SuzukiSavage.com - Dropped left side exhaust valve head.

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Dropped left side exhaust valve head.
07/06/16 at 18:39:56

Up for your consideration today ladies and gentlemen is a 2001 pastel blue Suzuki Savage LS650 with 32090.xx (thirty two thousand and ninety miles), purchased at 5000 miles for 1.1k USD

Who'll bid me......

The bike has a clone cam chain tensioner mod, leaky plug mod, raptor petcock mod with aux' fuel vacuum switch mod in line, s40 seat and the rear signals moved back to the license plate holder. Oil changed every 1000 miles.

Anyways...

Commuting to work one morning at 70 mph and I hear clunk them a loooong grinding noise and of course the engine cuts out.

My first suspicion was the cam chain had extended over way over to the other side and maybe interfering with the opposing side.

Nope! With the clutch cover removed it's a long ways for that to happen.

So then I inspect the exhaust port and discover the a valve head missing from the left side exhaust valve.

So... I do wrench when it is absolutely necessary and so my questions are these. based upon your collective invaluable experience do we think it is economically viable to rebuild with used ee bay parts (Cheap head assembly on the auction site, piston and blah blah), do we think the engine is flushable of the aluminum shavings without splitting the cases or do we think scrap the bike for parts and move on to greener pastures like a new zero percent financed bike.

Fyi I see used engines being sold for more than I paid for the bike. Sad

Has anyone brought a dead bike with a diagnosis like this back from the dead? How much chanting did it take?

And hey guys, what's the deal! I read posts all over that claim this bike is bullet proof, wtf? Huh

Oh.... and any clutch plates puzzle assembly Grand Masters on the forum? I get the pin thing.

Thanks for your constructive input

Bob.

87 Honda ch250 elite.
07 Vento Phantom R4i.
700c Roadmaster Wink

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« Last Edit: 07/07/16 at 14:23:01 by robinsoncrusoe »

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Steve H Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1223 Spartanburg, SC Gender:	Re: Dropped left side exhaust valve head. Reply #1 - 07/07/16 at 08:21:25 I had this happen on a Honda 350 one time. All damage was contained to the cylinder. It didn't break through the piston. It didn't damage the valve seat or cylinder walls. So, piston, rings, valve, smoothing of divets in the head and it was rolling again.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: Dropped left side exhaust valve head. Reply #2 - 07/07/16 at 08:38:50 I started a discussion about the engine dropping a valve occasionally....not sure we ever came up with a common cause or reason. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1445947173/0
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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Dropped left side exhaust valve head. Reply #3 - 07/07/16 at 08:45:25 Steve"s on the right track, why not pull it down and look at the damage,you only have 1100 in the bike ,could be cheaper to keep her than buy a new one.If it's to bad then put back together and sell,and you'll be able to tell the new buyer what it really needs.(honest John's used motrcycles).
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verslagen1

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Re: Dropped left side exhaust valve head.
Reply #4 - 07/07/16 at 09:23:26

Well, Dave, you have a answer to your question...
Dave wrote on 10/28/15 at 04:07:12:

I don't know the exact number - but I have seen several damaged engines and heads on this forum or on eBay. All of them have dropped one exhaust valve into the cylinder - I am not aware of any seats coming loose.

On some of the internet discussion about dropped valves, the cause is suggested as over revving the engine to the point that valve float occurs, and the valve does not follow the cam on the way back down.......and the piston hits the valve head. Until somebody that was actually riding the bike when the valve failed comes along and tells us what they were doing when the engine failed......we are just speculating about how the Savage engine occasionally drops a valve.

I also just got photos of the rockers and cam from this engine. With only 9,500 miles on the bike....how does this much wear occur on the cam and rockers? This is the same damage to the cam and exhaust rocker that was on the bike I just bought....and it had 3,800 miles on it. We can only guess that the oil the original owners were using did not have enough ZDDP in it. Wonder if the cam wear and increased valve clearance can lead to valve failure?

