Coolant getting in oil / Cracked Cylinder

Re: Coolant getting in oil

Well at least in my mind if the tech was performing a full service and going through everything it would include removing and flushing the radiator. I would expect that.

I hope he remembered to refill the coolant before starting it and overheating it before the test ride. That might warp the heads or even crack the block.

Re: Coolant getting in oil

Be sure to request that he save and return any parts, gaskets or supplies he uses during the repair. His cam removal method seems unusual and looks like a short cut. Wondering if this method any have caused a cracked head. The oil definitely has coolant in it. I would not suspect a water pump seal. If it wasn't leaking when it went in odds of it developing this problem without "help" from the technician are highly unlikely.

Chuck

Re: Coolant getting in oil

naustin said:

More pics. What is the round thing in the 4th picture that looks damaged?

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That's the fitting on the radiator where the cap attaches. It looks fine.

The first and fifth pictures do not bode well. If that much coolant is reaching the exhaust, my guess would be that something is allowing it directly into the cylinder and what's in the oil sump is blowing by the rings during combustion. It's more likely the top end than the bottom since it would take a combined failure of the block and a cylinder liner to dump coolant into both the combustion chamber and the sump. The top end is suspect because it was just disassembled. Either way, the engine's going to need a good clean-out after you figure out what went wrong.

Before you dump a lot of cash into repairs, it might be worth investigating replacing the entire engine with a used one. There are a carload of them on eBay at very reasonable prices, which is a pretty good indication that they're similarly-available on the salvage market. A wholesale swap might end up costing you less than repairs and is more likely to remain in good condition if the donor was last assembled by the factory. An engine from a 2007 model would be an ideal replacement, but a 2006, 2005 or possibly a 2004 would work, too. Don't get anything later than 2008, as there were changes to the FI system and I don't know if anything else in the engine changed.

--Mark

Cracked Cylinder

I posted last week about water in oil.

Motor has been torn down - cylinder is cracked and piston and head are damaged.

Bike is 2007 and looking to source a replacement engine. Someone previously posted that engines from later model year bikes might not be compatible. Looking for that info again.

Thanks,

Nick

Re: Cracked Cylinder

There are several posted on eBay, in the $450-$800 range. No idea of their condition or the reliability of the sellers.

Re: Cracked Cylinder

Pictures

Re: Cracked Cylinder

Nick, Pinwall Cycle Parts is a few miles from my house. They buy totaled bikes and part them out. They have a 2007 engine, but the pictures show the engine without heads. Price $427.45.
They are easy to find on the internet. Contact me if I can be any help.

Re: Cracked Cylinder

Could someone say why this would occur? Other than maybe overheat?

Thanks.

Re: Cracked Cylinder

Wow, any clue what caused the damage?

Re: Cracked Cylinder

At this point - my primary concern is whether an '09 or '12 motor will plug n play -- or, if I need to make sure and find an '07 to match?

Thanks for any help.

Re: Cracked Cylinder

dohboy said:

Nick, Pinwall Cycle Parts is a few miles from my house. They buy totaled bikes and part them out. They have a 2007 engine, but the pictures show the engine without heads. Price $427.45.
They are easy to find on the internet. Contact me if I can be any help.

Click to expand...

Thanks...

Re: Cracked Cylinder

It is obvious that a foreign object entered the cylinder and was caught in a "0" clearance area of the combustion chamber. The dent impression looks to be the same size and shape as a valve shim. After seeing the pictures in the previous thread where he had the cams twisted out of position, spark plugs out and no rags blocking the holes It's very likely (and unfortunate) one of the adjusting shims fell down the plug hole. That fully explains why there was no issue when it went into the shop and why there was coolant in the oil. Is he covering all of the costs? Save all of the old parts. You may need a second opinion.


Chuck

naustin said:

I posted last week about water in oil.

Motor has been torn down - cylinder is cracked and piston and head are damaged.

Bike is 2007 and looking to source a replacement engine. Someone previously posted that engines from later model year bikes might not be compatible. Looking for that info again.

Thanks,

Nick

Click to expand...

Re: Cracked Cylinder

I'm sure you could use the starter, alternator and even the throttlebodies are the same part number from 07 to 12, so I would think that any year would work, just make sure you use the rest of your electrical parts (ECM, wireharness, etc) over and above the basic engine.

Re: Cracked Cylinder

CruSTy said:

It is obvious that a foreign object entered the cylinder and was caught in a "0" clearance area of the combustion chamber. The dent impression looks to be the same size and shape as a valve shim. After seeing the pictures in the previous thread where he had the cams twisted out of position, spark plugs out and no rags blocking the holes It's very likely (and unfortunate) one of the adjusting shims fell down the plug hole. That fully explains why there was no issue when it went into the shop and why there was coolant in the oil. Is he covering all of the costs? Save all of the old parts. You may need a second opinion.



Chuck

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I totally agree - the impression left by the foreign object looks like a valve shim. Had to happen during a valve adjustment.

Re: Cracked Cylinder

A valve shim in the combustion chamber never crossed my mind when I first looked at the damaged surfaces, but I gotta agree with CruSTy's diagnosis on this. Makes total sense. Now to figure out how to get the shop to pay for their mistake.

Re: Cracked Cylinder

CruSTy said:

It is obvious that a foreign object entered the cylinder and was caught in a "0" clearance area of the combustion chamber. The dent impression looks to be the same size and shape as a valve shim. After seeing the pictures in the previous thread where he had the cams twisted out of position, spark plugs out and no rags blocking the holes It's very likely (and unfortunate) one of the adjusting shims fell down the plug hole. That fully explains why there was no issue when it went into the shop and why there was coolant in the oil. Is he covering all of the costs? Save all of the old parts. You may need a second opinion.

Chuck

Click to expand...

+1 - bike had zero issues going into the shop... needs new motor coming out... that doesn't just happen. Might need a lawyer.

Re: Cracked Cylinder

Thanks everybody. I appreciate the input. I will update as soon as I have more information.

Looks like my trip to Colorado in June is scrapped....

Definitely the impression of a valve shim.

Mistakes happen, Shop needs to see this for what it is and replace your engine with a like (Mileage) unit.

Keith

I'm thinking it may be a good ideal to run a magnetic pick up tool in the plug holes before finishing it up when doing a shim change. Just sayin.

+1 there is no doubt in my mind that is the exact shape of a valve shim. very unfortunate but could easily happen to anyone. This is unfortunately the hard way to learn about the importance of stuffing exposed openings with rags....
I don't see why a newer engine would not plug and play, I believe the ecm underwent a change somewhere around 08, but not sure if any mechanical changes where made to engine with this change.