Engine knock, HELP!

[overtheedge86]

I just got an 87 warrior as a trade for some electrical work. Put a new battery changed the oil and fired her up. The engine knocks on start and on shut down (read about starter clutch), but also while running (didn't read about this on starter clutch). I listened with a long screw driver/stethoscope and the knocking is most pronounced right on the starter itself, nothing in the crankcase or towards the head.

Could this still be the starter clutch? When i searched no one mentioned a knock while idling/revving in nuetral. I'm thinking about removing the gear that ties the starter to the clutch/gear and pinpoint this noise.

 

[alex456123]

It is the starter clutch going you should replace it.

 

[overtheedge86]

Thanks for the reply.

I searched and read up on the starter clutch but this did not mention any random knocks while running, only when starting and shutting off the motor. I know the starter clutch is going bad but is the random knock while running also attributed to the clutch?

 

[alex456123]

Yeah if it starts engaging while its running

 

[WV98YFM350]

If ya dig in to change this, word to the wise, check out your cam chain for wear while you are in there. May kill two birds with one stone. Just my 2 cents. Its not too bad to do but you will need a flywheel puller made for this machine to get at it.

 

[overtheedge86]

So i pulled the gear connecting to the starter and the one way clutch. ALOT quieter, but there was still a noise not consistent with rpm. I pulled the tank and valve covers to check them and also the cam gear cover. With the flywheel "T" lined up through the peep holes the cam mark was almost 180 degrees off!?! This motor runs, idle nice actually but the timings this far off, how can that bee? and is this likely the other noise i'm hearing almost sounds like something is rattling in the head?

 

[alex456123]

Turn the crank 360 degrees from that spot and it will line up, every two crank rpms the cam spins one rpm.

 

[overtheedge86]

Wow i feel like an idiot. I knew that too this thing is just frustrating me beyond belief. The thing runs great starts right up but has this inconsistent rattling/knocking in the engine.

 

[overtheedge86]

https://www.youtube.com/watch?v=bg4hOcttDA4&feature=youtube_gdata_player

heres a video of the noise. Valves adjusted, timing chain is loose but I had the cover off and watched it and I didnt vibrate or jump in conjuction with this rattle.

 

[overtheedge86]

So today i talked to the mechanic my buddy brought the bike to when this noise first started.

According to him the tappet nut fell off and he could not find it, he replaced it and advised my not to ride this until the nut is found. I'm going to pull both covers off clutch and stator and see what i can find if anything in the case. I've already looked through the valve covers into the head and can't see anything.

 

[overtheedge86]

piston?

What am I looking at spending for a basic rebuild of the top end? No big bore stroker anything fancy, maybe bore if the cylinder is scored but what's a basic top end rebuild run, and whats a reliable company?

 

[duneracerweston]

DO NOT CRANK THAT MOTOR AGAIN.

THOSE ARE PISTON SKIRTS.

time for a topend rebuild!