SuzukiSavage.com - 2000 Savage clanking noise

kojones

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Re: 2000 Savage clanking noise
Reply #75 - 07/29/16 at 03:59:40

Savageman wrote on 07/28/16 at 19:59:23:

As suspected the valve timing was out causing the piston to hit the valves. Probably due to stretch and maybe jumped a few teeth.

Yes, the PO has replaced the cam chain and the tensioner after tensioner failure. It also looks like he has replaced the valves as they seem to be fine.

I have no previous experience with engine overhaul, here's some pictures if anyone is interested to have a look: https://www.dropbox.com/sh/jaq0s270mgmh2ox/AABa-3jFUpYk3T3J_GEAfbmwa?dl=0
any thoughts?

And as a low budget traveller I'd like to get my bike running as cheap as possible, if the wrist pin is the only problem wouldn't it be a smart move just to replace the pin with oversized one? Just a few turns on a lathe.

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kojones Full Member Offline SuzukiSavage.com Rocks! Posts: 223 Finland	Re: 2000 Savage clanking noise Reply #76 - 07/29/16 at 04:10:11 Dave wrote on 07/29/16 at 03:57:43: Kojones.....Can you take a picture of the top of the piston for us? Was it only the exhaust valves that touched, or the intakes....or both? Both. https://www.dropbox.com/s/73v1m4lly887x3w/2016-07-29%2001.05.07.jpg?dl=0
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Dave

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Re: 2000 Savage clanking noise
Reply #77 - 07/29/16 at 04:15:42

Well that isn't right....the only time the valves are both open is at the overlap that occurs at TDC. I wonder if somebody tried to set the clearance and got them waaaaay too tight once?

It is possible that if the wrist pin is so loose....the piston could be moving around and hitting the valves at the overlap - however the stock cam is pretty darn mild on lift and the valves should be a long way from the piston (even at TDC).

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kojones

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Re: 2000 Savage clanking noise
Reply #78 - 07/29/16 at 06:59:45

Dave wrote on 07/29/16 at 04:15:42:

Well that isn't right....the only time the valves are both open is at the overlap that occurs at TDC. I wonder if somebody tried to set the clearance and got them waaaaay too tight once?

It is possible that if the wrist pin is so loose....the piston could be moving around and hitting the valves at the overlap - however the stock cam is pretty darn mild on lift and the valves should be a long way from the piston (even at TDC).

The pin it's not that loose, at least not when in room temperature.

Here's the piston without cleaning: https://www.dropbox.com/s/eq71c0peznb31l5/2016-07-29%2000.58.21.jpg?dl=0

A bit loose fit, maybe?

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18095 Camp Springs, Kentucky Gender:	Re: 2000 Savage clanking noise Reply #79 - 07/29/16 at 07:04:12 The cylinder and piston don't visually appear to have a lot of wear, certainly not enough to allow the valve to hit the pistons. You need to remove the rings, and use a feeler gauge to check the piston/cylinder clearance. The sides don't wear much....it is the front of the piston and cylinder that get the most wear.
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kojones

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Re: 2000 Savage clanking noise
Reply #80 - 07/29/16 at 11:06:10

Guesswork is over, I measured the piston:

https://www.dropbox.com/s/cczk463yfvrrw2r/2016-07-29%2019.41.21.jpg?dl=0

3 more pictures following that one, wear limit according to Clymer is 93,880. The side facing the camera was measured.

Crankshaft bearing and wristpin hole were fine. Next I'm going to order a 95mm Wiseco and get the cylinder bored and honed.

So, I've read that the DR650 camshaft will fit? Wink

Any suggestions with nozzle sizes that will go nicely with stock muffler and 666cc overbore but would later work better with less restrictive muffler?

