what did you wrench on today??

[Sandy]

A few weeks ago the wife and I went on a trip that included New York. For our 47th anniversary we bought ourselves a painting from a local artist, it was just the canvas no frame. So today I finished and hung the picture in it's new frame above our bed. I kinda like it.

V

[ATTACH=CONFIG]54593[/ATTACH]

Very cool Vince. I bet it matches very well all the other copper work you have in the house.

[Redman]

......My son and I started working on his bike, ...........

Any particular situation that is the main reason for this....?

.

[Steve]

That looks like fun, Steve!

And that is just the first one.

His bike was having problems. Caught the leaking petcock before any damage was caused. Have not replaced the petcock yet, so we decided to tear into his bike first. While we are waiting on parts and some machine work, we will likely get into Mrs. Steve's bike. It only needs steering head bearings, fork rebuild and brake pads. When all that is done, MY bike goes under the knife. It will look like this one, but will also get new pistons and rings in the process.

Gotta get them running good and looking right for our trips this summer. First to Brown County, then The Traveling Picnic, then our "little ride".

.

[Redman]

............
will look like this one, but will also get new pistons and rings in the process................

How does someone determine that need pistons and not just rings (the question that is delaying similar project for my bike).

.

[Carter Turk]

Fired up the Kat for the 1st time in 7 months.
It developed a weird ticking noise I thought was the cam chain tensioner, so I bought a manual one, noise is still there.
Not sure what I'm looking for, pulled the valve cover checked the valve clearance, all looser than when I did my last ride in September.
Adjusted them, still a ticking rattling sound when I fired it up. I picked up a used head last summer, lapped all the valves, new pistons, rings and a hone, did 20 heat cycles, bike seemed fine. Then a noise developed after a trackday. During the trackday a guy on modern gixxer came over in the pits and said I was blowing white smoke. Hmmm. I checked the plugs after the trackday, they were super white-running lean apparently. The jetting was exactly like it was before the top end rebuild. I pulled the carbs and bumped up the mains 2.5 sizes before the last ride, the bike seemed ok aside from the ticking, but I didn't rev it super hard.
I had intentions of pulling the top end, bought head and base gaskets, valve seals and exhaust manifold gaskets, but the rings only have about 400 miles on them, so the thought of tearing into it again seemed like a waste until I know what I'm looking for, which I don't.

I think I need another gear head to have a "listen" to help decide how to proceed.

[pete]

Fired up the Kat for the 1st time in 7 months.
It developed a weird ticking noise I thought was the cam chain tensioner, so I bought a manual one, noise is still there.
Not sure what I'm looking for, pulled the valve cover checked the valve clearance, all looser than when I did my last ride in September.
Adjusted them, still a ticking rattling sound when I fired it up. I picked up a used head last summer, lapped all the valves, new pistons, rings and a hone, did 20 heat cycles, bike seemed fine. Then a noise developed after a trackday. During the trackday a guy on modern gixxer came over in the pits and said I was blowing white smoke. Hmmm. I checked the plugs after the trackday, they were super white-running lean apparently. The jetting was exactly like it was before the top end rebuild. I pulled the carbs and bumped up the mains 2.5 sizes before the last ride, the bike seemed ok aside from the ticking, but I didn't rev it super hard.
I had intentions of pulling the top end, bought head and base gaskets, valve seals and exhaust manifold gaskets, but the rings only have about 400 miles on them, so the thought of tearing into it again seemed like a waste until I know what I'm looking for, which I don't.

I think I need another gear head to have a "listen" to help decide how to proceed.

Bugger! Is it an exhaust gasket leak at all? I do know a guy who had a weird ticking sound and thought he had a head issue only to discover he hadn't quite filled the oil enough. Topping it up made it go away... I suspect that's not your issue but thought it worth a mention...

[Carter Turk]

Bugger! Is it an exhaust gasket leak at all? I do know a guy who had a weird ticking sound and thought he had a head issue only to discover he hadn't quite filled the oil enough. Topping it up made it go away... I suspect that's not your issue but thought it worth a mention...

Hey Pete,

I think it's much worse then that, but I don't know for sure. It sounds more top end related, but could be lower, who knows. I'm hoping not a connecting rod or main bearing, however the sound is more rattly/smaller sounding, not a big knocking/lumpy sound. I recorded the sound on my android phone, but I'm too inept at knowing how to post it here. It would be great to get some 2nd opinions on what might be going on, as it sounds terrible at the moment.

I do have a new to me trackbike (04 750) to try this year, but I'll miss riding the Kat.

[pete]

Fingers crossed it's nothing too major! I understand missing riding the Kat... I've never ridden mine yet but I already miss it

[ddaniels]

Hey Pete,

I think it's much worse then that, but I don't know for sure. It sounds more top end related, but could be lower, who knows. I'm hoping not a connecting rod or main bearing, however the sound is more rattly/smaller sounding, not a big knocking/lumpy sound. I recorded the sound on my android phone, but I'm too inept at knowing how to post it here. It would be great to get some 2nd opinions on what might be going on, as it sounds terrible at the moment.

I do have a new to me trackbike (04 750) to try this year, but I'll miss riding the Kat.

My old GS1000G had a mysterious ticking noise that increased in speed with RPMs. I never figured it out while I owned it, but a later owner found out it was due to cam walk, or side to side cam movement. I'm not exactly sure what he did, but something to do with machining a specific thickness spacer or shim to take up the slack, and that's the extent of my knowledge on the subject. You should check into it on your bike.

[Grimly]

Exhaust leaks at the head sound just like something dire is going wrong, every time.

[Steve]

Any particular situation that is the main reason for this....?

.

It is leaking oil on his left boot and pant leg. Visible seepage from head and base gaskets.

How does someone determine that need pistons and not just rings (the question that is delaying similar project for my bike).

Well, the PROPER way to determine that is to measure the piston and the cylinder to see if they are both in spec. HOWEVER, ... I know I will be taking my bike down to replace the base gasket. I don't have that many miles on my bike (about 30k), but since the pistons will be hanging out in the breeze, I thought it would be a good time to replace the rings, as well. I have a set of NOS pistons that I got a few years ago as spares, so I figured it would be a bunch easier to just put the new rings on the new pistons and swap complete assemblies. Yes, I know to check the end gaps before installing, it will be done correctly.

.

[Steve]

Now, to answer what I wrenched on, I got the head and block back from the machine shop. I have seen some nice machine work before, but have never seen one quite like this.
Please note: I did not do anything more than wipe off fingerprints.



I don't think I got ripped off for $45. Yeah, another $45 for the top of the cylinder block.

.

[pete]

Oooh shiny! That's some nice work right there Steve!

[aclaytonb]

Built my own leakdown tool and tried it out. Good readings - all below 5%. Had my daughter help me disassemble the carbs in preparation for getting in some new jets for the 4-1 leanness I'm seeing. Also finally scored a #3 carb body for $20. Time to fix that wallered out pilot mixture jet.

[aclaytonb]

Doh. Pulled airbox to rejuvenate carbs (ref above carb pull) and noticed the airbox / air cleaner box gasket was half dislodged. Theres probably my leanness issue....