Help needed, at my wits end
Hi everyone! I apologize for the length of this.
I have a 2003 KLR650 with 22k on the clock. I've owned it since it was new. I stay on top of it's maintenance, valve adjustments, etc. At 15k I replaced the Doo with the eagle unit, the torsion spring, the balance chain, and guides. Nothing was broken with the original, but the stock spring stretched badly and i caught it in the nick of time.
Here's the problem:
I was leaving work recently when a crunching /growling noise came from the balancer side of the engine. Not wanting to risk anything, i decided to just haul the bike home instead of riding it. This noise is intermittent. At idle the engine sometimes sounds perfect and when you rev it, the noise kicks in and stays there even after it settles back down to an idle. Sometimes, it just disappears and idles quietly once again. When the engine is put under a load/ revved up off of idle, it comes back.
I can tell you that this noise is not normal. It's loud and it sounds ugly. I thought there might have been a balancer malfunction, but before taking it apart, I decided to look at lot of simple things to see if i could track down the problem. So, i removed my aluminum skid plate, still there. Checked the motor mounts, fine. Drained the oil, and checked both filters, nothing - filter and screen are spotless oil looked great for 1200 miles of use. Pulled and inspected the cam chain tensioner - reset it and it was perfect. chain guide moves freely. did the adjustment on the Doo, no change. clutch engagement makes no difference.
So last night i pulled the covers off on the flywheel side, pulled the flywheel, and i honestly can't find anything wrong. The chain looks wonderful, the tension spring is doing it's job, everything is spotless in there. Just for kicks i ran a magnet around in the oil pan and it turned up nothing. i reassembled it and like clockwork the noise came back, this time with a vengeance, it's much worse, but still intermittent. At times during idle, it sounds perfect, other times during idle and when throttle is applied, it makes the hair stand up on your neck.
The best i can tell, the location of the noise is right below the starter. You can hear it and you can feel it. For the life of me, i can't seem to figure this one out, and i'm at a loss as to what my next step should be.
If it would help, i could post a video of it.
Thank you so much!