V7 II Broke Down, Metal Flakes in Crankcase = Poops.

[Tom H]

You just posted the pics I was going to ask if you could do.

On the bad crank. Do your good thrust washers line up with the step? I'm thinking they do.

It would appear that the correct cranks are flat with no step. As you mentioned, is the step there from machining or wear? That is the good question.

I still find it odd that the bad cranks also ate up the outer throw out bearing, but the good flat cranks appear to not have done this. As mentioned. maybe a lubrication issue?

If it was a machining issue, there would be oil there, but probably not under pressure. So maybe when the clutch lever is pulled and the crank moves forward, the gap between the inner thrust and crank is now bigger allowing the oil to flow out toward the engine side leaving the clutch side essentially dry???

Wish I could go back in time and see the shelf of cranks and have a look at them to see if they have the step. And if so, all or how many.

Thanks for the good work,
Tom

[Kev m]

As we spoke earlier, sure sounds like Hamlin's theory was correct, the bad batch have a crankshaft machining problem that allow too much play and eventually the thrust washers come out of position and/or are eaten away.

[Dirk_S]

As we spoke earlier, sure sounds like Hamlin's theory was correct, the bad batch have a crankshaft machining problem that allow too much play and eventually the thrust washers come out of position and/or are eaten away.

Oh sure. I might even hop onto that other forum and share my findings on the engine thread. I know one or two members snapped back with some ‘how dare you suggest the crankshaft” comments.

[Dirk_S]

And we have a complete engine again:











Fingers crossed that I didn’t stink it up. Next up—add on the bell housing, gearbox, and we’LL be ready to begin installing it back onto the bike. Fingers crossed for a Christmas miracle.

[n3303j]

Good on you!

[Antietam Classic Cycle]

 

[Stretch]

Good on you!

This!   

                         -Stretch

[Kev m]

Holding my breath---- you got this! 

[czakky82]

 

[Bulldog9]

Good on you, and Kudos for taking this on. We are waiting to see how it runs, and are waiting to see what you will break next    Seriously though, very impressed.

It's obvious that this crank issue is a V7ii issue. I'm wondering if the failures are specific to sub models? I wonder if there is or we could have a poll to identify which models have had the failure? I'm tracking 4 V7ii sub models

Stone
Special
Racer
Stornello

I think that is it, and from my vantage point have seen Stones as the majority, and I haven't seen a Racer or Stornello, but I wonder if it would help to narrow down potential victims?

[Dirk_S]

Engine back in the bike:





…finished connecting all the bits and bobs yesterday:







…and started it up today.

Noticed my throttle and idle were erratic for a while—was it because I removed the evap canister? Is my timing off? Do I have a leak?—until I realized air was puffing out the side on the right cylinder. Fearing a blown head gasket, I stuck my hand down and felt the air coming out from the intake manifold. Thought maybe I didn’t have it screwed into the head tight enough, but then I saw it was coming out of the screw hole that the injector cover attaches to. Once I plugged it, she started singing sweet, sweet music.

After getting the engine up to temp, I dropped the oil and it came out like this:





I’m assuming this is just what break-in oil looks like? Didn’t see any metal debris—OK, I did actually see a minor amount on the rear drain bolt, but I think it was there from previous. Kinda hard to get ALL metal off those magnets.

Anyway, tomorrow I’ll take it for a 20 minute drive, drop the oil again, replace with the normal synthetic stuff, and to most people’s chagrin, hook the sidecar up immediately. Not out of the woods yet, fingers crossed!

[Antietam Classic Cycle]

 

[Vagrant]

That pic looks like it belongs in a Starbucks ad.

[Stretch]

Engine back in the bike and running with no funny noises?!

That's GREAT! 

My winter project(s) are not progressing as quickly, alas.......

                                                      -Stretch

[Beowulf]

Man that’s great. Congratulations and well done. Been following this with some interest

[usedtobefast]

Impressive work!  Thanks for taking the time to document/share this with us!   

[n3303j]

Can't quite figure why air would be puffing OUT of the intake manifold?
That should be negative pressure.
I'm assuming you got the valve timing and clearances at factory specs?

Glad to hear it's running properly. Enjoy. Around here, at least, they've canceled winter. It's hit 50 every day for the last few and there is no snow, ice or salt anywhere. Been riding pretty much every day.

Enjoy the ride. Don't lug the engine with the chair.

Good work. It's fun coming off the back side of these adventures with more knowledge about your machine.

[Dirk_S]

Let’s go ahead and do one final report and I’ll call this thread done…hopefully.

Took the bike out for a 10 mile ride, varying throttle and RPMs. No hard loads or lugging, no high screaming RPMs or complete WOT, but about 80% and 6k RPM a couple times.

I dropped the oil, and gazed through it, spying a little debris here and there, all tiny. However, expecting mostly silver, I did see some copper. I assume this is the thrust washer material. How big of a deal is that? Again, no sizable flakes, just small grains, and not a lot.

[John A]

Let’s go ahead and do one final report and I’ll call this thread done…hopefully.

Took the bike out for a 10 mile ride, varying throttle and RPMs. No hard loads or lugging, no high screaming RPMs or complete WOT, but about 80% and 6k RPM a couple times.

I dropped the oil, and gazed through it, spying a little debris here and there, all Tony. However, expecting mostly silver, I did see some copper. I assume this is the thrust washer material. How big of a deal is that? Again, no sizable flakes, just small grains, and not a lot.

I wouldn’t worry unless there’s part numbers on the bits. Keep a eye on it though, if there is something amiss,  go back in and fix it. Watch for fore and aft flywheel movement increasing. If you see that you’ll want to look at it. Up to about a millimeter max is ok in my experience. Pull the clutch lever as you visually watch either the flywheel or the alternator. Push or pry it aft.

[cliffrod]

Glad to hear about forward progress, Dirk.  Very cool.