Pete

UPDATE - It's still w**kered! In fact it's got worse At least now all I have to do is take it all apart and try again...

So here's an update for anyone that's been keenly following this thread. My new exhaust manifold gaskets arrived this morning at 9am so by 10am I was out in the garage dismantling my bike to have a better look at this dodgy downpipe. It took me about 2 hours to get the fairing off and drain the cooling fluid, so I could displace the radiator and get at the downpipes. That was really frustrating because whoever'd been down there before hadn't been too kind to the bike and quite a few bolts were nicely rounded off for me - sorted now though. Anyway, I finally got around to dropping the zorsts and after chipping away the bizarre cement-type stuff discovered this: http://i976.photobucket.com/albums/ae248/peteblakemore/DSC_0215.jpg?t=1254604116 Yep, the part where the exhaust stud was split in two! Who knows where the other half went. The other bummer was that the old stud had snapped off inside. Luckily there was about a centimetre left where I could sort of screw a new stud into, however it protruded a centimetre too much at the other end (so the downpipe wouldn't sit level - hence why it was wonky before). I got the stud in a vice and used a hacksaw to cut a bit off and got it level with the other studs in the rest of the manifold. After that I hit the shops looking for some sort of epoxy resin that would hold the stud in place. The first place I went to (B&Q) only sold stuff that went up to 60 degrees C heat resistance. Not good enough. In the end I went to Halfords and found some stuff that had "Great for exhausts, water boilers etc." so I got it!: http://i976.photobucket.com/albums/ae248/peteblakemore/DSC_0220.jpg?t=1254604119 It's just a stick off grey paste (quite firm) that had a darker streak running up the middle. All I had to do was cut a sliver off, mix the two parts and it was ready to use. I put a blob on the end of my newly cut stud, inserted it and then packed it out a little. Then I surrounded the whole lot in a bit more grey putty. It set really quick and the first time I had to use two different batches - one for the blob on the end of the stud, and another batch for packing it all out. Here's a picture I took while I was waiting for it to fully cure (impressively only an hour!): http://i976.photobucket.com/albums/ae248/peteblakemore/DSC_0219.jpg?t=1254604125 Actually it looks pretty lumpy and botched there. However that's my second attempt! The first time round I waited the full hour, started tightening the nuts onto the studs and getting the downpipes installed and the sodding putty crumbled away! This next time I waited 2 and a half hours, tightened everything except the faulty stud and then when it came to do that one I gingerly put the nut on. I finger tightened it and then gave it a quarter turn with a wrench: http://i976.photobucket.com/albums/ae248/peteblakemore/DSC_0226.jpg?t=1254604127 And another shot: http://i976.photobucket.com/albums/ae248/peteblakemore/DSC_0228.jpg?t=1254604128 The flash on the camera makes it look a lot worse than it is. The colour doesn't actually look that different from the black of the engine, and when the side panel's on I don't think anyone'll notice. If they do then I'll be painting over it with some heat resistant Hammerite paint! Until then I just hope it holds OK. Oh yeah and here's what the old gaskets look like compared to the new shiny ones: http://i976.photobucket.com/albums/ae248/peteblakemore/DSC_0223.jpg?t=1254605503 I haven't had chance to fire it up yet to see if the ticking sound has gone. I'm really, REALLY hoping it has because if it hasn't then it could be any number of problems, but almost definitely something to do with the engine (burnt exhaust valve anyone?). I simply ran out of time tonight but all I have left to do tomorrow is top the coolant back up and see what happens. Fingers crossed....

I'd always stick with semi-synth, never fully unless it's going into a bike with a dry clutch. Fully synth is more likely to give clutch slip (particularly on a new clutch). Fully synth is fine for cars and Ducatis, but I wouldn't use it in any other bike. Some people do and get away with it, but clutch slip is more likely to happen. The API rating (i.e. SL or SG, etc.) is better the higher the second letter. The manual will recommend something like SE, SF or SG, the higher up the alphabet the better. It's a minimum guide (so if you took your bike to India where some of the oil is rated worse than pee for sticking in your engine!). Therefore API SL is better than SG, because SG is the manufacturer's minimum recommendation for your bike. To be honest pretty much any oil you buy in the UK will be of a perfectly adequate quality. Also check for the JASO marking on the back which denotes that it's good for motorcycle use.

Like this one? http://baliwhat.files.wordpress.com/2008/06/fannypack.jpg

Some people think only losers wear bumbags...I've been thinking about it too and will probably get one A nice leather one'd be good, could pull my jacket over it.

