my 03 fe400e is poorly, anyone help?

bobber · Oct 15, 2014

I started my bike yesterday and it turned over a few times, rattled/clunked a bit then stopped. I dropped the oil to find shards of metal stuck to the drain plug magnet. I've so far removed the clutch and the bottom and top end of the engine rotate still so it's not seized. Any ideas as to what's wrong with her?
Cheers,
Rob

Taffy · Oct 16, 2014

hello Rob

could be anything but you have to look at the big end first I think followed by the mains.

mains you can tell by grabbing the crank and trying to rattle it.

big end is harder without stripping but as a guide I can tell you that the little end bushes are always loose so the following trick doesn't tell you much: try and turn the piston CW and ACW using your index fingers.

last chak is to get the piston to halfway and then rock the flywheel to see if the big end gives a signal?

if you need it proffesionally doing then give me a call. the site used to be full of the Hull mafia, long time since we've seen that location up here!

regards

Taffy

bobber · Oct 16, 2014

Thanks, I'll give those things a test, I've brought some tools home from work, hopefully I'll find the cause tonight

I'm a car mechanic by trade but bike engines are totally different... I don't really know where to start.
I haven't seen another supermoto in Hull I don't think.. Maybe the odd drz but that's about it, where have they all gone haha,
Cheers,
Rob

Taffy · Oct 16, 2014

moved on fella, they bought them your bikes age when they were new!

regards

Taffy

bobber · Oct 16, 2014

Well, I've found the problem. Camshaft bairing has collapsed. The cage that holds the bairings in place has been chewed up. The bad thing is, the cage on the opposite side has 7 bairings in it. I can only find 6. Does this mean ones dropped down somewhere? I took the engine cover off the left side and it wasn't in there

Goose916 · Oct 16, 2014

bobber said:
Well, I've found the problem. Camshaft bairing has collapsed. The cage that holds the bairings in place has been chewed up. The bad thing is, the cage on the opposite side has 7 bairings in it. I can only find 6. Does this mean ones dropped down somewhere? I took the engine cover off the left side and it wasn't in there

Well, you'll know soon enough since you're going to have to rebuild the motor anyway. Sorry about that.

Taffy · Oct 17, 2014

the balls can go behind the exhaust side springs. also they can sit in a gap behind the cam chain guide on the power side (pull).

you need to find the 7th. use sealed bearings this time fella!

regards

Taffy

ned37 · Oct 18, 2014

the missing ball can indeed be hard to find. look with a flashlite where taffy said and also use a telescopic small magnet to poke where you can't see, including the oil drain hole. try flushing with kerosene to see if it will loosen particles. make sure you get the cage pieces too. btdt

bobber · Oct 18, 2014

well, i found the rogue bearing

pulled the engine out today. it seems to be taking forever though as i don't have a clue what i am doing.
i have ordered a gasket set for it and gonna order the new bearings on Monday.
question i need to ask now is, how do i get the timing chain off or loose enough to get the camshaft out and get the head off? also, i need to split the block to get inside to clean it all out, i've took all the allen bolts out, whats the best way to get into it?
cheers,
rob

Kayeffess · Oct 18, 2014

Cam chain either has a master link or it is riveted ...chain breaker or die grinder.
Lots of rebuild info in the documents. There is a link in my signature.

Taffy · Oct 18, 2014

Kayeffess said:
Cam chain either has a master link or it is riveted ...chain breaker or die grinder.
Lots of rebuild info in the documents. There is a link in my signature.

I know this makes me pedantic but an angle grinder will send the crap up under the frame. a die grinder bounces off the cam chain and all the bits can go anywhere depending on the angle you grind it. it is too difficult to get right.

an angle grinder just sends it all up and away.

angle grinder (AKA "grinderette") is what you need!

regards

Taffy

bobber · Oct 19, 2014

Ok, thanks for the info. Just wondered if there was a way to do it without splitting the chain. Once the chain is split, can I get a new link or do I need a new chain? Also, would a pushbike chain tool work on a cam chain or are they still not strong enough?
Cheers,
Rob

Goose916 · Oct 19, 2014

Taffy said:
the balls can go behind the exhaust side springs. also they can sit in a gap behind the cam chain guide on the power side (pull).

you need to find the 7th. use sealed bearings this time fella!

regards

Taffy

I confess the 7th seal joke made me giggle. And for technical purposes, the balls are in front of my exhaust side spring.

bobber · Oct 20, 2014

Well, this is as far as I've got so far, I noticed the idler gear bearing feels a bit rough, do I have to heat up the crank case to get that bairing out? I can see there's a circlip in there too behind the gear on the inside of the crank case. Also, I can feel the tiniest amount of play in the bottom end bairing, it really is the smallest amount, I can only just feel it, but should there be no play at all? I'm only used to car engines and shells, I still have no clue what I'm doing :/

my 03 fe400e is poorly, anyone help?

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