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I've had a piston disintegrate on a 400.

Does anyone know of a way to do a flush, or other technique, to ensure all debris is cleared from the bottom end without having to split the cases?
 

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Fatjock said:
I've had a piston disintegrate on a 400.

Does anyone know of a way to do a flush, or other technique, to ensure all debris is cleared from the bottom end without having to split the cases?
WHOA........!!!!!!!!! How the hell did that happen.???? I would think that you would need to remove the engine to replace the piston and rings - SOOOOOOO - if it were me - I would do a hell of a lot more than just look for debris in some oil screen.!!! Turn the engine upside down and FLUSH, FLUSH AND FLUSH AGAIN WITH gasoline or kerosene from a garden sprayer ( The big kind with a 1 gallon container and a spray wand - and pump.........!!!!!!) At least 4-5 times..........! Holy crap. I might even go so far as to go ahead and split the cases..... GOOD LUCK and let all of us know what you finally decided to do.
 

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Discussion Starter #4
Yeah, I'm debating whether to repair or replace, but if I repair, I think I'm going to have to split the case halves, and do things properly.

Something Buffalo said on another thread makes me think there are some internals I need to check out, so if I'm going to do it, I might as well do it properly.

Thanks to all for the input, though.

I learned something new from this, and the day is never wasted when you do that.
 

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Discussion Starter #5

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To be honest there are no shortcuts here. Engine out, a good clean externally and then get it on the bench and dismantle, including splitting the case. if you take shortcuts you will end up doing it again.
 

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NormanB said:
To be honest there are no shortcuts here. Engine out, a good clean externally and then get it on the bench and dismantle, including splitting the case. if you take shortcuts you will end up doing it again.
:thumbup: +10...............NormanB
 

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Discussion Starter #8
Pulled the cylinder last night, and it's definitely toast, but with it out I could get a better picture of the bottom end, and with the evidence of debris, there is no other option but to split the cases, and make sure all is well.

But on the other hand, most of the non-damaged components( by which I mean those which are not the piston, or the bent valve) I'm seeing look in really good condition.

Here's a pic of the cylinder wall

 

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Looks like it ran with lack of oil. :cry:
 

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Desert Rat said:
Looks like it ran with lack of oil. :cry:

I've yet to drain it, but will measure what comes out......

I know the oil was checked and adjusted just before this ride, but as I've said previously, she did burn oil, but I never thought quite so prodigously!

Having said that, if there's enough in it, I may have to look at the oil pump.
 

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Discussion Starter #12
When I drained, a little over 400ml came out.
Oil level checked and adjusted the day before failure (over 200ml added).

Read an interesting post from Dave J regarding blow-by, and I thin that's the ultimate culprit here.

Anyway, to update, I got the engine out, removed the generator cover, removed and checked the oil pump, and made sure the under piston nozzle was clear.
This gave good vision into the bottom of the case, so I could see the debris.

I removed the oil sump cover and sreen filter, and the drain plug, and by jusdiciuos use of a syringe, a turkey baster, a pair of 10" tweezers, and a couple of gallons of cheap-ass oil, I was able to clean,all the debris out, and flush the small particles .

Very pleased I got this done without having to split the cases.

I think I may be able to get some "after" pics to post, which I'll have a go at tonight.
 

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Good deal, looks like you are well on the way to a rebuild.
 

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Is the big end ok? last time a saw a cylinder like that the big end had
gone and allowed the con rod to clout it.
 

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Bad luck you had that happen bud. Just one thing. How does the bottom end sound when you turn her over with the conrod? Any grinding or unusual noises from the bearings? Any play in the bigend other than what the manual says? If in doubt just split the case it's easier in the long run and actually doesn't take very long if you work methodically. I've worked on many engines in bikes over the years where this has happened (ex-tech) and there is often debris lodged in a bearing somewhere, particularly if it's an engine such as the Burgman with roller and ball bearings in the bottom end, inspite of the shielding. And if yours has run short of oil the bearings may be suspect as the case hardening always takes a battering in such cases. You may find it false economy not to strip her. It will give you peace of mind too. Good luck whatever you decide.
 
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