If I can get my zorsts fixed then I might be up for it I'll ask around some mates and see if they want to nip down too

Did you try putting them back in (washer and o-ring)? I wouldn't be too bummed out by it, the only thing this problem's going to cost you is time, not money. You'll need to take the carb out again and have a proper look at it. Take some pictures and stick them up here would be good. But yes, don't worry you just need to get it in the right place

What a bunch of ninnies! Got to agree with what everyone else is saying here and just ignore it (unless it is in the early hours!). Have the council actually stated what will happen if the complaints keep happening? My parents told me that when my oldest brother was born the next door neighbours complained to the council about excess noise. The neighbours were quite open about it though and would call my parents up to shout at them for "letting your Mark run down the stairs like that" or "we can hear you playing with your son in his bedroom PLEASE would you shut up!". Some people are just angry, and although it's easier said than done I think if it were me I'd probably end up turning the bike over more often just to rile them. Nothing illegal or that seriously takes the pee but running an engine to test heated grips is nothing. And having to push your bike into your garden - what if you dropped it? They wouldn't take any of the blame then, even though it was because you were trying to be considerate towards them. Sod 'em I say, poke some poo through their letter box and give them something to actually worry about (don't do that btw)! Maybe some people just don't like motorbikes. Well some people definitely don't like motorbikes, for some unknown reason. "They're noisy/loud/dangerous" and because they think that they just dislike ANY motorbike they see or hear (or probably can hardly hear in your case). So whenever they hear your bike fire up they think "there's that bloody bike again, dangerous noisy thing" when in actual fact their car probably makes just as much noise reversing up the drive in the morning.

You can also check to see if it's the steering head bearings by getting it on the centre stand, having someone carefully press down on the back end to lift the front wheel. When the front wheel is up grab the forks and see if there's any movement. There shouldn't be by the way. I agree with Frankie, sounds like steering head bearings. Not a hard job to fix as such, just very time consuming. Set aside a day to get it done, and make sure you have all the things needed before you start! Unless you get a mechanic to do it (but he'll charge you for the time)...

Last bike had a bit of a rattle in the collector Frankie, that's right! The new owner was fine with it though. Everything else seems solid as a rock, the downpipes and in fact the entire system looks almost new (stainless steel downpipes and link pipes, the cans are titanium so no problems there) so certainly no rust or bits dropping off. I'll be off to Halfrauds/local bike shop (whoever's cheapest or has them in stock) first thing tomorrow to get the gaskets and will take a look at this Loctite goop that ozz mentioned. I'm really hoping it's not a split in the engine manifold! Hopefully it's just badly fitted but I won't know until it's all taken apart. I'm not particularly looking forward to getting all that hardened goop off though, it's rock solid! Incidentally, is there a difference between getting copper or aluminium gaskets? I've noticed there's a choice between the two but can't imagine there's a difference, just that they're both soft metals and are equally as good at the job intended...

Thanks ozz, I'll get up Halfrauds first thing tomorrow!

Nice one ozz, top tip. I'd still need to put the metal gasket in with that though, right...or maybe not?! EDIT: Do you mean this stuff: http://www.halfords.com/webapp/wcs/stor ... yId_165691

Thanks again guys. To be honest I want it sorted, I bought the bike with a view to keeping it for a good few years (hence why I got a Blackbird, thinking it would be reliable - it is reliable, just this tapping noise!). I'm 99% sure it's coming from the suspect area ozz, but I was 99% sure it was the cam chain tensioner before that! Thanks for your thoughts too steer_rally, I hope I don't need to bodge it like that! What I'm hoping is that some twerp has, in the past, bought the new stainless downpipes, tried to fit them themselves and found it tricky and thought "stupid thing won't fit, I'll put sealant 'round the top" and left it at that. HOPEFULLY it's just a case of dropping the zorsts and spending some time cleaning it all up and making it fit properly (like it should have been). Worst case scenario is what you guys are thinking about either a buggered thread on the engine or a crack/split somewhere along the way. Fingers crossed it won't be anything that drastic. I guess the worst that could happen is I'll drop the thing, clean it up, realise it's buggered and just gum it all back up again until I can afford to fix it properly!! I'll give progress reports as I go. It might take some time, I only bought the bike 3 days ago and it took me quite a while just to get the fairing off this morning! I'm sure in future it'll be a five minute job but for now...well I'll just see how long it takes! I'll get pics up too so you can all have a good laugh

Cheers, thanks again ozz. I've considered just leaving it, but there's a definite rattle and that bugs me. I also don't like thinking a bodge job has been done on the exhaust/any part of my bike - call me a perfectionist! Also, if I drop the exhaust, examine it and "fix" it and the rattle is there it could be something more dodgy which I need to know about. The only downpipe that looks to be dodgy is the one with all the gunk on it! It's bloody rock solid though so god knows how I'm going to get it off. Oh crumbs!

Thanks ozz. To be honest the suspect on does look like it's been mounted a bit wonky. However, would it still be blowing/clicking if it's plastered with all this gasket goop? I mean if it's sealed would it really matter if it's wonky? What a ball ache. Unless someone comes up with any ideas as to what else it could be I think I'm just going to drop the exhaust this weekend and have a proper look at it. Oh and then hope that I can find any spare parts needed from B&Q!

