I don't know if I can explain this well enough but I'll try and hopefully has some kind of info to help me out here. I've got a 96 savage that's been running fine until this afternoon. While traveling up a slight uphill in 3rd, something sounded as though it broke somewhere inside the engine (not REAL loud) and the bike started dying. I pulled the clutch and coasted to a stop. The first time I tried to start it again it was a little bit clunky, the second time it just sounded as though there wasn't any compression. I just pulled the right cover off and it looks fine. Cam chain and adjuster intact, everything else fine. I pulled the left cover and same thing. As far as I can tell it's fine. Should I continue on with pulling the whole engine apart?? Maybe it's something to do with the piston or rings? Thanks for any help anyone can offer

First thing I would do is use a compression gauge to do a compression check of the cylinder.

Alright thanks that gives me somewhere to start. Gonna try to calm my nerves a little and start narrowing it down I hope

88pagan wrote on 07/28/08 at 22:04:54:




Well guy, I hate to tell you this but if I understand you correctly you've got a broken valve.  From what you've described it sounds like the stem is broken, which means the rest of the valve probably fell down into the cylinder.  That would explain the damage to the end of the spark plug. If a valve breaks and falls into the cylinder while the piston is going up and down, this usually does serious damage to the engine.  Whatever you do, don't try to crank the engine over.  You need to pull the head off the engine and have a look at the head and cylinder.  But remember, all is not lost.  If your engine is gone, used ones are available and thats a lot cheaper than a new bike or a professional rebuild.

If the piston is damaged, you can get a new piston and rings and you can replace your valves. With any luck the cylinder can be re-honed if it isn't damaged too badly.

After you pull the head and clear out the broken valve if the piston is broke, go ahead and pull the cylinder and piston and carefully turn the engine by hand listening for any noise. If you did shut it down in time the bottom end may still be good and you will only need a top end re-build which is a hell of a lot cheaper than a full re-build and not nearly as difficult.

I have read that if you take all the mounting bolts out and let it drop lower into the frame you can squeeze the head clear of the very long bolts/studs used to hold it in place.  

In other words,  it may be better to take it out.......  get a strong friend.  I read that it's only about 110 pounds but... it's a bugger to handle in a cramped space. ..... trust me....

Maybe it's too early to ask as this project is going to take me awhile..but I'm curious what may have caused this problem so I don't duplicate it IF I actually get the ole girl running again. Most likely just a part failure or may I have done something to cause it?

Ya that would be nice. The suspense is killing me! I wanna see how much damage I've got but don't feel comfortable pulling it out in the dark...wait that didn't sound righ