Author Topic: Help! Something's broken off my engine! (Read 9150 times)

Cyanide · « **on:** October 14, 2007, 10:01:18 AM »

I was on my way out to pick my gf up from college the other day when I heard an alarming rattling sound at 70mph. I slowed down but it kept getting worse before eventually cutting out. I got it started again but there was a huge ratting coming from the right side of the engine every time I touched the throttle, so I concluded that something had come loose/snapped off inside and called for a tow home.

I've just finished taking the engine covers off today. I've got both sides, the top and the oil filter off. I can't find anything loose in the bottom so far nor can I see anything missing that'd indicate something fallen off.

I'm getting rather worried as at the moment it's my only transport and as I'm moving to a flat with no garage in 2 weeks I'm really short on time, money and somewhere to store the damned thing while it's in pieces.

Does anyone have any ideas on whats the most likely thing to have come loose and how I can sort it quickly, ideally without having to take the whole engine out

Thanks guys

gsxr400 racer · « **Reply #1 on:** October 14, 2007, 11:40:42 AM »

rattling as in what , there are many rattles! cam chain , brocken rocker arm, rod knocking, bent valve hard to say mate let me know if i can help you out in anyway
cheers
jay

gsxr400 racer · « **Reply #2 on:** October 14, 2007, 12:44:53 PM »

also how many miles

Cyanide · « **Reply #3 on:** October 14, 2007, 02:32:51 PM »

Sorry, should have been more specific

It's a 1991 400cc with around 37k miles.

It sounds like there's a lump of metal in the bottom of the engine clanging about as it's hit by moving parts in the engine.

Hope that's a bit clearer

gsxr400 racer · « **Reply #4 on:** October 14, 2007, 03:12:24 PM »

i would say drain the oil and look in the pan you drained it into and see what you see then pull the oil pan off the bike, you say you have the side covers off and you didnt see anything loose have you grabbed the clutch basket and tried to shake that?
cheers
jay

turbofb · « **Reply #5 on:** October 14, 2007, 10:28:26 PM »

Sounds like a rod went.
Do you stay consistant with your oil level checks and oil changes?
37K isnt a ridiculous number of miles,but its up there, for a little engine like ours.If the knocking and rattling was enough to stop the engine from running,its probably going to be serious.Check the oil for metal flakes and chunks,then pull the oilpan as racer suggested.

pmackie · « **Reply #6 on:** October 14, 2007, 11:20:16 PM »

Hey Cyanide

Any loud rattle, knock or banging from the engine is likely something serious. Anything that comes loose, or falls off, is going to do some additional damage.

As the guys said, drain the oil and look for any metal particles, remove the right clutch cover and look at the clutch and primary drive gears for any damage.

Then go from there...

Cyanide · « **Reply #7 on:** October 15, 2007, 01:09:15 PM »

Well I've drained the oil and there was nothing in there and all the gears look in tact... but when I got a magnet on a stick and shoved it underneath the cogs it came back with small flakes of metal on it.

Am I going to have to whip the engine out to find out what's going on? If so does anyone fancy buying a project bike?

Cyanide · « **Reply #8 on:** October 15, 2007, 06:08:57 PM »

I've just taken the sump off and in the bottom were these chucks of orange fibre along with a large amount of metal flakes. Given the aparent circular shape of the fibre I'm thinking something to do with the pistons?

turbofb · « **Reply #9 on:** October 15, 2007, 06:54:15 PM »

Hmm......no fiber or nylon parts on the pistons,far as I know.

There are plenty of round objects inside an engine,so those could be from anything.....trans or clutch bushings, maybe.Im sure someone with experience opening up the B4 engine will ID those pieces quickly.

If you have access to the bottom of the connecting rods from the sump,try to give each of them a wiggle up and down and side to side.A failed rod would be obvious,as there would be very large parts scattered around the sump.But a spun lower rod bearing will give the same loud clanking,and only produce shavings and some bits of metal,unlike the catastrophic failure of a broken rod.

gsxr400 racer · « **Reply #10 on:** October 15, 2007, 09:54:05 PM »

you know i cant put my finger on that, but the the only thing that comes to mind is the oil pump gear behind the clutch basket. also while your at it take the oil pick up screen off and see what is stuck to that!

turbofb · « **Reply #11 on:** October 15, 2007, 11:40:13 PM »

Well,if the oilpump gear failed,that'd surely cause the big end to self destruct.......but youd also get an oil light on the dash as soon as the pressure was gone.

Cyanide,did you happen to notice if the red oil light ever lit up?

Banditmax · « **Reply #12 on:** October 16, 2007, 04:58:22 AM »

looks like gasket paper to me.

gsxr400 racer · « **Reply #13 on:** October 16, 2007, 11:01:42 AM »

you would see alot of brass if the big end went, could be gasket paper, Max. Your sure its fiber? Your clutch basket looks all intact? Is the red light not a low oil light and not a oil pressure light, i only say because some times when you start and stop they come on when they are going bad!

You know what that look like to me, it just hit me part of your fly wheel the coating that holds the magnets. Is the fly wheel loose would take a lot to wiggle it with the magnetic resistance and all, worth a shot.

Cyanide · « **Reply #14 on:** October 16, 2007, 05:57:24 PM »

It's definitely some kind of fibre/plastic/resin, hard to tell exactly what as there's not much of it.

Well I've taken another look around at the parts I can get to with the top, sides and sump off.

The cam chain looks fine and all the valves move when the engine's rotated manually, although there is a loose spot part way round when cranking.

I can't see anything out of the ordinary in there, there's nothing missing or broken as far as I can see except the metal in the sump.

There wasn't an oil light on when it went, the oil that came out was around 2.3l, which is about right. There was also no water in the oil and the coolant was clean so I reckon the head gaskets fine.

I'm thinking of ringing my insurance company tomorrow to see if my fully comp cover includes catastrophic engine failure and if not I'll have to cancel it and either find somewhere to lock the bike up till I can fix it (next year sometime) or see if I can sell it to someone who's got time to do it themselves.