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117 hrs then bang!

pollo

pollo

Joined Jun 2008
1K Posts | 98+
Simi Valley Ca.
Rode last weekend. I was cruising along 2nd and 3rd in some single track. Not really pushing it.
Then a bang and an initial jolt to the primary gear sprocket. It didn't lock up and the motor still seemed to
run and idle fine. Except now there is something rattling around inside the motor somwhere.
I am going to drain the oil and pull the valve covers to start , and take a look. :?

Pollo
 
Well I was out in the garage looking for some answers today. I decided to check the cam chain just
because it was on my agenda. I am at 12 clicks out with about 3 left. So I am due there.
Next I pulled the valve covers just to take a look and see. Looks ok.
Haven't drained the oil yet. There must be something interesting on the drain plug magnet.
Oil looks clean in the window. I change it frequently. 3 hrs.
So there's something inside not right. I'm gonna have to take it in the shop.
Pollo
 
Let us know what you found.

Is 117 hrs a long time between check ups? What sort of work has been done in this time?
 
Everything has been ok up until now. Except for a little weep hole leak.
Pulled the cylinder head top section. Cam followers and rocker arms look good.
Anyone know where I should check from here? :?

Pollo
 
The Primary gear nuts are fine. Just pulled the left side cover and checked.
 
pollo said:
Everything has been ok up until now. Except for a little weep hole leak.
Pulled the cylinder head top section. Cam followers and rocker arms look good.
Anyone know where I should check from here? :?

Pollo
Click to expand...

I hope that it's not the case, but that's a very similar description of my recent (well, last summer. My engine builder is, er, being very thoughtful in his approach to the job) blow up. Engine still ran and had power, would start and idle fine but off idle it was all rattles like bearings in a coffee can. Turned out to be bearings, shrapnel of, in the crankcase. Counterbalancer bearing let go. Probably would have been a much smaller repair if I'd stopped the motor but I rode the mile home. Like you, I couldn't locate the source of the noise on my own, it wasn't until the cases were split that the truth was known.

On the bright side for me, I had the opportunity to upgrade damn near everything in the motor. I should (knock wood) have the most reliable 'berg motor ever by the end. This end, I'm always told, is probably next weekend.
 
Well, I just pulled the motor out of my 05 650.
Put it into a heavy duty plastic bin and covered up the exposed areas.
I keep thinking why did this happen to me at 117 hrs. Seems way too soon.
And I kept good care of it. Changed oil every 3 hours.
I opened it up some from time to time, but their race bikes you know.
I'll get over it. Just didn't figure on spending money to split the cases and all
this soon.

Pollo
 
mate I feel ya my 05 650 sm shat the goose at 99hrs oil was changed every 5 to 700 km ( onlt road riden) now 16 hrs later broken valve spring but theres nothing like it took a husky 510 out thursday and gave it straight back. Best of luck with it.
 
Well I removed the motor last week and took it to my mechanic. It turns out that the motor runs fine except
that I have have some broken gear teeth inside the motor.
So that was the bang and rattle that I heard. One of the gears broken is probably 3rd as that was what I was in.
I am having it fixed and will have a new camchained installed also.
Daleo told me he is not too surprised about my broken gear teeth because of the number of hours I have ridden
on street. About 30hrs out of the 117hrs. So I am learning more all the time. Don't ride the enduros on asphalt or
concrete too much unless you have a cush drive hub like the motards.
I will be using it mostly for dirt from now on.

Pollo
 
And that is not a Berg idiosyncrasy, it'll happen to anything without a cush drive unless you are very careful.

I hope its not too expensive. While its apart, maybe the DVSK is worth fitting too, although you may have another 100 hrs left with the stock conicals.

Cheers
Steve
 
test post

sorry pollo

ok it works I can BS on the net :D

the DVSK is great, some expert made up the installed length on the instructions and you can't get it,

I whinged but he said I was trying to hard or summot like that but only used one word :D
 
Here's whats' happening with my 05 FE650. I am having 6 gears replaced. 2 had broken teeth, 4 meshed up some
on the 2 and wore incorrectly. One sucked in a piece of tooth. Anyway 6.
As for the rest of the motor. Even Dale EO would be envious. All bearings, piston etc.. look ecellant.
I'm not convinced it was a lack of a cush drive hub that di it. The little bit of street I did was mostly smooth
cruising. And Don't tell me how to ride DELO !! 8O
Now off road I do go off like snap crack the whip. . Whatever it was, it is being taken care of.

Pollo
 
good it was "only" the gearbox

starting to feel better now i've seen a few others go not just mine :cry:
 
I agree Bushie. Better than the motor going.
You kn ow, I was thinking some of those miss shifts had weakened a gear.
I occasionally had a miss shift which is not too uncommon. And it seemed to happen
in 2nd or 3rd. It probably just needs that one tooth to break and then a chain reaction.
Pollo
 
One of the techniques I learnt years ago when road racing and trying to avoid false neutrals is to maintain pressure on the gear lever until the clutch is released. Worth the effort, press and hold the lever until the clutch is out, and if the gear wasn't quite engaged it will fully engage as the clutch comes out. Feels strange at first, but worth the effort, and ultimately less wear and tear on the gearbox.

Steve
 
ive allways tried to do that and certainly haven't got any false neutrals when doing the shifting

I think either my boot or the ground or some rock or stick or even just inertia gives the shift lever a nudge and boom! happened twice. the detent arm spring and the shift lever return springs are really soft I think to give a nice fast easy shifting box.

first time was after a hard jump landing I reckon the lever moved down on impact and the second i was riding in 3rd for a minute or 2, tipped it into a corner gave it a handful, it jumped out of gear, reved up then when went back in before I coulld chop the throttle or pull the clutch, later I found there was a stick buried in the sand on that corner but I can't say what it really was exept dissapointing.

since I did the mods to the shift star and uprated the detent arm spring it shifts more positively and hasn't jumped out of gear seemingly "by itself" yet, but we'll see I guess.
 

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