SuzukiSavage.com /cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Re: Noisy Engine...Piston Slap? Video linked /cgi-bin/YaBB.pl?num=1666322941 Message started by Moarpower on 10/20/22 at 20:43:16

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/20/22 at 20:43:16 Taking a long screwdriver, The only place I can identify the loud tapping is at the intake valve cover, I can hear a slight noise in the middle of the head also https://youtube.com/shorts/SbAMFCubTto?feature=share

Title: Re: Noisy Engine...Piston Slap? Video linked Post by DragBikeMike on 10/20/22 at 22:43:33 Wow!  That's a lotta noise.  This is the animal that had all the busted up starter gears, right?   All those aluminum shavings indicate a problem.  I would open it up and find out where they are comin from.

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/20/22 at 23:02:15 Yes this had the starter gear issues where each gear was missing teeth after backlash issues. I have shoulder surgery next week so was going to sell the bike but won't let it go until I know what's wrong. I did have to grind down the stator cover to accommodate new gears so I assumed that was the source of the Aluminum. But I think it may be something else.

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/20/22 at 23:40:41 Ok I replaced the clutch plates and took it for a ride over 120km with new oil. Performance was fine. 120km highest speed with fresh oil. Drained the oil and no visible aluminum shavings. The oil however was quite glittery. I'm assuming this could be pretty standard especially with brand new clutch plates ?

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/21/22 at 07:11:40 Here is a video of the shimmer in the oil after approximately 160km with new clutch. https://youtube.com/shorts/BK6XEddtlaQ?feature=share There is less with each oil drain but it's still quite visible

Title: Re: Noisy Engine...Piston Slap? Video linked Post by justin_o_guy2 on 10/21/22 at 10:18:31 Autopsy the filter and see what it's filtering out.

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Ruttly on 10/21/22 at 13:26:36 And ! I like to capture with a jar the first bit of oil to come out. The rest goes in the drain pan , I’ll let the jar sit and settle for days . First I run a magnet thru it , inspect , then hold a intensely bright light behind it , no light coming thru lot of debri in suspension. After replacing clutch the oil will trap clutch materials from break in and make it so light won’t pass thru along with hydrocarbons . Generally the oil clarity is fouled by hydrocarbons from blow by. The sooner you loose clarity then sooner it should be changed.  Just sayin

Title: Re: Noisy Engine...Piston Slap? Video linked Post by TheSneeze on 10/21/22 at 16:09:41 Metal bits in your oil is bad, m'kay?

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/21/22 at 17:16:31 190623242E272B38214A0 wrote: Metal bits in your oil is bad, m'kay? Yes. Yes it is

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/21/22 at 17:17:10 7E6167607D7A4B7B4B73616D26140 wrote: Autopsy the filter and see what it's filtering out. Il do that today

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/21/22 at 18:51:49 Opening the filter revealed some small aluminium shavings and magnetic particles caught among the filter lint.

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/21/22 at 18:53:59 This is all the magnetic filter lint I was able to remove. There were very small particles of ferrous material inside. Some of the other dust will be from the new clutch. So as far as symptoms go, there is no smoke or loss of power, and compression seems fine.  Just the noisy motor ad the oil particles. Rebuild, sell for cheap or just ride it til it dies and look for another motor?

Title: Re: Noisy Engine...Piston Slap? Video linked Post by justin_o_guy2 on 10/21/22 at 19:47:52 I doubt it matters, I Think I saw that you adjust the valves to .09 mm? If so, the conversion I found said that is 3.5 thousandths which I think is a little bit tight.

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/21/22 at 20:03:04 Yeah the mm is meant to be between 0.08 and 0.13. might put them at 0.10

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/21/22 at 22:10:50 Tomorrow I'll remove the motor and open it up. This will be my first time opening one of these. Are there any warnings or special service tools needed when doing so? I have the service manual. If it requires a rebuild I might as well try to source some upgrade parts. Are there still cam upgrades available for these ? I also have some good machine shops nearby if I want to use a larger piston.   Are there still any useable pistons sold anywhere?

Title: Re: Noisy Engine...Piston Slap? Video linked Post by TheSneeze on 10/22/22 at 13:06:09 Draw the head cover on a piece of cardboard, and put each bolt in a hole in your picture.  Make sure all washers and seals are on each bolt.  Some bolts are oil sealing.  This way you will know which bolts go back where when you go to put it back together.  There are a couple special tools you will need to remove the clutch.  I ended up making my own.

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/22/22 at 17:40:43 425D787F757C70637A110 wrote: Draw the head cover on a piece of cardboard, and put each bolt in a hole in your picture.  Make sure all washers and seals are on each bolt.  Some bolts are oil sealing.  This way you will know which bolts go back where when you go to put it back together.  There are a couple special tools you will need to remove the clutch.  I ended up making my own. Thanks mate. Yes I will definitely be keeping track of all bolts

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/23/22 at 19:16:38 Another oil drain and it looks like the oil no longer has aluminum flakes in it. I'm curious as to wear they could possible have come from. There is still slight shimmer in there oil but no visible particles

Title: Re: Noisy Engine...Piston Slap? Video linked Post by justin_o_guy2 on 10/23/22 at 23:16:31 How is that slap?

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/23/22 at 23:26:47 No difference. Same as the video. The engine is out so let's see.

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/24/22 at 00:07:45 I've adjusted the valves to 0.10mm twice. But it looks like the damage to the valve rockers is done. The intake rocker is pitted but the exhaust rocker has a massive bur

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/24/22 at 00:19:23 As you can see in the following images. There is wear in the clutch side upper cam jounal. The head I'll have to check

Title: Re: Noisy Engine...Piston Slap? Video linked Post by justin_o_guy2 on 10/24/22 at 02:44:55 Ugghhh.. What does the cam look like?

Title: Re: Noisy Engine...Piston Slap? Video linked Post by Moarpower on 10/24/22 at 03:14:09 746B6D6A7770417141796B672C1E0 wrote: Ugghhh.. What does the cam look like? The cam actually looks and feels good. No serious  gouging or scratches. I pulled the cylinder.piston had only a small amount of greasy carbon build up that I was able to wipe away with a rag. The cylinder has no visible honing marks. It however doesn't have any scrapes are scatches.

Title: Re: Noisy Engine...Piston Slap? Video linked Post by justin_o_guy2 on 10/24/22 at 06:44:56 Well, I'm going to watch and see what the gurus say. Dangitt.

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