Rattling Noise on ZZR-600 (Video Included)

Simmy

Simmy

Simmy

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Afternoon all,

My bike has developed a rattle which seems to be getting worse and worse. I can't locate it and I know it's a long shot that you'll be able to locate it based on this video! But are there any common parts that come loose on the engine? The video makes it sound like a complete bag of nails
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I'm praying it's not coming from inside the engine. I'm fairly sure it's something external. Any advice appreciated.

http://www.smg-computers.com/hosted/bike/Rattling Noise.avi
 
Couple of questions,

Does it go away if you pull in the clutch and put it in gear
Does it change with engine temp (is it the same from stone cold)
Is it from the front/top/bottom/back of engine
If you go along a bumpy road with the engine off does it rattle (loose brackets...)
How many miles has it done ?
 
dont know what the problem is but it sounds terrible!! and very expensive to fix :p could be loose cam chain? has it got oil in it :p?
 
loose cam chain or need to re adjust tappett clearences...

eidt that have just heard noise through better speakers.... dude thats either cam bearings spinning or crank bearings.... engines dead fella unless youve got ££££££ to spend
 
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mrgubby said:
Couple of questions,

Does it go away if you pull in the clutch and put it in gear
Does it change with engine temp (is it the same from stone cold)
Is it from the front/top/bottom/back of engine
If you go along a bumpy road with the engine off does it rattle (loose brackets...)
How many miles has it done ?
Click to expand...

It's done 12,500 miles.
It sounds like it's coming from the bottom of the engine. It sounds like the manifold is rattling but if I touch that (with my gloves on :p) it still rattles.
It doesn't go away when clutch is pulled in/in gear.
The rattling is definitely worse when the engine is cold, but it doesn't disappear completely once it's warmed up.
Will try going on a bumpy road when the weather improves.
 
Simmy said:
It's done 12,500 miles.
It sounds like it's coming from the bottom of the engine. It sounds like the manifold is rattling but if I touch that (with my gloves on :p) it still rattles.
It doesn't go away when clutch is pulled in/in gear.
The rattling is definitely worse when the engine is cold, but it doesn't disappear completely once it's warmed up.
Will try going on a bumpy road when the weather improves.
Click to expand...

On the advice you have just had, do NOT ride it anywhere and go and get a mechanic to look at it.
 
I'd definately stop riding that, sounds very sick.

I'd hazard a guess at the timing chain aswell, sounds very loose chain like to me..
 
Sounds very much like a rattling camchain, that doesn't sound "external" (loose bracket etc) to me.
 
The springs can wear on the camchain tensioners on these.

Tried removing the tensioner, cleaning, greasing the teeth with Copaslip or similar and then refitting it?.

I replaced my tensioner with a brand new one and it made no difference, I concluded it was the chain itself but traded the bike in before investigating any further.

However, that noise sounds slightly more serious to me than a tensioner on the way out. :eek:

Won't be the valve clearances as even when really out of spec, they just tick, the tick in question getting louder and louder as time wears on. When did you last have them done?.

Have you stripped the bottom fairing off and checked the manifold for leaks, cracks and sheared bolts?.

Clutch rattle could be another possibility, but again, sounds too loud even for that.

Crossing my fingers for ya mate, hope its not too serious. As others have said, don't take any chances - trailer the bike to a mechanic and have them check it out.

Last time I heard a noise like that from a big Kwack, it was a mates old GPZ900R and his big end bearings had gone AWOL. :(
 
Could be the cam chain tensioner. Probably failed causing the chain to slap about.
What ever it is, DO NOT RUN IT ANYMORE!
 
Tensioner is pretty easy to check.

Now I'm going back a good few years since I had my ZZR ( A K plate D3 model ) so excuse me if I miss anything. :cool:

Remove seat and side panels for access.

At the rear of the cylinder block, you will see the camchain tensioner. Its got one big bolt head in the middle ( for the actual tensioner itself ) and two smaller ones either side to bolt it to the block.

REMOVE THE LARGE BOLT FIRST!!! - The one that is under tension from the actual toothed tensioner. Watch, as when you get to the last thread, it can pop out suddenly and cause you to drop the bits and pieces.

Then undo the two smaller bolts either side and the assembly will come out.

There is a plastic spacer/washer that can sometimes get stuck to the block after removal of the tensioner, so check for that.

Have a swatch at the teeth of the tensioner, move it back and forth in its housing and you will be able to tell if its slack or the teeth are "jumping".

Clean, grease up with Coppaslip. Then refit in reverse order ( I sound like a Haynes manual!!! :D ). As you push the large middle bolt into the housing you will feel the spring tension start to build up push it in as far as it will go but don't force it. The idea is it will take up the slack automatically, but this isn't always the case if they wear. Tighten the bolt up.

If you are changing for a new one, compare the old for new together side by side. You may see a bit of wear on the grooved teeth and also check the length of the tensioner springs side by side, the old one may be shorter thus contributing to any rattle.

There are also manually adjustable ones available from a mob called "APE".
 
That is knacked lol

Sounds abit deep for a top end rattle. Hard to diagnose via a vid but its an engine fault not summit else on the bike and sounds more bottom end to me .
If the rest of the bike is good i would source another engine rather than spend cash trying to fix that .

Persil
 
Main bearings rumble, big/small ends & camshaft float tend to knock & valves tap.

The only time I've heard a noise like that (28 years of Jap fours) has beem from worn clutch basket bearings (goes when in gear/clutch in), loose bracket/exhaust clamp or knackered cam chain / tensioner.

If you put a piece of wood/screwdriver against the engine and press your ear against it you can sometimes track the noise down.

Get advice from a couple of garages, bike shops are even more **** than car garages
 
I'm pretty gutted as it's my first bike and I've only had it for 6 weeks. I've done 2000 miles on it and it's been spot on until this - but I've done no maintenance/servicing in that time :( If it's the big ends I might be best off selling it on me thinks.

I think I was in denial and I just hoping it was something rattling outside the engine if I'm honest :p
 
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I was convinced my old GSXR1100 was dead a few years ago, god awful rattling but no performance change :confused:

One of the bolts holding the exhaust clamp had come loose on 1st cylinder and it was letting the collet rattle. There was no exhaust leak and everything felt tight, it was only when I went to drop the engine out that I found the slack bolt :o
 
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