Nice gauge setup . Might have to borrow it for a day . Also how did you adjust the mixture screws ,special tool?
Did you check valve clearances in the end? Though I think that rattle sounds like gearbox - when you pull the clutch in does it reduce the noise? It goes when you rev the engine, could be a wave in the timing chain. Idle is 25 revs per second, top end is 12.5, so it should be a faster rattle if the issue is there. P.S. if you switch the vac gauge to "dynamic" you can see if your valve clearances are different, and if you have the info, probably be able to know by how much.
With a little snap on flat blade screwdriver and a few burns from the radiator hoses I did valve clearances, timing chain, tensioner when I first bought the bike. Then I did clutch fibres, plates, springs and now the basket. Balanced the carbs on 3 separate occasions now. I am probably due for valve clearances again. I did flick the gauges onto dynamic briefly and everything looked fairly even I noticed that with all the vacuum stuff blocked off for balancing, and leaving the vac line for the fuel tap open to atmosphere, it revved a lot cleaner off idle. I think my next step will be to remove the primitive emissions doodad (fresh air valve) and fit a gravity fuel tap.
Shane, are you referring to Linkin or me in this post? My rattle goes away when bike is in gear and under load.
Do the Bearings ever make a rattle? I'm wondering if they're on their way out? The only other thing for me to do is split the cases and check everything for tolerances and spec. Not something I'm in a hurry to do.
Me either. While the basket was off, we checked the shaft, bearings felt totally smooth. Still leaves the other shaft though. In that photo, it looks like the head and bores are still attached. Can you just flip the motor and take the bottom off? If so, that's awesome... unlike the FZR motors where you have to take the head and bores off.
Yes, ZXR engine can be split that way. Was there any movement in the shaft? Normally, it's the other side bearing (drive shaft) that goes, but this rattle has me stumped. Anyone care to comment? Shane's Big-end bush issue doesn't sound (to me) like a rattle maker. More like a knock maker and an engine killer.
I big end bearing that is shot wont rattle.. it will be more of a knock and while it may be there at idle it would be most noticeable on dropping revs after giving it a big rev with no load.. Once you have heard a bid end about to go.. you never forget the noise.. ask me how I know
Yeah I know that sound, this was my R6 that let a big end go, it also had a cracked cylinder which was the cause of its blowby problems.
So, we're no closer to tracking down the rattle. I guess Linkin has checked solid plates for warpage and anything else clutch related?
You would have to think it is in the geartrain if the rattle goes away when you pull on the clutch...
Not quite. Since replacing the other clutch compontents (bearing, rod for the pressure plate, and the arm in the clutch cover) the clutch is very quiet. This noise only disappears when in gear and you load up the clutch (ie holding the front brake while stationary). On the move, it doesn't rattle at all.
You would still have to think it is in the geartrain... just exactly where will most likely remain a mystery unless either of you splits the crankcase and finds something obvious inside.
Pretty much. @Murdo was there when we fired it up. The rattle wasn't there previously when we fired the engine in the frame a couple of months ago. Only seems like a recent occurrence and seemed to get worse quickly. Dr. Murdo (Stethoscope in hand) checked it and it's definitely coming from the RHS of the engine. We thought cam chain tensioner failure or cam chain issue until I pulled in the clutch, put it in gear and eased it to take-up...and the rattle disappeared. I've had a quick look, but everything is where it should be, so I'll have to split it and have a look.
