rhvcmjack
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SuzukiSavage.com Rocks!
Posts: 3
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I have a 95 Savage that was run without oil. After rebuilding the engine, a loud tapping is present. This issue has been addressed many times in this forum, and i've tried all of the recommendations, but the tapping in my engine persists. Here is the history.
-after running with no oil, camshaft journals were worn beyond repair. Engine was rebuilt with used cylinder head and cover. -replaced camshaft with new and checked the journal clearance with plastigage. The range was .002 - .005, which is within tolerance. -started the bike and noticed tapping noise comming from the upper end of the engine. It is barely noticable at idle. While holding higher rpms, it is very loud. Once i let go of the throttle, it taps eratically until back at idle. Sounds like a classic case of valves tapping to me. -verified valve clearance with my feeler gauge. I had it set at .004, so i reset it to .003 if not tighter. -started the bike and had no change to the tapping condition. -replaced the timing chain as it was slightly out of tolerance, so i thought maybe the tapping was actually from the chain slapping as i've read about in this forum. At this point, i was very carefull to make sure that all timing marks were dead on and that i was at TDC before putting the cover on. Then, i was carefull to make sure i was at TDC on the compression stroke(waited for the intake rocker to go down) before setting the valve clearance. -started the bike and no change at all. -now i'm frustrated, but curious as to the cause, so i opened it back up and started taking measurements of all the parts and pieces to make sure they have not worn beyond tolerance. With my dial indicator, caliper and micrometer, i measured everything listed in my service manual(Suzuki not Clymers). I basically took the whole engine apart again and none of the parts are worn out of specifications. The rocker arms had a little indentation from contact with the cam, so i replaced them. -after re-assembly, i started the bike and had the same result. I'm 90% convinced it is not mechanical, so i started looking at the electrical side of things. -i took resistence measurements on the ignition coil, pickup coil and the ignitor. The only issue was the ignitor. The measurements were not quite what the book said. Could this be the cause? I was under the impression the bike would not start if the ignitor was faulty. -i also looked at the rotor key to make sure it didn't break. Then, I started the bike while using the timing light. The timing mark seems to advance with higher RPMs, but i can't tell how much .
I've included about as much as i can in the hopes that someone might have another suggestion for me to try. I remember the bike having a tapping noise before the oil incident, but not like this. Thanks in advance for any inputs.
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