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Engine Failure: Camshaft and Piston damage - Rebuild in progress

912 Views 24 Replies 6 Participants Last post by  Tamir
2
Hi all,
Hopefully Hello @Tamir as well, the one with the knowledge and kindness to reply the majority of threads!

My bike went in to mechanic for a new battery and fork seal maintenance as the right side was leaking.
Attached is the quote I got afterwards.

I noticed the black plastic (Can be seen on video, it's the black plastic round thing) is damaged, drove the bike home (5km) and there was a hard "klunk" sound on the front sprocket.

  • Drove slowly home after the sound and there is a definite something gripping or slipping whilst the shaft is turning.
  • Got stuck in second gear, after a kilometer or so my gears came loose again and was able to shift up to third and then back to 2nd and 1st. Now able to shift through them whilst testing parked.
  • I parked the bike and left town for a week.
  • Returned back to bike shop and showed them the attached video, they said bike needs to be loaded on trailer and brought in to shop.
  • Removed the front sprocket guard and took video, all teeth seem fine no chips or breaks.

My Question:
1. Redacted*

2. What is the possible cause to this issue?

3. Is it possibly just a loose sprocket?

Thank you for the time you take to read and respond to my issue.
Exmoz greatly appreciates your input!

Video:

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1. Could the damage caused to the black plastic be related to the issues I am facing?
(The mechanic claims he did not cause that damage, but I have photos of before I took in the bike in and after, as they damaged my front break fluid glass thing in December).
Hi there, this has been concluded to be completely unrelated.
The engine simply reached end of life due to excessive use, 66k km done, no idea how many owners the bike had.
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66k km is not that high a mileage on these bikes. I suspect something was done to the bike, resulting in your engine seizing. The fact that the external component, although unrelated to the engine, was damaged leads me to further think that something happened.

From the pictures you posted, the cylinder wall looks to be scored. Perhaps, the bike was serviced and the oil filter installed in a reversed manner. Or, perhaps, the engine was run dry accidentally?

Obviously, it's all conjecture at this time.
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Thanks for the input @TheoR
The filter seems to have been installed correctly as seen in one of the images.
Also cross checked it the other day with Tamir's guide.

The left side of the bike got dropped that's for sure, there is a big round thing on the left side casing that's supposed to be silver, but it's black, so they resprayed for sure.

Previous owner messed up the wiring, had led strip inside and no working headlight!

The air filter cover was removed off the bike when I got it, that little black lid.
Ordered and installed one about 3000km ago, motorcycle also ran in cold dry climate it's whole life, then moved to the coastal area and used in 30-40degrees.
Parts Ordered and recieved so far:

DID Gold Xring chain with new sprockets OEM standard size.
Main Crankshaft Bearing - Blue
Piston Rebuild kit - with cylinder included
Bunch of gaskets and O rings
Crankshaft replacement kit
Spark Plug - Although current one only has 2000km done on it.

---

Second order (mechanic needed more-parts) :

Main Crankshaft Bearing - Blue
Night Eye LED
Handlebar ends
Handlebar grips
Oil filter and Gasket for service after engine is broken in (1000km)
Neck Steering Bearings - they are due for replacement, might as well do now.
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66k km is not that high a mileage on these bikes. I suspect something was done to the bike, resulting in your engine seizing. The fact that the external component, although unrelated to the engine, was damaged leads me to further think that something happened.

From the pictures you posted, the cylinder wall looks to be scored. Perhaps, the bike was serviced and the oil filter installed in a reversed manner. Or, perhaps, the engine was run dry accidentally?

Obviously, it's all conjecture at this time.
Your hypothesis makes sense. I bought a motorcycle that was neglected. When I bought it, it looked good, it drove well, but I knew I was buying a motorcycle that had been neglected.

Several years have passed since then, and since the
I'm still chasing a fault, I started with what was easy and cheap to fix, and today the problem still exists.

My problem: The engine has difficulty starting when cold. Below 25 degrees I starting it with a rotation of one degree in the throttle. I bought the motorcycle in the summer and I could feel this problem, then winter came...
Now I only have the major treatment left, apparently (because this measurement is not accurate), I have a compression drop when the engine is cold, and when the metals expand from the heat, everything works normally. There is no smoke from the exhaust and no other evidence of oil leaking into the engine, but that is currently the main suspicion I still have: a compression drop.

My motorcycle has already traveled over 70,000 km, and the engine works smoothly and beautifully, except for the problem I mentioned.

I think I received the motorcycle after an event of overheating as a result of an oil leak from the coolant pump oil seal. A 250 engine that working at high rpm doesn't have much to do to destroy it, 70,000 km is very respectable. Maybe I did treatment to the upper engine, to improve the compression? But maybe not! Why to touch it as long as there is no oil leakage. Nothing will happen if at low temperatures my engine is starting with the addition of a tiny turn in the throttle(y):unsure:
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