SuzukiSavage.com - 87’ experienced a “Rapid Unscheduled Disassembly”

Celeste

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87’ Savage. Favorite
Cougar I’ve met so
far.

Posts: 37
Joplin Missouri
Gender: male

87’ experienced a “Rapid Unscheduled Disassembly”
05/08/23 at 19:03:39

So there I was, licking BBQ sauce off her… wait. Wrong story.

Ahem, My savage experienced a “RUD”.
The counterbalance decided it needed to see the light, get more air, fly like an eagle, etc…

Everything else in the engine is fine.
But I have questions….

(1) Why? What is the point of failure, is there other components of the engine I should be concerned about before rebuilding?

(2) Rebuild, or totally (used) new engine from EBay?

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Celeste YaBB Newbies Offline 87’ Savage. Favorite Cougar I’ve met so far. Posts: 37 Joplin Missouri Gender:	Re: 87’ experienced a “Rapid Unscheduled Disassemb Reply #1 - 05/08/23 at 19:04:37 Stepping out into the sunlight!!!!
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Celeste YaBB Newbies Offline 87’ Savage. Favorite Cougar I’ve met so far. Posts: 37 Joplin Missouri Gender:	Re: 87’ experienced a “Rapid Unscheduled Disassemb Reply #2 - 05/08/23 at 19:05:51 More pictures of the “Rapid Unscheduled Disassembly
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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5401 Manteca , CA Gender:	Re: 87’ experienced a “Rapid Unscheduled Disassemb Reply #3 - 05/08/23 at 21:58:42 How much time on the clock ? That’s the 4th one I’ve seen so far , in 7 years or so. That really sucks !
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DragBikeMike

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Re: 87’ experienced a “Rapid Unscheduled Disassemb
Reply #4 - 05/09/23 at 01:58:57

RIP. That motor is done. Salvage whatever parts might still be serviceable. Look for a replacement engine. Sorry for your loss.

These balancer blowouts are scary. It would be of great benefit to all of us if you could post some more photos.

Since the balancer is out of the way, could you take a picture like this one. See that drive pin circled in red. Do you have one of those sticking out of the crank, or possibly in the bottom of the crankcase?

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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4471 Honolulu	Re: 87’ experienced a “Rapid Unscheduled Disassemb Reply #5 - 05/09/23 at 02:00:47 That particular pin drives the balancer drive gear. It is pressed into the gear and rides in a hole in the crank. When things are correct, it should look like this, nice and tight in the drive gear.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4471 Honolulu	Re: 87’ experienced a “Rapid Unscheduled Disassemb Reply #6 - 05/09/23 at 02:03:21 Take the driven gear off the balancer shaft and inspect the drive key. Your pictures looks like the key may have failed. Can't tell for sure until you remove the gear. Is the key in good shape or does it look like this?
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DragBikeMike

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Re: 87’ experienced a “Rapid Unscheduled Disassemb
Reply #7 - 05/09/23 at 02:18:44

When you did your cam chain job, did you remove the cam sprocket from the end of the crankshaft? That particular sprocket is easy to break. The nut that holds on the primary drive gear and cam drive sprocket is left-hand threads. It's easy to overtighten the nut and fracture the drive sprocket. You must have at least removed the primary drive nut to retime your cam. How did you reassemble? Did you tighten it up with a torque wrench? What torque value did you use? ..........or......... Did you use a rattle wrench?

When the sprocket fractures, you lose the pinch that locks everything together on the crank. Once the pinch is lost, the system relies solely on that round drive pin to drive the balancer drive gear. The continual back & forth motion works the drive pin loose and the the balancer system goes out-of-time and the rod hits the balance weight. Kaboom!

This is a good drive sprocket.

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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4471 Honolulu	Re: 87’ experienced a “Rapid Unscheduled Disassemb Reply #8 - 05/09/23 at 02:20:13 This is a failed sprocket. I suspect the primary drive nut was overtightened, which caused the sprocket to fracture.
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Dave

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Re: 87’ experienced a “Rapid Unscheduled Disassemb
Reply #9 - 05/09/23 at 04:07:06

Wow.....I hate when that happens!

Ebay engines are a somewhat of a gamble. Some of them look like they could be running engines....a lot of them are are projects and need to be taken apart and built back up from the bottom. I see very few of them that are in good enough shape to "bolt in" and expect to be reliable.
.
Stuff like this is just insane:
https://www.ebay.com/itm/385587538743?hash=item59c6ceeb37:g:SiEAAOSwurtkUX55&...

I don't know your mechanical abilities....if you could get a good bottom end it is likely that you could build an engine using your existing top end. Gaskets/seals, etc always adds a considerable amount of money for me, as I never assemble an engine using 30+ year old rubber/paper parts. I also split the center cases and renew the sealant to avoid oil leaks.

Something like this might be a bolt in.....you have to pick it up in Florida.
https://www.ebay.com/itm/275752965059?hash=item40342853c3:g:xQMAAOSwZTFkGCnX&...

I have a 5 speed bottom end with a bad pulley shaft I will give you if you pay shipping......it has all the parts you need to replace your broken parts - except you will need to get a 4 speed case if you want to use your transmission (or you need a 5 speed output shaft or gear set if you want to use the 5 speed case).

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Celeste YaBB Newbies Offline 87’ Savage. Favorite Cougar I’ve met so far. Posts: 37 Joplin Missouri Gender:	Re: 87’ experienced a “Rapid Unscheduled Disassemb Reply #10 - 05/09/23 at 05:03:15 I intend to do thru and post everything that looks like a point of failure for the benefit of riders. I will be waiting until I obtain another engine.
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Celeste YaBB Newbies Offline 87’ Savage. Favorite Cougar I’ve met so far. Posts: 37 Joplin Missouri Gender:	Re: 87’ experienced a “Rapid Unscheduled Disassemb Reply #11 - 05/09/23 at 07:05:12 There’s no Pin. It’s gone. Must be the point of failure.
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och Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 639	Re: 87’ experienced a “Rapid Unscheduled Disassemb Reply #12 - 05/09/23 at 16:42:56 That is crazy, but at least used Savage engines are not very expensive.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: 87’ experienced a “Rapid Unscheduled Disassemb Reply #13 - 05/09/23 at 19:55:04 och wrote on 05/09/23 at 16:42:56: That is crazy, but at least used Savage engines are not very expensive. Dave showed us one that is Stuff like this is just insane: https://www.ebay.com/itm/385587538743?hash=item59c6ceeb37:g:SiEAAOSwurtkUX55&...
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och Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 639	Re: 87’ experienced a “Rapid Unscheduled Disassemb Reply #14 - 05/09/23 at 20:52:26 Someone needs to swap a KTM 690 engine into the Savage.
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