SuzukiSavage.com - 2003 Savage ticking? Please advise

ghkizer1 YaBB Newbies Offline Go COCKS! Posts: 36 Charleston, SC Gender:	Re: 2003 Savage ticking? Please advise Reply #15 - 09/13/14 at 18:30:27 one last pic
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: 2003 Savage ticking? Please advise Reply #16 - 09/13/14 at 19:57:51 ghkizer1 wrote on 09/13/14 at 18:27:37: Also the decomp lever, if it isn't touching it is EXTREMELY close to touching. I tried to go through the cycle a few times and it does seem to be super super close to the top of the rocker. Is this normal? I think that's your noise, you're gonna need to check cam wear.
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ghkizer1

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Re: 2003 Savage ticking? Please advise
Reply #17 - 09/13/14 at 20:12:30

Unfortunately the decomp arm isn't the ticking noise. I added some more oil and cranked the bike, while it was idling I rotated the decomp arm by hand, I could feel and hear when the rocker arm began to contact the decomp arm. The ticking noise was still there before and after... I have another engine being delivered in a week. Maybe I will be able to analyze the new engine and reverse engineer it to figure out the problem. Either that or this engine has been ridden hard and put up wet leaving major internal damage. I really hope that isn't the case.

Verslagen, THANKS SO MUCH FOR YOUR HELP AND PERSISTENCE!!! Is there anyway to tell if oil is properly circulating, I'm nervous that the top end isn't getting enough oil. Thanks again!

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verslagen1

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Re: 2003 Savage ticking? Please advise
Reply #18 - 09/13/14 at 21:04:42

unfortunately, there's no oil pressure port in the head.
about all you can do is loosen a bolt and watch oil spurt all over the place.

however, while you had the clutch cover off, did you notice an oil channel running along the top of the case?
At the end of it, it transfers over to the tranny and there's a brass restrictor. if that was missing the oil pressure to the head would tank.

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ghkizer1 YaBB Newbies Offline Go COCKS! Posts: 36 Charleston, SC Gender:	Re: 2003 Savage ticking? Please advise Reply #19 - 09/13/14 at 21:08:40 Would the right bolt to lossen be the one at the top to the left of the cam chain? Just saw the second part of your post, don't remember seeing that piece but I also wasn't specifically looking.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: 2003 Savage ticking? Please advise Reply #20 - 09/13/14 at 21:18:58 yep, that be the one.
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ghkizer1

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Re: 2003 Savage ticking? Please advise
Reply #21 - 09/13/14 at 21:51:57

Well I was hoping to report back covered in oil but I removed that screw, which was really loose btw, the screw itself is covered in oil but when I cranked the bike it didn't spew out from that hole or even drip out. I attached a picture to make sure I removed the correct screw. I can take the clutch cover off and check for the brass piece tomorrow if there is no other way. Thanks again!!

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1st2know Senior Member Offline Currently between Savages Posts: 295 Seattle, WA Gender:	Re: 2003 Savage ticking? Please advise Reply #22 - 09/13/14 at 22:12:02 ghkizer1 wrote on 09/13/14 at 12:59:52: ... I received this bike for free and do not know the history on it.... By the looks of the sealant smeared around the cam cover plug, someone has had the head cover off. If it were me, I'd take the head cover off for a look-see.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: 2003 Savage ticking? Please advise Reply #23 - 09/13/14 at 22:30:18 yep that's the one. at idle the pressure off the pump is 5psi or less if your idle speed is low. so pressure at idle at the head could be near nothing. give it a twist and see if you got a gusher.
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polarpilot YaBB Newbies Offline I love YaBB 1G - SP1! Posts: 34 Canada Gender:	Re: 2003 Savage ticking? Please advise Reply #24 - 09/14/14 at 04:33:21 Mine ticks too. But after a run at normal speeds the ticking noise disappears. So take your bike out for a ten mile run and listen to see if the noise is gone at the end of the ride.
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ghkizer1 YaBB Newbies Offline Go COCKS! Posts: 36 Charleston, SC Gender:	Re: 2003 Savage ticking? Please advise Reply #25 - 09/14/14 at 07:32:44 Thanks again for all the help! I cranked the bike up this morning with that one head bolt out, let it idle for a min or so then gave it some throttle watching that bolt hole. Nothing, wasn't gushing, dripping, spraying, nothing... I'm going to take the head off and have a look-see.
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ghkizer1

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Re: 2003 Savage ticking? Please advise
Reply #26 - 09/14/14 at 09:32:59

Well I took the head cover off. I think I found my problem. First and foremost I am starting to realize more and more this engine has been abused and worked on a lot before. The top bolts under the valve inspection covers in the middle between the rockers on the outside are both broken off, there is at least one other head bolt broken and the stud close to the decomp is some shady nut, not the stock one.

When I removed the cover I could see where the cam shaft is banging against the top of the cover. There are active metal shards on the top cover that haven't completely separated which you can see in the following pictures.

Is it possible this is an aftermarket cam shaft? Have you guys ever seen a stock cam shaft begin banging on the cover?

I am trying to make the best of this new found knowledge. I am thinking of pulling the entire head and have the parts cleaned and head bolts tapped out so it will be a good strong hold. I guess while I'm in there I could go ahead and get a new piston and rings and do a complete rebuild. I have never done anything like this before but am eager to learn.

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ghkizer1 YaBB Newbies Offline Go COCKS! Posts: 36 Charleston, SC Gender:	Re: 2003 Savage ticking? Please advise Reply #27 - 09/14/14 at 09:33:30 you can see the scratches on the top of the cover
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ghkizer1 YaBB Newbies Offline Go COCKS! Posts: 36 Charleston, SC Gender:	Re: 2003 Savage ticking? Please advise Reply #28 - 09/14/14 at 09:33:54 a close up
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ghkizer1 YaBB Newbies Offline Go COCKS! Posts: 36 Charleston, SC Gender:	Re: 2003 Savage ticking? Please advise Reply #29 - 09/14/14 at 09:35:09 cam shaft with damage
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