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May 9th, 2004, 02:03 AM   #1
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HELP!!!!2003 FE501e

not real happy about now.......

\
was just out riding 2003 FE501e with about 70hrs on. it lost a bit of power and started making a knocking sound. was near home anyway. dumped oil and oil screen full of fine metal particles(it has been clean since running in). oil changed only 2 hrs ago, and screen was clean then as usual.

i'm not real experienced with the four strokes......any ideas anyone?????

thanks in advance.
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May 9th, 2004, 02:13 AM   #2
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WAS IT A FINE, TICKING NOISE OR WAS IT A LITTLE MAN WITH A HAMMER?

you can learn a helluva lot by pulling both the sidecover and the ignition cover off. grab the end of the crank and pull up and down very hard feeling for the slightest 'clonk-clonk'.

the next place is the rockercover where you start looking at tappets and spindles etc.

more info please?

Taffy
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May 9th, 2004, 03:40 AM   #3
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thanks for your quick reply Taffy....you're a champ.


had a bit of a look at it. noise it made was like a loud tapping, not a thump or excessively loud noise.

bike was about due for a valve adjustment. took valve covers off. intakes seem to have about 4mm of slack(i can lift the rocker this far off the top of the valve). exhaust seem ok but have about 1mm lateral movement. i don't adjust valves myself so i may be mistaken here but i am just trying to relay what i'm seeing. valves still operate when crank turned.

no movement of crank, seems tight. however when i was getting TDC crank spun ok clockwise(from stator side) but made grinding noise when going back......is this normal?????grinding noise came from just back from crank inside cases.

thanks again Taffy and anyone else.
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May 9th, 2004, 08:58 AM   #4
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JJW

while i don't offer an answer. i'm sure someone else will. taking the rocker coveroff takes 7 screws so i would simply say take that off next.

pull the plug out and check for anything unusual on the end. kick it over and feel and listen for more.

again these three covers won't put you 'over your head' at this point.

the 4mm of slack in the tappets tells me it's your rocker arm spindle (shaft through the middle of the rockers). the bearings are known to fail.

Taffy
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May 9th, 2004, 10:07 AM   #5
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Hi JJW501,
Most likely you will find your primary source of trouble by simply removing the rocker cover. Pay particular attention regarding the camshaft ball bearing and roller follower radial play. Please let us know your findings and if possible submit a picture for reference.

Note:
I am assuming your 501 is an electric start model as they do indeed drag during reverse crankshaft rotation.

Hope this helps.
Best Regards,
Dale
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May 10th, 2004, 04:33 AM   #6
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ok pulled a few things off as suggested.......

the rockerarm roller bearing for the intake valves has collapsed. it has worn down a little bit, and unfortunately the cam is marked as well, mostly the addition of a sharpened edge on the ignition side of the intake lobe. suppose this means new cam too???

the bearings for the cam seem ok.

have talked with shop and will get them to do the rest, and have a closer look at it.

thanks again to those who replied, it really wasn't that hard after all but since it was the first time i was a bit hesitant. i took a couple of photos which i will upload when i get developed for reference of others.

hopefully will be fixed soon!!!!!!!!cheers.

Jeff
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May 10th, 2004, 05:47 AM   #7
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this is a 'common fault' so see if you can't get a good quote off them. the cam should be good if you can gently smooth DOWN any rough bits. a roller 'follows' the cam and as such there is no sliding but a rolling motion. i therefore think that the cam is very saveable. picture of it?

Taffy
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May 16th, 2004, 05:49 AM   #8
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ok finally got some pictures for you.........

anyone know how to post them in a message from a .jpeg file???

cheers,
JEFF
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May 16th, 2004, 06:27 AM   #9
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Hi Jeff,

Just upload them to your Gallery.

thanks,
json
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May 16th, 2004, 08:25 PM   #10
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thanks schwim, couldn't have been much easier!
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