motor noise

HRS PLY · 02-05-2012, 04:42 PM

I have a 03 z400 that I bought new. last aug I got a new bike and gave the Z to my son. I just noticed that it has a lod clattering noise that appears to be comming from the top end. Since I have owned this bike since new I know it has been taking care of. What is the wear point of the 400 motor? I cut the filter up and found 4-5 small specs in each pleat in the filter, it seems to be aluminum. Does the cam chain stretch and start rubbing or is it something else???? I know these bikes have been around long enough to show the weak points.

thanks for any info.........

Michael

Hughesc99 · 02-05-2012, 06:08 PM

Welcome!

You should probably check your valve lash. Also, you can pull out the cam chain tensioner and see how many clicks are left on it. Those 2 things will tell you if your cam chain is stretched beyond limits and also if your valves are in good condition.

Are you positive the metal is aluminum in the filter? Not sure off the top of my head what inside the motor thats aluminum and would flake off....

ltz400dave · 02-05-2012, 06:17 PM

welcome.... join the club i had the same on my 03 z turns out that i had 0 clearance on the valves and had to do a whole top end rebuild and wile your at it do a chain drze kits are cheap threw advantage cycle. if you have 0 clearance your valves are cupped and are NO GOOD dont re shim cus it will happen again real soon. just do the rebuild and be done with it drze kit with ferrea valves

Gusaroo · 02-13-2012, 07:12 PM

Im gonna hijack this thread...

How do you tell how many clicks the chain tensioner is out, when you remove it and inspect?

jasmf24 · 02-13-2012, 08:18 PM

Metal particles on the filter can be normal to a certain point. What condition is your clutch in? Time to start looking around with a close eye.

ltz400dave · 02-13-2012, 09:22 PM

Quote:

Originally Posted by Gusaroo

Im gonna hijack this thread...

How do you tell how many clicks the chain tensioner is out, when you remove it and inspect?

First pull the bolt and spring from your tensioner then pull your tensioner out the see how many clicks you have left there are I think 12 or 13 in total? just use basic math if you have 1 or so left time for a new chain.

HRS PLY · 02-14-2012, 10:01 AM

like dave said....... remove the large bolt in the center. It holds the spring in the tensioner. then remove the two smaller bolts. pull out the tensioner and see if you can pull it out further. Mine is on the last setting and cannot travel any further. Its maxed out.

My clutch is the stock unit , never been changed. gonna replace it also.

thanks
Michael

bparks23 · 02-14-2012, 10:17 AM

In my experiences, upper motor noise is usually a valve clearance issue as stated or timing chain slap which is what the guys are talking about with the chain tensioner. If your ACT is not rectifying the issue, your chain maybe stretched out past the limits of the ACT. I'd check the valves first to make sure they aren't the issue, if they are good, might have to replace the chain. I've been there, it's not to hard.

HRS PLY · 02-14-2012, 10:29 AM

ording new top end kit from advanced. I started another thread but it got moved to the repair section. one intake valve is at min clearance. chain tensioner is maxed out. Time for parts.

Gusaroo · 02-14-2012, 11:13 AM

Wouldn't the tensioner shaft be going in? Not out? ...as the chain stretches. So Id be looking to see how far in it is?

HRS PLY · 02-14-2012, 01:58 PM

no It start with the push rod at the shortest setting. as the chain stretches the rod gets longer and takes up the slack in the chain by pushing on it.

Gusaroo · 02-14-2012, 02:44 PM

I think we are both saying the same thing, but differently. As the chain stretches, the rod pushes into the motor (to keep the chain tight). So when the chain is all stretched out and time to replace, the rod would be all the way in, it would be on the last ratcheted teeth. When you remove the ACCT, the rod would look like it is sticking all the way out of the ACCT housing. Correct?

HRS PLY · 02-14-2012, 04:19 PM

yes

zookie400 · 02-14-2012, 06:22 PM

there were a few writeups done showing how to convert your ACCT to MCCT, just FYI. also some people running the ACCT are cutting the spring to reduce tension on the chain.

Gusaroo · 02-14-2012, 06:35 PM

Yeah, I had a DRZ400e with the mcct. I put it on immediately after I bought the bike, never even looked twice at the acct, took it off and chucked it. I dont have the cash to spend like I used too

so I'm trying to keep this quad up to snuff for the least amount of $. Might try to make my own mcct. Thx for all the input guys!

02-05-2012, 04:42 PM	#1 (permalink)
HRS PLY :::Rookie Rider::: Join Date: Feb 2012 Posts: 17	motor noise I have a 03 z400 that I bought new. last aug I got a new bike and gave the Z to my son. I just noticed that it has a lod clattering noise that appears to be comming from the top end. Since I have owned this bike since new I know it has been taking care of. What is the wear point of the 400 motor? I cut the filter up and found 4-5 small specs in each pleat in the filter, it seems to be aluminum. Does the cam chain stretch and start rubbing or is it something else???? I know these bikes have been around long enough to show the weak points. thanks for any info......... Michael

02-05-2012, 06:08 PM	#2 (permalink)
Hughesc99 :::Post Whore::: Join Date: Aug 2010 Location: Derby, KS Posts: 2,117	Welcome! You should probably check your valve lash. Also, you can pull out the cam chain tensioner and see how many clicks are left on it. Those 2 things will tell you if your cam chain is stretched beyond limits and also if your valves are in good condition. Are you positive the metal is aluminum in the filter? Not sure off the top of my head what inside the motor thats aluminum and would flake off.... __________________ 2006 Lt-Z434 Trinity IV Full Exhaust/OSHC/FCR39 w/AP Safety Wired/ Velocity Intake/Odi Rogue Grips/AC Nerfs Factory Suzuki Heel Guards/Durablue Rear Linkage +2+1 A-Arms

