Could it be a lifter that bled down and hasn't pumped up? How long did you run the bike?

I don't know too much about lifters but I've read a little.

 

If you only pulled the front cover, how do you know both cylinders are OK?

Sent from my Galaxy Nexus

 

Really not much can go wrong. Lifters were never out I'm assuming. Lifter blocks off so anti rotation pin could have not been reinstalled. That would be bad. Rockers not tightened down. Pushrods installed incorrectly.

Sent from my Galaxy Nexus

 

Ok. Forgive me and don't flame me...

When you say verify that they have a load on them but are not holding a valve open what do you mean?

If I get the front cylinder at TDC and on compression, the front pushrods spin freely and the rear pushrods do not turn.

 

No flame, I am here to help.

At TDC compression a lifter should have .100" preload. With out the motor running and creating oil presure you should be able to spin the push rod with some resistance. But there should be no play. And they both should be the same.

To confirm compression stroke, rotate the engine a little in each direction, niether rocker should move.

 

Lifters never came out. Only ran it for about a minute and killed it once I heard the noise. Started it back up for the video.

I hadn't pulled the second cover because it's a PITA. Had just pulled off the clips on the pushrod tubes to verify they were in the correct position. Just pulled the cover and everything appears correct.

 

Ok, so I should be able to spin all 4 pushrods or just the the one cylinder because I can spin all 4 but there is no play.

 

Just the cyl on TDC. But the push rods should not spin freely, they should have some resistance.

 

All 4 pushrods are spinning. The rear cylinder definitely has more resistance than the front. What am I doing wrong here?

1) Pulled rocker covers, clips on pushrod tubes and spark plugs
2) Put a piece of paper towel in the front cylinder spark plug hole and rotated rear wheel until it popped out. Used a pencil in the hole to verify it was at the top.
3) Rotated the wheel back and forth to verify and rockers didn't move.

 

What are you working on. Year, model, miles?