kz900 strange engine noise

In the meanwhile I have done just a little bit more of polishing. When I finished with my engine , people will have to wear welding goggles when they looked into the engine :laugh:

Also I made some special tools. Clutch basket and alternator rotor holder tool.

Next is rebuilding of camchain tensioner. I replaced tensioner shaft, bearing and bearing bushing.

Also, replaced complete starter clutch assembly.

...and rebuild starter motor...

...new rubber and new cables on alternator stator.

...weld 2 new nipples on alternator cover, and little more of grinding and polishing :silly:

Then I throw myself on assembling this poor old engine.

and finaly got this.

Engine first start was almost to easy. I kicked kickstarter few times without contact, then I turn the key, open chocke and start engine with kickstarter. It start from first attempt.
Then I try starting it with starter motor, and it start in a sec.

The only bad thing after all of this, is that I still have this annoying tuck-tuck....tuck-tuck sound from inside my engine I realy dont know what to do about that.
I was listening this sound and count with my stop watch. I count about 100 tuck-tuck sounds in 1 minute on 1000 rpm.
When engine is cold there is no that sound, just when engine is hot, after driving. When I pull clutch lever I still can hear that sound, in neutral and in all gears I can hear it till 2000rpm. Above 2000rpm there is no that sound or I just cant hear it.
Thing that driving me crazy is that, when I lean motorcycle just a little on the right side, sound disappear :blink: I dont know what part inside engine has this ability or some kind of free play to produce this sound!?
Beside that sound, engine works just perfect, has plenty of power.
Any kind of advice is welcome...

We needed a feature article on this bike but it seems you have posted it.

Great craftsmanship. Great work and great pictures.

I have one engine that has a weak oil pump and i have to keep the rpms up. Can you check your oil pressure?

It would make a big mess to run the engine with the cam covers off just to see if the engine was oiling good.

Did you repair (weld) the cracked area in the engine? Roy

Yes, I weld the crack, sanded with sand paper, cover that place with JB-weld and sanded again.

before

after

In metter of oil pressure, I think it is ok. Oil lamp turns of immediately after engine start and I can lower idle at almost 600rpm and engine will still running with ease...

OldSchoolHr wrote:

The only bad thing after all of this, is that I still have this annoying tuck-tuck....tuck-tuck sound from inside my engine I realy dont know what to do about that.
I was listening this sound and count with my stop watch. I count about 100 tuck-tuck sounds in 1 minute on 1000 rpm.
When engine is cold there is no that sound, just when engine is hot, after driving. When I pull clutch lever I still can hear that sound, in neutral and in all gears I can hear it till 2000rpm. Above 2000rpm there is no that sound or I just cant hear it.
Thing that driving me crazy is that, when I lean motorcycle just a little on the right side, sound disappear :blink: I dont know what part inside engine has this ability or some kind of free play to produce this sound!?
Beside that sound, engine works just perfect, has plenty of power.
Any kind of advice is welcome...

When u lean the bike to the right side gas flows through to the carbs on that side eliminating the lean condition causing the tuck tuck. Check the fuel passage to them and the amount in them? When it warms up and makes the tuck, is it on the kick stand? Center stand?

Very, very nice work I can see you're a craftsman with excellent attention to details

Have you tried just turning the engine over by hand? You can feel slack by hand, and it might be easier to isolate the sound.

Good luck!

larrycavan wrote:

Very, very nice work I can see you're a craftsman with excellent attention to details

After looking at the amount of work in that bike i'm thinking,

I am a junk yard dog.

Man this bike is one of the nicest i've seen.

I've got a couple of months to work on my bike and it will never never never look this good.

Great work.

Great bike. One thing. Never use FRAM oil filter::

Hawk1