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Sportster Motorcycle - Bottom End Cams, Cases, Gears, Flywheel, Piston Conecting Rods, Oil Pump, etc...

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engine noise, knocking, new build

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  #1  
Old 13th July 2013
jrwca's Avatar
jrwca jrwca is offline
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Join Date: Feb 2008
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Sportster/Buell Model: XL 883 Deluxe
Sportster/Buell Year: 1991
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Default Noise after rebuild

Hey everyone, it's been a while. Three years to be exact. July of 2010, I snapped my pinion shaft and started rebuilding my bike. Two states, two jobs and four houses later, I finally caught a little time to put her back together. I went from bare frame to complete bike over the past couple of weeks (spare parts are normal, right?).

I just finished up getting her ready for the road and fired it up. She started right up and was sounding good. But as I listen more, I have some noise that sounds like it's coming from the right side in the cam box.

Using my trusty rubber hose, I noticed that the sound is really evident at the nose cone (with the cover off). It sounds like a high pitch metal-on-metal pinging. I don't notice it on the left side of the bike and it's definitely muted everywhere else on the cam cover.

When I rebuilt the engine, I had a reputable shop in Orange County recondition a set of used 1200 flywheels and clean up the lower end. They installed all new bushings and line reamed the cam bushings. I reamed the wrist pin bushings myself using the Jims tools.

I installed a new set of N4 cams, valves and valve seals during the install. Just prior to the breakdown, I had rebuilt the transmission and installed several new parts including an oil pump, pushrods, lifters and rocker bushings. I am using the old pistons and rings (for now).

Any ideas what it might be? I'm planning to open it back up, but I'm really not sure what would make the sound I'm hearing.

Is it possible the pistons and valves are making contact and the noise is translating down into the cam box?

I'm gonna check to see if it's only happening when the engine's hot, but would appreciate any thoughts.
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  #2  
Old 13th July 2013
Bob s hog's Avatar
Bob s hog Bob s hog is offline
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Location: spencerville
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Sportster/Buell Model: sportster
Sportster/Buell Year: 2003
Sportster/Buell Model #2: 1200 xl sportster custom
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Default

please don't run it any more take the cam cover off and check to see whats wrong did you get the right side cover gaskit theres two different ones . id take a good look befor all that money you put in it get pissed away.
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  #3  
Old 13th July 2013
jrwca's Avatar
jrwca jrwca is offline
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Join Date: Feb 2008
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Sportster/Buell Model: XL 883 Deluxe
Sportster/Buell Year: 1991
Reputation: 83
jrwca is an unknown quantity at this point
Default

Ended up tearing it open this morning.

Seems the nut on the pinion shaft came loose. Not sure how that happened. I installed all that three years ago, so I don't know if I messed up torquing it or what.

Cleaned it back up and retorqued it with red Loctite. Unfortunately, it chewed up the bushing in the cam cover. Going to change the oil after replacing that bushing and try to get out any bits of the old bushing I can.
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