I have a 2024 KX450F motor with apparently less than 40 hours on it. I have the cases split. Once I split the cases, there is an internal oil screen that can only be accessed by slitting the cases. It is near the drain plug in the sump. It appears that there is an open passageway from the transmission to this spot.
I found a ton of metal shavings- yet to find the damage that created these- aswell as a few broken plastic? pieces jammed up against the oil screen. You can see in the photo that they likely were all one piece, in a "C" shape maybe? That's assuming this is all the pieces.
Anyone have any idea what these may be? Would love to hear from those who are particularly familiar with these motors firsthand. I looked at every OEM parts diagram and can't find something to match these pieces. I don't believe it is part of the cam chain guides (I have compared mine to pictures of others) and I do not believe they are clutch hub cushions- they are not rubbery or "Ripped" as much as they are "snapped" apart.
Any insight would be awesome. Thanks!
Timing chain guides ? check for chain wear in chain routing passage .
If anyone is curious, had an experienced motor builder who works on these motors check it out and he says it is a foreign object. I was almost certain of this.
Yeah, those look like boot buckles or knee brace clips to me. I hear those bikes suck (foreign objects into the motor)?!?
Sounds like your engine builder is at a loss, too. I've heard of clutch dampers and fibers breaking up. Are the pieces magnetic?
Non-magnetic, likely plastic. I think they were all part of one piece, you can kind of see where they could have connected together before snapping, maybe forming a u-shape piece? The ends are kind of "barbed" like some kind of clip. Bike had 2 prior owners, one of them could have been careless and dropped something, I don't know...very odd.
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Quite popular to modify the airbox on current gen kx450 ... related???
Hmmm not sure, will have to do some poking around when I get the chance and see if I can find anything related.
Even if it was sucked in from the airbox, one would assume that if it makes it through the throttle body, past the intake valve and into the combustion chamber it would just end up in the cylinder or in the exhaust. Theres no ports for it to end up in the bottom end, ya know?
Just a very strange situation all around.
Could be some assembly fixture that didn’t get taken out when the engine was built.
Very interesting indeed! Thanks for the update on what it was. I’m blown away.
Was it the oem clutch assembly in the bike or look like it was ever taken out? Only thing I could think it might have been part of a rekluse or something the guys used to lock gears so they didn’t spin and forgot to take it out. I’ve torn down many of these motors and have never see that before.
After much consultation with some mechanics, it was determined that it has to have been something foreign. Like, something that has no business being inside a motor, inside this motor. Have no idea what specifically, some kind of plastic though.
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