Unhealthy clutch/engine sounds after upgrade - 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 1 Old 08-27-2017, 11:51 AM Thread Starter
Join Date: Jun 2017
Posts: 13
Unhealthy clutch/engine sounds after upgrade

[SOLVED] All KLR guru's....

This sounds like it's from the clutch side.

2002 was running fine with all in good working order. During a series of upgrades and farkles, I had finally time for the EM doo and torsion spring upgrade. Following the EM instructions and some you tube vids, I am confident that all was done to spec (except for rotor bolt), with no lost washers or bits to fall into the case.

After all was done, it was time to install the Dirtrack crash bars. In doing so, I removed the clutch cable from the handlebar and removed it, while leaving the cable intact and undisturbed at the clutch housing. Re-routed the cable to it's original route and re-assembled the clutch handle to the bars and adjusted the clutch accordingly. I'm confident that the cable is adjusted properly. (The cable is threaded almost full slack at the lever, as opposed to about 3/8" outward adjustment before the removal of the cable...this is puzzling, since there was no adjustment at the clutch housing).

Bike starts fine and idles well, There doesn't seem to be any audible grinding, slapping, whining while idling. Time to test it with a very short cruise around the yard.

As soon as the bike is in motion, a whining/grinding, or otherwise unhealthy sound is coming from the lower case. My first assumption was something amiss at the balancer, since that was the upgrade just completed. Upon close listening inspection, I find the sound coming from the clutch side while on another short (100ft) test ride. Same sound after re-checking the clutch engagement and lever pull.

With a mechanics stethoscope, I check the operation of the engine while on the centerstand with the rear wheel off the ground. The noise is loudest at the clutch pivot adjusting arm while at idle. In gear and under idle the sound is increased, and gets louder as the rpm's are increased to about 1500 (i never had more than 15-1600 during my tests and rides.

The oil is topped off w/Castrol 4T semi syn. Time is of essence, and only have a few hours window to diagnose and make any repairs or adjustments.

You thoughts and experience are requested.
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Last edited by boots; 08-28-2017 at 12:08 PM.
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