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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Terrible engine knock. 2004 Suzuki LS650 /cgi-bin/YaBB.pl?num=1426644682 Message started by CodyAlanB5 on 03/17/15 at 19:11:22 |
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Title: Terrible engine knock. 2004 Suzuki LS650 Post by CodyAlanB5 on 03/17/15 at 19:11:22 Hey there, I recently bought a 2004 Suzuki Savage LS650 for a bobber project, it was a very clean bike with 19,000 miles and I paid 900 dollars for it. All is good, I have changed out the cam chain tensioner, changed oil, and performed the valve check. All these things have definitely improved the bike, but it has a terrible knocking noise, almost sounds like it is coming from the jug. The knock is most noticeable when the bike is under load, I mean it is a clang clang clang clang. Is anyone familiar with this, I know character engine sounds when i hear them and this is my third savage, but this sounds like knocking on something solid... |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by Kris01 on 03/17/15 at 19:14:27 Are you in the "right" gear and not lugging the engine? |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by justin_o_guy2 on 03/17/15 at 19:19:38 You installed a Verslavy tensioner? |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by CodyAlanB5 on 03/17/15 at 19:20:16 yes replaced the cam tensioner. |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by justin_o_guy2 on 03/17/15 at 19:25:58 You didn't answer the question.. |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by CodyAlanB5 on 03/17/15 at 22:09:39 Yes I replaced it the the Verslagen cam tensioner... |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by Dave on 03/18/15 at 03:23:46 Two of the forum members on this site (and I am one of them), have been fooled into thinking we have serious engine problems....and after tearing the entire engine down to the cranksahft - have learned that the flywheel nut have loosened. The flywheel and crankshaft joint is splined, and at low rpm's the darned thing bangs and rattles horribly. The noise is somewhat of a "clank" sound with each power pulse of the engine. As the rpm's increased the noise is somewhat reduced as the power pulses are more even, and at a high cruise speed you really can't hear the clanking over the road noise. The noise is hard to locate, as the left side of the crank does not touch the left side of the case...the clanking noise goes through the crank bearings into the case, and then can travel up through the cylinder and resonate through the fins. The bad news about this, is that it is not all that easy to check. You have to removed the left engine cover, remove the rotor with the special puller, then you can access the flywheel nut.....you will need a large deep socket and a holder for the flywheel to torque it to the 100 ft. lbs that it requires. I would first check and see how tight it is.....in both instances that this noised showed up the nut was finger tight. I would remove the nut and clean all the threads to remove the oil, and then install threadlocker when you install it and torque it down. You will most likely need a new gasket, and be careful with the washers on the starter torque clutch - a washer will be on both sides - with no washers on the other idler gear next to the starter. |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by MnSpring on 03/18/15 at 13:15:46 As being, that, ‘other’, person. :( I wonder how many others, have checked, the flywheel, when they, ‘hear’, a really terrible sound, like the motor about to grenade? If you do, and have had the same experience, please say so. Their could be another big crises averted. In my case, what was a ‘cheep’ bike, “Could”, have been fixed, with a relatively small application of, ‘elbow grease’, and (Borrowing) Special tools. Putting on new rubber, then Ride. Instead, it is now in pieces, and about 1/2 sold, http://tomradde.com/xt225/styled/index.html I would suggest, before ’throwing out’, this ICE, And you have done/tired everything else possible, to fix a, ‘loud, ‘clacking’, noise. See if, this loose flywheel/nut is the problem. All it takes, is 3 special tools, A new gasket, and time. Oh Yea, and probably some Amber Fluids ! ;) |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by verslagen1 on 03/18/15 at 13:37:05 I had a different clunk, probably typically called piston slap. the piston had burned and squeezed down on the rings. Still ran, couldn't find the cause till we tore it down. the small burn spot was visible from the top, if you had 1 of those eyeballs on a stick that'll fit inside the plug hole. |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by justin_o_guy2 on 03/18/15 at 16:37:13 someone had a