I would remove the piston with connecting rod then see if you can turn it over without problems, if still jammed remove the camshaft and try again, (that is if you already haven't done so) if still jammed remove the push rods and try again, remove one item at a time that way hopefully you see where the problem is. (before removing the piston put a mark on it and on the top of the cylinder) am sure you know anyway. come back with your findings..!
EngineMan -
Thank you for your response. I think we are on the same page regarding the process of troubleshooting mechanical equipment. For me, the three most important steps of the process are: 1.) Make sure you fully understand the nature of the problem... symptoms, timing, etc. 2) Double check ALL assumptions. (False assumptions can spoil and chance of success.) 3.) Investigate by process of elimination. What follows is a list, beginning with the occurrence of the problem to where I am as of now:
1. A couple or three years back.... while mowing (Troy-Bilt) the engine simply stopped. Simple investigation determined that the intake push rod was broken. I replaced the rod, set the valves but when trying to start, the engine would begin to turn and then lug. In short.... this is when I learned about what I see as a pathetic compression release system.... that I'm sure you are familiar with. (I couldn't believe that B&S had actually allowed that design on the market.) After resetting the valves at the 1/4 off TDC mark.... I was off and running. I then began to check the valve settings at least one or two times per season.
2. A few weeks ago.... I had the same experience.... this time it had run fine and I shut it down after mowing. When I tried to start it a week or so later.... lug again just as before. I first checked the battery (almost new), cables etc. Nope. So I immediately checked the valve settings. They seemed like perhaps they were a tad off.... so I reset them... again using the 1/4" off TDC. I set them perhaps 8 times. Still no luck.
3. Having read previously about the compression release system problems with the cam, I pulled the engine, removed the sump .... and BINGO .... there were the notorious broken pieces of the timing "spring lever" in the bottom of the case. I removed the cam.... and saw where the lever used to belong. I ordered a new cam, gaskets, etc.
4. While waiting for the parts, I thoroughly flushed the case with oil. I had kept the broken pieces, making sure I could account for any missing pieces that may have logged somewhere. Flushed the engine a second time and mopped it completely. Bear in mind that prior to this point... the starter would easily rotate the engine freely when the spark plug removed and by hand. When I installed the new cam.... I followed normal procedure to install and time.... cam and crankshaft gear timing marks lined up. This part may be critical: I noted that my attempt to place the crankshaft with the timing mark pointing toward the centerline of where the cam shaft goes .... I found it impossible to simply drop (wiggle) the cam into place. It was necessary to turn the crankshaft (CW when looking down at the flywheel) somewhat .... and offsetting the cam so that after it was installed and rotated, the timing marks would line up.
5. When everything looked all good.... having replaced and checked the governor setting .... new gasket, new seal .... lubed everything ... dropped the sump on .... wiggled the crankshaft and the sump fell into place. After having it all buttoned up was when I discovered that it would rotate (CW) somewhat.... then a CLANK ... and stop. If I rotated it backwards with channel locks it would break free. Regardless of how far I turned it in reverse.... it would still CLANK in the same place.
6. I removed the sump cover while the shaft was in the jammed position.... and noted that it was exactly when the timing marks were aligned.
7. At this point I began the process of elimination as noted in my original post. First removed the cam, of course.... and all turned fine without the cam. Replaced the cam.... CLANK. Removed the cam again... removed the rocker arms, push rods from the head and the valve tappets from the case. Everything still totally free with no cam. Installed the cam .... CLANK. I removed the head to watch the piston and movement appeared normal. (The head had the typical and expected amount of grime, easily removed and cleaned.)
8. I removed and inspected the crank shaft timing gear. It showed no visible signs of wear. Not assuming it was good.... sometimes it's difficult to see or feel a faulty part .... I ordered a new one, which will be arriving on Monday.
So... that is where I am in the process as of now. I will say that I seriously doubt that the new crankshaft timing gear will solve the problem.... but that's just an assumption! LOL!!
Again.... thank you for the response. One final step in my process came after fighting it for years. Don't be too proud to solicit advice! I continue to welcome ANY and ALL questions, comments or potential solutions.
Regards,
Bill