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« Last Edit: 07/29/16 at 15:45:18 by kojones »

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norm92de Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1180 El Paso TX Gender:	Re: 2000 Savage clanking noise Reply #81 - 07/29/16 at 19:42:50 I always thought that the thrust face of the piston exhibited the most wear. I.e. the rear of the piston on the Suzuki. Have I got it wrong?
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kojones Full Member Offline SuzukiSavage.com Rocks! Posts: 223 Finland	Re: 2000 Savage clanking noise Reply #82 - 07/30/16 at 05:39:25 norm92de wrote on 07/29/16 at 19:42:50: I always thought that the thrust face of the piston exhibited the most wear. I.e. the rear of the piston on the Suzuki. Have I got it wrong? So I've read, but it seems to be quite the opposite in my bike.
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kojones

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Re: 2000 Savage clanking noise
Reply #83 - 08/06/16 at 05:51:15

Still waiting for the piston, ebay global shipping program doesn't seem to be very fast...

But I did measure the clearance of the cam journals and they seem to be in very good condition, clearance was 0,05mm to 0,063mm. That was very good news, the piston is now the only thing that needs to be replaced. I also did a complete overhaul to a spare forks I had, now I just have the replace the leaking forks with the new ones. Also replaced the original #125 & #47,5 jets with #150 and #50.

Have to say that this is quite fun, I'm a total noobie when it comes to motorcycles or engines Grin

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kojones Full Member Offline SuzukiSavage.com Rocks! Posts: 223 Finland	Re: 2000 Savage clanking noise Reply #84 - 08/30/16 at 10:13:32 Fired it up yesterday after a bore job and with a new piston, idled fine until warm and I was a very happy camper. Replaced the forks today and started it up to find out that it's still clanking. Sh*t.
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kojones Full Member Offline SuzukiSavage.com Rocks! Posts: 223 Finland	Re: 2000 Savage clanking noise Reply #85 - 05/01/17 at 05:59:35 Replaced the valves as one intake valve was bent, still that same noise :'( https://www.dropbox.com/s/55r0vu7e8w04hbr/2017-05-01%2015.27.28.mov?dl=0
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Dave

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Re: 2000 Savage clanking noise
Reply #86 - 05/01/17 at 06:06:48

There have been 2 bikes on this forum that have had loose nuts on the flywheel. The noise was loudest at low speeds......at high rpm the sound was not very noticeable. The loose nut allows the flywheel to move on the crank - and the flywheel bangs on the splines. It is very hard to isolate the sound - as the banging goes into the crankshaft and is transmitted to the entire engine case.....it sounds like is is coming from everywhere on the engine!

It is possible that the flywheel nut is loose......the only problem in checking it is you will need to have a puller to remove the rotor on the left end of the crankshaft, and a deep socket....and a tool to hold the flywheel in place. I have tools I can rent - but it is expensive to ship them in the US as they are heavy...shipping them to you would be very expensive!

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kojones

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Re: 2000 Savage clanking noise
Reply #87 - 05/01/17 at 06:43:26

I took the magneto rotor off about a year ago, couldn't get the flywheel off as the nut was too tight. So I don't think it is that.

I'm quite sure the noise is coming from the clutch side cover, it comes and goes so there's something moving inside. The cover has been welded by the previous owner due to cam chain tensioner failure, I don't know if it's still deep enough for the tensioner and stuff

Some marks that could be from the tensioner: https://www.dropbox.com/s/ti613aal54fbs5j/2017-05-01%2017.41.10.jpg?dl=0
Measured about 11mm from the gasket surface to the oli channel. https://www.dropbox.com/s/z35l1jgbhddlgtk/2017-05-01%2017.57.08.jpg?dl=0

Anyone has a spare cover they could measure that distance? Wink

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« Last Edit: 05/01/17 at 08:05:33 by kojones »

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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: 2000 Savage clanking noise Reply #88 - 05/01/17 at 08:25:14 You said that the valve clearance was spot on at 10mm ,the valve clearance should be 5mm.(factory setting).
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kojones Full Member Offline SuzukiSavage.com Rocks! Posts: 223 Finland	Re: 2000 Savage clanking noise Reply #89 - 05/01/17 at 08:40:20 batman wrote on 05/01/17 at 08:25:14: You said that the valve clearance was spot on at 10mm ,the valve clearance should be 5mm.(factory setting). Nope, the clearance should be .08-0.13, I've adjusted them to .10. It's not the valves.
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