PowerGroove's Catastrophic engine failure and rebuild thread

This is a discussion on PowerGroove's Catastrophic engine failure and rebuild thread within the Mechanical and Technical forums, part of the ZX6R Forum category; You read that right... She's dead. At least for now. Some of you already know what happened, but for those that don't... let's bring you ...

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Old 01-12-2012, 06:06 PM   #1
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PowerGroove's Catastrophic engine failure and rebuild thread

You read that right... She's dead. At least for now. Some of you already know what happened, but for those that don't... let's bring you all up to speed, eh?

Was on the freeway after about 2 hours running about 80mph max most of the time. Hovering around 8000rpm and humming along nicely... then it happened.

She just cut out. No power... sounding like a 250... about to die but still sputtering along at about 65-70. I was 10 miles outside of anything with a lit area and a decent amount of population and it had just dropped about 15 degrees on an already cold ride in to visit the little lady.

I thought it lost a stick coil because it was still running... just not healthily. That was until I slowly went by a truck and saw yellow flickering off of the trailer... I look down to see a 3 foot flame coming from my tailpipe. "Come on baby... don't light on fire.... just get me to civilization." I remember saying.

She was going... but barely... maybe 6 minutes later I noticed the temp starting to climb. This was not good. "I'm sorry girl... just get me 3 more miles and we'll put you to bed." I said as I shook my head and pet the side of her tank. She was hating life... but damned if I didn't see the lights of fuel stops and fast food joints ahead of me!

Ahead.. side of the road and pulled off... a truck with a tow rig, lights flashing, working. A little further up I look and see a couple more rigs pulled to the side when, ""BAM! wiggle jerk..!!"" After my butt let go of the seat of my already dying motorcycle I realized I had just run over a doomed truckers tread the obviously blown tire the tow rig was changing. Thank the Gods I was still upright... and barely making this last mile.

I look down to see the temp now climbing up over 200* and fast. I pull to the shoulder about 1/4 mile from the off-ramp I was hoping to make it to, dropped her to about 45mph, and cruised 6th gear all the way in... kept her spinning enough to get rolling after the stop sign... and shut her down in the parking lot of a Chevron Station. White smoke (turned out to be a mix of oil and coolant) spewed from the tail pipe.

Called my lady and tell her the bad news.. "NOOO!!!" she says. And I'm just bummin'... Luckily her roommate was on that side of town. I asked the manager at Denny's if I could move her around back for the night. And we got home.

Preliminary tear down to the throttle bodies yesterday revealed the culprits. And further tear down today after getting my truck down to where I was and then the bike to the only other guy besides me to touch her revealed some optimistic views... but we're not out of the woods yet.

With luck the motor will be out by this weekend and we'll see the full extent of the damage.

I do not know which direction I'm going to go with it. Whether it will become a track only bike, or a newly race tuned street monster. But either way we are going to be doing some engine modding while it's out and torn apart. Needless to say I'm going to be calling Kawasaki and finding out anything I can about a 20,000 mile, meticulously maintained, bike dropping valves at 8000rpm.

Here are the photos...




Bright sides... No metal bits or shards in the oil or pan and no shards or metal in the cams. We'll see what the real damage is when the cams come out.



#4 intake valves



Only metal I found was in the airbox.
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Old 01-12-2012, 06:07 PM   #2
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OK... if you're reading from the top down... Probably gonna need to get a new motor... this one is going to cost more than a used engine would cost anyway. So if you crash your bike let me know!

This is January 29th 2012.

Engine is out...




Thrashed and mashed piston.


Last edited by PowerGroove; 01-29-2012 at 04:57 PM.
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Old 01-12-2012, 06:07 PM   #3
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1/2/12

Got the new motor up to the mechanics place and she'll be going in this weekend I'm hoping. Although my mechanic blew up his Aprilia so he might be rebuilding two bikes over the couple of days off he has.. hahaha


Some better pics of the carnage that ensued....






Last edited by PowerGroove; 02-03-2012 at 10:23 AM.
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Old 01-12-2012, 06:08 PM   #4
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saved for future rebuild info and pics...
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Old 01-12-2012, 06:08 PM   #5
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You guessed it...

I think that'll be good for now..
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Old 01-12-2012, 06:13 PM   #6
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Wow Bro, Sorry to hear about your baby blowing up on you! I don't know what I would do if that happened to my 6. At least you have the technical know how to get her back up and running! Good luck with the re-build!
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Old 01-12-2012, 06:14 PM   #7
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ouch man!! glad you kept her upright tho, i mean i understand wanting to get to civilization under her own power (whatever power was left) but that sounded pretty dangerous with the flames and all. idk what i would have done but i gotta say probably woulda pushed her as far as i could rather than take the risk of dropping her. make sure you take alot of pics of the internals, cant wait to see, but hopefully not too much damage. good luck!!
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Old 01-12-2012, 06:14 PM   #8
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Quote:
Originally Posted by PowerGroove View Post
saved for future rebuild info and pics...
Subscribed. Excited to see what she is going to become!
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Old 01-12-2012, 06:15 PM   #9
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The flames went out when enough coolant started making it's way into the cylinders..

Was only throwing fire for about 1/2 a mile I think.
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Old 01-12-2012, 06:31 PM   #10
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Dude u really should've just pulled over and called a buddy or tow company...u could've maybe salvaged more parts...hopefully the bottom end is good but highly doubt it with u running it do long after the valve dropped

Best of luck
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Old 01-12-2012, 06:34 PM   #11
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Yes I should have... but it would not have made it home that night. Would have sat on the side of the freeway. Nobody had a ramp anyway... I wasn't able to get a ride until the next day and it was a lucky shot... you you're totally right. Stopping would have been much better for the health of the engine... Too late for that now...

I'm pretty optimistic though so far.
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Old 01-12-2012, 06:45 PM   #12
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Dropped a valve at 20k with meticulous maintenance its whole life...that just isn't fair. lol
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Old 01-12-2012, 07:08 PM   #13
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This sucks man I'm so sorry to hear this.
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Old 01-12-2012, 07:10 PM   #14
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That sucks... Glad you got the bike to a safe area to leave it for the night. Can't wait to see which direction you are gonna go with it.
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Old 01-12-2012, 07:15 PM   #15
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Bro when I got my bike that is exactly what my air box looked like. I ended pulling the head to find cylinder #3 was beat to shit. Ended up replacing the motor. Don't want to crush you man but you brought back some bad memories with the metal chips in the air box. Hope you are riding again soon. It took me a month to find a motor and a day to put it in. Rode her for a while as a naked bike till I had the money for the fairings and now she is all pretty again.
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