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verslagen1

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Re: Dropped left side exhaust valve head.
Reply #5 - 07/07/16 at 09:31:12

robinsoncrusoe wrote on 07/06/16 at 18:39:56:

Up for your consideration today ladies and gentlemen is a 2001 pastel blue Suzuki Savage LS650 with 32090.xx

The bike has a clone cam chain mod,
leaky plug mod,
raptor petcock mod with aux' vacuum mod in line,
Oil changed every 1000 miles.

Quote:

aux' vacuum mod in line

What is this?

And what oil did you use?

Valve adjustment history... preferred setting? any changes lately?

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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Dropped left side exhaust valve head. Reply #6 - 07/07/16 at 09:51:49 WHAT HE SAID,and what's a clone cam?
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justin_o_guy2

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What happened?

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Re: Dropped left side exhaust valve head.
Reply #7 - 07/07/16 at 12:14:55

Wonder if the cam wear and increased valve clearance can lead to valve failure?

I have wondered that.

I liked setting the valves on the tight end of the adjustment range. I wanted every thousandth of an inch of lift I could get and the closer the lobe was to the rocker the less likely it is to Slap into the thing.

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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: Dropped left side exhaust valve head. Reply #8 - 07/07/16 at 12:51:19 The valve is more likely to stick if it's overheated. the valve is more likely to overheat if it adjusted too tight.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Dropped left side exhaust valve head. Reply #9 - 07/07/16 at 12:56:27 I don't get them Too tight. I spend time and get it on the tight Side of the adjustment Range. It ran like stink.. If someone is unsure of their ability to do it precisely, then they should play it safe.
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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: Dropped left side exhaust valve head. Reply #10 - 07/07/16 at 13:24:19 obviously.
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robinsoncrusoe YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 13	Re: Dropped left side exhaust valve head. Reply #11 - 07/07/16 at 13:44:36 batman wrote on 07/07/16 at 09:51:49: WHAT VRESY SAID,and what's a clone cam? Here is the clone C C T M
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robinsoncrusoe

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Re: Dropped left side exhaust valve head.
Reply #12 - 07/07/16 at 14:03:19

verslagen1 wrote on 07/07/16 at 09:31:12:

robinsoncrusoe wrote on 07/06/16 at 18:39:56:

Up for your consideration today ladies and gentlemen is a 2001 pastel blue Suzuki Savage LS650 with 32090.xx

The bike has a clone cam chain mod,
leaky plug mod,
raptor petcock mod with aux' vacuum mod in line,
Oil changed every 1000 miles.

Quote:

aux' vacuum mod in line

What is this?

And what oil did you use?

Valve adjustment history... preferred setting? any changes lately?

The auto fuel valve mod. It solved the forgetfulness of leaving the main fuel petcock open and the nasty idea of a stuck carb float etc. etc...

Oil used Rotella T6.

Valve checks 5K. I am or was of the opinion loose is better than too tight. Besides the bike would pull to in excess of 86mph with no problem..... on a private closed course.

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28660 Tucson Az Gender:	Re: Dropped left side exhaust valve head. Reply #13 - 07/07/16 at 14:12:12 70mph is around 4,800rpm... when the valve dropped... So in this case, it wasn't float... Did anything break off the spark plug?... (maybe some loose insulator wedged the valve open?)...
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verslagen1

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Re: Dropped left side exhaust valve head.
Reply #14 - 07/07/16 at 14:49:42

robinsoncrusoe wrote on 07/07/16 at 14:03:19:

The auto fuel valve mod. It solved the forgetfulness of leaving the main fuel petcock open and the nasty idea of a stuck carb float etc. etc...

I applaud your inventiveness but...
One of the key issues with the stock petcock is vacuum loss at high throttle settings.
At WFO there's no vacuum or at least not enough to open the valve all the way.
And this occurs even with a stock setup.

So... potentially, this maybe the issue.

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