99 Ninja 250 - Performed first valve adjustment - Now loud noise -smoke/burning smell

Ninja1991 · April 22nd, 2016, 06:16 PM

Wew that valve job is pretty tough for the first time. I think I screwed something up. I had a hard time adjusting the slotted screw that sits over the nut, which will tighten or loosen the valves (rocker arm?). I would loosen the nut, then adjust the slotted screw, but every time I would tighten the nut, the valve clearance would change and become much tighter.

Eventually after working with it, I found a level that I though was within spec. I would try to hold the nut and tighten the slotted screw. I was using .010mm for the intake and 0.15mm for the exhaust.

I started it up, and I thought it sounded great. I assembled the rest of the plastics and took it out in the driveway. When I started it in the driveway, I started to hear a really loud clacking sound. See ~0:20 for a very close resemblance: https://www.youtube.com/watch?v=E4eH0d2E73g or similar to this: https://www.youtube.com/watch?v=KvVLHhVw8do

I thought it may have just been the valves because they were really tight before. I took it around the block (1/4 mile at most), and when I got back to my drive way, there was a light amount of smoke coming out from under the gas tank! Uh oh.

I did some research and found that the cam chain tensioner (or CCT) is common to make this noise. I removed it, cleaned it, lubed it, and reinstalled it. There is a small chance that this was done wrong but I dont think so. When I reinstalled it, if fit very very tight, and the rod did not want to enter the engine. When I loosened the phillips screw, it did not immedietly drop in, and I had to loosen it and then I heard a (thunk) and it dropped in. This unfortunately, did not solve the problem. I am going to give it another shot in the morning however.

Given the fact that I have this loud noise, combined with a burning smell and smoke, what could it be? Did I make a mistake and screw up one of the valve jobs? Would that cause smoke? There is residual oil from the valve cover, that may have fallen onto the outside of the engine, but I didnt see any. I checked the valves before closing the lid, and I am pretty sure they were OK, but I will check them again tomorrow. The bike was running decent before this, and there sure was not any sound like this or smoke before.

Thanks for the help!

xorbe · April 22nd, 2016, 07:23 PM

You may have over-tightened and broken a retaining dog ear on one of the arms. You better open it up and have a look. Engine destruction is imminent if this is the case. I don't remember my bike becoming excessively loud afterward, just a little extra ticking/tapping as the clearance was opened up from zero. 2nd pic on the following link shows what a missing dog ear looks like.

http://n4mwd.blogspot.com/2013/06/ov...ts-during.html

Yeah without the clever little tool it's hard to adjust. I found that backing up about a 1/4" turn then tightening worked. Or was it 1/2" turn. It's been a while.

Ninja1991 · April 22nd, 2016, 09:23 PM

Quote:

Originally Posted by xorbe

You may have over-tightened and broken a retaining dog ear on one of the arms. You better open it up and have a look. Engine destruction is imminent if this is the case. I don't remember my bike becoming excessively loud afterward, just a little extra ticking/tapping as the clearance was opened up from zero. 2nd pic on the following link shows what a missing dog ear looks like.

http://n4mwd.blogspot.com/2013/06/ov...ts-during.html

Yeah without the clever little tool it's hard to adjust. I found that backing up about a 1/4" turn then tightening worked. Or was it 1/2" turn. It's been a while.

****, I noticed one of those guys being very loose. I was in a bit of rush and I thought it was because the cam lobe was not over it. Are they replacable without anything too drastic?

I'd like to note that the nut was never stripped or drastically tightened. I tightened all the nuts with about the same pressure.

Edit - just read the blog. Sounds bad. If I open the valve cover and all the rocker arms are in good shape, I'm OK? I honestly don't think I over tightened those nuts. It looks like the main problem is that the dog ear on the rocker arm breaks off from over torquing, thus resulting in catastrophic failure. As long as that didn't happen, there still a chance to retain the health of the engine?

Motofool · April 22nd, 2016, 10:02 PM

Quote:

Originally Posted by Ninja1991

.........
I'd like to note that the nut was never stripped or drastically tightened. I tightened all the nuts with about the same pressure..........

You should use a torque wrench for those nuts:

http://faq.ninja250.org/wiki/What_is...t_procedure%3F

Not more than 14, not less than 12 ft-lb.

Ninja1991 · April 23rd, 2016, 07:58 AM

I'm working on it now. The smoke is from a bit of oil that fell on the exhaust manifold. I cleaned and lubed the cct again, and I am not sure at this point if the sound is normal because of the valve adjustment, or if it is a loose/out of spec valve. I'm going to take it around the block.

Edit - two valves were out of spec (the last exhaust ones). Seemed loose and shakey. No dog ears seem to be damaged.

Ninja1991 · April 23rd, 2016, 10:52 AM

Great news! Looks like the two valves that were out of spec was causing the issue. Tripple checked the spec before assembling. As soon as I started the bike I could tell immediately that the noise was gone. Took it for a ride and it's back in business!

CaliGrrl · April 23rd, 2016, 11:07 AM

Awesome!

crazymadbastard · April 23rd, 2016, 01:27 PM

xorbe · April 24th, 2016, 08:43 AM

Congrats!

ZacharyB · April 24th, 2016, 06:53 PM

For the future, one of the cool tips that I heard, perhaps from faq.ninja250.org, is to use a deep 9mm socket to hold the nut (with your hands), then, take an flathead eyeglass screwdriver and stick it down the center of the socket to work the center screw. You can at least hold the screw in place as you tighten down the nut with your finger-held socket. Then, remove the eyeglass screwdriver and torque the nut with a torque wrench.

