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Discussion Starter · #1 · (Edited)
Hi all,

I recently did valve clearance adjustment. I kept 0.12mm - intake and 0.15mm for exhaust. Also done CAM timing as per manual (TDC #2, EX mark and IN mark was lined up to the edge of engine top cover and the chain link counted from EX mark to IN mark were 33 links).
Today, I was going on local street, after 15 minutes of ride the engine stopped and upon trying to start it make some clicking/knocking sound and the engine won't start!!!

Anybody had such experience? What would have happen?
In mean time, I am going to open the engine cylinder head cover to examine.

Any inputs on this would be appreciated.
Thanks in advance.
vmlp
 

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Sounds like an electrical issue. Possibly bad / disconnected rectifier and dead/weak battery. A non working or bad rectifier would not properly charge the battery. A dead/weak battery will make the relay make a clicking noise.
 

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^ Good point.

I wasn't thinking along those lines, but that makes sense if the clicking noise isn't coming directly from the engine. I was thinking that a rocker may have fallen off or something like that, but a dead battery that doesn't have enough power to fully engage the starter motor would do what he described.

When you say "the engine won't start" do you mean it turns over freely/quickly but doesn't light up or it doesn't want to turn over? Where is the clicking coming from?


Jay
 

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Discussion Starter · #4 ·
found valve Arm-rocker borken!

Sounds like an electrical issue. Possibly bad / disconnected rectifier and dead/weak battery. A non working or bad rectifier would not properly charge the battery. A dead/weak battery will make the relay make a clicking noise.
Thanks Blue Ghost,
I found 6 of arm-rockers were broken off!!!! Only 1 pair of Exhaust valve on cylinder# 2 are intact.
and one of broken arm-rocker fallen in to cam chain well.

May be something went wrong during valve clearance adjustment?
I had set them at close to the upper limit (0.12mm intake / 0.15mm exhaust side).

What else could cause the valve arm-rocker broken?

Thanks,
Vmlp
 

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Discussion Starter · #5 ·
Fond 6 arm-rockers broken!

^ Good point.

I wasn't thinking along those lines, but that makes sense if the clicking noise isn't coming directly from the engine. I was thinking that a rocker may have fallen off or something like that, but a dead battery that doesn't have enough power to fully engage the starter motor would do what he described.

When you say "the engine won't start" do you mean it turns over freely/quickly but doesn't light up or it doesn't want to turn over? Where is the clicking coming from?


Jay
Thanks Jay,
It was failing to turns over with some breaking noise..Sorry i don't have proper words to describe it...upon examining the valves (cylinder head portion) found 6 arm-rockers were broken off (probably more damaged were done during multiple attempt of re-starting the engine!).

At this point, I am looking for what precautions to be taken next time when i replace the arm-rockers and valve clearance adjustment.

Thanks in advance....

Vmlp
 

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Discussion Starter · #7 ·
arm-rockers broken!

Wow, that's a lot of damage. How did the bike run for those 15 minutes you rode it?
I didn't noticed much except the exhaust sound different -- thought that was because of valve clerance was done.

I believe, The Cam timing set went wrong!
I did tried according to manual but it didn't worked i guess!

If anyone has the timing procedure for 2007 ninja EX-250, please let me know or post it as attachment -- i will compare it with mine.

Thanks,
Vmlp
 
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