Bad crankshaft - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 9 (permalink) Old 3-20-2019, 9:10 AM Thread Starter
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Bad crankshaft

Does bad crankshaft causes blown headgasket? Jugs always getting bowed after some time, middle part goes up...
Also can someone provide me with basic symptoms of bad crankshaft for this engine. I couldn't find it anywhere...
Also bike has stronger than usual vibration on lower RPM.
Bike's been running on below minimum oil level for some time.
I will tear it apart and see if it can be rebuilt, or just find used engine in good condition.

Last edited by MARKO500; 3-20-2019 at 9:14 AM.
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post #2 of 9 (permalink) Old 3-20-2019, 2:13 PM
fog
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Quote:
Originally Posted by MARKO500 View Post
Does bad crankshaft causes blown headgasket? Jugs always getting bowed after some time, middle part goes up...
Also can someone provide me with basic symptoms of bad crankshaft for this engine. I couldn't find it anywhere...
Also bike has stronger than usual vibration on lower RPM.
Bike's been running on below minimum oil level for some time.
I will tear it apart and see if it can be rebuilt, or just find used engine in good condition.
Whoa, start over with your symptoms, before you decide the solutions.
Are you blowing head gaskets?
Solution may be simple lapping

Vibration may be something else you don't say what year ,milage and your location.

gen 1s destroy the flywheel magnets and they vibrate .

blown bearings will clatter loudly and it won't continue to run very long

more info

FOG

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post #3 of 9 (permalink) Old 3-20-2019, 2:47 PM
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Yeah, we'll need some more information before we can help you with a diagnosis. Need to start with the basics and the crankshaft is not the basics. You need to provide us with the year of the bike, mileage on engine and modifications (if any) to the intake, engine or exhaust system. It's also helpful to know how up to date maintenance has been (last oil change, last valve adjustment, is the carb clean, etc) and how hard you ride it (do you spend all day at 4,000rpm commuting or does this thing go to the track and average 9,000rpm).

Once that information is provided, we can then tackle the symptoms. Remember, just provide us with the symptoms, not your assumptions. A couple examples of symptoms are the temp gauge reading hot, different vibrations than usual and hard starting. An assumptions is any statement that goes along the lines of "My bike is doing X therefore Y must be the problem". While many assumptions are made with best intent, they are often not helpful and made more out of a desire to find a quick solution. In order to properly diagnose an issue, it's important to perform tests without the bias of assumption. So, to help us help you, just give us the symptoms for now.

That being said, running way low on oil for an extended period of time can cause all sorts of problems, one of which is fried bottom end bearings which will eat your crankshaft.

1990 EX500 - 139,000 miles as of April 29th, 2019
1993 Ducati 900SS - The real canyon carver
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post #4 of 9 (permalink) Old 3-20-2019, 5:38 PM Thread Starter
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'99 with 18k miles on it.
Commuting all the time.
Maintenance is done by manual (oil and oil filter change, air filter clean, carbs clean, valves adjusted etc etc)
Completely stock bike, no mods.
Compression is fine (around 190 on 1 and 205 on 2)
Good spark, no fouling after carbs were cleaned and adjusted.
Lapped jugs and head 2 times now, first time by myself, second time took it to someone and did it on lapping plate, both time it was straight as it can be.
Every time I rode it, after short time cooling system looses pressure and soon after white smoke comes out of right exhaust, bike struggles at idle and eventually dies.
PO rode it on low oil for some time but i don't know for how long.
Checked con rods, clearances on top end and everything seems fine and within specs. This confuses me and leads me towards bad crankshaft or bottom end of the bike...
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post #5 of 9 (permalink) Old 3-20-2019, 9:55 PM
fog
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Ok to avoide re lapping the head you can inspect the bottom end without removing the top. Pull the engine and crack the cases this will expose all the bearings for inspection . Even to use Spain gage to check bearing clearance.

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post #6 of 9 (permalink) Old 4-4-2019, 6:29 PM Thread Starter
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Quote:
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Ok to avoide re lapping the head you can inspect the bottom end without removing the top. Pull the engine and crack the cases this will expose all the bearings for inspection . Even to use Spain gage to check bearing clearance.

Fog
Checked and it was within spec so it's good. While I did check everything, I also cleaned oil filter inside engine, or however it is called, that snorkel thing in the bottom end. Found 3 shinny flakes sand grain size, sillicone parts, hair and few grains of sand. I know that sillicone is usual to find here along with other crap, should I be worried about metal flakes?
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post #7 of 9 (permalink) Old 4-5-2019, 9:32 AM
fog
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You said you inspected the bottom end did you open each bearing? did you check the clearance with plastic gage? if you had you would know the condition of your bearing and not be wondering what those flakes might be rom

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post #8 of 9 (permalink) Old 4-18-2019, 10:57 AM Thread Starter
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I checked bearings with plastigauge and everything was within specs, but i wondered where do this flakes came from. Found out they are not magnetic so its probably from the case.
Lapped jugs as flat as I could, left them on bench for a week until some orings and stuff arrive and found out jugs are warped again, just from sitting on the bench. Don't know reason for this, probably due to previous overheating that made major stress on jugs or something like that, this is just my poor guess.
So in the meantime I got used jugs, OS rings, did all the needed work, put everyting together and bike is running great!
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post #9 of 9 (permalink) Old 4-18-2019, 12:51 PM
fog
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OK prior to any re lapping. stress relieve the whole head in a oven @ 360 Deg For at least 2 hours, allow to slo cool.
This will eliminate any stress built up in or induced to the head and allow re lapping to be successful.

FOG
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