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something has gone horribly wrong piston hitting valve

  • Thread starter Thread starter m.qualls89
  • Start date Start date
m.qualls89 said:
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When I timed it the 1 was in line with the gasket surface and the 2 was straight up and down as specified. Now obviously they are not. I watched the piston go up and down on each stroke and it cleared the valve the first few times so I hit the starter just bumping it slightly. It went around a few more times then hit the valve again. I'm really at a loss of how it keeps jumping time, the cam chain is still tight...
Click to expand...

A strange situation, it looks like the cams have advanced past the crank, which is very odd as it is the crank that drives them.
 
I was thinking that there might be something down there. Ill look when I get home. And yes it is a very odd situation that the cams are advancing past the crank.
 
You might be able to see up to the crank from the oil pan. What I do to change gaskets is this.

Take off the tank and right side covers. Drain the oil. Then I take my big tarp and roll it up like a big pillow. Next I simply lay the bike over on the right side with the "pillow" under the engines points cover area. Do the work and then stand the bike back up.
 
Ok guys here is an update. And thanks to everyone who is following along and has been patient with me. So I put it back it time AGAIN, I watched everything catefully and it started binding up. Well it wasn't hitting a valve it was the cam chain binding. I could move it back counter clockwise but not clockwise. So I turned the tensioner knob and loosened it up a bit and I could turn it. About half a turn afterwards it jumped, the cams stayed still and the crank advanced. As soon as it happened I moved it counter clockwise out of curiosity and I could move it about a quarter turn either direction and the crank moved without the cams. Then it caught and all moved together after that quarter turn was done. Of course now it is out of time. So I'm in the process of taking the oil pan off to see if maybe the sprocket on the crank is missing a tooth, but its after 8p.m. here so time to get a shower gotta get up at 4:30. Ill get back at it tomorrow after work.
 
m.qualls89 said:
Ok guys here is an update. And thanks to everyone who is following along and has been patient with me. So I put it back it time AGAIN, I watched everything catefully and it started binding up. Well it wasn't hitting a valve it was the cam chain binding. I could move it back counter clockwise but not clockwise. So I turned the tensioner knob and loosened it up a bit and I could turn it. About half a turn afterwards it jumped, the cams stayed still and the crank advanced. As soon as it happened I moved it counter clockwise out of curiosity and I could move it about a quarter turn either direction and the crank moved without the cams. Then it caught and all moved together after that quarter turn was done. Of course now it is out of time. So I'm in the process of taking the oil pan off to see if maybe the sprocket on the crank is missing a tooth, but its after 8p.m. here so time to get a shower gotta get up at 4:30. Ill get back at it tomorrow after work.
Click to expand...

Check those cam tensioner guides I referenced on post 64, there's a link that shows the parts if you click on it. It could be a nut, bolt or something on the chain or sprocket that's a foreign object not supposed to be there binding it up.
 
Well the link jusy goes to a homepage when I click it. How do I pull them out?
 
Maybe because I'm on my "smart phone" lol ill try the computer in the morning.
 
Once the camshafts, cam chain tensioner and spark plugs are removed, you can turn the engine over by pulling on the cam chain by hand. You will be able to feel if it is catching on anything or something is stuck in the crankshaft sprocket causing the cam chain to misfeed or skip. I really doubt that is the problem.

Your photo to me looks like you're off by one pin on the intake cam sprocket and off two pins on the exhaust cam sprocket.
 
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First I want to say THANK YOU to all who have helped me through this ordeal. Without guidance and ideas of what to try and look for I would've been lost. I found the culprit causing me to jump time! It was the half moon cam end cap that I lost and could never find! I'll post pics below but one more thing guys. What is the best gasket to get? I need cam chain tensioner, valve cover, oil pan, and the cover on the left side of the case is leaking also. I'm going to try to put it back in time and see if it holds compression or if I need to put new valves in it. I really don't wanna spend the $ if I don't have to as I would like to put some sportier cams in it since it has oversized pistons. and that is gonna take some saving up. Any suggestions on cams? Once again thanks alot guys!
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m.qualls89 said:
First I want to say THANK YOU to all who have helped me through this ordeal. Without guidance and ideas of what to try and look for I would've been lost. I found the culprit causing me to jump time! It was the half moon cam end cap that I lost and could never find! I'll post pics below but one more thing guys. What is the best gasket to get? I need cam chain tensioner, valve cover, oil pan, and the cover on the left side of the case is leaking also. I'm going to try to put it back in time and see if it holds compression or if I need to put new valves in it. I really don't wanna spend the $ if I don't have to as I would like to put some sportier cams in it since it has oversized pistons. and that is gonna take some saving up. Any suggestions on cams? Once again thanks alot guys!
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Click to expand...

At least you found your half moon. I was going to ask if you were missing any tools, nuts, bolts, screws, washers, etc, but I figured you would volunteer that information unless you didn't know about it. Even though you created allot of work for yourself by accident you may very well have saved the head (hope).
 
rustybronco said:
If you set everything correctly and the chain tensioner is working properly, is suspect something has fallen onto the crank gear allowing the chain to jump over the gear.
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It's the only thing that made any sense...
 
Well, it looks like this story might have a happy ending.Glad to hear that. On the gasket subject, I just got a real gasket valve cover gasket made out of silicone. Not cheap, but it looks like it will be reusuable many times. Most people suggest using factory made gaskets. The valve cover gasket I got was $27.00 plus shipping. They come out of Tenessee.
Curt
 
Some say they have had little sucess with Real Gaskets as far as them NOT leaking. Seems that if you torque the bolts to spec, the silicone squishes and can tear..thus they leak.

Some have suggested the cure for this is to use semi permanent loctite and just barely snug the bolts. I am not so sure I like this idea. Another member here that I am friends with had one and never got it to stop leaking. Went to OEM suzuki gasket and not a drop.
 
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