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February 6th, 2011, 06:37 AM   #1
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2009 450 FE Engine Quit

Went riding yesterday and didn't get far from the truck when, without warning, engine made a grinding sound and suddenly quit running. Bike has 28 hours on it and has been totally reliable until yesterday. Rode it sixty miles the prior week end and it worked great. Engine still turns over easily and it has spark. Any ideas before I tear into it.
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February 6th, 2011, 07:10 AM   #2
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Re: 2009 450 FE Engine Quit-Additional Info

Just drained the oil (changed it just before my ride) and oil was full of silver specs and screen was coated with aluminum looking particles.
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February 6th, 2011, 07:38 AM   #3
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Re: 2009 450 FE Engine Quit

Check the camchain and tensioner.
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February 6th, 2011, 03:19 PM   #4
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Re: 2009 450 FE Engine Quit

Took it apart and the tensioner is the problem. Cam chain wore through to aluminum on the tensioner arm. Big question is why did it stop running almost immediately?
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February 6th, 2011, 03:27 PM   #5
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Re: 2009 450 FE Engine Quit

Just guessing, but no tension on the cam chain could have drastically changed the valve timing.
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February 6th, 2011, 03:53 PM   #6
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Re: 2009 450 FE Engine Quit

Originally Posted by pistolpete77
Just guessing, but no tension on the cam chain could have drastically changed the valve timing.
Not necessarily. The tensioner takes up the slack on the overun side of the chain, not the drive side which is kept under tension by the 'load' of turning the valve train so a slack chain on it's own would not directly affect the valve timing. The big danger is the chain could snap or jump some teeth on the sprockets which obviuosly would affect the valve timing. If this happened you could expect some valve/piston damage which would explain why it won't start (no compression). I hope this isn't the case. The chain would certainly thrash around alot though which has eaten away at the tensioner arm.

I've just experienced a tensioner problem at 15hrs.
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February 7th, 2011, 08:57 AM   #7
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Re: 2009 450 FE Engine Quit

The chain didn't break. Valve clearances are still good. The engine turns over freely. Has spark. When at top dead center, where should the flywheel mark(s) be. There is a line and a punch mark on the flywheel but I don't know where they should be when the marks are lined up properly (top dead center) on the cam gear. If the flywheel is incorrectly oriented relative to top dead center wouldn't this indicate that the chain jumped a tooth? Seems highly unlikely it would jump a tooth but this is all new to me.

I did find the root cause of the problem and it was me. I installed a Dirt trix Chain tension incorrectly as I installed the O-ring below the ridged shoulder as opposed to above it which cause the problem according to the Dirt Trix guys. I'm an idiot but told them they should put a warning in big red letters in the instructions since this is a very big problem if done incorrectly!
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February 7th, 2011, 10:50 AM   #8
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Re: 2009 450 FE Engine Quit

Looking at the the factory manual it makes no reference to any marks on the alternator flywheel when finding TDC. On the LHS engine casing remove the bolt just below the oil filler cap. At TDC there should be a groove in the crankshaft visible through the hole. When it is visible the timing marks on the camshaft sprocket & cylinder head should line up confirming correct valve timing. When you can see the groove in the crank through bolt hole it can be locked in this position with the crankshaft locking bolt (looks like nothing more than an extra long bolt). From the manual it looks like the alternator rotor is a taper fit with a wudruff key so it shouldn't move relative to the crank unless the nut comes loose and the key shears off. The crank sprocket locates on the crank behind the rotor.Is the rotor nut still tight?
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February 7th, 2011, 06:46 PM   #9
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Re: 2009 450 FE Engine Quit

Rotor nut is tight. Ordered a puller today to remove fly wheel.
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February 10th, 2011, 12:42 PM   #10
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Re: 2009 450 FE Engine Quit

Pulled flywheel and everything looks good other than the tensioner arm is worn out. Don't see how the timing chain could possibly jump timing. Doesn't make sense as to why the engine would suddenly stop but turn over normally when trying to restart it. I wasn't going very fast, motor dragged down briefly then died.
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