Engine Popped on Dyno

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Retro Rocketeer
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Engine Popped on Dyno

Postby Retro Rocketeer » Tue Jun 19, 2012 1:18 pm

Was dyno-ing the Ninja today and the engine popped. Case split right in front of the balancer. Anybody else had a similar failure?

Will need a new engine. Will a 2009 engine fit into the 2008 and older frames just fine? I see the 2009 and newer have rubber dampers for the mounts. Should I just be able to use my original 2008 nuts and bolts and mount it up?

Quick info is much appreciated.
truedef
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Re: Engine Popped on Dyno

Postby truedef » Tue Jun 19, 2012 11:59 pm

Retro Rocketeer wrote:Was dyno-ing the Ninja today and the engine popped. Case split right in front of the balancer. Anybody else had a similar failure?

Will need a new engine. Will a 2009 engine fit into the 2008 and older frames just fine? I see the 2009 and newer have rubber dampers for the mounts. Should I just be able to use my original 2008 nuts and bolts and mount it up?

Quick info is much appreciated.

I know the 2009 and up models have a larger radiator.
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Retro Rocketeer
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Re: Engine Popped on Dyno

Postby Retro Rocketeer » Wed Jun 20, 2012 1:21 pm

This happened to the race bike in my avatar. Using a larger customized radiator.

It appears to have been a bottom end failure. Split the cases in the bottom front of the engine, where the balancer shaft rides. Anybody know of a possible cause in that area? What's prone to breaking in that area of the engine?
truedef
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Re: Engine Popped on Dyno

Postby truedef » Wed Jun 20, 2012 7:20 pm

Retro Rocketeer wrote:This happened to the race bike in my avatar. Using a larger customized radiator.

It appears to have been a bottom end failure. Split the cases in the bottom front of the engine, where the balancer shaft rides. Anybody know of a possible cause in that area? What's prone to breaking in that area of the engine?

If it were me, I probably would have been stripping the bike down and tearing the motor apart to see exactly what happened.

Wish I could see it, got any photos
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Retro Rocketeer
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Re: Engine Popped on Dyno

Postby Retro Rocketeer » Wed Jun 20, 2012 10:33 pm

You can bet I'll be tearing it down. Got an R6 I'm finishing at the moment. Might be splitting the Ninja open this weekend. I'll share the failure if it can be pin pointed.
seized
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Re: Engine Popped on Dyno

Postby seized » Thu Jun 21, 2012 6:00 am

when running a tuned motor with standard con rods the rods will stretch and fail. so it possible this has happened to you, never seen one let go on a dyno before, not nice for the operator or the owner!!!
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BRP
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Re: Engine Popped on Dyno

Postby BRP » Fri Jun 22, 2012 8:08 am

All engines from every year will fit.
The only engine we ever blew, was from an abusive rider.
Only way he knew how to turn was by backing it in.
Leading with 30 minutes to go in a 6 hr endurance race, he blew it up in turn 1.
Down shifting form 6th to 3rd then dumping the clutch.
Snapped a rod in half.
You have to replace the rods every season.
I've been told by my source at Kawi, that 2011 ZX10 rods and pistons fit.
Pistons are overbore.
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Retro Rocketeer
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Re: Engine Popped on Dyno

Postby Retro Rocketeer » Sun Jun 24, 2012 1:09 pm

Here's what the freshly vented crankcase looks like.
Currently reviewing my options for disassembly: wrenches, reciprocating saw, hammer and sledge party.
"patience young padawan"
Grrrrrrrrrr.
You do not have the required permissions to view the files attached to this post.
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Retro Rocketeer
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Re: Engine Popped on Dyno

Postby Retro Rocketeer » Sun Jun 24, 2012 4:39 pm

The left rod snapped. Pretty ugly. Might have some spare parts for sale soon. Tranny, Flywheel, Clutch, who knows.
seized
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Re: Engine Popped on Dyno

Postby seized » Tue Jun 26, 2012 4:26 am

yes thats nasty, my advice if you go to the extent of tuning another engine put in a set of carrillo rods it will be your best investment and save this happening again, they never stretch no matter how hard you rev them, alot of engines with them in at this year's isle of mann TT
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BRP
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Re: Engine Popped on Dyno

Postby BRP » Tue Jun 26, 2012 7:54 am

It's been a while since I talked with Carillo.
But when I did, I was told you have to order 4 rods.
As there were not that many requests for them.
Might have changed, as it's the choice of many AMA flat trakers.
sportyaccordy
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Re: Engine Popped on Dyno

Postby sportyaccordy » Thu Jun 28, 2012 5:37 pm

BRP wrote:I've been told by my source at Kawi, that 2011 ZX10 rods and pistons fit.
Pistons are overbore.


Can you run a 7mm overbore in a ZX10? 650 has 83mm bore vs 76 in the ZX10. Maybe he meant ZX14 (84x61 vs 83x60)?

I also wonder if you can use the ZX14 throttle bodies on our bikes. Our throttle bodies are tiny for the cylinder sizes. ZX6s run 4 of our TBs.
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BRP
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Re: Engine Popped on Dyno

Postby BRP » Fri Jun 29, 2012 7:04 am

Must have been ZX14 piston and rods.
I tested 4 different TB combonations:
Stock 38mm with 39mm taper
39mm straight bore
40 & 42mm
On a stock bore race engine the 39's made the best power and curve.
The guy who used to build my engines, broke the land speed record with stock bore TB's.
steigs84
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Re: Engine Popped on Dyno

Postby steigs84 » Fri Jun 29, 2012 2:11 pm

Has anyone tried Falcon Rods? They have them for the 650R, $290.

http://www.faliconcranks.com/2pc.html
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Loki
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Re: Engine Popped on Dyno

Postby Loki » Thu Jul 12, 2012 2:50 pm

Holy dear god that's a mess. I have a Dynjoet III in my bike left over from when I purchased the bike from the original owner and never had anything like that happen!

I think it's set to stock settings as it's getting me a good 200+ miles a tank, which is pretty typical of stock 650r with decent shifting... I try to stay between 3-4K for casual riding...

I should probably install the software and check to see what it is at some point in case something funky happened over time... I'd def hate life if the dyno went and something this awful happened!
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Retro Rocketeer
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Re: Engine Popped on Dyno

Postby Retro Rocketeer » Thu Jul 12, 2012 3:54 pm

Loki:
You don't have anything to worry about accept regular oil changes. This was a race bike engine. For a season and a half it lived its life WFO with extended periods of 10000+.

I've already installed a replacement from an 09. Delivered $827.00 Where else can you race an engine into the ground for that price? 650 twins are the way to go.

The bummer is my head I'd ported was destroyed. I have a spare I'd started porting, its just a bummer to lose those work hours. That motor won two championships for me last year.
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cknauf
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Re: Engine Popped on Dyno

Postby cknauf » Wed Sep 26, 2012 10:33 pm

steigs84 wrote:Has anyone tried Falcon Rods? They have them for the 650R, $290.

http://www.faliconcranks.com/2pc.html


Almost as good as Carillo and you only have to buy two instead of four.

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