NinjaFinch
New member
Hi everyone,
I'm beginning to lose my mind over this project, but I'm hoping a fresh set of eyes might help here. I'll try to be as comprehensive as I can.
About a year ago, I bought an '09 DN-01 with a disassembled engine as a winter project. It's now becoming apparent that I've missed something along the line when putting it back together. The bike was originally taken out of service for an intermittent rough idle. And despite what I thought were the actual culprits, I can confirm the previous owner's complaints now that it's running again.
Original Complaint:
-Rough idle (intermittent, worse when warm, disappears at high speed)
-Excessive noise
Original Dealership Diagnosis:
-Stretched connecting rods (?!?)
Problems Found/Addressed During Rebuild:
-Idle Air Control Valve pins 2 and 3 (harness side) backed out of connector
-Water pump felt somewhat stiff when turned by hand (prevailing opinion from multiple shops was that it was still serviceable)
-Damage to exhaust packing ring between rear cylinder header and main pipe
-Spark plug boots arcing to cylinder head
During the first few test runs after reassembly (idle, neutral only, <1 minute), it wasn't exhibiting anything I would call excessive vibration. Same goes for the first powered run to function check the transmission (<3k RPM, cycled through drive/sport/manual, probably 2 minutes or less). For its first day back on the road, it idled and took off fine at first. But after ~5-10 minutes, it began shaking at idle exactly how the previous owner described. Idle speed fluctuates somewhere between 1,250 RPM and 1,500 RPM. Taking off from a standstill worsens the vibrations (felt in bars and seat), but disappears over ~30 km/h. Shaking and noise seems to be tied to temperature, as it will present immediately on a hot start.
There are absolutely no problems at highway speed. No oil pressure/level warnings or coolant temperature warnings are coming on during riding, and engine oil is fresh and correct. Spark plugs, plug boots, timing chains, chain tensioners, and air filter are all new (plug boots are NGK VD01F, per a recommendation elsewhere in this forum). IACV was properly cleaned and reset. No DTCs thrown or stored from either the engine or transmission computers. Engine power doesn't actually seem to be lacking, though I admittedly have no baseline for how a nominally running example should feel at these speeds. I'm personally suspecting it's something to do with how the transmission engages at low speed, though switching between neutral and drive doesn't seem to affect the sound and feel.
Current Suspects:
-Neutral/Drive clutch failing to fully engage/disengage?
-Transmission spool valve dirty/worn (per FSM, unsure of how it actually operates, was definitely not checked during reassembly)
-Faulty N/D solenoid? Tested in proper resistance range (15.6 Ohm @ 18C, nominal 14-17 Ohm at 20C), but haven't tested proper function yet
-Clutch wear? Clutch assembly was removed from engine by original dealership, but was never disassembled
-Internal transmission fault ($7k CAD non-serviceable part, RIP if true)
If I find a solution, the post will be updated.
Thanks in advance!
I'm beginning to lose my mind over this project, but I'm hoping a fresh set of eyes might help here. I'll try to be as comprehensive as I can.
About a year ago, I bought an '09 DN-01 with a disassembled engine as a winter project. It's now becoming apparent that I've missed something along the line when putting it back together. The bike was originally taken out of service for an intermittent rough idle. And despite what I thought were the actual culprits, I can confirm the previous owner's complaints now that it's running again.
Original Complaint:
-Rough idle (intermittent, worse when warm, disappears at high speed)
-Excessive noise
Original Dealership Diagnosis:
-Stretched connecting rods (?!?)
Problems Found/Addressed During Rebuild:
-Idle Air Control Valve pins 2 and 3 (harness side) backed out of connector
-Water pump felt somewhat stiff when turned by hand (prevailing opinion from multiple shops was that it was still serviceable)
-Damage to exhaust packing ring between rear cylinder header and main pipe
-Spark plug boots arcing to cylinder head
During the first few test runs after reassembly (idle, neutral only, <1 minute), it wasn't exhibiting anything I would call excessive vibration. Same goes for the first powered run to function check the transmission (<3k RPM, cycled through drive/sport/manual, probably 2 minutes or less). For its first day back on the road, it idled and took off fine at first. But after ~5-10 minutes, it began shaking at idle exactly how the previous owner described. Idle speed fluctuates somewhere between 1,250 RPM and 1,500 RPM. Taking off from a standstill worsens the vibrations (felt in bars and seat), but disappears over ~30 km/h. Shaking and noise seems to be tied to temperature, as it will present immediately on a hot start.
There are absolutely no problems at highway speed. No oil pressure/level warnings or coolant temperature warnings are coming on during riding, and engine oil is fresh and correct. Spark plugs, plug boots, timing chains, chain tensioners, and air filter are all new (plug boots are NGK VD01F, per a recommendation elsewhere in this forum). IACV was properly cleaned and reset. No DTCs thrown or stored from either the engine or transmission computers. Engine power doesn't actually seem to be lacking, though I admittedly have no baseline for how a nominally running example should feel at these speeds. I'm personally suspecting it's something to do with how the transmission engages at low speed, though switching between neutral and drive doesn't seem to affect the sound and feel.
Current Suspects:
-Neutral/Drive clutch failing to fully engage/disengage?
-Transmission spool valve dirty/worn (per FSM, unsure of how it actually operates, was definitely not checked during reassembly)
-Faulty N/D solenoid? Tested in proper resistance range (15.6 Ohm @ 18C, nominal 14-17 Ohm at 20C), but haven't tested proper function yet
-Clutch wear? Clutch assembly was removed from engine by original dealership, but was never disassembled
-Internal transmission fault ($7k CAD non-serviceable part, RIP if true)
If I find a solution, the post will be updated.
Thanks in advance!