noise that ended with the abrupt departure of the counterbalance weight. |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by FLDoug on 03/18/15 at 19:27:31 I had a clanging noise that was intermittent and when it occurred, it caused surges in power. It sounded like it was in the engine, but it turned out that a baffle in the muffler had broken loose and the clanging sound would resonate off the fins. At times, it would get wedged in the muffler, not make noise and the engine would run great. At other times it would get wedged sideways in the muffler and almost "choke off" the exhaust. I got the baffle straight drilled 3 small holes in the bottom and back of the muffler and inserted 3 sheet metal screws. It worked great for about 800 miles, then the same thing happened. I tried stainless steel pop rivets and they lasted about 1k miles and then I tried 1/4" self drilling screws and they lasted about 2k miles. My final solution will be to cut open the muffler and weld it in place. All that to say, that everyone who heard it, thought it was a terrible engine problem, but was not engine related at all. |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by CodyAlanB5 on 03/18/15 at 21:05:24 That Flywheel, wow, I don't know what but I just have a gut feeling that is what it is... This special tool? Why cant I just use a pulley puller? |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by Serowbot on 03/18/15 at 21:24:38 Relax just a little bit,... I remember that guy... He had welding on some balance weights that came loose and disintegrated... You haven't welding behind our backs, have you?.... :-/... ... might have been, Phelonious?... |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by verslagen1 on 03/18/15 at 21:32:24 220E0518200D000F2354610 wrote:
no way to get a grip on the sucka, the puller has the threads to match. |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by verslagen1 on 03/18/15 at 21:35:50 332C2A2D30370636063E2C206B590 wrote:
I think it was phelonious, or the other guy in WA decided to add a weight to the inside of the wrist pin so the high compression piston matched weights with the stock piston. weight came loose and jammed into the cylinder. |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by justin_o_guy2 on 03/19/15 at 05:10:34 Outsmarted himself,, bummer |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by Iceman4193 on 03/20/15 at 18:43:41 I think I may have this issue as well. It is like a metalic tap or dragging noise that seems to be coming from the jug. I figure it is either piston slap or the flywheel bolt. |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by CodyAlanB5 on 04/12/15 at 14:53:28 Well I checked the flywheel bolt, it was torque fine... So I am back to phase one... Thinking about just chunking the engine... |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by justin_o_guy2 on 04/12/15 at 16:43:14 I'm all about DIY, but I'd be consulting with a mechanic or three. Not just a Suzuki shop. |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by FLDoug on 04/12/15 at 19:41:45 Can you record it and post the recording so we can hear it? |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by Dave on 04/14/15 at 03:18:22 With the flywheel nut tight, and the cam chain secure....there really are just a couple things left to check. A few members have had cam lobe and rocker wear from using oils that are too low in ZDDP levels. Our bike does not have rollers on the rockers and the newer oils don't have an adequate level of ZDDP to prevent failure. This sound is more on the top end and sounds like really noisy valve clearance. You would need to remove the cylinder head cover to look at this....and it would be a good time to renew the seal on the rubber plug over the right front cylinder stud - which can cause a serious oil leak issue. There also have been several members whose piston is loose and making a lot of noise. If you don't find anything wrong with the cam or rockers then you need to pull the cylinder and see what it going on with the piston. With the cylinder off you can check the condition of the rod and crankshaft. If the piston is bad you can upgrade to a Wiseco if you want to spend money for the upgrade....or used piston/cylinders can be found for a reasonable amount. |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by justin_o_guy2 on 04/14/15 at 15:48:47 Knurled pistons |
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Title: Re: Terrible engine knock. 2004 Suzuki LS650 Post by KennyG on 04/14/15 at 16:55:42 Justin, Knurled pistons are from the olden times. I can remember for sure after I had a piston (or two) knurled for a motorcycle engine they seemed to last forever. Kenny G |
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