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General Category >> Rubber Side Down! >> Blew out round cap on side of cylinder going 70!
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Message started by King Rico on 05/22/15 at 08:27:39

Title: Blew out round cap on side of cylinder going 70!
Post by King Rico on 05/22/15 at 08:27:39

2004 Savage LS650 16xxxx miles

Replaced the infamous oil leak cap, rocker cover gaskets, washers under the three big bolts, new high temp silicone around. Took her for a test run and after about 5 miles of highway speed, the plug on the right side of the cylinder popped out and shoot steaming hot oil all over my leg.

My question to you guys:
What could make the cap pop like that?
Will I need to take off the cylinder top off again to replace the plug?

Thanks!

Rico

Title: Re: Blew out round cap on side of cylinder going 7
Post by Dave on 05/22/15 at 08:28:56

It sounds like you have a problem with the engine vent tube that is allowing pressure to build up in the engine.

Do you still have the stock air filter housing on the bike, and is the vent tube open and properly connected.......no kinks in the tube?

Title: Re: Blew out round cap on side of cylinder going 7
Post by Serowbot on 05/22/15 at 08:47:10

Too much rtv blocked the tube?... :-/...

Title: Re: Blew out round cap on side of cylinder going 7
Post by King Rico on 05/22/15 at 08:56:51

Sorry!!! I failed to mention I had removed the stock air box, a couple months ago! The breather tube on top of the cylinder is about 7in long and has a plug in the end of it. Is there a more efficient/correct way to block/cap the breather tube?

I will double check for too much RTV.

Thanks!
Rico

Title: Re: Blew out round cap on side of cylinder going 7
Post by Dave on 05/22/15 at 09:07:41

0220272E1B202A26490 wrote:

Well....now you know what happens if you "block" the breather tube.

The engine needs a vent......that is why the factory went to the trouble of installing one. The big single "huffs and puffs" as the pistong goes up and down....as the volume of the engine changes as the piston moves up and down in the cylinder, and the rings don't seal 100% of the combustion gases and some leak past the rings and has to go somewhere (out the tube to the breather).

Title: Re: Blew out round cap on side of cylinder going 7
Post by Serowbot on 05/22/15 at 09:13:26

They sell breather tube filters...
Like mini cone-filters...

Blocking it, is like putting a tater in yer' muffler.... ;D...

Title: Re: Blew out round cap on side of cylinder going 7
Post by King Rico on 05/22/15 at 10:12:14

Well, Ill take that as a lesson learned. Ill try going with the mini breather KnM style cone.

Anyone know if the top of the cylinder has to come off for the plug installation? I ordered the part today and should have it in about a week.

Thanks again!
Rico

Title: Re: Blew out round cap on side of cylinder going 7
Post by Dave on 05/22/15 at 11:53:51

Well it is supposed to be installed when you are putting the head cover on - but I don't believe it will hurt anything to try and get it back in similarly to how it came out.

Clean both the engine and plug, put some sealer on it, and try and bump it back in with a rubber hammer, or wood block and regular hammer. The wipe off any sealer that oozed out.

Title: Re: Blew out round cap on side of cylinder going 7
Post by justin_o_guy2 on 05/22/15 at 15:14:02

The one that blew out had ridges that sat in slots, the old
Tab A, Slot B trick.
Inspect to see if it's damaged.

You need to disassemble to put it back,I'd think.
As for RTV, that is not what the maintenance manual calls for.
I really have a hard time imagining that puny vent tube and its wimpy little wire " hose clamp" staying on and blowing that part out. I'd be really studying why the oil pressure was so high Right There.
Is it possible that it shifted and wasn't exactly where you wanted it while you were wrestling with all the other stuff that was demanding attention?
The thickness of the goo is important. It determines the cam bearings clearance and that, if its too loose, decreases oil pressure in that area.
But no, plugging that tube is not okay. That piston is pumping air every time it comes down and goes up. That tube allows the crank case to inhale and exhale. That thing that looks like a wadded up pan scrubber gives oil vapor something to hit , collect on and drip back into the engine, so, don't ditch it.
.

Of course you can take a shot like Dave said.. but certainly unplug the hose

Title: Re: Blew out round cap on side of cylinder going 7
Post by verslagen1 on 05/22/15 at 15:46:29

3E2127203D3A0B3B0B33212D66540 wrote:

I'd be really studying why the oil pressure was so high Right There.

No oil pressure there, there's an air gap between it and the cam.

Title: Re: Blew out round cap on side of cylinder going 7
Post by justin_o_guy2 on 05/22/15 at 15:54:06

I call that great news.. points to the plug in the hose, tho I still don't see how that popped out ahead of the hose popping off.. as long as the dude didn't hurt it, it's just a hassle,, and Dave's answer looks like a real low hassle idea.

Title: Re: Blew out round cap on side of cylinder going 7
Post by Dave on 05/22/15 at 18:21:28

I really have no idea how much pressure builds up in an engine that is not allowed to vent the crankcase fumes - but evidently it is a bunch. The plug in the vent hose most likely didn't blow as it is small diameter and the cam plug is a much larger diameter and had more surface area....therefore more of a force when the pressure built up. All of the seals where under that pressure as well....the neutral wire grommet, the seals, the gaskets - maybe it is a good thing this plug blew and saved the rest.

Title: Re: Blew out round cap on side of cylinder going 7
Post by King Rico on 05/22/15 at 19:22:28

@ justin_o_guy2- I ended up replacing the whimpy wire tie with a couple zip ties. I guess I had in on there fairly tight!

Thanks again for all the advice. You Savages are life savers.

I'll give the rubber hammer a shot. Might order two plugs just in case.

Title: Re: Blew out round cap on side of cylinder going 7
Post by justin_o_guy2 on 05/22/15 at 20:59:35

I'd certainly buy two unless they cost enough to make pulling the thing apart seem better.

If you don't think it will go in without breaking, maybe consider trimming it .
Tapered to go in, then stay in the groove, a bit of goo , maybe.

Title: Re: Blew out round cap on side of cylinder going 7
Post by justin_o_guy2 on 05/22/15 at 21:01:29

5270777E4B707A76190 wrote:

Dang dude, that wimpy hose clamp mita saved you a hassle.

Title: Re: Blew out round cap on side of cylinder going 7
Post by Serowbot on 05/22/15 at 22:06:03

We're too often, life savers after the fact.... ;D...

Title: Re: Blew out round cap on side of cylinder going 7
Post by thumperclone on 05/22/15 at 22:40:23

pcv