Loud Ticking noise in XJ1100, goes away with rpm >~ 1200

Hi Guys,

The bike used to run great, but about 2 years ago a loud clicking noise noise started coming from the engine. Tried a stethoscope, but couldn't find the source of the noise. Performance was not inhibited by the tapping on the way home (the bike has NOT been ridden since this problem occurred). It starts up like you wouldn't believe even after sitting (I'm now a carb god), but the ticking still persists. The ticking is only persistent at 0-1100 RPM, and goes away past that.

What have I done to address this problem?
-Checked valve shim clearances, swapped, and ran (no change)
-Grinded and inspected valves, checked tolerances (all good!?)
-Inspected wrist pins in pistons (TIGHT!)
-Inspected journal rods (TIGHT again!)
-Inspected oil pump and oil hardline (good, lots of oil)

I'm at a complete loss, where should I go next?
Thanks in advance for the responses

 

Have you adjusted the cam chain tensioner?

 

Yes, before and after this current disassembly. Done as instructed to in the service manual.

 

Slight blowing on one of the exhaust gaskets?

 

There doesn't appear to be any leaks, but that's something I can try once it's all back together again (though this tick is likely mechanical as it creates a noticeable vibration).

 

Crankshaft bearing?

 

I forgot one important thing:

Ticking only occurs when there is compression. If spark plugs 1 or 4 are pulled, there is no ticking, 2 and 3 make no difference so I consider them to be "good" cylinders. as for if its 1 or 4, 1 has a dark exhaust which is indicative of a "burnt" exhaust valve. However, It still falls within proper specs as per service manual. I have no idea why pulling plug 4 would remove the ticking, but hey, thats why i'm here!

 

Oh god, I really hope not. I'm going to check that tomorrow.

 

Last thing i'm going to consider now , could it be the HT lead or plug cap shorting on the engine?
I lied, are the pick up coils held firm?

 

Exhaust gasket.

 

Edit*** Can this tick occur near 0 RPM?

 

Found metal shavings in the strainer cover, oil also looks a little shiny. Maybe it's time to take the engine out...

 

Yes, and engine noise can cover that sound as engine speed increases.

 

Here's a link to a video I took.



No, the mic is not peaking: It's like a switch, the ticking is much louder than the motor, but goes away in entirety past 1200 rpm (with the occasional click near 1200 rpm).

 

Tight as can be

 

Listening to your vid, i would go back and check that you adjusted the cam chain tensioner properly.
It could be at the end of it's adjustment.

 

Agreed.
If not that then the alternator chain guide is toast.
It's definately the sound of a chain rubbing.

 

Cam chain was definitely adjusted properly before the tick, I had done it multiple times before with no issues. The cam chain tensioner operating properly with lots of spring force (pics attached). 48000 km, is it possible the cam the chain is toast already??? I'm not sure about the alternator chain itself (about 1/4-3/8" of slack), but guide has lots of meat left on er.

On another note: engines already apart, and the bearings look old so i'm replacing them no matter what (along with all gaskets including exhaust). I cant find the crankcase numbers that are supposedly hand "etched" into the upper case. Any clue as to where they would be?

 

I suppose if the engine is apart then it would be a good opportunity to replace the cam chain with a new one and eliminate that. I replaced mine with a D.I.D. brand.
Also, a lot of owners, me included, replace the original manual cam chain tensioner for an automatic one, i have on my XS, and i've fitted one from a 1200 V-MAX. Other models of Yamaha fit too and there was a complete list over at Forums - XS11.club Forums

 

Cam chain tensioner plunger looks quite extended in your photograph. How much more adjustment is left on it?