2007 Busa Engine Knock

[REEPR]

HEY GUYS MY 07 HAS 1500 MILES ON IT AND I NOTICED AT ABOUT 400 MILES AGO AT IDLE THE ENGINE HAS A IRREGULAR KNOCK...IVE BEEN A TECH. FOR 30YEARS AND TO ME IT SOUNDS LIKE A BALANCE SHAFT KNOCK OR ROD KNOCK ANYONE ELSE HAVE THAT PROBLEM??:umm:

[BU54 NFS]

hi there
i may have the same problem
i live in the uk and 6 months ago i brought a brand new 06 usa model busa
the first time i got the engine realy warm on a 20 mile run i heard a knocking noise when i blipped the throttle after i had stopped but the noise was not very load
i phoned the shop that i had brought the bike from and was told to wait until it got serviced and they would look at it, i waited and was told after the service that due to the bikes state of tune they made some funny noises and this was one of them
needless to say the bike has now done 2000 miles and the noise has got alot worse
the noise is not there when first started and if you turn the engine off for a few minutes after it is warm you wont here it then
but after you have done 5 miles and you stop you can here and feel it on tick over, its like a loud metalic knock
the bike is back at the shop right now and when i phoned today (wed 30 april) i was told they could find nothing wrong?
please help
dave

[Tybalt]

hi there
i may have the same problem
i live in the uk and 6 months ago i brought a brand new 06 usa model busa
the first time i got the engine realy warm on a 20 mile run i heard a knocking noise when i blipped the throttle after i had stopped but the noise was not very load
i phoned the shop that i had brought the bike from and was told to wait until it got serviced and they would look at it, i waited and was told after the service that due to the bikes state of tune they made some funny noises and this was one of them
needless to say the bike has now done 2000 miles and the noise has got alot worse
the noise is not there when first started and if you turn the engine off for a few minutes after it is warm you wont here it then
but after you have done 5 miles and you stop you can here and feel it on tick over, its like a loud metalic knock
the bike is back at the shop right now and when i phoned today (wed 30 april) i was told they could find nothing wrong?
please help
dave
welcome to the Site:cheers:


ask them to check the CCT's (cam chain tensioners) , thats my feeling:smoke:

[Tybalt]

HEY GUYS MY 07 HAS 1500 MILES ON IT AND I NOTICED AT ABOUT 400 MILES AGO AT IDLE THE ENGINE HAS A IRREGULAR KNOCK...IVE BEEN A TECH. FOR 30YEARS AND TO ME IT SOUNDS LIKE A BALANCE SHAFT KNOCK OR ROD KNOCK ANYONE ELSE HAVE THAT PROBLEM??:umm:

CCT's? with the GenI they have had 2 recalls with the cam chain tensioners, called the 1st cct genI +another genI and the final cct was called GenII. Quasar can be more specific, I have seen his write-ups on these genI cct's:thumbs up: perhaps he can jump in here:whistling:

[BU54 NFS]

i have been looking on many sites for some time to try and discover what the problem might be and think i have found it on another site
an engineer was saying that they had 6 busa 06 models with the same knocking problem and half were found to this problem
an improperly machined crank case with the main journals havin been bored outside their service limit
which i assume means your crank can can move about just a bit?

[Tybalt]

i have been looking on many sites for some time to try and discover what the problem might be and think i have found it on another site
an engineer was saying that they had 6 busa 06 models with the same knocking problem and half were found to this problem
an improperly machined crank case with the main journals havin been bored outside their service limit
which i assume means your crank can can move about just a bit?
Interesting, thank-you, i never heard that before, I learn something new everyday:smoke:

[Jonesr]

I have a 2006 I bought with 350 miles I have put about 200 miles on it and have the same irregular knock at idle after riding for 10 miles or so.

I am concerned this is a serious enough problem that I may not want to keep the bike. An improperly machined case can be serious.

Has anyone been able successfully diagnose and remedy this problem on their newer bike or is it a serious problem?

:confused:

[tyler73]

I have scoured the web for answers to this issue. I have the 'knock' that seems to only occur with no load on the engine - usually while idling. It only happens when the engine is warm, as in the end of a long ride.

The general consensus is that the straight cut gears of the clutch basket are the cause and that throttle valves being out of sync greatly increases this phenomenon. Setting the engine idle a little high to 1250+ may also lessen the effect.

