clack-clack-clack the cilinder head

[crazyfrog]

Hello. I am new to this forum. I have a GS500 with a "re borne" engine (new genuine pistons, piston rings, bearings, shims, gaschets).

my problem it is a clack-clack-clack in the engine. The sound appear to be from cilinder head.

this noise appear RANDOMLY only at idle with worm engine. The sound disappear progressively when increase rpm.

I check the valve clearance EX 0.04 and 0.04  and IN 0.04 and 0.05 .

Can you help me with this problem ?


PS: before this post i search this forum , and i found some posts related to this problem. sorry for my english.

[crazyfrog]

i have an .avi with that sound: http://www.motociclism.ro/forum/index.php?act=Attach&type=post&id=165903

[Jughead]

Before you do Anything Else Check the Counterbalance Shaft.Drain your Oil in a Clean pan so that you can reuse it and Look for metal shavings.If there aren't any pull the Oil Filter and Look there.The Counter balancer was bad in Mine when I bought it and it sounded like it was In the head too.I don't mean this to Scare you just Check it out just in Case.If it is the Problem you may be able to catch it before it kills your Cases.

[crazyfrog]

so the Counterbalance it is possible to be wrong assembled (if the two points do not match) - this is a new theory  - but if  this is true why the sound come and go randomly?
Can you tell me how can i check if Counterbalance it is ok without "crack the engine" ?


most people think that problem become
a- from valve clearance which is to small
b- from cam shaft end play

So can somebody tell me what can i do ?


PS: today i will change the oil. I hope this will solve the problem.

[spc]

OK  I'm a geology major, so I don't really care about grammer and all that BS, but holy shaZam! your post made my head spin!!!!!!!!!  Using the appropriate tense helps occasionally.  Also using the appropriate plurality of a word will make your post much more easily read.  Observing these rules will probably get you more responses   I need another beer after that post  and I just left my baby ( the GS ) behind a bar amd caught a taxi home, seeing as I tried to use my ID in the ATM.

[crazyfrog]

sorry for my english, it is not mai matern language. my english it is very very BAD.  SORRY

[spc]

Ohhh...shaZam!  I'm sorry then!!!  For english to be a second language you did fairly respectably    I deal with people who supposedly speak english as a first language all day and they speak it worse than you......  as far as the noise it could just be the minimal amount of play in the camshaft that suzuki never saw fit to change.  It doesn't really affect anything performance-wise, it's just a little annoying at stops.  So, i'd probably vote for camshaft play.  it's very common with the GS.  If your counterbalance was messed up you would be noticing a large amount of vibration.   Again, I'm really sorry about that little rant.  your english is very good for a second language.  Any other questions just ask.   What is your maiden language, just out of curiousity??

[crazyfrog]

Hello GS500 World!
My name is Cristian Vasile , i am from Romania/Bucharest. you can find some thing about me at http://ro.facebox.com/cristianvasile78 (under construction)

I have a '91  GS500  (GM51B) .

[spc]

Again, i'm really sorry, i feel like a complete ass!!!  the GS is a great bike!!!  hope you get it going strong.   So I take it you speak russian??  I took a semester of russian, it scared the hell out of me.  i know how to say  ' I need Vodka' and that's about it.  Seriously though, if you speak russian and your english is that good,  awesome job, there is a huge difference in the languages that most people never consider

[Jughead]

Welcome Cristian

The reason it could be Coming and Going is because the Bearing that goes Around the Left Side of the Counter balance Shaft could be Turning in the Cases.One Underneath the other and Chewing the Cases up.

If your Oil Comes out Clean without any Shavings and Isn't too Old it will be OK to reuse it.Other thanChecking the Oil for Shaings that is Just About the Only way without taking the Clutch Cover off and Inspecting for Damage.

I could be Wrong it is possible that it is Cam End play or Possilby a loose Cam Chain. I'm not a GS500 Expert.I usually Stick with Two Strokes but Know Enough From My tear down to know How everything Works Pretty well.

[crazyfrog]

in 450km from first start of the "new" engine i do not noticed some annoying different vibration, and most of the time the engine runs fine and smooth.


off topic:

so to clarify some aspects, in Romania the people speak in 90% Romanian language which is derived from LATIN language and it is like french. The Romania it is a "Franco-fono" country. I two words the Romania it is a great country situated between two big empires the capitalism at west and communism ant east.

But this topic it is for my bike problem. If you have some question about me or my country i am happy to answer.

[spc]

I knew Romania was near the Russian states........  Even considering the tie in that both english and your language are Latin-based,  your english is good.    I  checked online and it looks like Romania has some awesome country-side in which to ride!!!!

[Egaeus]

That could very well be camshaft end play.  It's known to be intermittent.  If it was something like piston slap, it would be regular.

You might take off the valve cover again, grab the camshafts and see if they move back and forth and make that noise. 

If so, then I know that you can get "special" washers to fix the problem from Suzuki, but I don't remember the part number or specs.  A search of the site would probably help you with that.

[crazyfrog]

That could very well be camshaft end play.  It's known to be intermittent.  If it was something like piston slap, it would be regular.

You might take off the valve cover again, grab the camshafts and see if they move back and forth and make that noise. 

If so, then I know that you can get "special" washers to fix the problem from Suzuki, but I don't remember the part number or specs.  A search of the site would probably help you with that.

10x a lot.

the part it is in image ? pls see the picture http://ro.facebox.com/cristianvasile78/photo/photoid=794341  (the arrow)

the cam shaft end play : the picture http://ro.facebox.com/cristianvasile78/photo/photoid=794503 it is corrent?

[scratch]

Yep, that would be it.

Another reason the noise goes away is the increase in oil pressure.  The oil pressure then lifts the balancer shaft and the shaft then floats on the oil.

You stated that there is only 450km on the new engine, so I would believe the cam is what is making the noise.

Did you rebuild the engine?

[onefastgs500]

counter balancer will give a steady sound NOT interrmittent the problem is most likely camshaft end play-shim w/ appropriate suzuki washers .

[crazyfrog]

yes. I rebuild the engine. All old and new(genuine) parts was checked by some people with experience in 4 stroke engines. I use the haynes manual. This is not my first engine rebuild.
I decide to rebuild the engine because "oil burn" - 1L at 1000km.


PS:
I am mechanic engineer but now that i do for leaving is programming (phone games). The mechanics is some kind a hobby and this engine rebuild was a challenge , "and i am going to win this fight" . This sound drive me crazy, and i want , most of all, to understand why this happened.

[weaselnoze]

i figured it out.  the sound is derived from the PINK WHEELS!!! hahaha nice bike man

[scratch]

Yes.  I rebuild the engine.  All old and new(genuine) parts was checked by some people with experience in 4 stroke engines.  I use the haynes manual.  This is not my first engine rebuild.

Then I wouldn't worry about the bearings; I suspect it is only the cam play.

PS:
I am mechanical engineer, but now what I do for a living is programming (phone games). The mechanics is some kind a hobby and this engine rebuild was a challenge, "And I am going to win this fight" . This sound drive me crazy, and I want, most of all, to understand why this happened.

Then you know what you're doing, but I can't explain the cam play.  Sorry.

[Jace009gs]

I'm not sure if you know what the top end sounded like before the rebuild, but from various other bikes I've owned the GS certantly makes the most noise from the top end......

Valves check
bearings [good]

spark/coil shortage? (would defently cause miss-fire and intermediate Poping sounds)
Most likely cam shaft related
-the cam chain tensioner is idiot proof....got to be a clearance issue