Increasing clattering sound from engine VIDEO and disassembly update -Finished!

[balkoger]

Hi all, a little update.
scooterfan: In this case (at such a torque) there are sliding bearing.

I start the easiest way take of the engine and take of the cilinder head + cilinder. I can measure the piston and piston pin, than crankshaft crank top and bottom axial and radial playing.

In the cilinder head plenty of oil, not signed any mayor abrasion, but the piston top are not nice, have carbon deposits.
The cilinder inner surface beautiful  , like a new, but the middle piston ring was stuck and piston have burned oil sign. The earlier owners maybe does not follow the good quality oil service, maybe that's why midle piston ring stuck and have the piston carbon deposits, or valve does not sit perfectly (that is another story later).
The piston pin doesn't play, as tight as it should be, but the crankshaft crank bottom have radial playing, more than specification.
So a have searched local mechanic, who has experience and find not only the fault, but also the root cause.

Now the engine splitted, measure many things, the crankshaft bearing have to be replaced because one section have abrassion (both bearing on same section) thats weird. It means to me the crankshaft "bended" or installed "not perfect well balanced" in a factory !!!!!
Now I send the crankshaft for rebuild, replacing the crank bottom bearing, and after compression balanced like a new.
I know that mayor rebuild not worth it based on certain criteria, but for me is the one bike now for pleasure ride 

[balkoger]

Hi All!
My journey still in progress, I'm waiting for ordered parts, which is coming slowly right now because of worldwide virus
I follow the kawasaki j300 more detailed service manual, and ordered many parts what was recommended when disassembling to replace it.
So all cheap special gaskets and O-rings stopped assembly work, while the big parts and manpower especially ready.

[balkoger]

Hi All !
I am fortunate to announce, before yesterday I put back the reconditioned engine afternoon, and catch the midnight cold start 
The engine noise gone 
 On the new video the engine not runing smooth at idle, because I have tor reset ECU as the service book mentioned and ECU need timet to learn from oxygen sensor, and throttle sensor (and many others) how to order the idle speed actuator. I didn’t want to pull the throttle grip all the way to the end for fresh engine.
After 70km ride yesterday, everything back to normal, the idle speed smooth, the engine more quiet like on the video, I teach ECU without high rpm, if someone need secret how, just let me know.
 The whole process cost me total 560 $ whereof the labor cost 250 $, so I have a lot of work in it.
For crankshaft renewal few other work done in the engine and change few parts for further trouble free operation.
- Cleaned cylinder head, valve and valve seat, change valve seal to the new one
- Clean piston and change rings to the new one
- The crankshaft bearing weared out, so change the 4 half bearing (need special tool for pulling out because that was nice smooth instead for pushing) and one left side crankshaft seal
- Clean all oil channels, change O-rings on presure actuator and all oil channels
- Checked and measured many parts, but visually there was no visible wear in many places (rocker arms,oil pump,water pump)
- Replaced many seals and O rings, what the service book mentioned.

https://drive.google.com/file/d/17hF-Tx8aAHyCKj0S-GiepKyGPBYe98E2/view?usp=sharing

Hi All!
My journey still in progress, I'm waiting for ordered parts, which is coming slowly right now because of worldwide virus
I follow the kawasaki j300 more detailed service manual, and ordered many parts what was recommended when disassembling to replace it.
So all cheap special gaskets and O-rings stopped assembly work, while the big parts and manpower especially ready.

[CROSSBOLT]

Very happy to hear your success! Good for a long life of riding!

[rdhood]

Good Work!  give us an update after a couple thousand kms