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7th May 2012
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Biker
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Join Date: Aug 2007
Location: In the garage
Posts: 94 Sportster/Buell Model: 98 1200+ Sportster/Buell Year: 98 Other Motorcycle Model: Vrod,Electra glide,XS 650 Other Motorcycle Year: 2006
Reputation: 174
 
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Well I reassembled the motor with new wrist pin bushings and it makes the noise still! Only other thing it could be is the Crank bearings are bad. Anybody know how to confirm this before splitting the cases?
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7th May 2012
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JESTER Mafia-Hooligan Div
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Join Date: Sep 2005
Location: West Central Indiana
Posts: 9,442 Sportster/Buell Model: 1200 R Sportster/Buell Year: 2005
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Quote:
Originally Posted by smokenjoep01
Well I reassembled the motor with new wrist pin bushings and it makes the noise still! Only other thing it could be is the Crank bearings are bad. Anybody know how to confirm this before splitting the cases?
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More of a bump than anything.....but my initial reaction is a huge.......groan!
Good Luck Man!  
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Stuff: YES
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7th May 2012
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Biker
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Join Date: Apr 2012
Posts: 32 Sportster/Buell Model: xlh Sportster/Buell Year: 1989
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Quote:
Originally Posted by BWP 5p
More of a bump than anything.....but my initial reaction is a huge.......groan!
Good Luck Man!  
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Officially seconded the groan! 
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8th May 2012
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Biker
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Join Date: Aug 2007
Location: In the garage
Posts: 94 Sportster/Buell Model: 98 1200+ Sportster/Buell Year: 98 Other Motorcycle Model: Vrod,Electra glide,XS 650 Other Motorcycle Year: 2006
Reputation: 174
 
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Went home last night and fired it up and listened one more time. Sadly enough it sounds very similar to a twin cam motor I just took apart that had,,,,,,,,,,, a bad Crank bearing!
So last night about 6:30p I started tearing it down. By 10:30p the motor was out and was on the bench with the cases split. When I spin the flywheels over by hand, just in the left side case only. I hear/feel a slight rumble. Im going over to the machine shop this morning and have them take a feel.
Based on the scratchs I had on the pistons and cylinders. There had to be some debris still left in the oil tank that went though the motor on start up. And trashed the crank bearing???? Possible. I will see after we get the left side case pressed off.
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10th May 2012
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Biker
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Join Date: May 2012
Posts: 1 Sportster/Buell Model: Sportster 1250 Sportster/Buell Year: 2005
Reputation: 10

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I have a good friend going through a very similar problem and we suspect crank bearing failure as well. Please let us know what you find out
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10th May 2012
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Biker
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Join Date: Aug 2007
Location: In the garage
Posts: 94 Sportster/Buell Model: 98 1200+ Sportster/Buell Year: 98 Other Motorcycle Model: Vrod,Electra glide,XS 650 Other Motorcycle Year: 2006
Reputation: 174
 
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Well, I had the machine shop double check the flywheels and rods. They were true and straight. Run out on the shafts were all within spec. Replace the crank bearings and races on both sides of the crank. I had the machine shop assemble everything and it still makes the same exact noise. The pitch hasent changed one bit. Im baffled!
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27th May 2012
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Harley Engineer
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Join Date: Dec 2004
Location: League City
Posts: 332 Sportster/Buell Model: XL1200S Sportster/Buell Year: 2003
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Break it in and if it don't make it then you'll find out what the problem is. Seems like you've tried everything. Sure it isn't gear wine from the cams? Once broken in Ride the dog pi55 out of it. If it don't break then well ya just gotta live w/ it i reckon.
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24th July 2012
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Biker
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Join Date: Aug 2007
Location: In the garage
Posts: 94 Sportster/Buell Model: 98 1200+ Sportster/Buell Year: 98 Other Motorcycle Model: Vrod,Electra glide,XS 650 Other Motorcycle Year: 2006
Reputation: 174
 
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UPDATE, After checking over evrything like looking for metal inthe oils. My boy went and road the bike for several hundred miles. It came back with the loudest most wrap I have ever heard.
Looked through the primary and all was good. Cam compartment looked good. Socket and pullbar on the mains shaft and you can turn the motr over about thirty degrees before the front piston starts to move! Looking like another rod bearing in the front.
Now I replaced the original crank/rods first when the bike came to me. The new crank/rods had the weird noise. I split the cases and had a independent shop go over my work and they also split the wheels and checked the rod bearings. Put it back together with all new bearings and it had the same noise. Thats were I had him ride it to see what it would do.
Now Im back at bad rod 300 miles later???????????? Whats causing it to were out the front rod bearing TWICE? I replaced every gasket, seal, bearing, new cams, new pistons/rings, bore job
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24th July 2012
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Senior Chief Master Mechanic
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Join Date: May 2011
Location: spencerville
Posts: 979 Sportster/Buell Model: sportster Sportster/Buell Year: 2003 Sportster/Buell Model #2: 1200 xl sportster custom Sportster/Buell Year #2: 03 Other Motorcycle Model: 1200 low sportster Other Motorcycle Year: 06
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that just sucks what kind of oil pressure do you have ?? buy the sound of it may be crank out of faze a little???
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24th July 2012
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Biker
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Join Date: Aug 2007
Location: In the garage
Posts: 94 Sportster/Buell Model: 98 1200+ Sportster/Buell Year: 98 Other Motorcycle Model: Vrod,Electra glide,XS 650 Other Motorcycle Year: 2006
Reputation: 174
 
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Great oil pressure! Pinion run out is perfect. Crank was trued and double checked. as well as broke down and redone by a completly indepent shop to make sure I was not missing anything. Keep in mind this was Two different set of flywheels and rods as well.
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