Results 1 to 14 of 14

Thread: catastrophic failure 30 min after full rebuild

  1. #1
    apriliaforum newb
    Join Date
    Nov 2018
    Location
    Spain
    Posts
    27

    catastrophic failure 30 min after full rebuild

    Hello everybody,

    I am desperate...
    I've spent the last 8 months to rebuild my engine; I've changed ALL , including cylinders, pistons, all bearings, all seals incuding the stator cover seal and oil pump seals, new timing chains, new valves etc etc.....
    After a nice first fire up and slow round at track I started hear a knocking sound ( clack clack clack), so I stopped the engine inmediatelly,
    I remove the engine; all was like new, except the front rod and bearing: it was completely destroyed in only 30 minutes. The crankshaft bearings and the rear rod bearing were like brand new.
    Please check the pictures:
    Click image for larger version. 

Name:	IMG_20190622_204355.jpg 
Views:	156 
Size:	93.8 KB 
ID:	383127
    Click image for larger version. 

Name:	IMG_20190622_204502.jpg 
Views:	86 
Size:	93.6 KB 
ID:	383128
    Click image for larger version. 

Name:	IMG_20190622_204417.jpg 
Views:	85 
Size:	93.6 KB 
ID:	383129
    Click image for larger version. 

Name:	IMG_20190622_204445.jpg 
Views:	85 
Size:	90.7 KB 
ID:	383130

    Click image for larger version. 

Name:	IMG_20190622_204355.jpg 
Views:	156 
Size:	93.8 KB 
ID:	383127
    Click image for larger version. 

Name:	IMG_20190622_183402.jpg 
Views:	83 
Size:	91.8 KB 
ID:	383131
    As you can see the crank is damaged.
    I followed the procedure, same for both rod, ordering the correct bearings which Aprilia said at manual in base of the rod/crankcases letters. I used the torque+degree torque process. I lube the rod bolts...I did all well, or at least that is was I thought...
    Also I checked the crank, inyecting oil with a syringe and making sure that the oil emanate through both holes. All was ok.
    I need to now what could fail, any idea? I donĀ“t want to spend hundred of euros and have the same problem again.
    please help me...I am losing the hope and I am starting to hate this bike...

    Thank you very much.

    P.D: I used Motul 300V 15-60 oil, and before firing up the engine move the engine ir order to lube all inside.

  2. #2
    apriliaforum expert
    Join Date
    Nov 2008
    Location
    Western Australia
    Posts
    1,720
    Can only assume it was the incorrect bearing...

    Sometimes the green and the blue mark look very similar...

  3. #3
    apriliaforum newb
    Join Date
    Nov 2018
    Location
    Spain
    Posts
    27
    Quote Originally Posted by S4R View Post
    Can only assume it was the incorrect bearing...

    Sometimes the green and the blue mark look very similar...
    I ordered it in base of the Aprilia SKU, and attending to the letters on the cases and rods. I bought same bearings for both rods and the other one was new.
    My mind is blowing... HOW CAN I HAVE SO BAD LUCK?
    Should I buy an Honda CRF ? I like so much the Aprilia but it is desperating me....

  4. #4
    apriliaforum Junkie undergrounder's Avatar
    Join Date
    May 2015
    Location
    holland
    Posts
    275
    Did the conrod move freely by hand on the crankshaft after installing ?
    or was one moving lighter than the other?
    My bike is my gym, my wheelchair and my church all in one. I'd like to ride my bike all day long but I've got this thing called a job that keeps getting in the way.

  5. #5
    apriliaforum Member
    Join Date
    Sep 2016
    Location
    Norway
    Posts
    215
    Measure the crank to see if it's been reground or just out of spec with to big clearance.
    How did it look when you tore it down before the rebuild and why was it rebuilt?
    New rods?

  6. #6
    apriliaforum prov-nov
    Join Date
    Dec 2017
    Location
    Chicago, IL
    Posts
    57
    So Sorry for your problems! I've been there.

    I've always learned not to trust colors and book recommendations and plastigage clearances. Also as stated above, check for out of round and run out and side clearances whenever rebuilding an engine.

    The crank can be repaired. There can plasma spray weld the crank to repair them.

    Good luck! Hope you get back on the track.

  7. #7
    apriliaforum Member
    Join Date
    Jul 2008
    Location
    Rotorua, New Zealand
    Posts
    183
    Maybe lack of oil pressure. It looks like the rod bearing that is damaged is on the drive side.
    ie furthest away from the oil feed. My engine did this recently after an oil pump drive failure.

