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1986 Honda Rebel 45
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61 Posts
Discussion Starter · #1 ·
Hello all. I have been trying to pin point this knocking that came out of nowhere with my 86 rebel 450. It’s been a dreaded journey for the last week or so trying to trace this and figure out this knocking sound I have. The chain of events that happened that day before it started to knock :

1: I changed the exhaust and was told to re jet the carbs so it wouldn’t run lean. Changed slow jet from stock 35 to 40 and main jet went to a 130 from I think was a 112. I changed the exhaust and rejetted the carbs then rode the bike and tested out the jetting. The oil may have been contaminated with gas also because I smelt So there’s that possible problem

2: came home and pulled the plugs after bike started to act up while riding. Plugs were black and sooty. While checking The bike out….

3 bike fell lightly into the dirt on left side. (Kickstand was in soft dirt) Peg and shifter lever went into the dirt
4: started the bike after it dropped and it started knocking
5. After it started knocking I was told to check out the valve clearance to make sure that wasn’t the problem. I adjusted the valves which didn’t make a difference in knock and returned the exhaust and carbs back to stock. Was told that it may be the top end. It’s very hard to figure out where the sound is coming from because the sound is equally loud at the bottom end and the top end of the motor. I also synched the carbs thinking the knock could be from unsyncd carbs. Knock was still there
I’m chasing down top end but trying to think out of the box maybe it’s not top end but bottom end from the the shifter hitting the dirt. I’m shooting in the dark but just trying to think logically. Nothing was bent shifter wise though and the shaft that the shifter bolts onto seems to be okay. It does move in and out slightly though but I think that is normal .
Other things I’m thinking about if the spark plugs were black and sooty it could be loaded with carbon and having a pre detonation problem but I really don’t know. It’s so hard to pin point where the sound is coming from. I’m going to get a stethoscope from harbor freight today and see if that helps alittle more. The shifter didn’t bend or nothing just had dirt on it from hitting the ground. Things that were also brought up after I had the valve cover off was the cam adjuster larger wedge doesn’t spring downward. It’s stuck up so maybe the cam chain is not adjusting? But then when I start the bike with plugs out or even in with plugs in and the wires not attached there is no knocking at all. If there was something internal of the top end it would be still knocking I would think. The bike only knocks when it is running at idle speed. If you rev it the knocking goes away. So now I’m thinking pre detonation? maybe the new cdi I bought is not functioning properly or the ignition coil. It does get spark though. I have just been a hamster wheel going nuts about this noise. Was looking for some insight or maybe if anyone has had this knocking before …
Thank you!! Here is a video of the knocking

 

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1986 Honda Rebel 45
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61 Posts
Discussion Starter · #5 ·
thanks for the response!

The cover was on when it fell over.

The oil wasn’t very thin from what I noticed but it did smell like gas. Even after a oil change the oil still smelt like gas. The oil light is normal. It doesn’t come on when the bike is running. There isn’t a knocking sound when just using the starter and cranking the engine. The knock is only there when the engine is running. I’ll check the piston tops when I get home today. Knock is still there when the clutch is pulled in.
 

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1986 Honda Rebel 45
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61 Posts
Discussion Starter · #7 ·
I adjusted the balance chain through the inspection hole on the side of the crank case. It self adjusted and moved up but the knock is still there. The piston tops look normal. I don’t see any score marks on the cylinder walls either. Was just wondering if it’s normal to see the exhaust valve when it opens through the spark plug holes?
 

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1986 Honda Rebel 45
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Discussion Starter · #10 · (Edited)
Hey. No it didn’t hit the exhaust. I also replaced the copper crush Gaskets.
But I just noticed something today It hit the left peg and the gear shifter had dirt on it from the ground. I got to thinking let me check around the shifter rod. Since the knocking happened after it felll. But I just noticed something today.

I was looking and hearing around the bottom end. I noticed that the shift rod that goes into the trans flexes when pushing it down in first gear. Not sure if it’s supposed to or not. Or does the side case eliminate that flexing when the cover is on? The sound seems to be more pronounced there and on the shift rod. But also the same sound at the top by the valve cover. So not sure if that flexing shift rod is normal or not. Here is a YouTube video. Thanks!

 

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1986 Honda Rebel 45
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61 Posts
Discussion Starter · #11 · (Edited)
Sorry I made a mistake with the balancer Before I loosened the nut the plate was up against the stud. When I loosened the nut the plate moved down. The stud is more towards the middle now. I didn’t take a picture of it but I will take a picture tomorrow when I get back to the bike
Here is another knocking video. The exhaust isn’t leaking. I wish it would of been that simple 😂
But that’s not my luck
Here is a video from before. I tried to hold the stethoscope ear piece to the camera mic but that didn’t work out to well. But you can hearing the knocking. In person it sounds loud by the shift rod and crank case but then it’s also loud at the valve cover. So that’s what’s driving me nuts. Can’t pin point it

 

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1986 Honda Rebel 45
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Discussion Starter · #15 ·
okay got it. Thanks. That’s what I was wondering. Now I’m back to tracing down the knocking. No oil leaks. Nothing else is bent or compromised by the shifter with the cover on. This noise is driving me mad! Did you get the knocking video to open?
 

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Discussion Starter · #17 ·
I have removed the valve cover and clutch cover today and here are some videos of my findings Please any help is sincerely greatly appreciated! 1st video is the valve cover removed and 2nd video is what I found with the clutch cover removed..


