Engine knocking on my 1999 Suzuki GSXR 600?

[stdisforthem]

Ok so after about 3months of setting I finally ordered a new stator for my bike. We installed it today and everything was looking good... Goes downhill from here. Apparently the brand new battery that was just put on it before it went into setting is crap so i need a new one... well so we decided to boost it off and see if it would run and just get a new battery tomorrow. After pouring about half a gallon of gas into the carbs she finally started! Good right? No! After about 5mins of running the bike started making a knocking noise! I don't know what the cause of it is so any help would be awesome! The bike was in perfect running condition BESIDES the stator when it was parked. Only thing i can think of is when we took the original stator off lots of oil came out. Also the noise seems to go away when the bike is revved.

 

[bikinkawboy]

Here's what I'd try in order of probability.

Did you have to remove the rotor from the crankshaft? If so, did you get it tightened properly? Were there any spacers, shims or washers on the crank that you removed? If so, they may be there to take up crankshaft end play. I'm trying to remember, but I think some Kawasaki engines use a rubber or fiber spacer/washer behind the starter clutch. There's 3 thicknesses and you use the one that sufficiently takes up the play behind the starter clutch or else it's rattles. Does your bike have something like that?

Is it firing on all 4 cylinders? Pull one plug wire and see if it makes any difference on the way it runs. Replace it and try the next and so on. If it's missing on a cylinder, is the plug wet with gas? If so, it could be the carb float valve is stuck and dumping raw gas into that cylinder.

It's common for lose some oil when replacing stators, but normally it's not that much unless you were nearly bone dry to start with. Is the oil pressure light coming on? If not, then it's unlikely it's oil related.

 

[Compton82]

You need to get it back to the specified amount of oil before you run the motorcycle. Of course it is going to knock with lower amounts of oil in the motor. After you replace the lost oil, start it and let the bike warm up completely before revving it. The noise should go away after that.