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Post by colinjay on Apr 21, 2008 17:37:58 GMT -5
A question for Stew and Carl, or anyone else who has some experience with 500 engines.
Yesterday arvo as I pulled up at home on my XT500, I heard a strange intermitant "rattle" like noise comming from my engine. It sounded as it it was from the flywheel side of the crankcase. I wheeled the bike into the shed and removed the flywheel cover but all was ok (I had fitted a SR flywheel and stator over the weekend to get 12v electrics). Starting the bike up and running it for a few minutes at different revs I could not get the noise to reoccour. I have been thinking if it might be the LH main bearing turning in the crankcase? Has anyone out there ever had main bearings turn in the cases on these engines, I know I have not in my 25 odd years of working on them, but there is always a first time.
CJ
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Post by curly001 on Apr 22, 2008 1:51:23 GMT -5
Colin,
My first thoughts are one of the stator screws is loose or the flywheel is loose. Or the old favorite one of the engine bolts is loose. Curly
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Post by StewRoss on Apr 22, 2008 2:11:20 GMT -5
Hi Colin, Yes I agree look there first...also check to see if the screw heads are contacting on the inside of the flywheel...allen headed screws can do this as they're higher than the phillips head screws. Not heard of bearings turning...is the flywheel solid if you try to move it up and down? SR  |
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Post by aero on Apr 22, 2008 2:46:06 GMT -5
I've only ever seen mains spinning in the case on 2 stroke mopeds. Made a dry hissing noise with generally rough running of the engine.
Didn't have a stone or a bolt caught in the bash plate?
did you get that mikuni list OK CJ?
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Post by colinjay on Apr 22, 2008 17:36:30 GMT -5
On Monday afternoon I checked the flywheel nut and it was tight, I tried to give it a descent "wobble" but after the 20 minute flogging on the way home it was a bit too hot to handle.
Last night I took the flywheel of and YES, the two small screw that hold the inner ignition coil assy to the backing plate were stuck to the magnets inside the flywheel and the coil itself was just hanging sort of in the correct position. I had discounted the screw being loose since the bike had been running so well while I was riding it. The last time I ever tried to undo two of these screws, they gave me all sorts of grief, so I just did not expect them to come loose. Anyway, a bit of Loctite 222 will make sure they don't come loose again, and the bike ran ok on the way into work this morning.
Monday way just one of those days! On the ride into work, the speedo chucked a wobbly and started making stange noises then stopped working completly. On the ride home, going through a 60kph bend on the dirt road that I frequent, there was a loud bang/crash noise which took me by some suprise, especially since something "flashed" before my eyes. Turned out I had cut the corner a bit fine and clipped my LH mirror on a "white Kangaroo" (roadside guide post to non country Australians). The thing that flashed pased my face was the shattered remains of the mirror. THen getting hove to find a strange noise in the engine really made my day. Anywonder I hate Monday's!
Luckily I believe that things happen in threes, some the bike should be ok for the Phillip Haydon 6hr Road Trial on 3rd May that I have been getting it ready for.
CJ
Areo, I got the list. I might make me sound a bit strange, but I found it interesting that there is so little difference in the bore diameters between the sizes.
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Post by joneill4 on Apr 22, 2008 21:43:30 GMT -5
Duuuude, if you broke a mirror on a pole without hitting your hand, and heard catastrophic engine failure sounds coming from two wayward screws that didn't damage anything in their travels, I'd have to say that Mondays are your lucky day!
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Post by colinjay on Apr 23, 2008 1:02:31 GMT -5
I suppose looking back at it I probably was luck that it was only two screws coming out and not a bearing failure.
As to hitting my hand, I have "Barkbuster" handguard fitted so the pinkies are well protected. For serious dirt riding I will remove the normal mirrors, but for day to day riding to and from work I like the big stick out in the wind standard ones so I can see behind me. The head would have been well clear, as the guide posts are only about 3 or so foot high.
