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Message started by jkhulon73 on 09/26/07 at 03:48:04

Title: What the... was THAT noise?!
Post by jkhulon73 on 09/26/07 at 03:48:04

Man, I hardly slept last night. Was riding home last night and noticed a different vibration start up about halfway through the trip. About a mile from home I stopped and took out the earplugs- there's something rumbling pretty deep down in the engine, down in the bottom end. And the tapping was a LOT louder, too. :P It ran though. Ran fine except for the horrible noise. Babied it through the subdivision and parked it.

I've got a bad feeling something popped out of somewhere and went somewhere it shouldn't be...

I'll crack open the case in a couple of hours and see. I'm pretty tired right now.

Title: Re: What the... was THAT noise?!
Post by skatnbnc on 09/26/07 at 05:48:16

How many miles on your bike?

Then check the usual suspect - the tensioner and cam chain. :P

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 09/26/07 at 07:00:07

According to the PO, the speedo was correct with 6,847. I rolled over 7,500 yesterday.

I've got a feeling the PO lied to me about the milage as well...

I may have to fire up one of those new, super-duper cam chains after all.

I feel like Han Solo, running around, trying to prep the Falcon to leave Hoth... "I just got her back together!"

Yep, I'm a geek.

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 09/26/07 at 09:33:32

http://w2.bikepics.com/pics/2007/09/26/bikepics-1036917-full.jpg

Just a shade under 20mm of piston >:(

If you look close at the top of it, you can see where the piston was rubbing on the cylinder...

Guess I'm stuck in the cage for a while...

Title: Re: What the... was THAT noise?!
Post by Savage_Rob on 09/26/07 at 09:39:10

jkhulon73 wrote:

From this angle I can't see if the cylinder was beginning to distort or not. It doesn't appear to be but I can't see for sure. Either way, it's good it hasn't yet separated - but it is time to install the VerSlavy mod.

Title: Re: What the... was THAT noise?!
Post by YonuhAdisi on 09/26/07 at 09:53:26

jkhulon73 wrote:

I feel like Han Solo, running around, trying to prep the Falcon to leave Hoth... "I just got her back together!"

Yep, I'm a geek.

I know exactly how you feel.

"I'm trying to get us outa here and you tear this apart now? Put it back together."

"No no no, that one goes there, and that one goes there, right?"

"Okay, try it now." Smoke and sparks. "No no no SHUT IT OFF SHUT IT OFF!!"

I'm a geek too as you can tell from my signature line

Title: Re: What the... was THAT noise?!
Post by justin_o_guy2 on 09/26/07 at 10:13:24

I dont see the cam chain tensioner as anything to do with a niose like you describe. That one looks better than mine did when I openned it up to inspect.

Title: Re: What the... was THAT noise?!
Post by verslagen1 on 09/26/07 at 10:33:16

If you take off the adjuster, on the backside where the tensioner guide rubs against the aluminum housing you can see scratch marks if the adjuster was flopping up and down. All the bad ones I've gotten have it.

Yes, that one still looks good. The place to check is where the plunger rests on the housing in this extended position. There can be some deep wear.

It's a subtile noise that alerts you to the problem. If you're really in tune with your bike, it feels like a jack hammer. ;D

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 09/26/07 at 10:58:30

verslagen1 wrote:

I ride with plugs in all the time- my hearing may have been jacked up last night, but that vibration just about set my teeth on edge! I'll have to fool around with it tomorrow- right now, I'm late for work :P

Title: Re: What the... was THAT noise?!
Post by Baldeagle on 09/26/07 at 13:48:00

While we are on the cam adjuster subject.......Can this be checked pretty easily by a 'not so gear head' or do I need somebody like Lancer or Justin-old-guy2? 05 S40.....7,000 miles. Will search for a post

Thnaks

Title: Re: What the... was THAT noise?!
Post by verslagen1 on 09/26/07 at 14:20:23

It's not hard to check.
You might need to replace the gaskets for the header or the clutch cover. So having these on hand is a plus.
You need to drop the oil and filter.
Remove right footpeg mounting plate.
Remove the header and muffler.
Disengage the clutch cable.
Remove the clutch cover.
Eyeball the adjuster.
You need to do something if the plunger is out 18mm to the shoulder of the plunger.
Replace in reverse order.
Clutch cover gasket may need a little sealant around the oil path at the top of the cover.
If you got to go further, it's a lot more effort but not difficult.

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 09/26/07 at 16:22:33

I look at it this way-

I caught it before it became a REALLY bad problem
This is an opportunity for me to tweak the bike a bit.

I did run a magnet through the oil this morning- kinda of quick like, but there weren't any flakes or anything on it, soooo, I'm gonna order the cam chain over there in The Marketplace and use the next... month and a half... to really nail down the paint, refine the seat & tail-lights, and pretty much completely rewire the bike.

It's going to suck not having anything to ride, though.

