Brand New 2022 Gen 3 Hayabusa Clicking Engine noise

Noises can be deceiving. If you have an engine stethescope, poke around and see if you can isolate the noise versus jumping into major disassembly.

Injectors can "tick", valve train can "tick", etc. Your recording is only so discernable. It would take lifting the tank, but the stethescope would help. Warm it up and home in on it.

Let us know what you find.

:thumbsup:
 
Yes! My BMW had my buddy wondering if there was something wrong with it when I rolled up to talk with him at his house. Ok, you can use a long screwdriver as a stethoscope if need. Put the handle up to your ear and touch the tip to different places as possible. Clutch, crankend, cams (pretty hard to get in there) anyway. Just listen around. Another way is a 1/2" hose. Same method... Works very well sometimes...,
 
@iron.head Check your manifold bolts to the headers. Make sure they are torqued to spec. Sounds like one might be a tad loose and letting some exhaust out which leads to these kinds of sounds. It's a normal sound. Just louder than should be due to a small exhaust leak. I had a similar issues and took me forever to figure it out. Also check the the airbox make sure it's on tight at the throttle body. It's basically internal engine sounds finding a way out to the enviroment. Just gotta find where the sound leak is at.
 
I have to agree with ZeePopo with it being a potential exhaust leak. I have heard noises like this in the past and it's usually the exhaust. But I also heard something similar on my Ls1 engine. That ended up being a bad lifter but that was a hydraulic roller valve train not solid roller. Also cold Ls1's had piston slap noises that didn't end up being anything detrimental to performance. But with now considering valve shim issues because of Willis Racing experiences I do wonder...... Next time I fire up the Gen 3 I will see if I hear anything unusual. My gut feeling is you're safe but of course keep an eye (and ear) on the issue.
 
I'm going to say this issue is being over analyzed. Take your exhaust headers off and take out the crappy gen3 exhaust gaskets. Install the gen2 exhaust gaskets and test again. Especially before you start to diag the engine in any way. If you didn't re-torque the 8 header bolts at your first oil change as instructed by the Suzuki service manual then I would 100% start there.
 
GSXRme said:
I'm going to say this issue is being over analyzed. Take your exhaust headers off and take out the crappy gen3 exhaust gaskets. Install the gen2 exhaust gaskets and test again. Especially before you start to diag the engine in any way. If you didn't re-torque the 8 header bolts at your first oil change as instructed by the Suzuki service manual then I would 100% start there.
Click to expand...
thank you. I'll begin by re-torqueing the header bolts before removing the gaskets. would you be able to confirm the torque spec for the header bolts please?
 
I did 18ft lbs but the service manual calls for a little less. The factory gaskets are copper and crush once and they don't seal right. The gen2 are a normal material used on automotive gaskets and are more forgiving.

Keep in mind when you remove the gen3 gaskets, use a flat head screw drive, get behind them and it takes a little amount of force. It almost feels wrong removing them. I only had 600 miles on my gaskets before the Brocks kit was installed and removing the factory gaskets was unsettling.
 
GSXRme said:
I did 18ft lbs but the service manual calls for a little less. The factory gaskets are copper and crush once and they don't seal right. The gen2 are a normal material used on automotive gaskets and are more forgiving.

Keep in mind when you remove the gen3 gaskets, use a flat head screw drive, get behind them and it takes a little amount of force. It almost feels wrong removing them. I only had 600 miles on my gaskets before the Brocks kit was installed and removing the factory gaskets was unsettling.
Click to expand...
thank you. i will order new gaskets from the dealer and look at this.
 
i checked the torque on the header bolts and they were not loose.

the noise would earlier go away on revving. even in neutral.

the noise now sustains up to a low rpm. the frequency of noise increases.


i believe it's the cam chain and a bad cam chain tensioner.

the chain may have a bit more slack due to chain wear over the course of recent riding. and because the cam chain tensioner is not doing it's job, the noise has increased.
 
i moved out of the country for the winter and have the 5 year warranty so delayed looking further into this issue.

my greatest surprise is that nobody else in the world has encountered this issue!!!

anyway here is the update:
Suzuki agreed to replace the cam chain tensioner but not out of their own strong belief that that's causing the problem but out of my insistence. i have it all on email. i tried to check the exhaust bolts and they seemed to be super tight. i will have another go at them in the summers when i am back to Canada.
 
I am confident there are other Gen 3s with this noise.

On my bike after 5000 miles the noise (when it happens) also increases (in frequency) with an increase in throttle input. Only at idle. Once the bike starts moving it always goes away.
 
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