April 22nd, 2016, 06:16 PM	#1
Ninja1991 ninjette.org member Name: Alex Location: Georgia Join Date: Apr 2016 Motorcycle(s): 99 250 Posts: 11	99 Ninja 250 - Performed first valve adjustment - Now loud noise -smoke/burning smell Wew that valve job is pretty tough for the first time. I think I screwed something up. I had a hard time adjusting the slotted screw that sits over the nut, which will tighten or loosen the valves (rocker arm?). I would loosen the nut, then adjust the slotted screw, but every time I would tighten the nut, the valve clearance would change and become much tighter. Eventually after working with it, I found a level that I though was within spec. I would try to hold the nut and tighten the slotted screw. I was using .010mm for the intake and 0.15mm for the exhaust. I started it up, and I thought it sounded great. I assembled the rest of the plastics and took it out in the driveway. When I started it in the driveway, I started to hear a really loud clacking sound. See ~0:20 for a very close resemblance: https://www.youtube.com/watch?v=E4eH0d2E73g or similar to this: https://www.youtube.com/watch?v=KvVLHhVw8do I thought it may have just been the valves because they were really tight before. I took it around the block (1/4 mile at most), and when I got back to my drive way, there was a light amount of smoke coming out from under the gas tank! Uh oh. I did some research and found that the cam chain tensioner (or CCT) is common to make this noise. I removed it, cleaned it, lubed it, and reinstalled it. There is a small chance that this was done wrong but I dont think so. When I reinstalled it, if fit very very tight, and the rod did not want to enter the engine. When I loosened the phillips screw, it did not immedietly drop in, and I had to loosen it and then I heard a (thunk) and it dropped in. This unfortunately, did not solve the problem. I am going to give it another shot in the morning however. Given the fact that I have this loud noise, combined with a burning smell and smoke, what could it be? Did I make a mistake and screw up one of the valve jobs? Would that cause smoke? There is residual oil from the valve cover, that may have fallen onto the outside of the engine, but I didnt see any. I checked the valves before closing the lid, and I am pretty sure they were OK, but I will check them again tomorrow. The bike was running decent before this, and there sure was not any sound like this or smoke before. Thanks for the help!

April 22nd, 2016, 07:23 PM	#2
xorbe ninjette.org guru Name: xorbe Location: Bay Area, CA Join Date: Jun 2013 Motorcycle(s): N650 (and others) Posts: 408	You may have over-tightened and broken a retaining dog ear on one of the arms. You better open it up and have a look. Engine destruction is imminent if this is the case. I don't remember my bike becoming excessively loud afterward, just a little extra ticking/tapping as the clearance was opened up from zero. 2nd pic on the following link shows what a missing dog ear looks like. http://n4mwd.blogspot.com/2013/06/ov...ts-during.html Yeah without the clever little tool it's hard to adjust. I found that backing up about a 1/4" turn then tightening worked. Or was it 1/2" turn. It's been a while.
	1 out of 1 members found this post helpful.

April 23rd, 2016, 10:52 AM	#6
Ninja1991 ninjette.org member Name: Alex Location: Georgia Join Date: Apr 2016 Motorcycle(s): 99 250 Posts: 11	Great news! Looks like the two valves that were out of spec was causing the issue. Tripple checked the spec before assembling. As soon as I started the bike I could tell immediately that the noise was gone. Took it for a ride and it's back in business!
	1 out of 1 members found this post helpful.

April 23rd, 2016, 01:27 PM	#8
crazymadbastard I'm crazy,your excuse is? Name: Winston Location: Connecticut Join Date: May 2013 Motorcycle(s): 250 2007 ninja Posts: A lot.	__________________________________________________ My Cafe Racer Build My intro post

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April 23rd, 2016, 07:58 AM	#5
Ninja1991 ninjette.org member Name: Alex Location: Georgia Join Date: Apr 2016 Motorcycle(s): 99 250 Posts: 11	I'm working on it now. The smoke is from a bit of oil that fell on the exhaust manifold. I cleaned and lubed the cct again, and I am not sure at this point if the sound is normal because of the valve adjustment, or if it is a loose/out of spec valve. I'm going to take it around the block. Edit - two valves were out of spec (the last exhaust ones). Seemed loose and shakey. No dog ears seem to be damaged.

April 23rd, 2016, 11:07 AM	#7
CaliGrrl ninjette.org certified postwhore Name: Kerry Location: Ventura, CA Join Date: Jan 2016 Motorcycle(s): Ninja650 Posts: A lot. MOTM - Apr '18, Apr '17, Apr '16	Awesome!

April 24th, 2016, 08:43 AM	#9
xorbe ninjette.org guru Name: xorbe Location: Bay Area, CA Join Date: Jun 2013 Motorcycle(s): N650 (and others) Posts: 408	Congrats!

April 24th, 2016, 06:53 PM	#10
ZacharyB ninjette.org member Name: Zachary Location: Queens, NY Join Date: Jan 2016 Motorcycle(s): 1994 GN 125, 2004 EX 250 Posts: 10	For the future, one of the cool tips that I heard, perhaps from faq.ninja250.org, is to use a deep 9mm socket to hold the nut (with your hands), then, take an flathead eyeglass screwdriver and stick it down the center of the socket to work the center screw. You can at least hold the screw in place as you tighten down the nut with your finger-held socket. Then, remove the eyeglass screwdriver and torque the nut with a torque wrench.