02-05-2012, 06:17 PM	#3 (permalink)
ltz400dave :::LT500 Rider::: Join Date: Nov 2011 Location: Fuquay NC Posts: 1,242	welcome.... join the club i had the same on my 03 z turns out that i had 0 clearance on the valves and had to do a whole top end rebuild and wile your at it do a chain drze kits are cheap threw advantage cycle. if you have 0 clearance your valves are cupped and are NO GOOD dont re shim cus it will happen again real soon. just do the rebuild and be done with it drze kit with ferrea valves __________________ ltz400 DRZE kit, pro taper bars, Nerf bars, Holeshot tires, hollowed out stock can with a straw for a header, ripped up seat, slightly over sized battery, stock jetting with removed snorkel, bent up skid plates, but its MINE WIFES: 99 Eclipse RS, 04 KFX400 bone stock NEW ADDITION: 97 F150 King cab Triton 4.6 v8 and a Suzuki jr80 dirt bike. DON'T JUDGE ME, it could be bad for your health

02-13-2012, 08:18 PM	#5 (permalink)
jasmf24 :::KFX 400 Rider::: Join Date: Mar 2011 Location: Pittsburgh Posts: 923	Metal particles on the filter can be normal to a certain point. What condition is your clutch in? Time to start looking around with a close eye. __________________ 2004 KFX400, 12.2:1 Wiseco, HMF full exhaust, FCR-39 (170 M/ 42P/ 40L/ NCVQ, DRZ-E boot w/ compact head-stay), OSHC's, K-W valves w/ drz springs, Dyna Fs NP, Raptor Petcock, Wiseco cam chain, 400ex boot, Oversized clamp on UNI/K&N no lid, DRZ-E Base, DRZ Flywheel, LTR450 Front Shocks, blob-less ProTaper Contour bars (ATV High) w/ hot-start reverse, odi grips, Tusk nerfs, Full skids, 14/40, (R) Holeshot ITP HD (F) Rzr2, Port-N-Polish by me.

02-14-2012, 10:01 AM	#7 (permalink)
HRS PLY :::Rookie Rider::: Join Date: Feb 2012 Posts: 17	like dave said....... remove the large bolt in the center. It holds the spring in the tensioner. then remove the two smaller bolts. pull out the tensioner and see if you can pull it out further. Mine is on the last setting and cannot travel any further. Its maxed out. My clutch is the stock unit , never been changed. gonna replace it also. thanks Michael Last edited by HRS PLY; 02-14-2012 at 10:03 AM.

02-13-2012, 07:12 PM	#4 (permalink)
Gusaroo :::Rookie Rider::: Join Date: Jan 2012 Posts: 19	Im gonna hijack this thread... How do you tell how many clicks the chain tensioner is out, when you remove it and inspect?

02-14-2012, 10:17 AM	#8 (permalink)
bparks23 :::LT500 Rider::: Join Date: Mar 2010 Posts: 1,059	In my experiences, upper motor noise is usually a valve clearance issue as stated or timing chain slap which is what the guys are talking about with the chain tensioner. If your ACT is not rectifying the issue, your chain maybe stretched out past the limits of the ACT. I'd check the valves first to make sure they aren't the issue, if they are good, might have to replace the chain. I've been there, it's not to hard. __________________ 2006 Arctic Cat DVX 400 --UNDER CONSTRUCTION--

02-14-2012, 10:29 AM	#9 (permalink)
HRS PLY :::Rookie Rider::: Join Date: Feb 2012 Posts: 17	ording new top end kit from advanced. I started another thread but it got moved to the repair section. one intake valve is at min clearance. chain tensioner is maxed out. Time for parts.

02-14-2012, 11:13 AM	#10 (permalink)
Gusaroo :::Rookie Rider::: Join Date: Jan 2012 Posts: 19	Wouldn't the tensioner shaft be going in? Not out? ...as the chain stretches. So Id be looking to see how far in it is?

02-14-2012, 01:58 PM	#11 (permalink)
HRS PLY :::Rookie Rider::: Join Date: Feb 2012 Posts: 17	no It start with the push rod at the shortest setting. as the chain stretches the rod gets longer and takes up the slack in the chain by pushing on it.

02-14-2012, 02:44 PM	#12 (permalink)
Gusaroo :::Rookie Rider::: Join Date: Jan 2012 Posts: 19	I think we are both saying the same thing, but differently. As the chain stretches, the rod pushes into the motor (to keep the chain tight). So when the chain is all stretched out and time to replace, the rod would be all the way in, it would be on the last ratcheted teeth. When you remove the ACCT, the rod would look like it is sticking all the way out of the ACCT housing. Correct?

02-14-2012, 04:19 PM	#13 (permalink)
HRS PLY :::Rookie Rider::: Join Date: Feb 2012 Posts: 17	yes

02-14-2012, 06:22 PM	#14 (permalink)
zookie400 :::Post Whore::: Join Date: Aug 2007 Location: Connecticut Posts: 2,685	there were a few writeups done showing how to convert your ACCT to MCCT, just FYI. also some people running the ACCT are cutting the spring to reduce tension on the chain. __________________ You are the result of 4 billion years of evolutionary success. NOW ACT LIKE IT.

02-14-2012, 06:35 PM	#15 (permalink)
Gusaroo :::Rookie Rider::: Join Date: Jan 2012 Posts: 19	Yeah, I had a DRZ400e with the mcct. I put it on immediately after I bought the bike, never even looked twice at the acct, took it off and chucked it. I dont have the cash to spend like I used too so I'm trying to keep this quad up to snuff for the least amount of $. Might try to make my own mcct. Thx for all the input guys!

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