A Vstrom 650 mystery

DavidFL

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Jan 16, 2003
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Chiang Khong
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The Vstrom in the shop has some issues.

There is a noise coming from under the tank / top the motor.
It resembles a "clacking," "clackety-clack" sound - a cam chain or a tensioner?
Ride the bike at a steady 30 to 40 km/h, and you cannot hear it.
Only when the throttle is closing can you hear it.

Place the bike on the centre stand and run the engine in both gear and neutral, and you are unable to replicate the sound. Everything is normal.
You can only hear the sound when riding the bike.

The front sprocket checks out all ok.

The mechanic has removed the cam chain covers to check the cam chains and tensioner.
Everything is ok he says.

If you run the bike engine for 20 minutes, get it hot, you still cannot replicate any unusual sounds. Everything sounds normal.

So, my only suggestion now is to dump the engine oil & check for any excess metal.

Any ideas - what or where to look next?


I'm mystified by all this as this is my 3rd 650 Vstrom & have 300,000 kms trouble-free mechanical kms up so far.

Vstrom # 1 had 190,000 kms on the clock when i sold it.
Bulletproof. Absolutely 100% standard motor. Only ever changed engine oil & filter, spark plugs, air filter. It never burned any oil.

Vstrom # 2 was the same, sold it at 90,000 kms. Zero mechanical issues.

Vstrom # 3, bought 3rd hand, has been reliable the same too. Until a few days ago riding home in the dark.
 
An interestring AI analysis.

First: Is the V-Strom 650 an interference engine?​


Yes — the Suzuki V-Strom 650 uses a DOHC 645cc V-twin engine (same family as the SV650), and it is an interference engine. This means that if the cam timing is significantly off, valves and pistons can collide.

Potential Damage from a Jumped Cam Chain:

If the chain jumps more than 1–2 teeth, you risk:
  • Bent valves (most common damage)
  • Damaged pistons (due to valve contact)
  • Broken valve guides or seats
  • Camshaft or crankshaft timing misalignment
  • Possible head damage from valve breakage
  • Damaged cam chain tensioner or guides (if this is what failed originally)

️ What to Check:​


If your bike has jumped timing, you’ll want to inspect:
  1. Compression test – Low or zero compression in one or more cylinders is a red flag.
  2. Cam timing marks – Verify if cam timing is out of sync.
  3. Borescope inspection – Look into the cylinder for piston/valve damage.
  4. Cylinder leak-down test – Can show if valves aren't sealing properly.

Worst-Case Scenario:​


If the chain jumped badly and valves hit pistons:

  • You'll need a top-end rebuild at minimum (new valves, possibly pistons)
  • In severe cases: complete engine replacement might be more cost-effective
 
Problem solved, I believe, but it may be interesting to follow for some.

Discussing the possibilities with Dave DKT he sent another AI search link.

The V-Strom 650, specifically the DL650 model, can experience cam chain tensioner issues, often resulting in rattling or grinding noises, especially at lower speeds or when idling. A failed or malfunctioning tensioner can lead to a stretched timing chain, potentially causing damage to valves and pistons if the chain jumps teeth.

Symptoms of a Failing V-Strom 650 Cam Chain Tensioner:
  • Rattling or Grinding Noises:
    A noticeable rattling or grinding sound coming from the engine, particularly at low speeds or while idling.

  • Poor Engine Performance:
    Reduced power, especially at lower speeds, and possibly an increase in fuel consumption.

  • Misalignment:
    A check engine light may illuminate, indicating a misalignment between the crankshaft and camshaft.

  • Check Engine Light:
    Codes like P0016 (misalignment) or P0017 (camshaft and crankshaft synchronization) may appear.
Causes of Cam Chain Tensioner Issues:
  • Poor Maintenance:
    Neglecting oil changes and proper maintenance can lead to the buildup of sludge and varnish, affecting the tensioner's functionality.

  • Wear and Tear:
    Over time, the tensioner's components can wear out, reducing its ability to maintain proper tension.

