R1100S cam sprocket not aligning
 

One of the cam chain tensioner rails broke on my 2003 R1100S (Boxercup Replika). I set about replacing it (heads and cylinders off and block split) and all was going well until yesterday when I came to refit the right cylinder head. The problem I have is that the camchain sprocket does not align with the bolt hole in the end of the camshaft. It is almost as if the chain is about 3 mm too short ,so I can't pull it out far enough to bolt the sprocket to the camshaft.

My Clymer manual says this may be due to the chain not engaging correctly with the sprocket on the auxiliary shaft. But a) if I look down the chain tunnel I can see it is on the sprocket and b) if I gently rotate the crankshaft using the bolt on the front pulley - whilst keeping gentile tension on both cam chains, all runs smoothly with no jumping or notchiness (I just let the right chain run around my finger). I'm loathe to split the engine again so was wondering if there is anything else I could try.

I don't know if it is related but when I check the camshaft end I can see that when the sprocket is fitted, the timing arrows will be about 20 degrees off the horizontal with all valves closed. I assume there is no likelihood of the problem being with the camshaft. It hasn't been touched.

Many thanks for reading this far. Any advice would be very much appreciated.
Ian

tensioners out? did you get the right rails on the correct side

Thanks Brent. I'm pretty sure I did and everything lines up as should (rail bolts and tensioner springs). But you know how self-doubt creeps in :).

I'm going to use a borescope to see if I can see anything untoward in there.

I'm also trying to loosely fit the camshaft sprocket before I've fully tightened the cylinder head. I assume that when everything is tightened up I will gain a little, but I just can't see it being enough.

Thanks again for responding.

Ian