This site may earn a commission from merchant affiliate links, including eBay, Amazon, and others.

'03 FE400 Clicking within engine

Joined Aug 2004
35 Posts | 0+
Minneapolis, MN USA
I am concerned. A few weeks ago I made a post detailing my sudden loss of power on the trail and a clicking/ticking sound emanating from within the engine.

At that time Dale suggested cam followers as a potential problem. Sounding like a good explanation, but I investigated and found the rollers to be fine.

Then, after reading some historical posts, I surmised it was related to the semi-auto, comp-release, actuated by the kick start. That seemed to be it, since when I dismantled the clutch side components, I found damage on the kick start shaft caused by the decompression lever. I removed the entire semi-auto system and replaced with a plug. Still the noise.

I have adjusted valves three times. I am reluctant to pull the head, but is that my only recourse? It runs, but it ticks away like a sewing machine and usually stalls quite quickly.

For full disclosure, the breakdown happended the first ride after I installed a Scotts damper; in that process I rerouted the manual decompression cable, (hence my attention to the decompression system.) The ride lasted about one mile before loosing power and clicking. I over-revved slightly on a fast downhill, but the break did not manifest until I stopped for a road and crossed to the other side.

I am at a loss? Valve's are all I can think of, but would it run at all?

Help. Thanks in advance for your always intuitive, collective genius.
 
Hi Sean,

When you rerouted the manual compression release cable you may have changed its adjustment, causing the head cover mounted decompressor to keep the exhaust valves from fully closing.

Joe
 
Joe,

thanks. That was my working hypothesis. I was sure that my re-route had caused the the decomression system to partially engage, thereby causing the damage I saw on the kick start shaft. Unfortunately, after taking out the kick start actuated decompression altogether and readjusting the manual cable, I still have the problem. Do you think that this was the preliminary problem which then caused some damage to the exhaust side valves?
 
It could be that they are leaking now, have a 'leak down' test performed.

Joe
 
I doubt any damage was done. I am sure you could see it if there was.
On my 470 I run a return spring on the arm for the manual decompression shaft. I noticed it would not return all the way at times. This would cause hard starting on occasion.
 
there is no way that your exhaust valves have hit the piston using the manual decomp system. so that's the good news. what it is that's wrong is a little tougher to sort out.

Taffy
 
Taffy,

just read your response to Chizzler...I looked inside for a little man with a toffee hammer and sure enough...

I put put down some mouse traps and my ticking went away immediately.

Amazing.
 
Dismantle the engine, you probably have problems on the piston or in the piston pin with the connecting rod
 
husby

that's a bit OTT isn't it?

the little end (brit) wrist pin (yankie funny way to speak) will make a knocking noise only when you rev. every time you rev-the little man with the hammer knocks!

doesn't happen at all on decel, barely audible on even throttle and hammers like hell on WOT.

maybe it's jorge 'aspar' martinez? (little joke for the hispanics out there doncha know!)

regards

Taffy
 
Doesn't the 400 2003 bike have a domed piston ? It will mean the piston top comes into the cylinder head ?

If the valve is touching the top of the piston this will sound like a tap increasing in frequency as u rev the engine.

Otherwise check the nut on the end of the balancer shaft they come undone sometimes.

Lloyd
 

Register CTA

Register on Husaberg Forum! This sidebar will go away, and you will see fewer ads.

Recent Discussions