Knocking at 10,xxx miles.Resolved

[Badot]

My '91 has a rattle around 4-4.5k under load, possibly the same noise. Noticed it a couple months after I got it, was never sure if it was there before or it started when I replaced one of my valves. Been running it for well over 10,000 miles that way without a change. I think it might be some form of valve/cam noise.

[robfriedenberger]

Just the the gaskets, and hardware in yesterday. Depending on how tired I am when I get off of work in the morning I should have an update! 

[robfriedenberger]

Well I couldn't help my self I worked on it all day once I got home and here's the fished product!

http://youtu.be/regpJd-VFV8

It's running much better now!


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[robfriedenberger]

So another update, the white plastic cap has been repaired and it dose make a huge difference. After it broke I rode it a few miles and I was kinda giving up on the idea of a 500cc motorcycle, and "lack of power". I'm still not 100% sure what that cap dose or how it works I just know it did improve over all power, with that said who knows how much I was losing to the starter clutch.

[burning1]

The white cap on the carbs seals the vaccuum diaphragm chamber. The pressure differential between that chamber and manifold pressure is what causes the CV slides to raise and lower.

If the cap is broker, the chamber will normalize to atmospheric pressure. Since atmospheric pressure is always higher than manifold pressure, even at wide open throttle, the slide will never raise up. This severely restricts airflow into the engine, resulting in a massive loss of power. It also prevents the main jets from working correctly, since the jet needle is tied to the CV slide.

Basically, on the broken carb, you effectively wouldn't be able to get past 1/5 throttle or so.

Probably resulted in vibrations, since the issue would have thrown your cylinders way out of balance.

[robfriedenberger]

Burning1,

Thanks for the reply, I should of posted more information about the repair of the cap. So I did was took a finishing nail heated it up until red hot and pushed it though the other plastic tube, increasing the nail size until it was close in diameter. Than I used a hot knife to close up the existing hole.

[Black_Ghost]

hello,

Just picked up my 04 gs500f with the same sound from the lower left side of the engine. i have just taken the flywheel bolt out and my next question is does the flywheel actually come off with the  magnet housing with the 3 bolts or does the housing just come off and the flywheel stays on?

im at this point. just wanting to know if the flywheel comes off with it or stays there. thanks

[robfriedenberger]

Mike a spacer 36mm that fits inside the crankshaft (10mm) than thread the swing arm bolt into the flywheel. Now you will be able to remove the flywheel and get to the starter clutch


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[Black_Ghost]

Sweet thanks I'll try that tomorrow.

[robfriedenberger]

Check this out!

[Black_Ghost]

got it off thank you. That video is awesome as well.

Ended up finding one broken bolt and two loose bolts.

[robfriedenberger]

Yeah, mine were all lose and stretched, its kinda crazy that happens.
Use some thread lock and new bolts (got mine at ace), the book has the spec but i think its 15-20 lbs

[Black_Ghost]

Just wanted to give an update on my bike.

Cleaned everything installed new bolts with lock tight and new springs(mine were smashed) put it back together runs smooth at idle

Thanks for your help!

[robfriedenberger]

Glad that it worked out for you, yeah some thing weird was up with my pins/springs as well. But glad it worked out!

[HPP8140]

The 2002 GS I bought a week ago has a thud sound below 2-3k

There is a thud, then the rpm briefly drops less than 100rpm. Seems sporadic.

Does this sound like cam knock or starter clutch bolts?

Can't believe this!! Now this bike is probably out of commission along with my 95, which this was supposed to replace.