Engine problems - VERY LOUD Rattling/Knocking!!

[Richardandsam]

Ive had to have the engine out of the bike twice so far in the past month cause stupidly I ran it on Halfords own Part Syn 10w40 CAR Oil, and its developed a VERY LOUD rattle or knocking if you like.

Ive done all the Valve Clearances, BRAND NEW Clutch Plates/Friction Plates/Damper Plate/Basket/Pressure Plate/Springs, Changed to New Motul Oil, Champion Filter, Clutch Cable.

I originally thought that it might be the whole clutch or the gearbox that had given up or maybe even a simple fix like a bearing that needed to be replaced, but it seems not.

The only thing that I haven't changed is the Clutch Actuator Rod in the bottom of the Clutch Casing, Needle bearings for such or the rod that comes out of the Pressure plate as these all seem spot on with no free play.

Ive done the screwdriver trick all over the engine and determined that its definitley coming from the right side lower of the engine tho.
So I dropped the engine out and split the casings in two. What did I find?

Well, the Starter Gear Ring behind the Alternator Magnet is slightly warped but not enough to cause this racket! The gearbox cogs, bearings, dogs, shafts all seem fine, and like I said above, I changed the WHOLE Clutch assembly to rule that out.
While I was in there with the block upside down on the bench, I noticed that No:3 Lower Crank Bearing Shell had a very small chip out of it, but after talking to a Kawasaki main dealer they say its not enough to cause this racket! So im back to square one!!

Symptoms:

Listen too and watch the video below.

Rattles VERY LOUDLY all the time in idle with Clutch in or out.

Increases with revs when out of gear.

Rattles like this when on the bike but as soon as you hit 3000 to 3500 rpm under load in gear it goes!

So, took it back to main dealer this morning who now reckons that it could be a Big End Shell gone awry on No: 3 or 4 and that the sound is transmitting. Is that a possibility?

Before this lot started, the bike was rumbling and vibrating like a goodun with the car oil in it, in and out of gear and that's what lead me to believe that id destroyed the clutch after realizing my mistake with the bloody oil!

So now im sat here with the bike in the back garden, missing all this good weather, in pain cause of an earlier accident, and getting mad cause the bloody bike is turning to scrap before my eyes and winding me up by nearly pulling my hair out with the agro from it.

Here's the YouTube Video link:

https://www.youtube.com/watch?v=m2NamHeXgYg

Can you diagnose the problem or give some pointers or ideas please??

52,000 with new clock mileage.

Never run it without oil!

Im totally stumped! So you reckon its loose bearings on con rods or crank bearings?

Been told these can be done with lump still in bike by dropping sump, etc?

KWAKA mechanic told me to me to drop sump and have a feel at the bottom of the con rods by the crank for any looseness there. Reckons its easier than dropping the engine again.

I actually don't mind dropping IF i HAVE to, but what does scare me is if i take the head off is retiming the thing!

Any further help before i bite the bullet tomorrow?

[Blau Zedong]

Is this so important you need to post in both General and workshop forums?

Engine's fucked, get another one.
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[Richardandsam]

[c_dug]

Can't offer much on the knocking itself but I very much doubt the oil caused the issue, I've used car oil at some point on every one of my bikes and never had an issue.
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[MarJay]

Yeah I'd probably drop the sump because then you should see if there is any swarf in there.

It does sound like big end bearings TBH...
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Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.

[nowhere.elysium]

[Richardandsam]

This is a duel post....Sorry!

Have a look at the main thread in the WORKSHOP forum.

[mysterious_rider]

Has it been stored for quite a few years without use then?
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KAWASAKIIIII

[Richardandsam]

[Wonko The Sane]

I've got a spare ZZR600 E engine for sale in Manchester

It's supposedly been completely re-built and dry stored (so needs oil putting in)

I've never run it.

[Richardandsam]

[Pol Anorl]

Ah i know exactly what this is!!

I know someone who had this issue once, i had it on an old kawasaki too..

i was riding home from work when it happened, everything was fine weather was good, sat at the legal limit just relaxing as normal, around 3am so only 2 or 3 cars on the road, anyway coming along the a2 i noticed a silver or maybe black car infront about half a mile obviously going slow so i checked my mirrors, indicated and moved into the right hand lane.

I carried on my way for the mile or so it took to catch up and overtook him, i gave a him a little glance as i went by but no pleasentrys where exhchanged.

Anywhoo.. still sat at the speed limit on the a2 nearing home only about 4 maybe 5 miles to go and i noticed the sky was rather clear! absolutely beautiful motorcycling weather!!

about 30 seconds later disaster struck!!!

Id missed my bloody turning!! so i had to go even further out of my way to get home which was kind of annoying as i was tired but the weather was nice so meh.

But yeah let me know if you get this sorted buddy.
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[sickpup]

Big end or main has gone.

When you changed the oil did you change the filter as well? When you started the bike afterwards how long did it take for the oil light to go out?