New issue: possible cracked valve rocker arm - Page 3

detours · 03-16-2016, 12:16 AM

Quote:

Originally Posted by Inroads

Most Japanese bikes have a wire mesh screen downstream from the air filter,
I wonder if our RX3 has that ?

Maybe we can retrofit one in front of the throttle body. I'm interested.

BlackBike · 03-16-2016, 12:55 AM

I guess it's a moot point but would be nice for a pm on that object "screw".

SpudRider · 03-16-2016, 01:19 AM

Quote:

Originally Posted by Inroads

Most Japanese bikes have a wire mesh screen downstream from the air filter,
I wonder if our RX3 has that ?

Yes, a mesh screen is built into the holder of the foam air filter.

http://www.cscmotorcycles.com/Articles.asp?ID=254

1cylinderwonder · 03-16-2016, 03:06 PM

I'll bet the screw in the center of the air filter fell into the intake port, or one of the 5 screws holding the air filter assembly accidently fell into the intake plumbing.

The most probable,
The screw in the center may have been stripped and disappeared without the "mechanic" or "tech" being aware it was loose or missing when assembling or cleaning the filter. And ended up in the intake tract behind the air filter assembly.
Just my theory?

SpudRider · 03-16-2016, 03:17 PM

That sounds plausible, except the screw fits on top of the airfilter assembly, above the mesh screen.

detours · 03-16-2016, 06:33 PM

Quote:

Originally Posted by 1cylinderwonder

I'll bet the screw in the center of the air filter fell into the intake port, or one of the 5 screws holding the air filter assembly accidently fell into the intake plumbing.

The most probable,
The screw in the center may have been stripped and disappeared without the "mechanic" or "tech" being aware it was loose or missing when assembling or cleaning the filter. And ended up in the intake tract behind the air filter assembly.
Just my theory?

That was my first thought too, but Gerry checked it and the screw was still in the air filter. He also checked the throttle body, but all screws were present there too.

SpudRider · 03-16-2016, 06:48 PM

Were any of the bolts missing which hold the air filter cover in place? I can't fathom how you could be responsible for letting a piece of metal enter the air box, throttle body, et cetera.

I think this foreign object must have entered the air box, throttle body, et cetera, at the factory.

BlackBike · 03-16-2016, 08:05 PM

This is good theory . Factory tech goes to install screw, fumbles, then installs another . Seen this on new cross trainers at the bottom of the plastic housing rolling around, or lost inside tube frameing. In this case ,screw finally jars loose and ingested? Don't know what rx3 box looks like but sounds plausable. Is there a inner cavity in the airbox that an errant screw could hangout?

Tiger12XC · 03-17-2016, 11:51 AM

Wow that is crazy to find bouncing around in the cylinder and intake. I would get the old motor back and rebuild it for a spare. Can't ever have enough spares. Glad to hear Gerry figured it out and will have your RX3 back soon.

detours · 03-22-2016, 06:08 PM

So rojo_grande and marzhere dropped off my bike last night

I rode it to work this morning and it runs great! For whatever reason, it actually runs a lot quieter than my original engine ... even before that piece of metal fell in and started rattling around. The new engine just purrs ... so much nicer.

Gerry also installed the 45T rear sprocket, new chain and progressive shock. I rode to work this morning and the shock handles rough road repairs and potholes much easier.

The gearing is noticeably lower with the extra tooth in back. Combined with my 13T front sprocket, it's going to really help offroad. But I'm not sure I like it on road ... probably because I have to stay under 7000 RPM during break in. We'll see how I like it when I can go full speed at 10,000 RPM.

Also, Gerry sent back all my old parts, including the original engine. Looks like all the nuts and bolts are there, but not the piece of metal that caused the problem. I may try polishing the cylinder head and maybe rebuild the engine ... in all my spare time

Anyway, I couldn't be happier with Gerry and CSC. Another company would have denied all warranty because of the foreign object damage. But CSC gave me a new engine and installed my shock, chain and sprocket (which I had already purchased) for $950

jbfla · 03-22-2016, 06:32 PM

Excellent news, Detours!

Glad you are back on the road.

to Gerry and CSC.

jb

rtking · 03-22-2016, 08:29 PM

Quote:

Originally Posted by jbfla

Excellent news, Detours!

Glad you are back on the road.

to Gerry and CSC.

jb

Ditto! Great to hear that you're up on 2 wheels, Detours!

