Hi guys...new "old" gal here with a Savage issue regarding a clacking noise after carb rebuild...or maybe something entirely different!

Here's the info:
* 2004 Savage
* Bought 2010, approx. 2000 miles on it, from a lady (it's only owner)
* Ran fine, had typical backfire (which I was not familiar with at the time), so took it to local Suzuki shop for it's "regular maintenance" check, as she indicated she never took it in for routine checks since it had such low miles.
* Shop said backfire normal, did oil change and checked specs, etc.
* Bike runs fine for the next 4 years!

Fast forward to fall 2014...4700 miles on it now (Yeah, I only put about 650 miles or so on it per year, I live local to EVERYTHING and only 6 miles to my work) bike starts running a little rough - won't idle evenly (runs good, then drops, then back up), power not great. I figure I'll tackle this issue in depth in the spring since it's time to put her away for the winter (I'm in NH)! Tank was 99% empty, added a little Sta-bil, removed battery, stored in my shed for the next 4 months or so.

* Spring 2015 - bike wouldn't start...meaning it would crank, but not turnover. Read some stuff online (this group, for one), talked to my brother-in-law, general consensus was needs carb work/rebuild.
Bought a rebuild kit from online, followed instructions carefully and slowly (hey this is my first time doing this!), and low and behold...she fired up!

* Ran great for about 1 month, before I started hearing this "clacking" kind of noise (I attached a video), which quieted upon deceleration.
I thought it might be an exhaust leak so I replaced the seal gasket on the pipe on the front of the engine. No change.
* Next I checked all the valve clearances - they were all within specs, but added a little clearance to one on the intake (brought it to .10mm as it seemed a little snug at just barely .08mm).
* Next I checked the cam chain tensioner - it should still have plenty of life in it, as it's only out about 13mm.

So here I am (sorry so long winded, wanted to give you all everything I had for info!) wondering if there might be an exhaust leak at the other end of the engine, where the carb enters? Would this make this noise or am I looking at something entirely different? Like I said, I'm new at this and taking it slow but I'm willing to take criticism and learn! Thanks for any input you may have!

PS...I'm having a *witch* of a time downloading the video...sorry, I'll get it, just gotta figure out what the problem is!

It sounds more like a machine gun, or like my chain is loose....sorry, should have described the sound since my video won't load 😞

sundanz26 wrote on 07/05/17 at 07:34:38:

Recommended to store full so it don't rust above the gas line
Quote:


Try to isolate the location of the noise.
check the drive pulley, if it's loose that's a major cost.
remove the pulley cover, make a mark where pulley meets the lock washers, with the bike off and in gear, have someone push it back and forth to see if the mark shifts.

other noises, speedo, headlight, mirrors, pulley cover, then just above anything bolted on.

Here's a short video of my bike and the sound it's making.
https://youtu.be/r8Cvn56l9C4

Having a hard time trying to determine the exact origin because it's loud at every point all around the engine.
Going to check that other exhaust connection as well as some other ideas you guys have given me. Gotta get this fixed so i can ride this summer!

I heard the video ,it sounds like valves ,did you adjust them ? they may be to tight and bouncing off the seats.

Todd James wrote on 07/11/17 at 20:58:35:

Might be this, remove the exhaust valve inspection cover.
on the inside by the decomp lever will be a little cam that hits the rocker.
rotate the engine, if the rocker is hitting it then your rockers are worn out.

Thanks, guys - I will check that cam/rocker possibility today.
My question on that is how would the rockers be worn out at less than 5,000 miles? Unless it had something happen in it's history that I didn't know about?
Also, to answer justin_o_guy2...I used Valvoline Full Synthetic Motorcycle 10W40.

Ok, now if I'm looking at the correct pieces, it does not appear that the rocker is hitting the cam.