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Message started by sundanz26 on 07/05/17 at 07:34:38

Title: Exhaust noise/clacking after carb rebuild...or...
Post by sundanz26 on 07/05/17 at 07:34:38

Hi guys...new "old" gal here with a Savage issue regarding a clacking noise after carb rebuild...or maybe something entirely different!

Here's the info:
* 2004 Savage
* Bought 2010, approx. 2000 miles on it, from a lady (it's only owner)
* Ran fine, had typical backfire (which I was not familiar with at the time), so took it to local Suzuki shop for it's "regular maintenance" check, as she indicated she never took it in for routine checks since it had such low miles.
* Shop said backfire normal, did oil change and checked specs, etc.
* Bike runs fine for the next 4 years!

Fast forward to fall 2014...4700 miles on it now (Yeah, I only put about 650 miles or so on it per year, I live local to EVERYTHING and only 6 miles to my work) bike starts running a little rough - won't idle evenly (runs good, then drops, then back up), power not great. I figure I'll tackle this issue in depth in the spring since it's time to put her away for the winter (I'm in NH)! Tank was 99% empty, added a little Sta-bil, removed battery, stored in my shed for the next 4 months or so.

* Spring 2015 - bike wouldn't start...meaning it would crank, but not turnover. Read some stuff online (this group, for one), talked to my brother-in-law, general consensus was needs carb work/rebuild.
Bought a rebuild kit from online, followed instructions carefully and slowly (hey this is my first time doing this!), and low and behold...she fired up!

* Ran great for about 1 month, before I started hearing this "clacking" kind of noise (I attached a video), which quieted upon deceleration.
I thought it might be an exhaust leak so I replaced the seal gasket on the pipe on the front of the engine. No change.
* Next I checked all the valve clearances - they were all within specs, but added a little clearance to one on the intake (brought it to .10mm as it seemed a little snug at just barely .08mm).
* Next I checked the cam chain tensioner - it should still have plenty of life in it, as it's only out about 13mm.

So here I am (sorry so long winded, wanted to give you all everything I had for info!) wondering if there might be an exhaust leak at the other end of the engine, where the carb enters? Would this make this noise or am I looking at something entirely different? Like I said, I'm new at this and taking it slow but I'm willing to take criticism and learn! Thanks for any input you may have!

PS...I'm having a *witch* of a time downloading the video...sorry, I'll get it, just gotta figure out what the problem is!

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by ohiomoto on 07/05/17 at 08:38:29

If it's a running out of gas type crackling/almost backfiring noise and you don't have power, then you need to check your petcock (if you don't have a raptor already installed).

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by sundanz26 on 07/05/17 at 09:25:36

It sounds more like a machine gun, or like my chain is loose....sorry, should have described the sound since my video won't load [ch128542]

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by ohiomoto on 07/05/17 at 09:51:15

Noise under load? Start by checking the final drive or sprockets. Make sure the motor is secure. Beyond that, this sounds like it could be expensive.

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by verslagen1 on 07/05/17 at 12:53:32

52544F45404F5B1317210 wrote:

Tank was 99% empty, added a little Sta-bil, removed battery, stored in my shed for the next 4 months or so.

Recommended to store full so it don't rust above the gas line

Quote:

* Ran great for about 1 month, before I started hearing this "clacking" kind of noise (I attached a video), which quieted upon deceleration.

Try to isolate the location of the noise.
check the drive pulley, if it's loose that's a major cost.
remove the pulley cover, make a mark where pulley meets the lock washers, with the bike off and in gear, have someone push it back and forth to see if the mark shifts.

other noises, speedo, headlight, mirrors, pulley cover, then just above anything bolted on.

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by batman on 07/05/17 at 18:55:53

You should read through the Technical section ,to gather info on adjusting the fuel mix screw and maybe doing the spacer mod.they may lessen your backfire problem.you checked the gasket at the head pipe /cylinder ,but there is another at the headpipe /muffler.

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by sundanz26 on 07/11/17 at 18:42:45

Here's a short video of my bike and the sound it's making.
https://youtu.be/r8Cvn56l9C4

Having a hard time trying to determine the exact origin because it's loud at every point all around the engine.
Going to check that other exhaust connection as well as some other ideas you guys have given me. Gotta get this fixed so i can ride this summer! 8-)

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by ohiomoto on 07/11/17 at 19:34:32

That doesn't sound good and it doesn't sound like it would be related to any carb work you might have done.

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by batman on 07/11/17 at 19:35:44

I heard the video ,it sounds like valves ,did you adjust them ? they may be to tight and bouncing off the seats.

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by Todd James on 07/11/17 at 20:58:35

The metallic, clacking noise in the video sounds like it is on the exterior
of the bore and crankcase and on the upper end of the engine.
Since you have checked the valve adjustments, then I suspect that the
noise is coming from the decompression release mechanism.

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by verslagen1 on 07/11/17 at 21:39:38

49626E6670576C6767030 wrote:

Might be this, remove the exhaust valve inspection cover.
on the inside by the decomp lever will be a little cam that hits the rocker.
rotate the engine, if the rocker is hitting it then your rockers are worn out.

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by justin_o_guy2 on 07/11/17 at 21:51:06

What oil are you using?

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by sundanz26 on 07/12/17 at 05:42:10

Thanks, guys - I will check that cam/rocker possibility today.
My question on that is how would the rockers be worn out at less than 5,000 miles? Unless it had something happen in it's history that I didn't know about?
Also, to answer justin_o_guy2...I used Valvoline Full Synthetic Motorcycle 10W40.

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by Dave on 07/12/17 at 06:25:28

585E454F4A4551191D2B0 wrote:

Using a motor oil with a low ZDDP level can ruin the cam/rockers in a very short time. Warming up the bike while it idles on the sidestand can also ruin the exhaust lobe/rocker.....I believe the low oil pressure at idle does not get enough oil to the exhaust lobe - which is at the uphill side of the bike when it is leaning over on the sidestand. I bought a used bike with only 3,800 miles on it that had a damaged exhaust lobe/rocker......starting the bike and idling it on the sidestand to charge the battery in the winter is a really bad idea.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1447331708

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by sundanz26 on 07/12/17 at 08:13:59

Ok, now if I'm looking at the correct pieces, it does not appear that the rocker is hitting the cam.

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by sundanz26 on 07/12/17 at 08:17:18

Just to clarify, yes i was turning the engine...counterclockwise. I did this a few times to make sure i was looking at the right components. Did i miss anything?

Title: Re: Exhaust noise/clacking after carb rebuild...or
Post by batman on 07/13/17 at 02:09:12

The PO didn't ever take the bike in for the 500 mile check ,she may not have ever changed the oil either.If so the engine could have seen a lot of wear! I'd be pulling the top cover to look at the cam and rockers as well as the side cover to check on the cam chain /tensioner.