First problem with my new Blackbird and I haven't even had it a week! Ever since I got the bike there's been a distinct clicking sound coming from the front of the bike. At first I thought it was the cam chain tensioner, a common fault on blackbirds. I ordered one yesterday for £46 and installed it today. Still the same sound. Outraged, I sat and pondered on what the noise could be. I inspected all the exhaust manifolds and, to my surprise one of the bolts on the middle left manifold was so loose it was about to drop off! I tightened it up, crossed my fingers and fired her up. Same noise. Then I checked all the other bolts (burnt my hand a lot ) and then when I got to the far right manifold noticed a lot of gum/paste/crap surrounding it. I removed the fairing on the other side and looked at it closer. The noise is almost definitely coming from there. I tried to tighten the bolt (in red circle below) and it just kept spinning...then fell out! The exhaust is after market so my first thought is that whoever fit it originally did a bad job. I'm worried that the gum is there because some numpty stripped the thread where the bolts screw into, hence why the one that dropped out, dropped out! http://i976.photobucket.com/albums/ae248/peteblakemore/wonky.jpg?t=1254223463 Now you can guess I'm not best pleased. Why the hell is all that gum stuff surrounding the manifold? I'm worried if I chip away at it I'm going to find something I don't like/expensive. My initial thought is that the clicking noise is that it could be the gasket rattling around inside as I can't feel any air escaping when I hold my hand close to it. I think I just need to bite the bullet and take the downpipes off, remove the gum and inspect it further...but what do you lot think? Firstly does anyone know what this stuff is?! Oh, by the way for anyone wondering what an exhaust manifold should look like here's one (probably from a tractor or something!): http://image.automotive.com/f/techarticles/engine/9609265+pheader/131_0703_01_z+1992_jeep_wrangler_yj+exhaust_manifold.jpg

You won't get any "bad" effects as such. There's no rule/law saying you must have exactly the same brand/model of tyre for front and rear. What you do need to make sure of, and is the law, is that they are the same TYPE of tyre (i.e. radial ply, diagonal cross ply, bias belted) look here for more info on tyre types: viewtopic.php?f=5&t=25161

My new blackbird came with Avon Storms fitted - to be honest I thought "Avon = budget"! However I did some reading up on them and quite a few people prefer them after comparing them to the Bridgestone BT020's (especially in the wet). After riding the bike with them on I highly recommend them, they're super grippy and at a good price too.

Show Grandma Bill how to spin the old gal up so she can let it run for 5 minutes every couple of weeks! That'll keep things in order!

Nice one, keep us posted!

Seems like the Ducati bashers are out in force again...usually people who have never even sat on one I might add. Ducatis aren't that expensive if you keep up with maintenance....same as any other bike. And to be honest you can do the servicing yourself, it's easy once you've done it once. If you take any bike to a dealer they'll charge £50 or £60 to take the fairing off, so do it yourself! Even timing belts and valve adjustments are easy. Insurance on a Duke ST4s (996 engine) is cheaper than the Blackbird I'm about to buy, running costs (i.e. MPG) on the ST4 (916 engine) and the ST4s are better than I used to get on my old 600 Suzuki, and the handling on all Dukes surpasses pretty much any other bike (fact, not opinion!). And there's the sound to top it all off. If you like it then it's great. The Kwak is also a great bike, but it's more of a tool. Not just a tool, it's a nice bike, but the Duke is nicer (my opinion)! EDIT: And my first bike was a 600, fully comp insurance was £350

One thing's for sure, the Redex wouldn't have done anything bad. I've chucked about 3 bottles down my bike's neck and it loves it! Seems to me to be a fuelling issue, so I think you're on the right lines. Have you checked/cleaned/replaced the fuel filter? Could just be that it's gummed up with crap and fuel isn't getting through. Have a look in the end of the exhaust, is there a lot of black dust gathering? If there is then it's most likely to be running rich and that black dust is from fuel that hasn't burnt properly (which would mean it's not the fuel filter if too much is getting through!). If you've cleaned the carbs already then they probably won't need doing again. Easier to check the fuel filter first IMO. Oh and I know you said that whistling noise is common on ER-5's but are you sure it's not something more sinister? I could be wrong of course, I've never owned one but I don't like that sound! And I don't remember either of my old instructor's bikes sounding like that. Cam chain tensioner gone perhaps? EDIT: Have you cleaned it any time recently? My old GSX600F used to go a bit "lumpy" for a few miles if water accidentally got down the exhaust. I ended up cable tying a sandwich bag over the end to stop water getting in.

I'd check your sparks are screwed in to the right torque. My old bike was a GSX600F (feels weird calling it my old bike, only sold it 4 days ago!) and that had a rattle that turned out to be a loose spark. Also check when your valve clearances need doing. You don't want them f**king up!

You do have a home, don't you Mr M? I don't want to come round for tea otherwise...