SuzukiSavage.com - CCT Destruction!

Andy RN

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CCT Destruction!
05/23/17 at 12:51:27

>18mm?

The opening to the adjuster housing got a good thrashing...

And this is the face you make when you can't cry (like when your GF is taking pictures)...

Put me down for 43,838 miles!

The spring came out of the housing, but it appeared to be in good shape - no bends or anything, which leads me to believe it sat in the bottom of the clutch cover (rather than swim around). So I can hope.

So now that I know... where else should I check for damage?

Thanks!

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US Navy (99-03). Novice, self-taught mechanic. 2003 Savage with 44k miles. 2015 S-40 with 5k miles.

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Andy RN Full Member Offline Posts: 107 Eugene, OR Gender:	Re: CCT Destruction! Reply #1 - 05/23/17 at 13:17:13 Wait... there's a spring lodged inside the plunger... So can anyone tell me about the spring that did fall out when I removed the clutch cover? Show here beside an 8mm socket for scale: Thanks!
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Tocsik Serious Thumper Offline the singularity Posts: 1161 Denver, CO Gender:	Re: CCT Destruction! Reply #2 - 05/23/17 at 13:27:43 My guess is the spring broke and a few coils are what is lodged inside the plunger. The rest is what was inside the cover. Bummer man. Hope it all turns out OK.
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norm92de Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1180 El Paso TX Gender:	Re: CCT Destruction! Reply #3 - 05/23/17 at 14:02:21 Mr. Verslagen is where you need to go. If there are no other bits floating around you may have dodged a bullet. Metal in the engine is your worst enemy. Andy, I hope it all turns out well looks like you may get away with it.
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norm92de Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1180 El Paso TX Gender:	Re: CCT Destruction! Reply #4 - 05/23/17 at 14:10:28 Andy, How long did it run like that? Must have made a hell of a racket. :'( Are the gears ok? They look good.
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Tocsik Serious Thumper Offline the singularity Posts: 1161 Denver, CO Gender:	Re: CCT Destruction! Reply #5 - 05/23/17 at 14:14:13 There are some places you can stick a magnetic pickup tool through to the other side of the lower end of the motor. If you have one of these, it would be good to fish around and see what comes up. Down where I have the paper towels stuffed in the pic.
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norm92de Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1180 El Paso TX Gender:	Re: CCT Destruction! Reply #6 - 05/23/17 at 14:31:34 Andy, Find out if anybody knows how many coils are on the stock tensioner spring. It may be possible to prove that the remaining spring pieces are all there is. The aluminum that is missing in action may be your worst problem. I've got my fingers crossed for you.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: CCT Destruction! Reply #7 - 05/23/17 at 14:36:11 I'd have both sides off, light wire, small rags, diesel,, compressed air would be great.
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Andy RN

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Re: CCT Destruction!
Reply #8 - 05/24/17 at 15:42:13

Thanks, guys.

Norm - Life's got me busy, but I will remove the spring and count the coils ASAIK. It did make noise, but it wasn't as bad as I would have thought. I didn't have a place to work on the bike, and it was my only transportation, so I put near 300 miles on it after the noise started.

Justin - What would I use the light wire for? What would I be checking on the other side?

Everybody - Do you think I need to remove the engine? I mean, I was thinking that I would probably have to measure the cam chain (the 21-pin thing) to make sure it's in spec - and I would have to remove the engine for that, right?

Also, I have read that these kinds of failures can cause timing problems, and that the valves can hit the piston and so forth... like here:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1172586621/56#56

So I would have to take out the engine to check all that, right? Or is there another way to proceed?

Many thanks, again!

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US Navy (99-03). Novice, self-taught mechanic. 2003 Savage with 44k miles. 2015 S-40 with 5k miles.

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justin_o_guy2

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What happened?

Posts: 55279
East Texas, 1/2 dallas/la.

Re: CCT Destruction!
Reply #9 - 05/24/17 at 16:15:54

Sorry,,

I'd be flushing it with diesel and looking for any tiny specs to mop up with the little rag tied to my wife..
I'd be gutting the oil filter and looking for signs of metal in it, any metal, aluminium,
I would consider trying to back flush the oil galley, if there is much sign the engine ran a bit pumping carp in the oil.
Maybe, its a thought,,
That's a bit much, see what the others say.
I get really anxious about chunks of ground up metal running around, oil pumps can be hurt, rotten mess,, good luck with it.

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The people never give up their liberties but under some delusion.- Edmund Burke.

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Andy RN

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Re: CCT Destruction!
Reply #10 - 05/24/17 at 17:55:26

Oh, don't be sorry. I'm a novice mechanic, so I have to ask questions that are pretty basic. For example, you mentioned flushing the oil galley, and I don't know what or where that is Tongue

When flushing, what tools would I need? Specifically, would I need power tools or an air compressor (I think someone mentioned that earlier). All I have now are hand tools - hence I ask.

I'm pretty sure the oil filter had fine grains of metal in it, but I will take a pic and post it just to be sure.

I'm going to read up on the forum and Clymer's before I move forward. As I have a day job, this process might take several weeks before I have a game plan and gather all the tools/instruments I need. So please accept my apologies if I periodically shoot out emails and beginner questions over the next few weeks. Thanks in advance for your patience!

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US Navy (99-03). Novice, self-taught mechanic. 2003 Savage with 44k miles. 2015 S-40 with 5k miles.

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Dave

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Re: CCT Destruction!
Reply #11 - 05/24/17 at 18:17:10

I doubt that you got anything in an oil galley.....it would first have to get past the screen on the bottom of the oil pump, then get through the pump, and then through the filter - there won't be anything large enough to cause any damage coming out of the filter.....it's job is to stop that kind of stuff.

There could be something laying in the bottom of the sump, and it wouldn't hurt anything to try and flush that out the drain hole with a diesel fuel or kerosene wash.

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Someday I will be old......But not today!

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: CCT Destruction! Reply #12 - 05/25/17 at 06:09:31 Take Dave's post . I'm clearly not firing on all three cylinders.
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Andy RN Full Member Offline Posts: 107 Eugene, OR Gender:	Re: CCT Destruction! Reply #13 - 05/25/17 at 10:26:01 Thanks, Dave. I will put diesel sump flush on my list of things to do. If this happened to your bike, would you do anything else? Additional info: I'm over 43K miles and I think I have the "dreaded head plug leak".
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: CCT Destruction! Reply #14 - 05/25/17 at 10:56:14 If this happened to your bike, would you do anything else? Yes. You should do your best imitation of the winner of the big prize on the Price is Right. Usually they are D.O.A. when the tensioner pukes the spring. You made 45,000 miles? I wonder if anyone has ever been in there...
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