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Rebuilt top end, 200 miles it's later losing compression!

219 views 10 replies 4 participants last post by  reogem  
#1 ·
I am way better at repairing than diagnosing!

about 8 months after doing a new head, piston, rings, cylinder on my 96 400, its started running terrible all of a sudden. I had been fighting carb issues too, so at first I thought it was that. Long story short put a compression tester on there and I'm only getting 60 psi! Not even sure how thats enough to run at all but it is. It just falls on it's face on anything more than 10% throttle. I pulled the oil fill cap while running just for giggles and it sprayed oil everywhere and dang near sounded like an exhaust leak coming out of the crankcase lol. ( i know thats not advised but I wanted to see)

Kind of at a loss as to what could have failed as it ran great for 203 miles after the work I did.

Leaning towards the head gasket as the new one I put in had a rivet that was getting pinched between head and cylinder, so I cut the rivet out and manually aligned the gasket with sheer luck and the alignment pins(when the rivet was removed the gasket flayed out a bit on one side)

Everything had been fine until now. A few other issues I was having may help point a finger
1. my oil cooler fan is dead but never once got an oil temp light(other than when key is on and engine is off)
2. Carb is running an odd mixture of rich and lean and I'm not very good at carb tuning. No power/falling on face at high rpms, but smells gassy at other times when on moderate throttle. plug wasnt fouled or white just the usual tan ish color. Maybe the temps got too hot and smoked my gasket??

Thank you for any help. Dan
 
#3 ·
Those little beast have really high numbers
Oil spraying out the dip stick tube is normal.

A short list of possible causes,
head gasket as you mentioned
Broke piston
bad rings
Bad valve/s

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#6 ·
unless my brain isnt thinking this through, valves could cause the compression leak but the blowby? even if they leaked could it pressurize the crankcase or wouldnt it just leak past the seat either into the exhaust or intake side? I guess theres always the stem seals
 
#4 ·
First thing, which top end parts are you using?
some of the chinese kits are hit or miss, always check the ring gap, also measure the cylinder to make sure its in spec and round.
the gaskets tend to be the weak point, I always recommend guys run oem gaskets or even a decent aftermarket replacement like cometic.
Probably wouldn't hurt to pull the head off and have a look. have you noticed any oil consumption?
 
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#5 ·
First thing, which top end parts are you using?
some of the chinese kits are hit or miss, always check the ring gap, also measure the cylinder to make sure its in spec and round.
the gaskets tend to be the weak point, I always recommend guys run oem gaskets or even a decent aftermarket replacement like cometic.
Probably wouldn't hurt to pull the head off and have a look. have you noticed any oil consumption?
It was a kit from Niche. Not the best not the worst. Had piston, rings, cylinder, head, gaskets/orings, and maybe some other little goodies that I am forgetting.
I filed the compression ring gaps. dont recall numbers, it was whatever I found on the internet when I did it. They were just barely touching when I checked them in the bore, or maybe just short of touching. I was not having oil loss issues after the rebuild until this problem happened, then it started blowing oil from pretty much every side cover/gasket. Its leaking compression back to the crankcase pretty bad.

I only rode it once since this happened. Took off to ride around town and had no power, major bogging. By the time I got home it had started leaking oil pretty good.
 
#8 ·
Did you have the piston fit to the cylinder?
 
#10 ·
I pulled it apart tonight. I can see no sign of the head gasket having been the issue, but I will note it appeared to be a small amount of oil sitting on top of the piston (keep in mind I havent started this thing since June)
There was a small tear in the lower gasket between the cylinder and the case but that may have happened when I pulled the cylinder off. In my head I thought there was a big O-ring down there. If there was its smushed into a non recognizable thing now. I do have some pictures but Im using this forum on my pc not phone so loading them is a pain.

Also the area above the valves looked nice and clean with no sign of a leaky stem seal or oil in there. I think at this point Im just going to order gaskets and another set of rings and try again
 
#11 ·
Oil on top of the piston could be (a lot of) blow by or valve seals.
There is an O-ring #2
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