Cam-swap/engine won't start

So I finally got off my backside and decided to use the intake cams from the dead engine as exhaust cams. Bad start was had when I couldn't get the timing inspection cover to come off because it's welded itself in place. Bent a bar trying to do it, which I was impressed with, as I expected the suzuki-cheese bolt to round before that happened. As a result, I ended up taking the plugs out and turning the engine over using the starter to get the right markings into places I could work with (as I also couldn't find a 17mm socket. Go figure.)

So, decided to go for the rear cylinder first because it's a bit more accessible (although the CCT location made me regret that decision). Managed to get it in, 16 pins between the 2-mark on the intake to the new 3-mark on the new exhaust (marked out as the next valley to the left of the 1F marking as per this image):
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I didn't take the CCT out because I didn't see much point in putting myself through that much pain, given that I've got a long screwdriver and skinny hands. I regret the decision a bit now, because at one point the cam-chain slipped off both cams while trying to wriggle the new cam into place. I'm about 99% certain that it went back on at the same place it came off...but there's that 1% chance I was wrong.

Being the slightly paranoid guy that I am, I tried very short presses on the starter to turn the engine over (no 17mm socket, remember? Which is a shame). No big clunks, everything turns over lovely and smoothly. Excellent. Decide to try to fire it up with just the rear cyl done to make sure I've not broken anything. Put everything back together, plugs in and caps back on, turn motor over. Front cylinder fires. Rear doesn't. Take off front plug to make sure...still no firing.

Bike now runs on one cyl only, which is peeing me right off. Any ideas on what I've done wrong?

[Sid Squid]

Where to start? Could be anything - re-check everything you've disturbed. Particularly the cam timimg obviously.

See above comment on not being able to get the timing cover off. That's the problem I've got, really

[Richie]

check for a spark on the rear plug, might had cracked the insoluation on the plug, but I would believe you would have allready checked...

Yep, plug sparks fine, swapped front and rear sparks and they're both working (and were both running before, obviously)

ok nothing to add bout the cams as i no nothing about it but on the mt-owners-club forum one of the blokes had the front cylinder not firing on his mt-01 1600cc twin and to force start it he put some fuel in the spark plug hole (not sure how much) then obv replaced the plug back in there and it started up not sure if this is worth a shot ?

[yorkie_chris]

You got the cam pointing the right way? Look at cams and go through it in your head, intake compression combustion exhaust

I'd assume there's only one way it can go in if it's lined up correctly with the 2 and 3 pins

Originally Posted by Neeja

I'd assume there's only one way it can go in if it's lined up correctly with the 2 and 3 pins

Assumption is the mother of all fu*k ups. You can put the cam in 180 degrees out and it'll turn over ok but not fire.

But if it's in 180 degrees out of alignment then the 3 marking on the exhaust cam would then also be 180 degrees out of alignment...which would mean it wouldn't be 16 pins away