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Tanner – First off the condition of the generator and regulator have absolutely NO effect on the ignition performance at startup. So you can forget about them for the time being… As the others below suggest your ignition timing is all messed up. A couple things to keep in mind here: 1 – Simply setting the pulley at the TDC mark and seeing the #1 piston at the top of it’s stroke can result in your timing being off by exactly 180 deg, since the #1 cylinder can be at either TDC compression or TDC exhaust. 2 – The “clock” position of the distributor rotor at TDC itself is meaningless. All that matters is that the rotor be pointing at the #1 plug wire nipple when the #1 cylinder is at TDC compression. (However the “correct” position is at about 2 o’clock) Here’s how I’d reset the timing: First set the crank to #1 TDC compression. Can either remove the rocker box, then while watching the #1 intake and exhaust valves, turn the crank until you get the timing mark at TDC with both valves closed. Or you can stick your thumb over the #1 spark plug hole then have an assistant slowly turn the crankshaft. When you begin to feel compression with your thumb continue to rotate the crank until the TDC timing mark aligns with the pointer – about 1/3 of a revolution more. Next set the distributor: Put a mark on the side of the dist housing in line with the #1 plug wire nipple on the cap. Now remove the cap, then rotate the distributor housing until the rotor points to the mark you just made on the side of the housing. Then rotate the distributor slightly in the direction opposite normal rotor rotation (counterclockwise) until you see the points just start to open and tighten the distributor down. Finally install the cap, plugs, plug wires, etc and give it a try. If you did it right it should start right up. You’ll probably need to adjust the distributor a bit for best running, but the above will get it going for you. Good luck!
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