And the world famous CSC Customer Service! Way to go Gerry and the CSC Team!

SpudRider · 03-22-2016, 08:40 PM

X3.

I'm glad you are riding once again, and kudos to Gerry and the excellent customer service from CSC.

tinman tim · 03-22-2016, 08:59 PM

Glad to hear detours

Here's my story/theory. As I try to educate myself on the inner-workings of the Rx3, I read alot of the threads here. And as it's been 'winter', I fire up the heat in the garage and go out to check for 'issues' on my bike, based on what your guys issues have been.

Awhile back, one said issue was the air filter needed oiled. While I had been under the seat adding electronics and the like, I had not looked at the air filter. Decided I had better do it. So when time presented itself, off came the seat. For whatever reason I struggled with what seams to be a straight forward task. Seat, easy. Side cover, easy. Filter door, easy. So now, to pull the filter out, not so easy. Doesn't wanna come out with my fingertips. Look thru the slots in airbox at the top of the filter. And what do I see laying atop the filter? Can't quite make it out. Flashlight and needle nose pliers, and I preform an extraction of the still unidentifiable substance.

As I pulled it thru the slot, I knew instantly what had happened. As stated before, I was under there a couple weeks before doing electronics. Well as I like to lose myself in these projects, sometimes the wife comes out to check on me. And if she shows up with a sandwich, even better. And if there's a candy bar with the sandwich, then she still loves me. Well this time, it was a PayDay in fact. How can I remember this you ask? Well on the end of my needle nose is the piece of PayDay that I dropped on my first bite of it. Single peanut and a little nugget. Had I not struggled to get the filter out, this little morsel could have been easily ingested by the intake.

Now if this is how easy it is to lose something to a 'potentially bad' spot, I wonder how much more protection the seat would offer to a fast moving object coming off the road/trail/tires? Can't stop it all for sure.

My plan, the next time I'm under the seat, is to put some screen over the slots to keep the big stuff out. Held in place with some well-placed screws or possibly some Velcro.

Just an idea

Jay In Milpitas · 03-22-2016, 10:06 PM

Quote:

Originally Posted by tinman tim

My plan, the next time I'm under the seat, is to put some screen over the slots to keep the big stuff out. Held in place with some well-placed screws or possibly some Velcro.

Just an idea

An excellent idea! Very fortuitous event, and great that you discovered it!
Thanks for sharing it!

03-16-2016, 12:55 AM	#32
BlackBike Join Date: Feb 2016 Location: George West, Texas Posts: 4,097	I guess it's a moot point but would be nice for a pm on that object "screw". __________________ ***************************************** 2015 Bashan"Blaze" BS250GY-31 (DB-07K-250) GONE 2017 Suzuki V Strom 650 XT "We are all born ignorant, but one must work hard to remain stupid." ~Benjamin Franklin~
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03-16-2016, 03:06 PM	#34
1cylinderwonder Join Date: Dec 2015 Location: Pismo Beach Posts: 387	I'm betting on a screw from the filter I'll bet the screw in the center of the air filter fell into the intake port, or one of the 5 screws holding the air filter assembly accidently fell into the intake plumbing. The most probable, The screw in the center may have been stripped and disappeared without the "mechanic" or "tech" being aware it was loose or missing when assembling or cleaning the filter. And ended up in the intake tract behind the air filter assembly. Just my theory?
	0

03-16-2016, 03:17 PM	#35
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	That sounds plausible, except the screw fits on top of the airfilter assembly, above the mesh screen. __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

03-16-2016, 06:48 PM	#37
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Were any of the bolts missing which hold the air filter cover in place? I can't fathom how you could be responsible for letting a piece of metal enter the air box, throttle body, et cetera. I think this foreign object must have entered the air box, throttle body, et cetera, at the factory. __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
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03-16-2016, 08:05 PM	#38
BlackBike Join Date: Feb 2016 Location: George West, Texas Posts: 4,097	This is good theory . Factory tech goes to install screw, fumbles, then installs another . Seen this on new cross trainers at the bottom of the plastic housing rolling around, or lost inside tube frameing. In this case ,screw finally jars loose and ingested? Don't know what rx3 box looks like but sounds plausable. Is there a inner cavity in the airbox that an errant screw could hangout? __________________ ***************************************** 2015 Bashan"Blaze" BS250GY-31 (DB-07K-250) GONE 2017 Suzuki V Strom 650 XT "We are all born ignorant, but one must work hard to remain stupid." ~Benjamin Franklin~
	0

