- Posts: 142
- Thank you received: 5
82 KZ440 LTD Rod Knock Sound
- Jbosh
- Topic Author
- Offline
- User
- 1982 Kz440 ltd D4
Attached here is something that I hope will help a few others in diagnosing thier bikes if they have a bad internal ticking in thier engine.
This is what was found.
Attachment image-2-3-4-5.jpeg not found
This crank shaft is out of round because there was found to be no crankshaft journal bearing for the right side.
This is the sound it makes.
Attachment trim.8EF95743-C059-415F-879E-045C21B84024.MOV not found
That is about 3/16" of play in the right side connecting rod on the crankshaft.
There was initial thoughts of a loose cam chain or of a loose starter clutch but both of those have been eliminated since disassembling the engine.
Hope this helps!
As long as I get to learn something, I'm happy!
Please Log in or Create an account to join the conversation.
- Nessism
- Offline
- Sustaining Member
- Posts: 7507
- Thank you received: 2823
Please Log in or Create an account to join the conversation.
- Jbosh
- Topic Author
- Offline
- User
- 1982 Kz440 ltd D4
- Posts: 142
- Thank you received: 5
I go into more detail in my build page as the bike has apparent history that I'm discovering over time as I work on it. I had no cause for concern when I bought it. Sounded great! Just purred! No clanking. Didn't even get 100km on the bike and then came a loud ticking noise more noticeable on the right. The only slight trace is a very very small amount of metal shavings that came up on the oil after. But it's like it didn't have a bearing shell as you are calling it because I can't find the rest of it!
As long as I get to learn something, I'm happy!
Please Log in or Create an account to join the conversation.
- Tyrell Corp
- Offline
- User
- "You were made as well as we could make you"
- Posts: 1650
- Thank you received: 261
Cranks, cases and conrods are all individually measured and marked in size 3 ranges, shell bearings then fitted to make up the right clearance.
Selective assembly allows manufactureres to work to precise tolerances but also fast production allowing for wear in tooling.
1980 Gpz550 D1, 1981 GPz550 D1. 1982 GPz750R1. 1983 z1000R R2. all four aces
Please Log in or Create an account to join the conversation.
- car5car
- Offline
- Banned
- Posts: 534
- Thank you received: 20
96 Yamaha Royal Star
82 Yamaha Virago 920
Please Log in or Create an account to join the conversation.
- SWest
- Offline
- Sustaining Member
- 10 22 2014
- Posts: 22972
- Thank you received: 2749
Jbosh wrote: Hey all,
Attached here is something that I hope will help a few others in diagnosing thier bikes if they have a bad internal ticking in thier engine.
This is what was found.
Attachment image-2-3-4-5.jpeg not found
This crank shaft is out of round because there was found to be no crankshaft journal bearing for the right side.
This is the sound it makes.
Attachment trim.8EF95743-C059-415F-879E-045C21B84024.MOV not found
That is about 3/16" of play in the right side connecting rod on the crankshaft.
There was initial thoughts of a loose cam chain or of a loose starter clutch but both of those have been eliminated since disassembling the engine.
Hope this helps!
Crank is toast. DUH :blink:
Steve
Please Log in or Create an account to join the conversation.
- 650ed
- Offline
- User
- Posts: 15344
- Thank you received: 2829
swest wrote: Crank is toast. DUH :blink:
Steve
Looks pretty bad for sure as arrow shows in image below. I wonder if the journal could be turned and oversized bearings used to compensate for the smaller diameter? Ed
Attachment 00003a-2-3-4-5-6-7-8-9-10-11-12-13-14-15-16-17-18-19-20-21-22-23-24-25-26-27-28-29-30-31-32-33-34-35-36-37-38-39-40-41-42-43-44-45-46-47-48-49-50-51-52-53-54-55-56-57-58-59-60-61-62-63-64.jpg not found
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Please Log in or Create an account to join the conversation.
- SWest
- Offline
- Sustaining Member
- 10 22 2014
- Posts: 22972
- Thank you received: 2749
Steve
Please Log in or Create an account to join the conversation.
- mark in Portugal
- Offline
- User
- Posts: 25
- Thank you received: 4
So I seriously doubt it's economically viable to repair a crank like the one under discussion on a machine with very low value. like an '82 KZ440.
Of course it can be done; most likely there's too much wear for an available undersized bearing so the crank would be welded to add metal, then reground. It's done all the time for high value engines, but as you can imagine, it's not a really cheap procedure.
Please Log in or Create an account to join the conversation.
- car5car
- Offline
- Banned
- Posts: 534
- Thank you received: 20
Machine shops weld journals all the time, it is not a big deal. About $100. I am talking about real machine shops not bike shops.650ed wrote:
swest wrote: Crank is toast. DUH :blink:
Steve
Looks pretty bad for sure as arrow shows in image below. I wonder if the journal could be turned and oversized bearings used to compensate for the smaller diameter? Ed
]
Find out bearing sizes, and measure journal. I use digital measuring caliper, $30 from HomeDepot. People usually use micrometers.
Bearings can be +.25mm and +.5mm.
Find out specs for the crank and deduct .5mm
96 Yamaha Royal Star
82 Yamaha Virago 920
Please Log in or Create an account to join the conversation.
- SWest
- Offline
- Sustaining Member
- 10 22 2014
- Posts: 22972
- Thank you received: 2749
mark in Portugal wrote: I had it happen on my 1977 kz400; for me the cheapest way out was to buy an entire used bike, take the crank and rods out, and throw away the rest.
So I seriously doubt it's economically viable to repair a crank like the one under discussion on a machine with very low value. like an '82 KZ440.
Of course it can be done; most likely there's too much wear for an available undersized bearing so the crank would be welded to add metal, then reground. It's done all the time for high value engines, but as you can imagine, it's not a really cheap procedure.
Use to be done all the time in the day. I'd be concerned about what else has been munged up. :dry:
Steve
Please Log in or Create an account to join the conversation.