 

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Discussion Starter · #19 ·
Hey, I will have a more detailed response later on when I get to the bike. Thank you for the info. The spring plate doesn’t wobble. There isn’t any wobble of the whole clutch assembly. Just that back and fourth play. Where you can hear it making noise. A friend was nice enough to take his cover off his spare engine and he also had that play. Maybe not so much as mine but he indeed have play. Mine seems to make alittle more noise though. I’m just trying to find anything that would make a noise before having someone or myself tear into the engine.

my problem is I can’t Reproduce the sound without the engine running.

the clutch basket nut is definitely tight and still staked. I haven’t tried to tighten it up more yet because I don’t have the socket to get on the nut.

Sorry about the confus with the double thread. I just didn’t want to get the information lost in the other thread bringing up this clutch basket.

Here is a picture of the balancer adjuster. I will get pictures of the cam later on. Thanks again for the help.
 

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1986 Honda Rebel 45
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Discussion Starter · #23 ·
Hey. Yes the clutch basket nut seems tight but again I don’t have a socket yet..
The play in and out is tough to measure.

Top cam chain adjuster bolt tight or loose ?

Top cam chain adjust bolt is definitely tight.

Cb400n and the 450 version ( 250 the same ) are prone to left cylinder big end failure, as it is the last shell bearing to get any oil.
The left cylinder has 145 psi when I did a compression test and right cylinder had 165 I think. Left was definitely 145 though.

No marks on piston crown.



I assume electric start works all ok ?
Yes electric start works perfect
A quick ten second engine run would be sufficient.....possibly ?

The bike makes the noise cold or warm. It seems to dissipate when engine is revved over idle speed.

back to the top under the valve cover. The large wedge seen at the back of the head does not spring down. I was told it’s supposed to. The smaller wedge does however spring down.
I was told to adjust the tension with the 2 bolts behind the cylinder and I did do that
Automotive tire Bicycle part Gas Rim Plumbing

Gear Bicycle part Bicycle chain Auto part Household hardware

Engineering Motor vehicle Gas Auto part Automotive wheel system

Automotive tire Tire Motor vehicle Rim Auto part
Hood Motor vehicle Automotive tire Gas Automotive design
 

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1986 Honda Rebel 45
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Discussion Starter · #24 ·
I have done that with the spark plugs in and out on each side. The noise is the same taking plug wire off from one side and then the next. The sound stays the same. Clutch in or out the sound is the same. It just disappears above idle. Example: if I was to raise the idle to where you did not hear the knocking and ride it you would not hear the knocking. It’s just at idle speed. That’s what’s driving me nuts. Also to add when starting the bike with plugs out there is no knocking at all. It’s just when bike is running
 

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1986 Honda Rebel 45
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Discussion Starter · #25 ·
I would like to start the bike with the clutch cover off and the valve cover off to see if I can locate the sound but I’m not sure if that is a smart idea or not there will be no oil in the bike and I’m not sure if the oil pump would have to be re-primed starting it without oil in it what do you guys suggest? The self texting does not add. In between sentences sorry for that
 

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1986 Honda Rebel 45
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Discussion Starter · #26 ·
Well started it for a couple of seconds and still have no Idea where the noise is coming from. This really sucks now. So hard to pin point the noise. Ever with the covers off
 

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1986 Honda Rebel 45
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Discussion Starter · #29 ·
Thank you for all that info. A closer inspection of the brand new oil I just drained out shows metal flakes. A lot of them so I think it’s time to seak professional help and or give up on it and sell it. I have a couple of motorcycle mechanics at work that may be able to rebuild the engine but than again I paid 1500 for the bike. Don’t even know what they would charge me.
i did run the bike with the covers off only to find I still cannot locate where it’s coming from. Also the oil light and neutral light does not illuminate at all anymore since running it without the covers. Feeling way beyond defeated right now. Not happy at all. Have to think of what to do now. Not sure if it’s a top end piston problem/ low end crank shaft problem/ or oil system not working correctly. Would hate to pay to have a engine rebuild and not have the oil system not up to par and repeat the whole process over again with lack of lubrication. I don’t know. I really don’t know at this point. I’ve tried what I can. I think myself digging into the engine with limited knowledge of these engines and lack of information from a online manual is a no go for me. This is the oil I drained out before I pulled the clutch cover off. It was brand new oil and the oil pan was very clean before I drained the oil.

Astronomical object Circle Tints and shades Metal Serveware

Liquid Tableware Dishware Ingredient Fluid
 

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1986 Honda Rebel 45
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Discussion Starter · #33 ·
Update to the one problem of the oil light and neutral light not illuminating. Both bulbs have blown out. I verified that with a good bulb into the oil and neutral sockets. Oil light goes off when engine is started so that crisis has been avoided. That makes me feel better. Engine still with problem makes me feel worse 😩😂. Atleast I know that there is oil pressure !
 

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1986 Honda Rebel 45
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Discussion Starter · #35 ·
i will try some of your suggestions tomorrow. I put the clutch cover back on and filled with oil. Not many videos at all on YouTube about this rebel 450 engine. Was wondering what the closest engine would be to it. Maybe I can find more videos on those? I think the cm400 engine is close. Are there any others. I see the cb engines are different.
 

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Discussion Starter · #36 ·
DD I tried what you said but no I don’t hear any knocking or any weird noise. I’m only able to look through the small piston hole though. The cylinder head is not off. I’m just probling the top of the piston with a long screw driving trying to see if it moves or not. But no I don’t hear anything weird.
 

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Discussion Starter · #38 ·
In the middle of this testing I was able to muffle the exhaust and get a better listen. The sound is pretty much the same from bottom of the engine to the stop of the cylinder cover

 
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