Jump to content
Sign in to follow this  

New crunching noise

Recommended Posts

Thats rite, my 2002 plated e with about 2,500 hard miles on it just started making a pretty nasty crunching noise in the top end while breaking in a new motorcross track. If I had to pinpoint where the sound was coming from I'd have to say the left side of the bike. It's not a constant sound, does not have a rhythm to it or any thing like that, but it be heard every 10 or 20 seconds at idle. It almost sounds like a rattle or when our motors shut off and take that half turn backwards. I already checked the stator to see if the bolts had backed out, but that whole area was tidy as when I did the loctite fixs. Valves where checked and in spec 500 vicious miles ago, oil changed to 15-40 ester based oil about 70 HARD offroad miles ago. I still have the ACCT so I'm not ruling that out, other than that the only other thing I can think to check is the starter...The bike is running amazing rite now and the sound cannot be heard nor felt while riding it. I'm stumped and trying not to chew my greasy nails rite now, someone splease shed some light on me.

Share this post


Link to post
Share on other sites

Might be worth pulling the valve cover off and just looking around. Post pics of the cam chain on the cams.

If you think it might be the starter, take the wire off the starter terminal and let it run. Although I'd be scared to let it run with much of a noise.

Share this post


Link to post
Share on other sites

I cant hear it under load, but then again i have a mrd/ssw installed.

Share this post


Link to post
Share on other sites

I could very well be mistaking this sound for a rock randomly rattling around under the skid plate, it just does not seem likle a common top end noise. Guess I need to check the cam chain to see if its loose...I thought the ACCT made them run to tight though..

Oh and the starter shaft seems to have the slightest bit of play in all directions.

Share this post


Link to post
Share on other sites
...I thought the ACCT made them run to tight though..

The 2002 models had the early ACCT where the failure mode was that it let the cam chain tension go completely loose when the cam chain tension on the "slack" (adjuster side) went too high - like under hard deceleration. Suzuki "solved" the problem with another version with a ratcheting mechanism, but it applies too much constant chain tension - prematurely wearing out the cam chain.

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Reply with:

Sign in to follow this  

  • Similar Content

    • By Bignerd0100100
      Hey all, 
      I'm looking at buying a 2004 Suzuki DRZ400EK or at least I think it's an EK according to Vin lookup websites, but it does not appear to have a kickstarter. I was told the bike was owned by a motorcycle dealer and that it has a current green sticker, and a California license plate but has not been registered for the streets since 2011. I want this as a dual sport but am not clear if the fact that it already has a plate means I am good to register it or if maybe they took away the ability to register it after it was plated, California loves to do that kind of stuff. Since the bike was owned by a dealer I would think they were up on the latest regulations in California, but who knows. Can anyone add any insight as to what I should look for on the bike itself like the carburetor, model numbers etc? Or do I just try my luck at the DMV?
    • By smokey9lives
      Hi,
      I have a 2003 DRZ (actually a KLX400) and the head tube bearings are shot.  I ordered a new set to install but I'm wondering if anyone has any recommendations on other parts I should replace while I have the front disassembled.  I was thinking about new rubber fork protectors, but are there other things that wear out on the DRZ front ends that you can only get to when disassambled?
      I also broke off a replacement key that I got for the steering lock.  I must have been made of cheap pot-metal.  Should I just remove the whole lock mechanism?
      Any tips or tricks for getting the old bearings out and the new ones in would be welcome!
      Thanks!
    • By antonyp
      Hey Guys,
      I recently bought a 2003 DRZ400S and thought it would be a good idea to check the valves clearance etc . I timed the engine on TDC with the magneto mark aligned as per the manual but I find the cam timing slightly odd. The arrows pointing upward are on the 1st and 15th pin as they should but with the magneto timing mark aligned they are not perfectly straight. Same goes for the arrows that should be parallel to the cylinder head casing. Is this normal or should they be absolutely perfect ?
       

×