Title: Re: What the... was THAT noise?!
Post by Savage_Rob on 09/27/07 at 05:55:17

jkhulon73 wrote:

I did run a magnet through the oil this morning- kinda of quick like, but there weren't any flakes or anything on it

At least nothing ferrous anyway. That's the only problem I have with my magnetic oil drain plug... much of the engine is non-ferrous.

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 09/27/07 at 07:15:30

Savage_Rob wrote:

At least nothing ferrous anyway. That's the only problem I have with my magnetic oil drain plug... much of the engine is non-ferrous.

I was going to run the oil through a coffee filter as well, but I'm not really in the mood to even go out in the garage this morning, much less spend an hour or so waiting for cold motor oil to drip through a piece of paper. I may just take some more pictures of the tensioner...

Migraines rawk >:(

Title: Re: What the... was THAT noise?!
Post by youzguyz on 09/27/07 at 07:59:38

jkhulon73 wrote:

Heat the oil up first and it will flow faster.
Make sure you use the "Significant Other's" absolute best pot to heat the oil. :P

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 09/27/07 at 08:33:19

Looks okay, I guess. No obvious distortion...
http://w2.bikepics.com/pics/2007/09/27/bikepics-1037730-full.jpg

Oops... Little bit of polishing down on the bottom corner. The piston channel is still round...
http://w2.bikepics.com/pics/2007/09/27/bikepics-1037731-full.jpg

Same deal with the piston. Bit o' surface abrasion...
http://w2.bikepics.com/pics/2007/09/27/bikepics-1037734-full.jpg

Looks reusable to me...

As far as warming the oil first, I'll just use my cast iron skillet. Needs to be re-seasoned anyway :o ;D :P

Man, that chain is loose...

Title: Re: What the... was THAT noise?!
Post by verslagen1 on 09/27/07 at 08:59:49

Looks in good shape, ready to upgrade.

FYI, when it occurs, wear in the housing bore would be visable if you had turned the housing just a little more to look down the bore in picture #2. And ovaling would be evident on edge of the bore.

Title: Re: What the... was THAT noise?!
Post by Savage_Rob on 09/27/07 at 09:02:08

jkhulon73 wrote:

Bit o' surface abrasion...

http://w2.bikepics.com/pics/2007/09/27/bikepics-1037734-full.jpg

Looks reusable to me...

Yeah, that slightly shiny area on the side of the piston looks like it was beginning to wobble in the cylinder a bit but there is no obvious distortion to the cylinder. I'd send it off to Verslagen1 for modding.

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 09/27/07 at 09:59:27

verslagen1 wrote:

I have another pict of the bore straight on- still as round as can be determined by the naked eye. The wear inside the bore pretty much matches that on the piston.

I'm gonna have to liquidate some assets before I can do the upgrade. $$$'s a little tight right now (considering my weekly gasoline expendatures just tripled >:()

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 10/01/07 at 13:04:52

I guess she's been benched for the rest of the season...

http://w2.bikepics.com/pics/2007/10/01/bikepics-1042351-full.jpg

Guess what's been leaking?

http://w2.bikepics.com/pics/2007/10/01/bikepics-1042352-full.jpg

Yep, you got it...

http://w2.bikepics.com/pics/2007/10/01/bikepics-1042354-full.jpg

It was just sitting in it's little cradle. No seal at all. Nice. ::)

In my limited experience, I'd say the cam shaft sprocket looks fine...

http://w2.bikepics.com/pics/2007/10/01/bikepics-1042357-full.jpg

Figured since I had it out and easily accessible, I'd pull out the starter. Now I know why it's called The Black Hole. Just plain nasty...

http://w2.bikepics.com/pics/2007/10/01/bikepics-1042360-full.jpg

:P

Title: Re: What the... was THAT noise?!
Post by verslagen1 on 10/01/07 at 13:15:13

millipeds?

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 10/01/07 at 13:43:37

There's some pine straw, leaves, and God only knows what else down in there, all soaked in 20 years worth of oil and road grime. :P

Title: Re: What the... was THAT noise?!
Post by demin on 10/01/07 at 14:41:23

Make sure when you removed your speedo cable the O-ring didn't fall in there.

Title: Re: What the... was THAT noise?!
Post by islandwahine on 10/01/07 at 15:41:40

verslagen1 wrote:

OY!
I'm gonna have to do all that to replace the cam chain?
Hats of to you jkhulon73, that just looks like a bit too much challenge! Think I'll start using weights, looks like I'll need it!

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 10/01/07 at 15:56:20

demin wrote:

Make sure when you removed your speedo cable the O-ring didn't fall in there.

Oh, it's still in the cable. I made darn sure of that! I dropped it last time I had the tank off and it took me half an hour to find it. (Lighting in the garage sucks)

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 10/01/07 at 15:58:40

islandwahine wrote:

Think I'll start using weights, looks like I'll need it!