I only offer this information as a suggestion and will post a follow up once I have performed a sync of the throttle valves and some other required maint. later this week.

[tlrbandit]

Hope this helps:

I have two 06 LE Hayabusa, both having the same knock you are referring to although one was much worse than the other. The one that was real bad was fixed under warranty and here is what the problem was, incorrect crank bearings. Suzuki knows that they had a run of 06 Busa's that were assembled with the wrong size crankshaft bearings, but because there was no reported failures they refused to recall the affected bikes as well as refusing to acknowledge that the problem exists. To my knowledge there is only one other 06 Busa that had it's crankshaft bearings replaced under warranty. I had to gamble and have the dealer pull the motor apart, agreeing to pay the bill if everything was in spec. The problem is that the tolerances are so big, even with the wrong bearings they could argue that it was still in spec. The Regional Manager approved the warranty repair so the shop had to order new bearings (they are color coded - mine ended up needing the Yellow bearing - I don't know what the specs are) and install them. My Dad and I got to review all of the internal pieces and only 2 bearings actually had scour marks on them. After the motor was put back together with the correct bearings it runs super smooth. No more knock, and it is actually faster and getting better gas mileage than my other 06 LE which has never been apart. Both bikes have a little over 10,000 miles on them and are still going strong.

[Tybalt]

Hope this helps:

I have two 06 LE Hayabusa, both having the same knock you are referring to although one was much worse than the other. The one that was real bad was fixed under warranty and here is what the problem was, incorrect crank bearings. Suzuki knows that they had a run of 06 Busa's that were assembled with the wrong size crankshaft bearings, but because there was no reported failures they refused to recall the affected bikes as well as refusing to acknowledge that the problem exists. To my knowledge there is only one other 06 Busa that had it's crankshaft bearings replaced under warranty. I had to gamble and have the dealer pull the motor apart, agreeing to pay the bill if everything was in spec. The problem is that the tolerances are so big, even with the wrong bearings they could argue that it was still in spec. The Regional Manager approved the warranty repair so the shop had to order new bearings (they are color coded - mine ended up needing the Yellow bearing - I don't know what the specs are) and install them. My Dad and I got to review all of the internal pieces and only 2 bearings actually had scour marks on them. After the motor was put back together with the correct bearings it runs super smooth. No more knock, and it is actually faster and getting better gas mileage than my other 06 LE which has never been apart. Both bikes have a little over 10,000 miles on them and are still going strong.
:cheers: thank you and Welcome-Duane

[Jonesr]

Thanks a lot for the information. It eases some of my concerns about the knock and catastrophic failure but, makes me question the manufacturer's approach to providing a quality product whcih they will stand behind.

[Quasar]

CCT's? with the GenI they have had 2 recalls with the cam chain tensioners, called the 1st cct genI +another genI and the final cct was called GenII. Quasar can be more specific, I have seen his write-ups on these genI cct's:thumbs up: perhaps he can jump in here:whistling:

As of 2001 Hayabusas through and including 2007's, the oil ratchet CCT mechanism was standard issue.

It was only the 1999 & 2000 model year Hayabusas that had to go through the 2 recalls of the CCT mechanism.

One cause for the knocking sound "at idle" is an idle that is adjusted too low in RPM. Naturally, you could have another issue, but your Hayabusa should be idling between 1,200 to 1,250 RPM when the engine is fully warmed up.

When the Hayabusas' engine idles too low, its two cams tend to cause more cam chain slap as they lack inertia. Keep in mind that the cams rotate at just HALF the RPM of the crankshaft, so an RPM of 800 to 900 RPM equates to camshafts rotating at just 400 to 450 RPM, or a mere 6.66 to 7.5 RPS (Revolutions Per Second), which isn't all the fast thereby reducing their inertia compared to a decent idle RPM of 1,200 to 1,250 RPM.

Believe it or not, some people think the Hayabusa's engine can idle appropriately at these low RPM when it actually cannot in a reliable manner. Additionally, Hayabusa engines are known for their extremely low oil pressure at low RPM, which can leave then somewhat oil depleted and make them noisier.

[wildchildbmx6]

I have an 06 and I hear the same knock. should i get the bearings changed or is it something i should not worry about. i would hate for my bike to lock up at 180mph. how often does this fail?