Need Help with Diagnosis

[plato1]

Hello,

I have read a lot of post about ticking noises and valve adjustment and etc. Here's my story:

2007 GZ, with 37,000 miles on it. I have a ticking noise that sounds like it's on the exhaust side, but not sure as I can't seem to pinpoint the noise. Whatever it is, it sounds horrible!.....I changed oil and filter. Noise still there. Then I did a valve adjustment, a .05 on the intake valve side, and a .09 on the exhaust side. Noise still there.

I took it apart further-removed cylinder head cover. The exhaust rocker arm had significant wear. I bought a new exhaust rocker arm, put it in today and the noise is still there. I did not change the cam shaft as the wear wasn't horrible and the intake rocker arm was still concave, so I didn't change that either. Now I am wondering if I should have replaced the cam shaft.....Has anyone ever just changed the rocker arm on one side but not the cam shaft? I am wondering if my old rocker arm wore into the cam shaft and now the new rocker arm is not settling in on the cam shaft properly????

I have talked to a few knowledgeable mechanics, and they have also heard the bike. One noted the rocker arm was worn, and should replace, but was not likely my issue. He was right! lol. He was thinking more towards the cam chain, guides, and maybe the chain tensioner. So, I took all that apart too.

I removed the clutch cover and inspected everything inside. Cam chain seem okay, gears inside all had teeth, no wear, the guides seem to be operating properly. The only thing I am not sure about is this "automatic" cam chain adjuster. I took it out, and turned the screw clockwise as noted in the manual, and it seemed to be working okay to me.

As a second opinion, I had also taken the bike up to Suzuki. The mechanics there said valve adjustment. Then after I told them that was done, both of them said it sounded like the rocker arms. Which is why I did take it apart and found the exhaust side worn. The next day, I brought them the cam chain adjuster---the mechanic looked at it and said it was fine. Can anyone explain how that thing is supposed to work? I mean from the perspective of how the heck do you know if it's bad? The manual said to turn the screw clockwise and make sure it moved unobstructed. Which, I did. When I turn the screw all the way to the left, it locks up (which I think it's supposed to do). The only thing I notice is the spring coil seems to be off-centered when I turn the screw, and when I let it go, it slowly coils back to it position. Do anyone know if this may be a problem with this thing???

Another mechanic (scooter mechanic) mentioned to me that there are bearing in the camshaft??? From the manual, it doesn't appear to be any on the cam shaft. He tells me to remove the cam chain sprocket and there are bearings there? He says they all have bearings....Does anyone happen to know if there are bearings in the whole one-piece cam??? And could that be my noise issue because it's knocking the timing of the valve off????

I am starting to wonder if there is damage to the exhaust valve itself, since that rocker arm was worn pretty bad. All of the mechanics have told me it's not likely the valve. Does anyone have any thoughts, experience with this type of issue, or anything that might help me figure this out??? Thanks......

Here's some pics--I some of the parts---



The exhaust is on the lower portion of pic....



cam shaft worn??? Should I replace?






Also, here's a pic of the clutch side off....everything in there looked good.....? Cam chain looks slack because I had the cam chain adjuster out.....But when in, the chain is tight, no slack....

[bwader]

Have you made a recording of the sound? Post it on here.

I had a ticking noise on a china 150cc scooter I had. I adjusted the 2 valves twice, it had and still made the noise afterward. I took it for a test ride and went a few miles and the engine seized.

When I pushed it home, it having an automatic transmission so I wasn't stuck there. The piston rod went through the engine casing. Only 3,000 miles on it, changed oil when first got it then at 100 miles, 300, 600, 1000, 2000, and at 3,000 miles. Spark plug was a good shade of tan.

So after that I got me a Suzuki GZ, screw that china crap.

So anytime I hear of people with ticking engines and adjust their valves and it doesn't go away, I worry the same thing might happen to their bike.

[plato1]

Thanks for sharing Bwader, I have recently spoken with someone who mentioned that sometimes the noise can be a loose connecting rod, and/or the piston/rings slapping around in the cylinder, which ruins the head and god forbid something just blows while riding......Unfortunately, I don't have a good way to record the sound, I have tried with my phone, but it doesn't give a true representation of the noise.....I will try and record it again with something else.....

From the different people I have talked to, I think I may have to just take the head off and inspect everything.....I am not looking forward to doing that as it means I have to disconnect everything to drop the engine out of the bike....However, it seems to be my only choice left, or to start replacing random parts to see which makes the noise goes away, which may put me into removing the head anyways......

But before I do that, I am going to readjust the valves one more time.....I have been using Suzuki's site glass for finding TDC, but was told by the Suzuki mechanics, that they don't even rely on that and stick a hanger or something down the spark plug hole and find the TDC that way....

It seems to me that if Suzuki mechanics don't even rely on that site glass, then maybe the manufacturing is not accurate or something.....So, I am going to try and readjust the valves one more time to see if the noise goes away....If not, I guess I will be tearing that engine apart.....I will post an update soon.....Thanks.........