Rebuilding Junior - died and LIVES AGAIN!

Started by adidasguy, April 28, 2012, 02:26:06 PM

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slipperymongoose

How many miles are on it? Looking at the gears. Your tooth wear is even which is good, I wouldn't worry just get all the metal out, go new slugs, small ends, barrels in good nick and yeah top end. Just pray no metal has made its way into the crank or big ends or journals.
Some say that he submitted a $20000 expense claim for some gravel

And that if he'd write a letter of condolance he would at least spell your name right.

Big Rich

Hmmmm......plastic in the motor.......what about the original epoxy used on the stator? It looks like plastic after it gets old and thru some heat cycles.

Remember though, I've never touched a GS500. So this isn't the gospel.
83 GR650 (riding / rolling project)

It's opener there in the wide open air...

adidasguy

About 34k KM on the clock (Canadian so KM not miles). He's a 1992 model.
Since it happened on a down shift and the engine momentarily died until clutch released, I thought transmission. It seems a damaged piston due to the stress of engine braking is a possibility.

Big does suggest various possibilities. I suppose it might be wise to pull the head and jugs. if it is a piston, then it can be repaired in the frame. If not, it wouldn't hurt the check them anyway.

Any more ideas based on my previous post and still what is the plastic?

adidasguy

#43
as a PS: I went no more than 10 miles after the problem first appeared at that down shift. Noise kept getting louder the longer I rode to get home.

PS. PS.: As I recall, the noise occurred when in neutral or the clutch pulled in. Seems more related to engine RPM. The transmission did shift through the gears - at least through 5th. I don't think I went fast enough to get into 6th. Oh, wait - I did get into 6th when the problem first occurred. So it did shift through the gears OK. Noise with clutch in or in neutral.

Plastic identified - yes it was epoxy from the magnet rotor as Big suggested.
However - I don't have any pet goats.

bombsquad83

With that much metal in the oil pan, I think you have something that's gone all wrong in the bottom end.  I'm pretty sure you will find it if you crack the case open and have a good look.  My guess is that it's time for a new bottom end for Junior.

Funderb

I bet you spun a bearing in a bad way.

I'm not thinking piston wear because you said it had normal power, and 10mi on a piston with unusual wear is ususally more than enough to destroy it.

Or your oil pump killed itself, its hard to tell without looking at it.  :dunno_black:

Just a guess from far away.
Black '98 gs500 k&n Lbox, akrapovic slip-on, kat600 shock, progressive sproings, superbike handlebars, 40/147.5/3.5washers

"I'd rather ride then spend all my time fiddling trying to make it run perfectly." -Bombsquad

"Never let the destination cast a shadow over your journey towards it- live life"

mabrio

Sorry to hear that! But im sure he will get back on track soon!

Ride Safely!

Mabrio


GS500E - Classics
Dynojet Stage 3
K&N Drop in Full System S/S Custom
Barnett Clutch
Iridium DPR8EIX-9
Progressive Front Forks
RK O Ring Chain
GIVI 21ltr Mini Cruiser
GIVI Windshield
GIVI Monorack MR4

http://gstwins.com/gsboard/index.php?topic=58809.0

cobalta70

My guess is that the epoxy bits came off the rotor first. They would have then made their way to the sump/pump and plugged things up, reducing oil flow. The reduced oil flow would have then caused the rest of the carnage.

Question is, why would the epoxy have come off of the rotor in the first place?

madjak30

Arm chair mechanic...so could be totally off base...

But you mentioned the crank case was smokin' hot when you stopped...I'm assuming this was after the "klunk"?? and I'm with cobalta70, the plastic probably caused the intake for the oil pump to be blocked or partially blocked...little to no oil circulation would cause extreme friction issues (there's your heat)...then the break down of metal bits is from tolerances tightening due to the heat...metal could be bearings (brass & lead), oil pump, casing from journals (block is aluminum isn't it?)  and the play on your shift shaft is a little concerning...may just be a clip that's now bent or fell off, but there is probably a problem in there as well...but my guess is bottom end problems like a spun bearing.

You may need to rebuild the spare engine to go into Junior, then crack open Junior's engine case to see if it is salvageable...and all this at only 34,000kms ~ 21,000miles on the clock?  pretty early...crappy luck!  :confused:

Later.
** If you're not having fun, you're doing it WRONG**

Riding since May 2010


Check out my blog @ http://madjaksmotormouth.blogspot.com

scottychop

I'm still with you on the original plan of swapping bottom ends, or the whole motor for the spare.  You've got something chewed up inside that will never be clean enough to run without a total inspection.  My first, but reaction was oil pump.  Metal shavings could be just about anything down in the bottom end. 

1. Rebuild the donor motor.
2. Ride like the wind.
3.  Slowly and methodically open up motor number one and learn a bunch!


adidasguy

Pulled engine out of Junior. Now with 3 or 4 engines of parts all over the place I've reached the limit of a one man job. Have to wait for an extra set of hands to put something together. I know you should have 2 people to put a head on so the pistons go in the jugs. Plus I need an expert to advise me.

I'll now tidy up this weekend. Maybe try to take the head off of Junior to see if the pistons were what broke.

Here's the mess as it now sits.


codajastal

I am not interested in anything you have to say
Don't bother talking to me, I will not answer you

slipperymongoose

Some say that he submitted a $20000 expense claim for some gravel

And that if he'd write a letter of condolance he would at least spell your name right.

codajastal

I am not interested in anything you have to say
Don't bother talking to me, I will not answer you

slipperymongoose

Suppose you could do tge camera work
Some say that he submitted a $20000 expense claim for some gravel

And that if he'd write a letter of condolance he would at least spell your name right.

codajastal

Quote from: slipperymongoose on May 05, 2012, 06:29:43 AM
Suppose you could do tge camera work
fark you. Don't bother calling me next time you need a hand then :flipoff:
I am not interested in anything you have to say
Don't bother talking to me, I will not answer you

slipperymongoose

Some say that he submitted a $20000 expense claim for some gravel

And that if he'd write a letter of condolance he would at least spell your name right.

adidasguy

Anyone can fly in to help. I have a spare bedroom and lots of parts you can take home.

adidasguy

Seems I have identified the problem.
This bolt/gear should not move (other than rotating).
It might be why Junior was slowly making more noise and just went out on a down shift. So seems tran is OK and pistons are fine.

Please watch the video
http://www.youtube.com/watch?v=Atq4nKfh7kg



slipperymongoose

From what I can gather from looking at my haynes manual that is your balancer shaft. And in the book it doesnt say anything about play in the shaft. So bad news is that its a block split to get at it, as for the culprit it may be your inner or outer driven gears something has gone wrong there possibly just looking at the exploded view in the haynes manual and guessing a bit. Its a bit hard to diagnose half way round the world and in a different hemisphere lol.
Some say that he submitted a $20000 expense claim for some gravel

And that if he'd write a letter of condolance he would at least spell your name right.

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