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Unread 02-26-2010, 12:21 PM   #1
Not Yet Wild
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Join Date: Jan 2010
Location: NorthWest
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Default Overhauled G-9, Questions

[B]Hello All, Well I need to turn to those more experienced than myself. Need a little advice. I did a complete overhaul on my first cart. A couple bugs that need worked out. While overhauling the engine the bore was to big for oversized so I had the cylinder bored over to fit a G-14 standard piston or 75mm instead of the 73mm series. All went pretty well, in addition milled the head .030 and ported and polished ports.New valves,guides,bearings etc.
Got the engine running the other day and heard what sounds like a rod knock. I am really undone because of all the care and love that went into this o/h. Even plasti-gauged the crank brgs to find inspec. The noise presents off idle thru mid-throttle no load in neutral. Goes away completly at WOT ,no noise on decel but comes back on re-accel when driving.I am running straight 30w oil for breakin, premium fuel,have a 4* adv key, ...This cart did not run when I got it as all was in a box. Not thinking this is a normal noise.... any ideas or suggestions... Thanks
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Unread 02-26-2010, 01:11 PM   #2
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Location: Reddick IL
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Default Re: Overhauled G-9, Questions

First thing, you did a very nice job with the paint and accents.

Does the g9 engine have a counter weight shaft? I have read that if worn they knock.
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Unread 02-26-2010, 01:30 PM   #3
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Default Re: Overhauled G-9, Questions

Hey Dooms Thanks.. Yes they do have a balance shaft, mounted in roller bearings which I replaced the bearings and fit snug on the shaft ends.. The camshaft however , the bearing surface is just aluminum case which seemed to be ok not worn and fit shaft nicely. I really dont want to have to pull this engine out & apart again... But I am concerned for the longevity of it.
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Unread 02-26-2010, 04:51 PM   #4
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Default Re: Overhauled G-9, Questions

Did you check your clearances with the new piston and deck height?
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Unread 02-26-2010, 05:11 PM   #5
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Default Re: Overhauled G-9, Questions

Beautiful detail work.

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Unread 02-26-2010, 05:12 PM   #6
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Default Re: Overhauled G-9, Questions

Yes,, checked installed piston to deck clearence and was good . I was just out in the shop and did a few things to diag. Let me run it by you guys.
With plug out wooden dowel on piston rotated engine by hand with pressure on dowel and no difference.
In certain spots on rotation of engine free hand moving crank, noise is worse than other times .
Almost sounds like metal to metal clunking type noise, when I roll engine back & forth in the "noise zone"
used stethescope to try to narrow point and location of noise to no avail, can hear it quite easily but dont know what it is
Is it possible for the gear teeth in the engine, either cam,crank,or balance shaft to be worn enough to cause this noise?
I do not hear the noise at WOT just runs real good. Real noticable on light run up to mid 3/4 throttle,either neutral or in gear.
Has anyone had any trouble with this type of concern? Thanks,, Joe
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Unread 02-26-2010, 05:21 PM   #7
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Default Re: Overhauled G-9, Questions

How is your drive clutch? Is everything OK in there?

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Unread 02-26-2010, 05:22 PM   #8
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Default Re: Overhauled G-9, Questions

Are you sure you got the balancer back in correctly? That's what it sounds like to me, they can be a little tricky, especially if it wasn't marked before teardown.....
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Unread 02-26-2010, 06:07 PM   #9
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Default Re: Overhauled G-9, Questions

My 2 guess's (without hearing it). Like Flint say's, could be 1 tooth off on the balance to crank. I checked today and the G14 piston is the same hiegth and has the same piston skirt as the G2, but the G14 piston (in a G14 engine) calls for a G14 head and G14 head gasket. I beleive you shaved the head, could the piston be hitting the head gasket/head at tdc? I'm shure you accounted for that, but had to ask. Sorry I can't hink of anything else. Keep us posted. Dave
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Unread 02-26-2010, 08:33 PM   #10
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Default Re: Overhauled G-9, Questions

Hey All, Thank you for all the thought going into this... I know its tough to diag. without hearing it or having put your hands on it.. With that said,, I completely pulled the drive clutch apart , cleaned inspected and lubed all components all looked good inside clutch and very nice smooth operation, This noise happens when running obviously, but al;so when I hand crank or move the drive belt pulley rock back & forth at certain spots, not even at tdc but lower in the stroke. Its really strange and odd.. I did mark all the gears and checked for proper alignment before final assy.If I remember correctly there was a hole in the balancer that lined up with a dash mark on the crank. I painted all marks when I pulled the eng. apart.
If the balancer was off would I have excessive eng vibration ? I do believe I read that factory put a inkstamp or mark that sometimes goes away on the balance shaft gear. If so how do you find the proper location?
Keep in mind, I can hear & feel this tap type noise sounds like metal/metal while rolling crank back & forth at certain areas of complete revolution. Thanks & let me know if ya think of something. I really hate to pull it apart again, but....
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