Knocking/Clanking motor - 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 19 Old 11-04-2015, 04:36 PM Thread Starter
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Red face Knocking/Clanking motor

Hi guys

I have a 1987 KLR650A. She runs absolutely great, heaps of power, but.....

When my bike is idling, at about 1300rpm, which i think according to my Clymer manual is about in the correct range, the motor sounds rather "clanky", if you know what i mean. And it almost like i can hear the bearings on the crankshaft turning(louder than other bikes that i have owned before), is this normal for this bike. When i'm in a slightly higher gear, and accelerate, the bike is a bit "jumpy" and "clanky".

Sounds like an odd explanation, but this is the best i can describe it. I'm pretty sure it's not piston "knock", but then i could be wrong.

Cheers
Justin
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post #2 of 19 Old 11-04-2015, 04:54 PM
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Are you familiar with the term "Doo-Hickey"?
ie, Engine Balancer Chain Adjustment Locking Lever and its spring tensioner system.

#2,
The older -A series are noisier than 1996 and newer. The 2008 and newer are quieter than the 1996-2007s.

pdwestman
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post #3 of 19 Old 11-04-2015, 05:15 PM Thread Starter
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Hhhmmmm, the infamous "Doo-Hickey", heard a lot about it. You thinking this might be my problem?
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post #4 of 19 Old 11-04-2015, 05:38 PM
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Quote:
Originally Posted by Justin Capitao View Post
Hhhmmmm, the infamous "Doo-Hickey", heard a lot about it. You thinking this might be my problem?
Have you ever adjusted it?? Is it still the factory part? Ya that could be the problem. Easy place to start.

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post #5 of 19 Old 11-04-2015, 06:06 PM Thread Starter
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I'll have a look then Will keep you updated.
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post #6 of 19 Old 11-05-2015, 06:48 PM Thread Starter
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Can i just lie the bike on it's right side and work on the "doohickey/cam chain tensioner", without having to drain the oil, which i have just replaced? Replaced the oil that is!
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post #7 of 19 Old 11-05-2015, 08:14 PM
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Excuse me, we are not worried about the "cam chain" at the moment.
Engine Balancer Chain!!!

Yes. By all means, lean it over and have a look.

Last edited by pdwestman; 11-05-2015 at 08:17 PM. Reason: Engine Balancer Chain!!!
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post #8 of 19 Old 11-06-2015, 12:36 PM Thread Starter
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Hmmm, seems like I'm going to have to modify a 32mm spanner! Also going to have to turn up a flywheel puller. Anybody know of the cuff what that thread size is in the flywheel bore? Looking at YouTube videos it seems to be 3/4" or 1" diameter?
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post #9 of 19 Old 11-06-2015, 01:32 PM
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Take a look at this post.

Rolled threads would probably be a better option for this application than turned threads.

Tom

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post #10 of 19 Old 11-06-2015, 01:40 PM
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Quote:
Originally Posted by Justin Capitao View Post
Hmmm, seems like I'm going to have to modify a 32mm spanner! Also going to have to turn up a flywheel puller. Anybody know of the cuff what that thread size is in the flywheel bore? Looking at YouTube videos it seems to be 3/4" or 1" diameter?
Use 22 x 1.5mm for the puller.
Don't use soft metal. Soft pullers have been known to strip and get stuck in the rotor. Consider buying a good 22mm bolt. I was able to buy one from eaglemike.com cheaper than from my fastener supplier considering freight.

Last edited by GoMotor; 11-06-2015 at 01:57 PM.
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