03-17-2016, 11:51 AM	#39
Tiger12XC Join Date: Oct 2015 Location: Texas Posts: 146	Wow that is crazy to find bouncing around in the cylinder and intake. I would get the old motor back and rebuild it for a spare. Can't ever have enough spares. Glad to hear Gerry figured it out and will have your RX3 back soon.
	0

03-22-2016, 06:08 PM	#40
detours Join Date: Sep 2014 Location: Arvada, CO Posts: 1,004	So rojo_grande and marzhere dropped off my bike last night I rode it to work this morning and it runs great! For whatever reason, it actually runs a lot quieter than my original engine ... even before that piece of metal fell in and started rattling around. The new engine just purrs ... so much nicer. Gerry also installed the 45T rear sprocket, new chain and progressive shock. I rode to work this morning and the shock handles rough road repairs and potholes much easier. The gearing is noticeably lower with the extra tooth in back. Combined with my 13T front sprocket, it's going to really help offroad. But I'm not sure I like it on road ... probably because I have to stay under 7000 RPM during break in. We'll see how I like it when I can go full speed at 10,000 RPM. Also, Gerry sent back all my old parts, including the original engine. Looks like all the nuts and bolts are there, but not the piece of metal that caused the problem. I may try polishing the cylinder head and maybe rebuild the engine ... in all my spare time Anyway, I couldn't be happier with Gerry and CSC. Another company would have denied all warranty because of the foreign object damage. But CSC gave me a new engine and installed my shock, chain and sprocket (which I had already purchased) for $950 __________________ Red 5 standing by! 2015 CSC red RX3 with 19" front wheel, Shinko 804/805, skid plate, tall seat, 13T/45T sprockets, progressive shock, Winyoochanok windshield, GENSSI LED headlight, SW-Motech tankbag, Shorai Lithium battery 2014 Ural Patrol
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03-22-2016, 06:32 PM	#41
jbfla Join Date: Oct 2015 Location: FL, GA, NC Posts: 771	Excellent news, Detours! Glad you are back on the road. to Gerry and CSC. jb __________________ 2016 Honda CB500F......2017 Triumph Street Twin 2014 XT 250........
	0

03-22-2016, 08:40 PM	#43
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	X3. I'm glad you are riding once again, and kudos to Gerry and the excellent customer service from CSC. __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

03-22-2016, 08:59 PM	#44
tinman tim Join Date: Oct 2015 Posts: 30	Glad to hear detours Here's my story/theory. As I try to educate myself on the inner-workings of the Rx3, I read alot of the threads here. And as it's been 'winter', I fire up the heat in the garage and go out to check for 'issues' on my bike, based on what your guys issues have been. Awhile back, one said issue was the air filter needed oiled. While I had been under the seat adding electronics and the like, I had not looked at the air filter. Decided I had better do it. So when time presented itself, off came the seat. For whatever reason I struggled with what seams to be a straight forward task. Seat, easy. Side cover, easy. Filter door, easy. So now, to pull the filter out, not so easy. Doesn't wanna come out with my fingertips. Look thru the slots in airbox at the top of the filter. And what do I see laying atop the filter? Can't quite make it out. Flashlight and needle nose pliers, and I preform an extraction of the still unidentifiable substance. As I pulled it thru the slot, I knew instantly what had happened. As stated before, I was under there a couple weeks before doing electronics. Well as I like to lose myself in these projects, sometimes the wife comes out to check on me. And if she shows up with a sandwich, even better. And if there's a candy bar with the sandwich, then she still loves me. Well this time, it was a PayDay in fact. How can I remember this you ask? Well on the end of my needle nose is the piece of PayDay that I dropped on my first bite of it. Single peanut and a little nugget. Had I not struggled to get the filter out, this little morsel could have been easily ingested by the intake. Now if this is how easy it is to lose something to a 'potentially bad' spot, I wonder how much more protection the seat would offer to a fast moving object coming off the road/trail/tires? Can't stop it all for sure. My plan, the next time I'm under the seat, is to put some screen over the slots to keep the big stuff out. Held in place with some well-placed screws or possibly some Velcro. Just an idea Last edited by tinman tim; 04-01-2016 at 10:37 PM.
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