    Just my thoughts

    Wayne
    In New Zealand

  8. #8
    apriliaforum newb
    Join Date
    Nov 2018
    Location
    Spain
    Posts
    27
    Quote Originally Posted by S4R View Post
    Can only assume it was the incorrect bearing...

    Sometimes the green and the blue mark look very similar...
    Could be... but both bearings were the same, and the other rod and bearing were like new, so I assume that the size wasn't the problem.

  9. #9
    apriliaforum newb
    Join Date
    Nov 2018
    Location
    Spain
    Posts
    27
    Quote Originally Posted by undergrounder View Post
    Did the conrod move freely by hand on the crankshaft after installing ?
    or was one moving lighter than the other?
    Both moved freely, very smooth

  10. #10
    apriliaforum newb
    Join Date
    Nov 2018
    Location
    Spain
    Posts
    27
    Quote Originally Posted by jcw View Post
    So Sorry for your problems! I've been there.

    I've always learned not to trust colors and book recommendations and plastigage clearances. Also as stated above, check for out of round and run out and side clearances whenever rebuilding an engine.

    The crank can be repaired. There can plasma spray weld the crank to repair them.

    Good luck! Hope you get back on the track.

    SO , do you advise to repair the crank? Is it safe?

  11. #11
    apriliaforum newb
    Join Date
    Nov 2018
    Location
    Spain
    Posts
    27
    Quote Originally Posted by vfr_nz View Post
    Maybe lack of oil pressure. It looks like the rod bearing that is damaged is on the drive side.
    ie furthest away from the oil feed. My engine did this recently after an oil pump drive failure.

    Just my thoughts

    Wayne
    In New Zealand

    I thought the same. When I rebuild the engine I replaced the oil pump seal and I cleaned inlet grating. The inlet grating was clean when I opened the engine. How shoul I check the oil pump? What should I pay attention? Is it possible to make a pressure test? Anyway, my dashboard didn't warn about low oil pressure.

  12. #12
    apriliaforum expert levisik's Avatar
    Join Date
    Sep 2014
    Location
    Poland
    Posts
    1,619
    I think of 3 possibilities:
    - bushing spots in rods were oval not rounded - did you meassured them before bushing installation ?
    - clearance between bushings and crank was wrong
    - oil path in crank was not fully clear.

    are you sure that oil seal in magneto cover was installed in good direction ?
    2006 Aprilia SXV 450
    Tuneboy Cable available in Poland

  13. #13
    apriliaforum Member
    Join Date
    Jul 2008
    Location
    Rotorua, New Zealand
    Posts
    183
    Quote Originally Posted by mondraker View Post
    I thought the same. When I rebuild the engine I replaced the oil pump seal and I cleaned inlet grating. The inlet grating was clean when I opened the engine. How shoul I check the oil pump? What should I pay attention? Is it possible to make a pressure test? Anyway, my dashboard didn't warn about low oil pressure.

    Oil galleries blocked even partically (crank and cases) and oil seal leak in stator cover

  14. #14
    apriliaforum expert
    Join Date
    Nov 2008
    Location
    Western Australia
    Posts
    1,720
    From looking at the crank it didn't get excessively hot...

    I would say your issue wasn't lack of oil...

    I would say your issue was incorrect bearing clearance due to incorrect bearing shell...

    Maybe a possibility of conrod big end not being round...

    But having been on the end of incorrect bearing supply myself, I expect that is where the issue lies...

Similar Threads

  1. Upstart after minor rebuild - failure! (RXV450)
    By Henke in forum 2006-2011 Aprilia RXV, SXV, MXV 4.5/5.5 V-Twins
    Replies: 25
    Last Post: 06-28-2014, 07:13 AM
  2. I'm baaack, after full motor failure.
    By ckevinhood in forum 2008-2016 Shiver 750 / Dorsoduro 750
    Replies: 6
    Last Post: 01-14-2014, 05:45 PM
  3. help!help!engine cuts out after 30 mins
    By bennettstrt in forum ETV1000 CapoNord (2001-2007)
    Replies: 4
    Last Post: 01-08-2008, 08:21 PM
  4. OT - Cheap R6 For Sale - 30 Mins Left
    By IK_25 in forum RS125 Euro-archive
    Replies: 3
    Last Post: 06-14-2005, 07:00 PM
  5. after thhe rebuild
    By empire in forum RS250
    Replies: 3
    Last Post: 01-25-2005, 03:38 AM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •