It stopped with a bang! Broke a valve.

[gsJack]

Decided I'd check the valve clearances on the 02 GS500 a couple days ago.  Has about 21k miles on it and I last checked it about 10k.

No change in valve gaps, no shimming needed, so I didn't change a thing.  I've mentioned that I had a sticking valve bucket (tappet) on the #2 exhaust valve here before.  It held the valve open a bit when cold but warmed up in 20-30 seconds and ran just great for the 17k miles I've had the bike.  Had good compression on #2 as soon as it warmed a bit, so I just let it go until now.

When I buttoned it up and started to crank it with a jump from the 97 GS winter bike appearently the exhaust valve stuck wide open and was hit by the intake valve and the cranking stopped with a bang.  I pulled the valve cover again and everything appeared OK.  Pulled the spark plugs and there it was.  Could see the intake valve hanging there at a strange angle.  Poked it with a long skinny screw driver and it fell off.

Crank will only turn a short distance in either direction now before it hits a stop.  Guess I'll have to pull the head now and check the damage.  Can't put it off any longer.    :dunno:

Sure glad the old 97 still runs good, won't be bikeless while I take my time working on the 02.

[mp183]

Sorry about your misfortune.
I took my 2002 GS to work today and was just thinking
that it's running better than new.  I hope I did not jinx myself.
Mike

[sprint_9]

That sucks.  Damn valves  :guns:

[davipu]

so are you intrested in a used valve and maybe a piston?

[dgyver]

That sucks. I always seem to trash the exhaust valves when they hit.

[scratch]

I hope it's only one valve that you need.

[Jake D]

This will be the perfect time to try to fit that twin turbo project you've been talking so much about !

[RedShift]

Ah man, Jack.  What a bummer.  Hope it's a relatively simple fix.

I was also feeling guilty that I hadn't checked my valve clearances since the 600 mile mark.  So I took it in to the local dealer to check'em.  They found all four to be within spec.

Haven't run the engine since I retrieved it.  You can bet I'll be crossing my fingers when I turn it over in a few weeks.

Glad you have a spare (bike).  Must make the pain just a tad more bearable.

Roy...

[The Buddha]

The exact same thing was wrong with the savage I just got. stuck exhaust hit by piston ... now somehow the spark plug seems to have hit the piston as well ... funny thing is the exhaust that is stuck is on the opposite side of spark plug ... plug in that bike goes on left and the right exhaust is stuck ...
Cool.
Srinath.

[werase643]

good thing valves are cheap

[The Buddha]

OK mine is more severe than I thought ... I have a broke off exhaust valve, and it was the closer one to the plug ... duh ... and a hole in the piston ... and there is many marks on the head from that exhaust valve flying around ... I know I should replace piston and rings, valves, guides and stuff, but do I need a new head ... or is one which looks like someone took a chisel to it ... salveageable ... and who will do it best for the least $$$ ...
More importantly ... did it hurt the bottom end how to tell ...
Cool.
Srinath.

[werase643]

Srinath
swap out one of your spare engines
save you a head ache

the diff between your and GSjack's bike....yours was running and really beat it up

since you have a spare...use it

[The Buddha]

I wish i could swap out the motor ... its no a GS its a sausage ... aka savage, 1 cylinder cruiser made by suzuki ... belt drive, nice small cruiser.
Heck we could attempt to shoe horn that GR650 motor of yours in it ...  :lol:
Cool.
Srinath.

[cernunos]

Srinath, wanna sell that ol' sausage? Watcha want for it? Love the Baby G and this forum.

C.......

[Blueknyt]

I got a complete GS450 that would fit in it,  twist a set of custom pipes out the side OCC style,  set of flashing sparkplug boots and some nice lime green LED's tucked into the frame work and we are Bling

[sprint_9]

Does it have an aluminum head?  If so you can probley take it somewhere and have it welded in and then reshapped, or just leave it alone.  We had a valve break off on the sprint car one year and fly around inside the engine, if I remember correctly we just left the head alone.  I think I would replace all the bearings in the bottom end since they most likely took some shock, but the main stuff should be ok, just check it over real close

[The Buddha]

Srinath, wanna sell that ol' sausage? Watcha want for it? Love the Baby G and this forum.

C.......

Love to ... but you are 1500 miles away .... thought you were getting one ... I am looking for a motor for it ... might make it easier for me ...
Cool.
Srinath.

[werase643]

Srinath,
I think the local shop has some big 600 cc single....
i think it came out of a savage

i'll check next week

[The Buddha]

OK the engine better be cheap and good ... yea the 2 most dreaded words ...
My bottom end is fine, rods are fine, the piston and rings $65, head parts should be under $125 ... yea 1 cyl ... whooo hoooo Labor ... maybe $50 at local car engine shop ... gaskets $50 ... yes the bloody thing adds up to the wrong side of 250 ...  but essentially I have a low low low mile (under 5K) bottom end on a new top end ... The dumbass wrecker I talked to wanted $800 for a 12K motor ... and 200 for a head ... I guess I'll re build mine with kibblewhite stuff at that $$ ...
Cool.
Srinath.

[dane_lindsay]

what exactly is valve sticking(besides the obvious)? what leads to it, and how does one know that it is happening?