• 4 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
     TE = 4st Enduro & TC = 4st Cross

  • Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

Mysterious Engine Knock 2009 SMR510

banana944

banana944

Husqvarna
AA Class
My 2009 SMR510 was running great, quite no ticks no noises with just 4k miles. I had an unfortunate stator failure that flatlinned the bike. Stator mount bolts backed out and took out the stator. I replaced the stator and flywheel with good used units. At the same time I installed the RR water pump. Pulled the cover and removed the nut holding the impeller. Was trying to work the impeller off the shaft when it pull the shaft with it and threw off my timing.

I posted a previous thread about my issue and timing the engine. It can be found here for some backround information. http://www.cafehusky.com/threads/need-help-timing-2009-smr-510.84165/

I got the engine timed and set (incorerectly marked cams from factory caused grief, see previous thread). Upon startup I had a pretty serious knocking noise. I am pulling my hair out trying to track down the source. It is really not apparent at starter cranking speed, but once it fires to life it is very audible. The rate of the knock increases linear with RPM. The engine seem to run, idle, and rev nicely besides this knock.

What I have tried:

1. I purchased a used Exhaust cam to make sure I wasn't having any issues with my incorrectly marked exhaust camshaft. I reinstalled and the knock still persists.

2. Bench tested the cam chain tensioner. Teeth look good, and ratchet mechanism holds when smacked against the work bench.

3. I pulled the head off and all timing components. The piston shows no sign of kissing a valve, and all the valves look good. This confirms my timing procedures were done correctly. I have not removed jug to check condition of rod.

Currently I have recieved my last bits from Hall's and I am looking to reinstall the head this weekend. The head will be reinstalled with all new timing components, guides and chain. What makes me very frustrated is that I still have not found any obvious sign of what is wrong. I am afraid I will get the bike reassembled and the knock will persist.

Can anyone else think of any suggestions before I reassemble the engine?
 
don't smr's have a counter-balancer? ...might check that if you can.

(...the nut is still on the impeller too, right)

you've been concentrating on the valve train and, given your bike's history, you're probably right in being suspicious. But have you tried a mechanic's stethoscope (or hose, screwdriver, wrench etc) to isolate the noise? (btw, $3.99 at Habor Freight). You've confirmed you don't have a sticky valve, right?

next guess: rod bearing (hopefully, the little end) or something stuck to your rotor (it looked good when you bought it? probably balanced okay then).

sorry, you got a head-scratcher. good luck.
 
SMR's do have a counter balancer, not sure there is any way I can check that besides splitting the cases. This is a head-scratcher for sure, and I can't imagine how this could be a problem in the bottom end considering I havn't touched it, and it was running fine.

I remember trying to isolate the noise with a screwdriver, but was not able to determine bottom or top end from it. That was quite a few months ago. No other way to test now than to reasemble.

I also ensure the waterpump nut was on and the impeller wasn't hitting the housing. I even tried running it without the water pump impeller or housing off and the noise persisted.
 
banana944 said:
...I remember trying to isolate the noise with a screwdriver, but was not able to determine bottom or top end from it. That was quite a few months ago. No other way to test now than to reasemble.
Click to expand...

well, if you had a hard time discriminating a sound between the upper & lower end- a mechanics stethoscope is for you. They are amazing at isolating sound (the ear buds not only allow you to hear what the pin is on, they also isolate outside noise [read: exhaust noise] ...and you don't hafta contort your body). No disrespect, but I am going to assume you put the screwdriver to your ear.

after actuating the valves by hand if possible (turn the cam?) and giving them a super-hard look- I'd guess you're gonna hafta re-assemble the motor.

I also ensure the waterpump nut was on and the impeller wasn't hitting the housing. I even tried running it without the water pump impeller or housing off and the noise persisted.
Click to expand...

good check; and semi-easy. would've been a hair puller to find out the noise was in the waterpump.

good luck.
 
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