Motorcycle Repair: 1995 Sportster Cams, pinion shaft, rocker boxes


Question
QUESTION: Hi Mike,
I have 1995 sportster 883.  My question is this, do I have to be at TDC when installing cams?  If so, how can I tell when I'm at TDC?

ANSWER: You dont need to be at TDC to install the cams. Youw ill have to rotate the pinion shaft so you can get the marks on the cams lined up.
Good luck and happy riding
Mike

---------- FOLLOW-UP ----------

QUESTION: Thanks Mike.  All went together nicely.  Have a new problem.  When I hit the start button the motor turns over once then the solenoid starts clicking.  Battery tested good.  When I bypass and go directly to the starter the starter just spins and doesn't engage.  Any ideas?

ANSWER: Check your battery wires at both ends to make sure they have good contact. If they do, then I would replace the starter relay.
Good luck and happy riding
Mike

---------- FOLLOW-UP ----------

QUESTION: Thanks Mike for all your help.  I was able to finally get this Sportster started and it's not running very well.  I hear a knocking sound up by both rocker boxes and the front cylinder seems to be running weak. The rear cylinder sounds solid. When the bike is running it just sounds off in the front cylinder.  This bike sat for over 3 years.  When I originally installed the cams 3 years ago I didn't do it correctly.  Could I have bent my valves trying to start the bike with the cams out of alignment?  I haven't let the bike run for more than a minute or so since getting it started again in fear of tearing something up.  What do you think?  Again, thank for your help.  I really do appreciate you taking time out of your day to help me.

Answer
Your knocking sound could be several things. With it sitting that long your lifters might have to pump up which will take a few minutes. If you got the cams to far out you could have hit the valve on the piston and either damaged the piston or bent the valve. I would do a compression check on it to determine if you have a bent valve.
Good luck and happy riding
Mike