Got a new to me bike

Forks and wheels are done and back on bike.

Working on engine now, have it down to cylinder head so far.
Found a bunch of metal shavings trapped by chain guide. Valve and piston surfaces looks good, no carbon deposits really and no marks of something hitting.

Valve clearances were pretty off, mostly exhaust side. Should be at least .22 but I have two at .14 and .17, the rest at .19.
Intake side is better, two are way below, the rest at the minimum spec.

Brakes also need a rebuild. Waiting for new seals at the moment.

 

Shaving look to be aluminum; from something moving by that cover and then peeling it back like you would an apple? Have any clue what that would be coming from? Did you have anything in the oil pan that looks the same?

 

Haven't gotten that far yet. Everything took a bit longer than expected, mostly because I bagged and labeled everything from engine while taking it apart. And reading the manual, a lot. Plus triple measuring the valve clearances, chatting with neighbors etc

I need to see what else needs to come off before I can split.

 

So far I have not yet seen a reason for that metallic noise, which is a bit of a concern.

 

So far I have not yet seen a reason nor indication for that metallic noise, which is a bit of a concern.
I'll do the transmission first and maybe remove valves.

 

Did a close up of the timing chain from your original picture:


Looks to me that it is quite mangled in the section that is at the top of this picture? I'd be taking a close look at that.

Tony

 

Possible it's my camera setting that blurs out the background. But I'll definitely check every link. Didn't notice anything while working on engine today.

 

Just checked. Was camera setting and the chain looks good, inside and outside

 

Tomorrow morning I will spend some time and hopefully split the case. Want to order parts early this week

 

Removed oil pan to drain and now draining oil.
A lot of debris in filter.

 

That picture really threw me off.

Unfortunately looks like it's got a serious failure, and sure you'll discover it once you get the engine all apart.

Tony

 

Right. There must be some obvious damage in the lower part of the engine. Everything that I took off so far looked good. But those are some big chunks.
Good thing is that the top end looks good from what I can see.
Didn't have a big enough socket to remove clutch hub/basket. Could probably split without removing but might as well and inspect. Plates need to be replaced as well. They look pretty worn and are at the minimum spec.
Engine must have taken a pretty good beating.
Crazy, it's only got 7800 miles

 

BTW, the new fork springs really made a huge difference. Frontend is nice and tight now.

 

Case is open.
Haven't taken gears out, that's for tomorrow.
The only thing I have seen so far are markings on the clutch basket. This one doesn't rub against anything though, or is close to anything. so that's a bit weird.

 

I found first shift related issue.
One of the gears (no idea what they are called) was not sliding to engage with the bigger gear next to it. It only did it twice and very randomly.
I took the gears off, checked for marks and cleaned. After putting it back together it works perfectly and every time.

Here the gear I'm talking about.


A small bearing ball fell out when I removed it. Possible it got stuck somehow.

Tomorrow I am removing the shift forks. I don't know what they should look like and will consult manual / internet pics.

Also, one of the shift forks does not move smoothly on that drum and I can feel a bit of resistance in one spot. I will inspect tomorrow.

Now, with almost everything removed, I am yet to see any major damage that would explain all the metal chips I found.
Starting to think it might be debris introduced to engine at some point.

Also, still no clue where the marks on the clutch basket are from. Maybe manufacturing?

 

Shift forks



Drum. Not sure and need to compare to new part but I think the one in the middle of the pic should be more round. The corner is kind of flat.

 

Found some grooves where the transmission shaft sits, exiting to starter motor.
Running finger over you can definitely feel that material was grinded off.

 

There are random marks in multiple locations, definitely material came off. This would explain the debris I saw. Here some pics. Random places. And there are more. I guess I'll never figure out what caused it. Nothing feel out of engine, at least nothing i'd have noticed.









Here a pic of the debris I found. Possible it was introduced at some point, dowel pin, maybe? Even though all are accounted for.

 

Could some of that grinding been done at the factory to take of slag or extra material at the seams? I am hoping that is what I am piking up as some of those spots look like cracks. I am guessing its marks from when they pored the engine cast.

All the bearings were good?

 

Bearings look good so far. Still a few parts to remove before I can clean everything and check thoroughly.