Noisy under load KLR - 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 7 Old 01-01-2010, 12:13 PM Thread Starter
Join Date: Jan 2010
Posts: 3
Noisy under load KLR

I made a small vid so you can hear the engine.
1st gear with brakes on loading it with the clutch.

I need some expert advise.. How tough are the big end bearing and small ends?

I can't post urls yet.. please search you tube for klr 650 noise or id qJJ-L9mXToo

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post #2 of 7 Old 01-01-2010, 12:17 PM
Pretty in Pink, dunno why
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post #3 of 7 Old 01-01-2010, 12:27 PM
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Ok.. I'm going to ask the classic question..

Have you done the Doohickey? Sounds to me like chain slap/grinding because the adjuster (Doohickey) is broken and not tensioning the chain..

Sorry about not being able to post the link, but forcing users to have a certain amount of posts is one of the only ways we can keep spammers from posting links to porn/drugs/wigs/shoes/phones/ etc..

Last edited by Paper; 01-01-2010 at 12:30 PM.
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post #4 of 7 Old 01-01-2010, 12:54 PM Thread Starter
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Thx Tom for posting the link !

Paper, I just bought her about 10 days ago. Fitted new battery, tyres and exhaust. Gave her a complete service and cleaned the carburator. What worries me is the fact I only drained about 750 ml black old oil out of her.

When cruising along fast or slow its noise free.. but the moment you apply throttle the scuffing noise starts, the lower the rpm the more noise. I think above 3500 rpm no more noise even on full throttle

I did not do the doohickey, I live far far away from the states.. will get one though. I did check the tensioner when I did the service and it is still intact. The spring is totally compressed, doing nothing. the adjuster is almost at its end, looks like the chain is stretched. I did not have a tool to pull the magneto..will get or make one and do justice to that tensioner.

btw..your quick reply is busted..retyped this twice
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post #5 of 7 Old 01-01-2010, 01:09 PM
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Quick reply's screwy?? I haven't had an issue, but I know how frustrating it is when you have to retype an entire post.. Sorry..

Well, I'd start with the cheap/simple stuff first.. I'd try to locate a spring of the right tension and length, or contact Eagle Mike at and let him know what you're finding and what you found with the spring being completely closed and the chain stretch.. I don't know if you have Skype, but it's a cheap way to make international calls and might be the ticket for this..

I know what you're up against as far as looking for parts.. Here in the States we're spoiled with a hardware store or well equiped motorcycle dealership within 10 minutes of most places. I've worked in industrial parts of South Africa and still have scratched my head as to where I'd find something I can normally locate easily when at home..

Anyway, I'd hit up Mike by email or phone (both listed on his website) and see what he suggests.. He's had more of these motors around than many have ridden.. It is currently 10am on the West coast as I type this, but it's also New Years Day holiday, so I'm not sure how available he would be today..
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post #6 of 7 Old 01-01-2010, 01:12 PM
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Bossie, Both of your other postes are here, but say they were deleted by you. Not sure what's up but maybe it's something to do with your account or maybe even your internet supplier?? Not sure..

I'll physically remove your other two posts, since they're the same as what you posted the third time.. Please let me know if the issue continues and I'll have the administrator look into it.
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post #7 of 7 Old 01-03-2010, 05:44 AM Thread Starter
Join Date: Jan 2010
Posts: 3
well, most engine noise and that klaking disappeared after I manually adjusted the thin stock steel tensioner.

both my balancer sprockets are those big ones with little springs in them, they have slight play on, is that ok ?

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