CJ
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Post by StewRoss on Apr 23, 2008 1:51:34 GMT -5
It's great to get it sorted isn't it... Must have cut in close to that sign! SR  |
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Post by aero on Apr 23, 2008 5:52:07 GMT -5
CJ Many happy hours have been spent with a micrometer and a box of tiny drill bits. Its good enough to get you in the right area, and buying the correct size jet (just for piece of mind) hasn't changed the way the engine runs over a jet I've drilled out.
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Post by colinjay on Apr 23, 2008 17:20:02 GMT -5
Stew, The bike is running well, had a great ride home from work and didn't cut the corner in question as close this time. Yes, it was a bit close Monday morning, but it was one of those "flexible" plastic guide post not a sign post, I am a bit more wary with sign posts, plus the mirrors stick out like Mickey Mouse ears (se pic).  Aero, If I get a change over the weekend, I want to check my set of number drills against the chart too see how well they line up with the jet sizes. CJ |
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Post by caferacercarl on Apr 27, 2008 2:27:18 GMT -5
Go stew, the recommendation on the stator screws was a winner, just got back from classic dirt5 CJ, oyu would have loved it, John Behrens rode my HL500 and said it was simply amazing, Joel Robert signed a program for me, etc ,etc, wish you were here... may come over for the XT,TT muster in SA, and sample the Knappstein direct from the brewery in the clair valley, AND, catch up with you... Carl.
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Post by colinjay on Apr 27, 2008 20:23:47 GMT -5
Carl,
I would have loved to have been able to make it to CD5, but it was just a bit too far for me. I used to ride enduro in and around that area back in the late 70's early 80's and probably would have been able to catch up with a few people that I haven't seen for years.
Some good did come for me staying home over the weekend. I meet a guy at the breakfast following dawn service on ANZAC day, who has a preocupation with 1970's Kawasaki AG bikes, he has over a dozen. Anyway in the course of talking he mentioned that he had the remains of a 1971 Honda XL250(K0) Motorsport. I went around to his farm and for $75 got myself an engine (and a lot of other bit) for the XL250 Motorsport that I have been collection parts for ever since I found a rolling chassis on the local garbage tip several years ago. Suprisingly the piston and bore (305cc big bore kit) in the engine are near perfect and the head has been re-bushed and is servicable there was also another servicable head and 2 servicable cylinders amoungst the bits. The only down side was the camshaft was missing. Hopefyully I should be able to pickup a "hot" camshaft. So I now have another project to add to the ever growing list of project bikes, this one I intend to build into a pre-75 MX bike.
CJ
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Post by StewRoss on Apr 28, 2008 5:07:45 GMT -5
Well done...the 305 kits make them go pretty well. My mate had one in a CB250 RS, and I rode one years ago that had a Motosport engine mounted into a CR250M chasis...great little bike! I went to a classic rally in Griffith otherwise I'd have gone down to the MX to get Joel Robert to sign something for me...ah well, I'll wait for De Coster to come out next time...I'll take the 370 tank to get signed! John Behrens eh...good rider in his day... SR  |
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Post by caferacercarl on Apr 29, 2008 3:16:34 GMT -5
You've got a 370!! you've been holding out on me,A or B? an RM i presume, what a bike!! all those years and I never knew......had I known about the honda CJ I would not have thrown away a complete engine when I shut the shop in Bathurst, a hot cam is only about $160 and at CD5 I saw a brand new forged 350 piston, $30, you guys really need to "fess up" about whats in the shed so I can get these parts for you when I see them.... regards Carl.
Oh, this Anzac day was the first that I could control myself over the memory of my very much loved pop Joe Batey, 243rd commando div, 6th AIF highly decorated and loved a curry and a beer with me, and rode a bike in the middle east campaign, a single.... there is a genetic link, at about 25 I even found out dad had owned a jam pot 500 AJ and a 350 matchy........thump thump thump......
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Post by narleyfab on Apr 29, 2008 11:02:41 GMT -5
CJ, I noticed you have a TT500/Husky conversion.I'm doing the same conversion and I'd like to see how others have addressed the carb clearance ,airbox and oil tank.
Thanks mate
Shawn
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