up with mark on head. After doing this and turning motor over by hand something felt odd. Like the piston was hitting a valve. So I stuck my inspection camera in the spark plug hole. For some reason when the "T" is in the window my piston is not at TDC. It is past it and already heading down on what would be the Power stroke. So some how I messed up the timing on the crank? I didn't think that was possible since the Woodruff key only goes in one spot for the actual flywheel. Looking for any help to get this figured out. I really don't want to have to split the case again. But I am not sure where I went wrong. I will probably hit myself when someone tells me, because I am sure it was a stupid little mistake.

Thank you in advance for any help! I really do appreciate it.

 

The key fell out when you shoved the flywheel on and crank moved round as you tightened the flywheel.