1997 Kawasaki Bayou 300 2x4 (klf300b) Runs Bad

[JacobSlabach]

its in time, but every other time I reach top dead center, the rocker arms are really loose, the tight, then loose, then tight....  every time I reach tdc.

[Frank Angerano]

Adjust the valves as described and fire it up. See how it sounds.  It should be fine. 

[JacobSlabach]

ok but which tdc should I try it on?  loose tdc or tight tdc?  I guess thats what I was asking...lol

[Frank Angerano]

Ohhhh tight sorry. 

[JacobSlabach]

lol sorry I guess I wasnt saying that right..

[Frank Angerano]

Ok let me know how it goes.   I’ve been curious to see how this whole thing turns out.

[JacobSlabach]

ok.  got some feeler gauges.  will update you on how it runs.  so just double checking so I dont screw up something:  adjust it at TopDeadCenter when the valves are tighter (they still are loose, just dont have 1/4 inch gaps on that stroke)

[JacobSlabach]

hopefully the valve slap stops and hopefully I haven't bent a valve...  I only ran it a couple seconds, herd the popping, and turned it off.

[Frank Angerano]

Hopefully you didn’t.   That’s why I sent the video. When in doubt go to the manual and YouTube.  That video is your engine so it really explains how it’s done. I could try to write and explain but video is the best. 

[JacobSlabach]

yep and thanks for the vid!

[Frank Angerano]

You are welcome!!! Now let’s hope all that hard work turns out to be worth it.  This long distance troubleshooting thing is not easy 🤣 

[JacobSlabach]

set the valves correctly.  still has a loud ticking noise like before.  I dont know what else to do.  Its in time with the "Top" on the head and the "LF300" mark on the cam sprocket;  and the 'T' on the flywheel.  It never did this before I rebuilt it.

[Frank Angerano]

What’s the clicking like ? Is there a compression relief on the head ? And if so does it feel right ? 

[Frank Angerano]

You can also take them valve cover caps off the head and start the bike for a minute. Just be prepared for a little smoke. Maybe you can see or hear better as to what’s going on.  

[JacobSlabach]

43 minutes ago, Frank Angerano said:

What’s the clicking like ? Is there a compression relief on the head ? And if so does it feel right ? 

yes there is and it works like it did before I did the rebuild.  It releases and makes it easier to pull start the bike.

[Frank Angerano]

Ok so what’s the tap sound like is it a low oil sound ? Tap tap ? Or a knock 

[JacobSlabach]

33 minutes ago, Frank Angerano said:

You can also take them valve cover caps off the head and start the bike for a minute. Just be prepared for a little smoke. Maybe you can see or hear better as to what’s going on.  

ok I will try that..  I'm weary of running it because I'd not like to bend a valve if its hitting..  

[Frank Angerano]

I can’t imagine you would bend a valve. So try this, take the caps off the head and rotate the engine and watch the valves move slowly and see if they get too tight as you hit the top of the lobe on the cam or if they still feel loose at the top. Also check that the head is wet from oil pumping up. 

[JacobSlabach]

I've never ran or heard an engine with low oil so I dont know what that sounds like, but there is oil oil in the bike to the viewing window and I changed it in July.  Its more of a knock in the top end-  I dont think its piston slap because the knuckle joint was pretty tight with no wiggle.

2 minutes ago, Frank Angerano said:

I can’t imagine you would bend a valve. So try this, take the caps off the head and rotate the engine and watch the valves move slowly and see if they get too tight as you hit the top of the lobe on the cam or if they still feel loose at the top. Also check that the head is wet from oil pumping up. 

when I took the caps off today, there was oil in the head around the valves and the cam.  I'm not sure what you mean about watching the valves hit the top of the lobe on the cam or if they feel loose at the top...?

[Frank Angerano]

The only knock I can think of was on my bayou 400 and it was where the cam sits. It’s called a journal where the cam sits.   The cam was actually hopping up and down. I should hope that’s not the problem.  

Here are a few pics of my old head where the cam sits. Did you take any pics or notice this condition ? 

[Frank Angerano]

Just rotate the motor and watch the valve move up and down. When it gets to the highest and tightest spot then that’s the top of the lobe on the cam  feel how tight the valve is.  

[Frank Angerano]

When you get the engine to top dead center and the T is in the small window on the flywheel and the marks are lined up on the cam sprocket with the head yiu are at top dead center.  Is there play in the valves ?

[JacobSlabach]

14 minutes ago, Frank Angerano said:

The only knock I can think of was on my bayou 400 and it was where the cam sits. It’s called a journal where the cam sits.   The cam was actually hopping up and down. I should hope that’s not the problem.  

Here are a few pics of my old head where the cam sits. Did you take any pics or notice this condition ? 

cam seemed snug to me- mine slid out the side off the head because my head doesnt come apart like yours.

2 minutes ago, Frank Angerano said:

When you get the engine to top dead center and the T is in the small window on the flywheel and the marks are lined up on the cam sprocket with the head yiu are at top dead center.  Is there play in the valves ?

you mean side to side or up and down?

[Frank Angerano]

Got ya I know it slides out but I was wondering if you inspected it before you put it back together. 

Check that valve clearance like I said after that I’m stumped as to what the knock can be unless somethings not put back right ?

[JacobSlabach]

the cam on mine had bearings on it and I didnt see any metal shavings or wear on it.  It looked brand new condition wise.

[Frank Angerano]

I’m sure but I’m hoping that the bearing is not bad leaving play.  It may look ok but that means nothing.  Anyway check the valves like I said see how that goes.  

[JacobSlabach]

the bearing had no play in it.  ok will do!

[Phil]

Your doing okay Jacob, I'm still watching this post  to see how you go.

[JacobSlabach]

1 hour ago, Phil said:

Your doing okay Jacob, I'm still watching this post  to see how you go.

thanks--  I'm just at whits end trying to figure out what could be causing the knocking/tapping/slapping noise on this bike....

[Frank Angerano]

Going to have any time to start looking into the head ? And check the valves ?