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Sportster Motorcycle Motor - Top End Discuss Sportster Motorcycle Top End issues. Rockerboxes, Valves, Cylinders, Pistons, Rings, Lift Rods, etc...

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Old 16th May 2019
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Default Valve to piston contact

I found my front cylinder clatter. Exhaust valve has put a good dent in the valve pocket. I'm assuming I have a bent exhaust valve but when I squirted a little brake cleaner in the exhaust port, it seemed to be sealed. Is this possible? And what caused it? Or is there another reason for the contact and the valve possibly Ok? I can actually feel the ridge the dent left in the valve pocket.
Number 4 cam gear off a tooth?
This happened on first start up after a cam install but I was positive everything lined up. Shut it down right away and did a 1200 to 1250 and lifters and clatter was still there. This is what I found yesterday after tearing it down again.

Last edited by 60Gunner; 16th May 2019 at 13:46..
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Old 16th May 2019
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That looks like a really hard hit. Something's way out in the weeds.

I don't normally do customer service on the web, because the noise level can get real high, but let me list out the most common causes:
  • Sometimes guys line up all the dots properly, but don't realize the pinion gear has a mark too.
  • Sometimes guys inadvertently swap the #1 and #4 cams.
  • Sometimes the pinion key gets sheared (tons of discussion on that on this board)
  • Sometimes rocker boxes get installed without positioning the motor at compression TDC first. This can cause the valves to hit each other and get bent, which of course causes a valve to get hung up and not close and thus the piston runs into it.
  • Sometimes guys install a rocker box and then turn the motor over before giving the lifters time to bleed down.

Now of course could be something else, like misground or mismarked cams, slipped drive gear on the #2 cam, etc, but those are all real low probability items. It's usually one of the above.
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  #3  
Old 16th May 2019
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Default

Pinion gear mark lined up with #1 as well.
1&4 not swapped.
Key would've had to shear immediately on 1st startup so unlikely. I did the bronze drive gear and torqued to 70 ft.lbs. too.
The next one is possible the first time. It was dead of winter in an unheated garage that I heated up some to work. But not the next 3 installs including with the 1250. Same with the bleed down.

Pushrods don't appear to bent. Valves actually held break cleaner yesterday which really surprised me at this point. 40 to 50psi lower than rear on a compression test tho.

Obviously I'm going to pull the cam cover too and verify. Hopefully today yet. Storms on the way in and I pulled it down in my back yard instead of the garage down the street I use like a dumb ass. So it's buttoned up really well right now to ride it out.

Is that piston still ok?
FWIW, the bike ran fairly well the little I've run it. Heat cycled and 1/2 mile tops in town. Idled a few minutes hear and there a couple more times. The rear cylinder anyway.
It would be my luck, Aaron, to have a mismarked cam or a slipped drive gear.

I talked to Alex yesterday about sending the heads in. I want to pin down the issue first tho of course. Haven't pulled the rear head yet either.

When I pull the cam cover, I'll snap a pic.

Last edited by 60Gunner; 16th May 2019 at 15:18..
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Old 16th May 2019
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If the valve is holding brake cleaner and the compression is low, check your pushrod lengths.
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Exhaust is 10.75 in.
Intake is 10.68 in.

Sorry, my digital caliper isn't long enough. That's with my tape measure in 32nds of an in.
The intake is an 1/8 shorter than exhaust. Don't appear bent when I roll them.

I should be able to get the cam cover pulled shortly. Was hoping wouldn't have to but not looking likely.

Last edited by 60Gunner; 16th May 2019 at 17:06..
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I meant check to see that they're the right length.
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Quote:
Originally Posted by aswracing View Post
Stock pushrods. Exhaust longer than intake. Off to pull the rear rocker box then cam cover.
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Old 16th May 2019
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I always do the clay and solder clearance tests when installing any new
parts like cams or ported/decked heads.

BTW what cams?
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Quote:
Originally Posted by decman View Post
I always do the clay and solder clearance tests when installing any new
parts like cams or ported/decked heads.

BTW what cams?
570s and these heads have never been ported or decked. Everything was stock as stock can be motor wise.
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Old 16th May 2019
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Cams all look good.
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