New Chain and Sprokets CLUNK! - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 12 Old 06-14-2008, 11:30 PM Thread Starter
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Join Date: Oct 2006
Location: Anchorage, AK
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New Chain and Sprokets CLUNK!

Today I replaced my stock Chain and Sprocktes with an O-ring chain and "JT" sprockets.

When I got done I took it for a test ride and I was getting a CLUNK in the rear. It kinda of sounds like the chain is hitting something It doesn't happen all the time, but when it does happen its got a tempo to it which leads me to believe that its at least something spinning.

I'm out of time to work on it tonight but in the morning i'm going to take the countershaft sprocket off and see if its anything is being hit behind it. And I'm going to take the rear wheel to make sure I've got all the spacers in the right spot etc..

If you guys have any idea what it might be, or things for me to look for I'm open to just about anything.

Ugh! I'm leaving for D2D on wed. and can't believe this kind of stuff always happens right before a big trip.

Thanks,
Brian

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But if life gives you lemonade be careful.... Its probabaly pee!
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post #2 of 12 Old 09-18-2008, 07:12 AM
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Join Date: Apr 2007
Location: Omaha NE
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Mine is doing the same thing!
What did you find wrong on yours????

K1


Quote:
Originally Posted by KLRless View Post
Today I replaced my stock Chain and Sprocktes with an O-ring chain and "JT" sprockets.

When I got done I took it for a test ride and I was getting a CLUNK in the rear. It kinda of sounds like the chain is hitting something It doesn't happen all the time, but when it does happen its got a tempo to it which leads me to believe that its at least something spinning.

I'm out of time to work on it tonight but in the morning i'm going to take the countershaft sprocket off and see if its anything is being hit behind it. And I'm going to take the rear wheel to make sure I've got all the spacers in the right spot etc..

If you guys have any idea what it might be, or things for me to look for I'm open to just about anything.

Ugh! I'm leaving for D2D on wed. and can't believe this kind of stuff always happens right before a big trip.

Thanks,
Brian
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post #3 of 12 Old 09-18-2008, 09:50 AM
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Join Date: Oct 2006
Location: Evansville, Indiana
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I could be thinking of something else, but I believe there are some o-ring chains wider then stock that will scrape the stock chain guard and you'll have to either modify the white stock chain guard, get an aftermarket or take it off. Again, I could be thinking wrong, but it's worth checking.

Also... Check your wheel alignment!
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post #4 of 12 Old 09-18-2008, 10:14 AM
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Join Date: Apr 2007
Location: Omaha NE
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I ran the bike with the chain guard off and the engine sprocket cover off and it still made the noise so I disassembled the rear suspension and greased the needle bearings, needed it anyway, still did it, so the rear wheel bearing were replaced, needed them too, and it still does it, tightened the spokes and still does it, took ALL the body work off and rode it sitting on a towel and it still does it. It's like you could reach down and touch it!

The bike is taunting me!!!!!!

It does it worse with the shock at setting 1 and less, much less, at setting 5 on the spring compressor.

K1
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post #5 of 12 Old 09-18-2008, 02:31 PM
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Location: Corpus Christi, TX
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This stuff will make you crazy.

Only thing I can think of is wrong pitch chain or wrong sprocket. Try putting the old chain and/or sprockets back on and see what happens.

Or maybe a faulty chain link that's not flexing.
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post #6 of 12 Old 09-19-2008, 06:29 AM
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Did you put the front sprocket on correctly? The factory counter sprocket has a built in shim to throw it out towards the outside of the engine. We originally put our 16t sprockets on incorrectly and they made the chains have that clunking noise you mention, just like it's hitting something but isn't. I think the chain is getting into a bind as it is rotating because it may be pulling in towards the engine too much. Our sprocket had a washer with it and it ended up needing to be put behind the counter sprocket to shim it outwards. That fixed our clunking sounds. Just an idea to check.

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post #7 of 12 Old 09-19-2008, 09:45 AM
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I have no doubts this stuff will drive a man crazy! I just recently went through an identical ordeal with an annoying little swish swish that turned in to grind grind that turned in to more of a clunking grinding extremely bad sounding noise over the time I was trying to figure out what the heck was going on. Funny thing though... I had adjusted the chain tension several times thinking that was the problem and at some point had the wheel a full adjustment mark from left side to right side out of alignment and didn't notice. The noise went away and I thought the problem was solved and must have ridden 3-400 miles that way before checking everything again and noticing the alignment issue. I corrected everything and BAM... the noise came back!

At 13,000 miles and plenty of it offroad, I started thinking maybe the cheap stock sprockets and chain were just done and decided to get new sprockets and chain... NOISE GONE!! I got the same stuff you did... JT sprockets and DID O-Ring chain.

There wasn't a washer with the JT, but there is a rimmed edge on one side that goes on toward the inside and lines up with the recessed edge on the casing.
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post #8 of 12 Old 09-19-2008, 10:00 AM
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Join Date: Sep 2008
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It has begun..

Mine started the clunking last night. Yes, I am trying to fiddle with the allignment and chain tension to see if I can work it out, but I have a feeling I am headed for a new chain and sprockets. At least it is Fall and the riding is about over for Nebraska.

Related question: My KLR is a 2007. Should I be predicting dohickey issues? If so, what are the symptoms that tell me the thing may be shot?

Tornak
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post #9 of 12 Old 09-19-2008, 04:19 PM
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Join Date: Apr 2007
Location: Omaha NE
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I was hoping you were right and I put the sprocket on backwards but as Wanderer said the JT sprocket has a built in washer so you can only put the lock on with the sprocket in the right position.
I would really like to figure this out!

K1

Quote:
Originally Posted by DXKLR View Post
Did you put the front sprocket on correctly? The factory counter sprocket has a built in shim to throw it out towards the outside of the engine. We originally put our 16t sprockets on incorrectly and they made the chains have that clunking noise you mention, just like it's hitting something but isn't. I think the chain is getting into a bind as it is rotating because it may be pulling in towards the engine too much. Our sprocket had a washer with it and it ended up needing to be put behind the counter sprocket to shim it outwards. That fixed our clunking sounds. Just an idea to check.
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post #10 of 12 Old 09-22-2008, 08:09 PM
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DXKLR is probabaly right on with this one....

The after market 16 tooth sprockest has an inside and an out side...... trust me I found out same as you......

Lay your new sprocket and your stock sprocket on a table and notice the difference in height (thickness).

You would think the after market guy would put a sticker and or lable on it
IN - Out.

Good luck

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