Hello everyone

Ive been riding a 2011 s40 for a few months now and I lurk here. Got it with 17k its now around 19k.
I'm in Florida..I'm 25 but this isn't my first Rodeo Ive been tearing chit apart and building/tinkering with mechanical things since I was a little kid.
Before this I built some racing scooters lol. High compression ceramic piston titanium valves bla bla.. So I have a thing for thumpers I love the sound.

This bike was very neglected it looks much older since it has been left in the elements its entire life until I rescued it haha.

Ive already rebuild the carburetor, jetted it and added a K&N filter.
Drilled out this carcass of an exhaust..
The carb float was leaking depending on the temperature outside and engine temp.. it would seal once warmed up and eventually stopped sealing filling up the airbox with gas and coming out of the overflow float bowl hoses. I think some got into my oil and might be a factor in this "slapping sound"
New NGK sparkplug
Amsoil with zink additive (if it works in a ceramic coated airsol 11.4:1 high compression 91cc 1.5mm stroker living at 13k rpm why not the s40) lol
Valves are in spec and cams look brand new.
Chain tensioner is getting close to flying out it had about 5mm left. Just ripped that thing out and I'm sending it to Verslagen  

So this slapping sound was present since I purchased the bike.

At idle the bike sounds fine..once you give it a little throttle it makes a "slap"ing sound. I thought it was the piston. My buddy's 80cc made a similar sound and it was his piston rings they were completely worn out from mileage and it burned oil. So I assumed when I got it that it would need some work.

It progressively got worse but never present at idle. Only when your on the throttle. When you start rolling it would only happen at some rpm's.. kind of random. After my last long trip it was BAD and did it at any speed but not at idle. I used a stethoscope to listen and it sounds like its coming from around the counterbalance area.  

SOOO
Ive torn the entire thing apart engine's out and on my workbench. I'm getting a flywheel puller to see what the heck is going on.

Hope to share the experience and ill have pictures once I'm allowed to post some LOL  

I will definitely let you know Dave! I got lucky and found a flywheel puller at reasonable price.

I think I might need a flywheel holder but who knows I might rig up something that will work.  

That wad of meshy metal is an official Suzuki part...make sure you put it back where you found it!  If you leave it out - be prepared to get a lot of oil out the vent tube.

Your head looks pretty good, and it is not uncommon for that little odd shaped O-ring to be a little deformed by sealer.  I finally discovered why that seal is oddly shaped......the head was drilled and plugged in that location when they were making the oil channels in the head cover....and the machining made an oval shaped hole around the head stud - so they made a oval shaped O-ring to match.  A little extra sealer and a deformed O-ring in that spot is OK....but it would be nice if you could control the application of sealer a bit better. I use the SuzukiBond, and I squirt it into a small syringe so I can get good control when applying the sealer.

Also...the little rectangular area beneath the center of the cam is a trough that holds oil, and allows the cam lobes to dip into the oil as it rotates.  Don't put any sealer on the front or back of the little well....look at the head cover to see where there is nothing for the sealer to be in contact with on top....and leave sealer off the well in that area (I have take some bikes apart that had a line of sealer on the edges of the well).

Dave, are you saying that sealer in that area won't contact anything above it? It will just dry on top of the bathtub and not do anything?

SOOO  

Got my 46mm deep impact socket and the flywheel nut was torqued on with about 5lbs or less LOL! (WTF Dave had a similar issue WHY did this happen to us? Suzuki's fault? previous owners abuse???)

EDIT: clutch basket nut was out of torque spec hand tight and the flywheel nut was out of spec.  

The crankshaft roller bearing has some play in it.. Like I thought I have to replace that.

Ill be cleaning up some stuff and splitting the cases soon as I get my chit more organized. My workbench is a nightmare currently.

Dave's thread is similar to my issue.. Ill find out even more once I pull the head and jug.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1342319094/0

I wanna know why my flywheel nut was so loose.. I just want to ride my darn bike again.. lol
At least I will have peace of mind once my bike is all back together..

Thanks for everyone help and wisdom.

Here's some porn

Yeah both need to be changed.. MAN now you have me thinking... I pray that all my other bearings are in spec.. or else I have one hell of a rebuild on my hands lol... I will find out soon haha.

Yep! I got a tensioner coming from Verslagen!!! Hes busy but I'm not in a rush and very patient. He has also helped me a lot with basic info.  

I also thought about buying a brand new hardened cam chain so I don't have to stress any of that crap for a bit longer.

I plan on getting the Suzuki head sealer.

I'm still shocked both the clutch lock-nut and flywheel nut were so loose..

Also for the engine would fleabay suzuki gaskets be the way to go?? or is there anyplace recommended I get some gaskets?? Ive made my own before but I don't want to hobble together some hillbilly gaskets. LOL

http://www.ronayers.com/oemparts/#/l/suz/505a0b2ef8700203b4ed1771/2011-boulev...

I was going to get some parts here.. seems legit  

You are on your way to recovery!

Don't know why some bikes get a loose flywheel.  This is the 3rd bike to suffer from it on this forum.

When I put my bike back together I used the red (permanent) threadlocker on it.  The manual doesn't require it - but quite frankly I never intend to need to take that nut off again....and if I do a little heat and impact wrench will get the nut off easily.

I have about 6,000 miles on my bike since the engine was put back together, and it is working just fine.