Hey All,
Thanks for the replies thus far.
Went to the dealership today to see for myself and sure enough the combustion chambers are carboned up pretty badly. The number two cylinders exhaust valves are stuck open due to loose carbon bits caught under them. During a leak down test they leaked like a sieve. All intake valves are seated tightly. Two other exhaust valves are leaking very slightly which could be fairly normal or they could have some debris under them as well.
We'll know more once the valves are out of it.
I took the head to Bore Tech because Bill is a friend of mine and I trust him with the job of sorting it out.
To answer some of the other questions:
Brian,
It really wasn't a "bang' more of a loud click. So no indication of something catastrophic.
No I haven't heard of modern sportbikes having a carbon build up problem either. Neither has anyone else I know. But, now I know that it is, in fact, the current problem. Just don't know what caused it except it being fuel related.
Back in the sixties (maybe earlier) the Gov mandated that gasoline companies put additives (with a minimum standard) in their gas that would inhibit combustion chamber deposits. It didn't work very well then.
Today the gas companies still have a minimum standard but is even less (50%) than it was in the beginning, so it is even less effective now. They are now more concerned about emisions than keeping your engine clean, except that Shell seems to be attempting to address the issue in their fuels.
Cam chain, tensioner, and timing were all ok.
Mister T,
The PC3 is programmed for the flies out and stock pipe. No soot in the tail pipe and I averaged 38 MPGs for the total Colorado trip while getting an average of 43MPG on the slab alone. So no excessive fuel consumption here.
Virginia Jim,
I buy fuel at a lot of different stations because of my travels on the bike but, I do buy most of my gas at one particular station (Marathon) when I am staying around locally. I guess you could say that most of my gas is purchased there. And I do run FI cleaner through it about every 4-5000 miles just like I do on my other FI bikes. The FI cleaner, however, won't address the combustion chamber issue.
STP has come out with a product called STP Total Fuel System Cleaner that is supposed to address the intake valve and combustion chamber deposits. I figure that if STP has developed a product for this, there must be someting going on with the gasoline we are buying. Doing a search for this issue I found quite a bit of info on the problem.
The BMW M5 forum and a couple of other sports car forums that I found seem to be discussing this like it is an up and growing problem, especially among vehicles with engines that have very close tolerances and tight squish clearances (our bikes??)
Gonzo,
I will have some pics that Bill at Bore Tech will take for me (I didn't have my camera, doh!)
The dealer had already cleaned up the piston crowns, but said that some of the buildup had to chipped off as it was hard caked on the piston. Some of it came loose in little flakes.
Fretka,
Interesting that you brought up VVT failure because at some point we are going to check that out. Also there is no indication that the valves and pistons contacted one another.
Son of Pappy,
Doh!!! I haven't yet checked the air cleaner. I'll run that "full system" idea past the financial advisor. Hah!
The head should be done sometime next week and the bike back together after ??
That's about all I have for now.
Will keep you updated as to how this is going.
Dean