  • Stretched Timing Chain:
    A stretched timing chain can cause the tensioner to overcompensate, leading to failure.
Solutions and Prevention:
  • Regular Maintenance:
    Adhere to the recommended oil change intervals and ensure proper maintenance to prevent sludge buildup.

  • Tensioner Replacement:
    If a tensioner failure is diagnosed, it should be replaced by a qualified mechanic.

  • Timing Chain Inspection:
    If a tensioner is failing or has failed, it's recommended to inspect the timing chain for wear and stretch.

  • Consider a Manual Tensioner:
    Some V-Strom owners have opted for manual cam chain tensioners (MCCTs) as an alternative to the hydraulic ones, according to a video on YouTube.
Accessing the Tensioner:

  • Accessing the cam chain tensioner on the DL650 can be challenging, often requiring the removal of parts like the gas tank, air box, and throttle body, according to a Reddit thread.

  • Replacing the left-hand cam chain can involve removing the alternator rotor, while replacing the right-hand cam chain sprocket may require removing the clutch, as noted in the same Reddit thread.

Damn I thought this sounded just like it, BUT we could not replicate the sound with the bike on the centre stand and engine running.
Although Kong the Mechanic in Chiang Rai agreed the sound seemed to be coming from under the tank top of the motor when test riding the bike at 30-40 kph.
This could take a while to sort out, ordering parts & getting back on the road.
I got a tip for the "top rated" Suzuki mechanic in the North.
Recommended by Suzuki Bkk and Suzuki Phuket.
Someone I had not heard of before and was unaware of, since Sahaphanich the Suzuki big bike dealer in Chiang Mai stopped selling and servicing Suzuki big bikes.
My son Jason went to the shop to speak to the guy & had him talk to Kong in Chiang Rai.
Nah, cant be the cam chain. It's a Vstrom, never happens in Thailand, Kong told me later.
I waited a few more days & rode the Nmax scooter over to Chiang Rai to check on progress.

At Kong's the bike is parked outside in the street, ready to go.

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What I thought?
You can't have done cam chains & tensioners without parts already, could you?
No.
I just replaced the front wheel bearing. It was totally knackered. Adjusted the steering head bearing. Replaced the rear sprocket bearing.
Checked and cleaned the front brakes that were giving you trouble.
Please take the bike for a test ride. There is definitely no engine noise now, & the bike is running smoothly as ever.
WTF, I thought. Impossible. We both agreed the noise was coming from under the tank/top of the motor???
I spoke with the Suzuki chang in Chiang Mai and we both thought it couldn't be the cam chain.
So I discounted the engine & looked elsewhere first.
Yes, but we both agreed the noise was coming from under the tank.
Right, but I replaced the front wheel bearing & there's no noise now at 30-40 km/h. Please go & test ride the bike.
So I did. No noise & I still can't believe it!

A longer, gentle test ride beckoned.
A 100 km ride down the flat, straight highway to Phayao.
Safety first, I thought. On the main road, no inclines, no twisties to load up the motor or cause any damage.
And if I broke down, plenty of passing traffic for help.
And it was an uneventful ride to Phayao.
In Phayao I hooked up with Dave DKT for a lengthy chat by the lake.

1746012744967.jpeg


Dave is an engineer too, and we discussed the wonder of my V-Strom's missing engine noise and the front wheel bearings.
Oh that's easy to understand; it's the Doppler sound effect
  • When the source of the wave moves toward the observer, the waves get compressed, leading to a higher frequency (or pitch, in the case of sound).
  • When the source moves away from the observer, the waves are stretched out, leading to a lower frequency (or pitch).

Ok I give up. Bearings it is & "nothing else."
Can I have some rags to wipe all the egg off my face, please?

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The rain came down for Dave DKT & me to enjoy a longer chat reminiscing over earlier rides & planning for some new ones in the future.

When it rains in Phayao, it certainly comes down; such is my experience.

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40 minutes later, it had cleared, and it was time to hit the road.

1746013556724.jpeg


With a smile on his face, he set forth to arrive home in Chiang Khong at 8pm.
Pleased that he is back on the road with the V-Strom.
Next, get the Yamaha Nmax scooter back to Chiang Khong city. Stay tuned.
 
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