Engine only weighs 119 lbs by itself. I probably didn't need to pull it to replace the cam chain, but there some other things I needed/wanted to do with it (like clean it and paint it)

Title: Re: What the... was THAT noise?!
Post by islandwahine on 10/01/07 at 17:05:15

jkhulon73 wrote:

Engine only weighs 119 lbs by itself.

Well....that's more then I weigh!! So it's a good thing I don't need to take it out to do the cam.

Title: Re: What the... was THAT noise?!
Post by DanGill on 10/02/07 at 05:57:04

Wahine, you just need to find a big Samoan friend to lift the engine for you. :)

I'm 6' and 220#. When I went to my brother's funeral in Oahu a couple of years ago, I got hugged and lifted up to my tiptoes by a half dozen women. Lotta love in that crowd.

Title: Re: What the... was THAT noise?!
Post by verslagen1 on 10/02/07 at 07:13:35

islandwahine wrote:

OY!
I'm gonna have to do all that to replace the cam chain?

That's just to check the cam chain, a lot more fun to replace it. ;D

Title: Re: What the... was THAT noise?!
Post by justin_o_guy2 on 10/02/07 at 12:29:01

IW,,I've seen what you can do. You can replace the cam chain. Maybe different tools to buy, maybe a couple different diagrams( I like using a cardboard box & slicing X's in it with an exacto & drawing the case, sticking each bolt in an X on the outline, keeping all the bolts in their respective holes & doing the same with the head cover) The one that HAS to be in before it goes together? I put that one thru backwards with a note on it.. I didnt USED to have to do stuff this way. I have changed the frames on 2 ford pickups & dropped bolts in buckets & used no notes, but that was using a whole different set of brain cells.. like 25+ years ago.

Title: Re: What the... was THAT noise?!
Post by islandwahine on 10/02/07 at 15:36:26

I know what you mean, I'm no springchicken either!!
Gotta make do with what my brain can still do, and figure out ways to give it a hand!! LOL

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 10/05/07 at 09:07:21

Now I've gone and done it...

Decided to remove the head and clean out some of the carbon?

Got the four nuts on top off fine.

Snapped the rear stud underneath the head and instantly stripped the nut on the front.

Right now? I'm looking for my 12 guage deer slugs...

...or a cold shower. Which ever I can get to first.

Title: Re: What the... was THAT noise?!
Post by T-Mack1 on 10/05/07 at 11:11:05

a cold shower, a cold beer (hey, what's a few more brain cells) and a deep breath.

Just remember, studs are replaceable. Only issue is how broken off they are and whether it might be better to find a machine shop to get them out.

I'm lucky, my riding buddy is a machinist. Got the cylinder rebored for $0. Just had to do some computer tweaking for the shop owner.

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 10/05/07 at 11:41:03

A cold beer would have been nice, but unfortunately, I had to go to work.

It was No.'s 13 and 14 in the cylinder head microfiche that got boogered. I should be able to get 'em out myself no problem (once I get that stripped nut out of the way). I just ordered replacement studs from bikebandit...

Good news is, my clutch cover gasket showed up before I left for work. Hooray.

And I have cold beer waiting for me when I get home.

*EDIT: several cold beers

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 10/06/07 at 16:37:49

http://w3.bikepics.com/pics/2007/10/06/bikepics-1047744-full.jpg

Got the head off today.
The Dremel is your friend...
(So are vise grips...)

http://w3.bikepics.com/pics/2007/10/06/bikepics-1047745-full.jpg

If anyone is interested, this is how I mounted the motor to the work bench...

http://w3.bikepics.com/pics/2007/10/06/bikepics-1047746-full.jpg

Title: Re: What the... was THAT noise?!
Post by islandwahine on 10/06/07 at 18:43:58

So that's how the inside looks like!
Interesting........No, not tempted to do that.......well, maybe just a tad!!

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 10/06/07 at 19:13:04

It's like tattoos- once you start, you never stop...

Title: Re: What the... was THAT noise?!
Post by T-Mack1 on 10/06/07 at 19:31:45

jkhulon73,
Not sure it will help now, but I just posted in the tech ref section a parts list I made by copy& paste from the local dealers "OEM parts finder tool. It's mainly for my 2001 but has some other years and many parts are interchangeable.

It's real handy to see how things fit and it's easier to use than the Microfische web tool.

I printed a copy (at work on the fancy printer, don't tell the boss),...... I sort of old school and like the feel of paper in my hand when I'm working on stuff.

http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1191723403

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 10/06/07 at 20:03:31

Sweet!

Title: Re: What the... was THAT noise?!
Post by jkhulon73 on 10/07/07 at 19:24:40

20 years of carbon... gone.

http://w3.bikepics.com/pics/2007/10/07/bikepics-1048959-full.jpg

...and all it took was an hour and most of a can of Chem-Tool.