Something gouged the dipstick shaft?

[dinkydonuts]

So I finally got a new cylinder head put on, and then it took a few days of pulling my hair thinking there was an air/fuel problem, and it turned out the left side ignition coil had a disconnected wire. Let's just say I may have run the engine on one cylinder a few times, but it was quick to die each time (within a few minutes).

She finally started up, although the damn idle air screw was far too in and immediately revved to 5k RPM until I shut it off.

There is an intermittent noise I'm hearing now that seems to be coming from the head, so I will be tearing it down AGAIN to check the valve clearances (they were all within spec when I built it up).

Then, I go to check the oil and if my memory serves me correct, there wasn't a 1/2 inch gouge in the dipstick shaft about an inch above where the measurement hashes are.

I pray that I don't have to play mechanic anymore, but is there even anything in the crank that would be close enough to damage the dipstick? Keep in mind that all my work was done on the cylinder HEAD, so I never had the cylinder block off, and to the best of my knowledge, nothing fell into the crank case except some light dust when I was taking off the old head. The dipstick was always put in as intended (not at an angle or anything) and really it only threads in if it is in there correctly.

Pictures and video below:

http://i.imgur.com/DhmJmNb.jpg


In the video, you can hear it better at around 35 seconds in. The sound only occurs every 2-3 seconds or so. Sounds like someone clacking some wood dowels together.

[weedahoe]

Look straight down through the dipstick opening and you will see some gears

[dinkydonuts]

Look straight down through the dipstick opening and you will see some gears

I saw that, but this still makes no sense. The dipstick really only threads in a certain way, and in that position it shouldn't be touching anything inside.

Do either the primary drive or the clutch have a way of popping out?

[adidasguy]

Did you take it in or out with the motor running?
Is it bent - even the slightest bend and it can scrape gears.
Did you run the bike with it just sitting in the hole, not screwed in?

[dinkydonuts]

Did you take it in or out with the motor running?
Is it bent - even the slightest bend and it can scrape gears.
Did you run the bike with it just sitting in the hole, not screwed in?

None of those....

I'm hoping this is a case where the gears are harder than the dipstick and I've just got some shavings at the bottom of the pan. I plan on putting in fresh oil and a filter, anyway, so that should hopefully help.

Otherwise, I guess I'll be taking off that right side cover and checking for damage. I was glad to see that anything that could have been affected should hopefully be serviceable with the right side cover off (and not the engine out of the frame).

[adidasguy]

Picture of the dip stick?

Dipsticks are soft steel. Gears are really hard.

It could have gotten dinged at anytime and you might not have noticed it for a while. Tight clearances for the dip stick so if motor running or dipstick loose, crooked or not seated it might get scraped by a gear.

Any shavings would have fallen right down to the oil pan. They would get filtered and if you had a magnetic drain plug, might end up there.

[dinkydonuts]

Picture of the dip stick?

Dipsticks are soft steel. Gears are really hard.

It could have gotten dinged at anytime and you might not have noticed it for a while. Tight clearances for the dip stick so if motor running or dipstick loose, crooked or not seated it might get scraped by a gear.

Any shavings would have fallen right down to the oil pan. They would get filtered and if you had a magnetic drain plug, might end up there.

Thanks for the advice. I'll try to get a pic of the dipstick against a clear backdrop.

That aside, today it was 65*F here, so I changed the oil and WENT OUT AND RODE AND IT WAS AMAZING. 

[The Buddha]

I have seen damaged dipsticks a plenty. Especially on honda's, those are plastic and go deep in the case. Literally under your foot. The biggest reason is Idiot owners are careless ... they sit it on the seat when filling oil, the thing  rolls off ... they step on it etc etc ...
I wouldn't worry too much ... just make sure its not loose in the cap, its held in with a tension pin.
Cool.
Buddha.