I recently bought a 13500 mile 2005 k5 400 Burgman with tatty bodywork and an engine noise that can be best described as clattering. My plan is to strip the scooter and rebuild the engine, repaint the frame and body work where needed and then replace brake hoses, disk pads and anything else that needs replacing.

My question is this: Has anyone else refurbished a 400 engine of this age with a similar noise and what was the cause found to be. I can eliminate the cam chain tensioner as I've taken that out and it is working as it should. I've also taken off the variator, belt and clutch, so they can also be eliminated.

Cheers,
Mark

You may find parts very expensive and more economical to buy a another engine

Smoke ?
Oil warning light ?
Does it idle smoothly ?
Does the noise change as rev's are increased ?
Have you done a compression test?

I'm not sure if K5 had oil pressure warning light up to K2 they didn't so it could have run low on oil .I've been looking a K3/5 burgman for my Spain trip few with 30K still going and earlier carb .I'd be inclined to run it as it is for a while .

The Bern wrote:Smoke ?
Oil warning light ?
Does it idle smoothly ?
Does the noise change as rev's are increased ?
Have you done a compression test?

Smoke: A little when its cold. more like the extra fuel of a choke being on.
Oil warning light: not seen one.
Does it idle smoothly: Yes
Does the noise increase as revs are increased: Yes... but the noise is more pronounced when doing a quick rev from idle.
Have you done a compression test: No not yet but it is on the list.

Cheers,
Mark

Can you video the noise and do youtube link

Many people mess up setting the tappets, check them out, think they are screw and locknuts, could be a damaged tappet. Is the clatter half engine speed?

Id agree with doing tappets first to iliminate

Dave Weller wrote:Many people mess up setting the tappets, check them out, think they are screw and locknuts, could be a damaged tappet. Is the clatter half engine speed?

Thanks for the reply. I understand the sound of tappets. This sound is lower and at the same speed as the crankshaft. I am suspecting either little end (wrist pin) or big end. The scooter has run low on oil at some time in the past, I know from the previous owner.

Cheers,
Mark

That's what I suspected low on oil as they will do loads of miles if looked after .