[alexzx6r23]

I completed a valve adjustment on my 07 zx6r with 13k miles. It ran perfectly fine before but now it has a loud knocking sound that is terrible. I'm guessing it could be the chain tensioner but I have a 2nd complaint. The threads on the hole to spin the crank are stripped, I have it RTV'd to maintain oil pressure (lol) but if I replace the CCT i'll need to rotate the crank for the CCT to adjust properly.

1) What's causing the loud knocking sound, is it the CCT?

tbsync.mp4

drive.google.com

2) How can I replace the starter clutch cover? Do I need to split the cases?

 

[KevA]

You can replace the cover easy enough it details the proceedure:-
In the Service Manual Section CRANKSHAFT/TRANSMISSION 9-31

Noise sounds like a very loose clearance/s to me.

 

[Rich T]

Noise sounds like a very loose clearance/s to me.

Maybe a good question is did you (intend to) significantly reduce any shim thicknesses (to significantly increase any clearance)?

That noise is really loud...

I'd be immediately concerned with:

1. did I leave something (socket, etc.) in the engine?
2. did I align crankshaft and camshaft properly?
3. did a shim pop out under a bucket? (or did I put two shims under one bucket?)
4. did I tighten the camshaft caps?

I think it's immediately worth re-opening the engine...

Did you go thru the whole "valve clearance inspection" procedure before buttoning things up? And did you manually rotate the crankshaft thru at least two revolutions first?

 

[Rich T]

PS probably not much of a surprise, but from the audio track, it's 120ms between knocks. That'd be exactly two revolutions if your idle is 1000 rpm -- pretty much what we expect for anything wrong up at the camshaft -- a 2 revolution period... Did you count your shims (outside the engine) both before and after the procedure?

 

[alexzx6r23]

I can't find my sheet where I measured the old shim and the new shim and done the calculation. It's been 2 years since the valve adjustment I just now got around to dewinterizing the bike.
The intake valves didn't need adjusting afaik.

I feel like it could be valves that are too loose, I may have measured at the wrong cam position. Hopefully my timing is still good and it's just valve guide noise or something like that. I'll be doing a tear down in the following weeks.

 

[alexzx6r23]

Maybe a good question is did you (intend to) significantly reduce any shim thicknesses (to significantly increase any clearance)?

I found some of my measurements I think yes, I did reduce shim thickness to increase clearances. Here's for my exhaust clearances:

I did a+b-c=d
a = present shim
b=measured valve clearance
c= specific clearance
d= replacement shim

1.848 + 0.145 - 0.275 = 1.718

So all of the old shims are 1.848 or 1.845 mm. All of the new shims are 1.70, 1.75, 1.65, 1.60.

 

[Rich T]

So you increased clearance by 0.2mm to 0.25mm on two cylinders, and the clearance spec is maybe a third of that?

Your big fear is "first contact" missing the gradual "opening ramp" on the cam lobe -- because the lobe will smack the valve where the lobe is raising quickly, rather than where it is raising slowly.

(I don't know if there are any published camshaft lift curves for these engines -- that would tell you how high the ramp is...)

So possibly you have multiple valves contributing to the noise -- though it looks from the imprecise audio like just one is leading the charge:

I think you want to open it right up and double-check everything -- I've heard loud before, but never that loud (though it's hard to be sure with a video)...

Pay special attention to your camshaft timing as well...

Rotate the engine by hand thru two full revolutions and look and listen, in addition to measuring all clearances...

PS I'm almost thinking lift each bucket as well, just to make sure there's nothing under one that does not belong...

 

[KevA]

Did you check the clearances again on the ones you changed when the Camshafts were Torqued back down before fitting the Cam Cover back on ?

 

[riverszzr]

I found some of my measurements I think yes, I did reduce shim thickness to increase clearances. Here's for my exhaust clearances:

I did a+b-c=d
a = present shim
b=measured valve clearance
c= specific clearance
d= replacement shim

1.848 + 0.145 - 0.275 = 1.718

So all of the old shims are 1.848 or 1.845 mm. All of the new shims are 1.70, 1.75, 1.65, 1.60.

you would have had to have had zero clearance or less to need that much change in shim size!!!

going from a 1.85 shim down to a 1.60 shim is approx.... .010" change.......... it is very rare to need that much change (although I do see it far too often)

1.85 down to a 1.65 is about .008"
1.85 down to a 1.75 is about .006"

I concur with above.............

DID YOU MEASURE THE CLEARANCES AGAIN ONCE YOU PUT IN THE DIFFERENT SIZE SHIMS!!!!!!!?????

I BET SOME ARE WAY TOO LOOSE OR OR OR...........

Stop running it and take it apart and see what is wrong!

 

[alexzx6r23]

I went back and rechecked the adjustments.
2 of the exhaust valves were at 0.33mm
1 of the exhaust valves were at 0.37mm

The spec is 0.24-0.31mm for exhaust.
The reason why I got such a loose clearance was I got lazy and used x2 1.65mm and x1 1.60mm shim since I didn't want to order a new set of 1.70mm shims. Amazon has some for $12 with 1 day shipping! You guys think the tapping sound will go away once I put it back together?

No obvious damage to the cam lobes or buckets.

So possibly you have multiple valves contributing to the noise -- though it looks from the imprecise audio like just one is leading the charge:

View attachment 112837

Seems like you might be correct. 3 valves out of spec, with one leading the charge

 

[rockbrook]

I went back and rechecked the adjustments.
2 of the exhaust valves were at 0.33mm
1 of the exhaust valves were at 0.37mm

The spec is 0.24-0.31mm for exhaust.
The reason why I got such a loose clearance was I got lazy and used x2 1.65mm and x1 1.60mm shim since I didn't want to order a new set of 1.70mm shims. Amazon has some for $12 with 1 day shipping! You guys think the tapping sound will go away once I put it back together?

No obvious damage to the cam lobes or buckets.



Seems like you might be correct. 3 valves out of spec, with one leading the charge

Theoretically, yes. Once you fix the out of spec clearances, I think you should be good. Be sure to update us! I need to check my valve clearances soon.

When I read your first post, I thought you stripped out the hex head bolt to turn the engine, that happened to me the first time I attempted my valve clearance lol.

 

[riverszzr]

double check that your cam timing is correct too!

 

[RJ2112]

Good to have you back on board, Lloyd.

 

[Visk636]

Good to have you back on board, Lloyd

I agree

 

[Scumbag]

double check that your cam timing is correct ya fkn moron before that thing blows all to hell and your in here asking a bunch of dumbass questions!!!

Jeez riverszzr. Calm down. Grouchy ass.

 

[riverszzr]

Jeez riverszzr. Calm down. Grouchy ass.

you fucking scumbag wanker..................

nice fucking edit of my post............

I will try and keep up the good work in the future.........

 

[KevA]

WTF I'm confused, What's occured ??

 

[RJ2112]

WTF I'm confused, What's occured ??

Scumbag tweaked Lloyds comment as a joke…. They’re both laughing about it….

 

[KevA]

Scumbag tweaked Lloyds comment as a joke…. They’re both laughing about it….

How to win friends and influence people

 

[riverszzr]

WTF I'm confused, What's occured ??

Is it really that confusing??????

I know I have been gone for awhile, but people did not dumb it down this much did they............... and you'alls memory haven't faded so much you don't remember my typical response to stupid shit for more than a decade.......