FE570S: Lots of metal on oildrain plug magnet

Are you perhaps one of these people that change gears without using the clutch?

As you know that is to much metal on the magnet
some thing is failing in the engine
Start with the easy parts to check.
I think you said you had metal at the top screen in the head, not good!
Check valve clearance, roll, the roller 1/4 turn and check again keep doing this for a full turn, sometimes excessive clearance tells you of roller pin and needle wear.
Rocker arm rollers , rollers pin wear is hard to check for wear you might have to carefully disassemble the rocker, use care, check the cam and cam bearings for wear.
If you have metal in the top of the engine your problem is most likely in the valve train
If no problem in the top end pull your clutch cover, check all parts
Check the generator for rubbing, you would probably hear that problem
just a few ideas!
I have over 16,000 miles on my 2010 FE570
My magnet and screen are spot less no metal at 600 to 800 mile oil change intervals.

Yes you can replace the head gasket with the motor in the frame. I would deck both surfaces to be sure, the valves must come out to deck the head. I used a copper head gasket on my 570 and 610 motors with success. The motor must come out for transmission servicing this will make replacing the head gasket much easier

That is a lot of metal , looks expensive

Mmmm? The piston is non ferrous, so no magnet pick up from aluminium swarf.
With the top end removed as it is now, can you turn it over.. Holding the con rod and ensuring the cam chain is not snagged ! With A socket on the crank nut or ring spanner..
Also holding the con rod, can you feel lateral play..not smooth rotation.. Moving out of round... Your looking for play in the bottom end. All that swarf is more like bearing shell debris !!! Possibly the mains on the crank..
The pick up on the piston could be heat seizure or oil with steel swarf got thrown up the bore??
The cam looks like its also been a bit too hot at the bearing end
Many moons back I rebuilt a Kim that had heat seized at speed.. The oil pump that sprays up the bore had stopped.. A cheap bit of plastic caused devastation of the bank balance and engine..
Once you have identified the fault you need to determine the cause... General wear and tear or mechanical failure.. Or both..
You need to wash out the full lot with paraffin and an an air gun.. Not to shoot yourself, but to blow out all the crud..
The cylinder bore, if not badl scored might be saved??? Buy a glaze buster and spin it up and down the bore.. It's worth a go.. But the piston and rings are beyond repair..
You need surgeons fingers and feel to nurse this back to health..
Check your manual for a lubrication diagram.. And also the bearing specs as these can be sourced at a good engineering supplier cheaper than branded supply's.
sorry mate but it looks like a complete strip down.. But at least you'll know you took every step to cure it properly.
And if the cam chain tensioner let go, I reckon it would have been knocking itself to death..

You have something in the engine going bad, throwing metal into the cylinder area of the engine, your oil filter should trap some of the metal trash if the metal is coming from the transmission area,your oil screen along with the drain plug, the oil screen should of been covered with metal??
The metal on the magnet is not from the cylinder.
With the scoring on the piston you should check your rod bearing and main bearing carefully for damage, they can be difficult to check when they just start to go bad, they will throw trash(metal) into the cylinder before the oil filter traps it and damage the cylinder and piston just as your picture shows.
Your piston is junk, don't use it, it will have metal inbedded in the thrust surface
Have your cylinder honed, at a professional automotive machine shop that has diamond precision honing equipment such as a Sunnen honing machine, this is very important for proper ring bedding. BE sure to use a diamond hone.
If there are ANY scores in the cylinder after a light hone(hone no more than .0002") have the cylinder replated or buy a new cylinder and piston as a match set, very expensive.
Check your oil filter, cut it apart and check the pleats for metal
Check your oil pump gears, both pumps.
Is there damage to the top of the piston, looks weird in the picture.
All the oil jets and passage ways need to be cleaned, the engine need to be cleaner than a hospital operating room before assemble!!
keep us informed of what you fine

Great Pictures.
It's not my field of expertise, so I shouldn't comment, but when I looked at the piston marks I first thought it looks like it ran out of oil or was over heated.
I also read on a thread ages ago of clutch material blocking an oil gallery or oil squirter. I will see if I can find it.

Thanks for all the pictures.

Hi Davo
That was one of my post on the clutch fiber on the oil screen causing low oil pressure.
It did cause the piston to have a slight seizure from over heating.
It looks like the scoring on this piston is from metal contamination, like it's been sanded with 40 grit sand paper, Not overheating.
I'll be interested to hear what he finds the problem is.

Re the crank... Lets not give it the kiss of death just yet.. :lol:
The piston and seal kit.. Kick the arse out of the tinta web and this site plus others.. Taffmeister ships all over the planet
Even the tax dodge of havin it shipped private from a friend abroad as a gift.. 8O
We await more news from the operating theatre.....

The piston kit from thumper racing is most probably a CP unit and high quality so I'd go for that, it would pay to scrutinise your main bearings as well due to the amount of metal thrown out by the failed big end.

I do big end pin and bearing kits so that is a cheap option, but I'd expect the inside of the rod to be run as well I'm afraid! but for the big end to go it sounds like the oil began to break down.

regards

Taffy

i was going to say: the only way you can get metal shavings on the ignition pick-up is if the mains have gone..... (1st photo)

anyway, you got there.

regards

Taffy