A scary new noise...

About My Baby:
She's a 1994 XJ600S with 9700 on the clock. I've always had a bit of a fairing buzz between 4k and 5.5k RPM. Oil level is good.

The Problem:
After a short trip on the highway last night, I noticed a new noise, which sounded like it was coming from the motor (upper half maybe? hard to tell...). The noise sounded like a scraping metal sound. Only happened around 4-5k rpm. At first I thought something was vibrating, but it really seems like the sound is coming from inside the motor.

Also, it started leaking oil the past few weeks. Not a lot, only a drop or two when I park it after riding... can't even tell where it's coming from, the spots on the ground aren't below the drain plug or filter.

Any ideas? I called a dealer and they said (over the phone) it could be the cam tensioner, but with only 9700 miles? Thanks for your thoughts...

 

Do you have the stock exhaust? If so they are double walled and the inner pipe can crack and make noise at certian RPM's. My Maxim X made the noise between 2k and 4K RPM. It was not a hard fix, it was hard to find the cracked pipe. I had to remove the head pipes and hit with a rubber mallet. When I found the broken one it had a distinctive buzz when hit with the mallet. To bad the mallet trick won't work with the pipes on the bike.
The only idea I have about the oil leak is to clean your bike real good then look for the oil spots.

 

Hmmm... I'll take the stock pipes off tomorrow and have a look at it. I hope that's the issue, although I really think the sound is coming more from the front of the bike. Appreciate the help!

 

Are either your speedo or tach mechanically (cable) driven?

If yes, suspect cable or instrument.

 

Check the easy sutff first like tach and speedo and timing chain tensioner. Taking exhaust apart is not easy and could result in some broken studs.

 

UPDATE:

OK, thanks for the tips guys. I stripped off fairings and removed speeedo cable, still have metal scraping/buzzing sound. I want to check the cam chain tensioner. I've ordered a manual for the bike, but would like to get started... Can someone give me a few general steps? The only engine work I've ever done was adjusting valves and syncing carbs on my old ninja 250.

Thanks for all the help, and I've really enjoyed reading up on the back posts on this site.

-Dennis

 

Cam chain tensioner checked out, seemed to work fine. Same problem. I'm removing the valve covers now... and such a nice day :x

 

After removing the valve cover, the chain across the middle (timing chain, right?) looked fine... no damage to it or the casing. The tensioner was keeping it nice and tight, almost no free play. Took off the exhaust and banged 'em with a rubber mallet, but no "buzz" sound. LOL, I've got this thing in a million pieces now,and still no answers...

 

A book will explain the procedure to re-tension the timing chain. I type too slow to cover that. Shine a light down each exhaust header and see if you can find any cracks. Try hitting them at different angles and see if the sond changes.

 

PROBE the Engine to isolate EXACTLY where the noise is originating from.

Buy a Wooden Dowel, cut a length of Fiberglas Driveway Marker, a Broom, Mop Handle or Ski Pole.
Hold the Probe like a Ski Pole. Place one end of the Probe on the Engine.
Put your fist around the opposite end. Apply pressure on the Probe with your thumb on the End of the Probe.
"Listen" to the Probe.
Place you ear on your thumbnail and actually listen to the Engine.
Roll tape, rubber stopper anything to put your ear too and hear the vibrations carried by the Probe.
Make notes.
The noise is located at this spot.
Knock, vibration, rotational, scraping sound ... etc,

Isolate where the noise is coming from.
Rule-out exhaust leaks!
"Flag Check' for exhaust leaks.
Tape a tissue "Flag" on the end of a Screwdriver.
Check Flanges and Clamps with the Flag, ...
It will flutter if theres a leak.

Check Mounts.
Lay a wrench or tap on Motor Mounts with a Hammer.
Ring = Loose
Thud = OK -Tight.

Probe by the Oil Lever Sight Glass
If you hear a "Tinging" type noise.
Loose Oil Guide Plate (Splash Plate, Splatter Plate)

 

Awesome Advice! Thanks a lot guys. I'm going to a concert today, but Sunday I'll be back in the garage. Love the flag idea. Really hope its an exhaust leak.