Need help diagonosing a noise, may be clutch related - RESOLVED - Kawasaki KLR 650 Forum
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post #1 of 43 Old 07-14-2010, 11:01 AM Thread Starter
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Need help diagonosing a noise, may be clutch related - RESOLVED

I have a noise. OK, yeah, another thread on diagnosing a noise.

I first heard this noise back on my trip ‘round California, but I thought it had gone away.

Here’s the deal – when starting up normally in first gear I hear two distinct clunks as I let the clutch out. Under normal start-up they are separated by about a second or so.

The noise sounds like a “shuck”…”shuck”, or a “clunk”…”clunk”. The noise is very similar to the noise that I associate with shifting from first to second, only softer, if that helps characterize it.

When I was on the trip ‘round California and first noticed it we were in heavy traffic and I actually thought it was Dave shifting into second behind me.

I don’t always hear the second clunk. Occasionally I can feel sort of a shudder or vibration, very light, as the clutch gets fully engaged.

Theorizing, could it be that the clutch plates have some play on their shaft and are slipping into final position? Would the shudder be indicative of the clutch going south? The bike started this at about 12,000 miles. That seems short for clutch life. I’m generally easy on the bike, but have worked it pretty hard off-road. Might’ve sustained some sort of damage.

I use Rotella Dino oil, and have since the bike was new. The oil currently has about 500 miles on it.

Any thoughts or theories would be appreciated.

Tom

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post #2 of 43 Old 07-14-2010, 11:07 AM
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First and easiest thing to check would be the condition of the cush drive. Pull the wheel and sprocket carrier and see if there is any rubber left.
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post #3 of 43 Old 07-14-2010, 12:09 PM
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Quote:
Originally Posted by Tom Schmitz View Post
I have a noise. OK, yeah, another thread on diagnosing a noise.

I first heard this noise back on my trip ‘round California, but I thought it had gone away.

Here’s the deal – when starting up normally in first gear I hear two distinct clunks as I let the clutch out. Under normal start-up they are separated by about a second or so.

The noise sounds like a “shuck”…”shuck”, or a “clunk”…”clunk”. The noise is very similar to the noise that I associate with shifting from first to second, only softer, if that helps characterize it.

When I was on the trip ‘round California and first noticed it we were in heavy traffic and I actually thought it was Dave shifting into second behind me.

I don’t always hear the second clunk. Occasionally I can feel sort of a shudder or vibration, very light, as the clutch gets fully engaged.

Theorizing, could it be that the clutch plates have some play on their shaft and are slipping into final position? Would the shudder be indicative of the clutch going south? The bike started this at about 12,000 miles. That seems short for clutch life. I’m generally easy on the bike, but have worked it pretty hard off-road. Might’ve sustained some sort of damage.

I use Rotella Dino oil, and have since the bike was new. The oil currently has about 500 miles on it.

Any thoughts or theories would be appreciated.

Tom

Is the clutch slipping at all? Kinda hard to burn up a KLR clutch I would think unless one really abused it off-road. A shudder would indicate a clutch problem, have you checked and lubed the cable? Lever feel normal?

Could be the cush drive I guess. Grab the sprocket and see how much play there is. The cush mostly just softens aburpt transitions to the rear wheel. Once you're moving it's not much of a factor unless it takes you a long time to shift!
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post #4 of 43 Old 07-14-2010, 01:50 PM
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Huh. That's weird. You mean when it's already in gear and you let out the clutch it makes that noise, right?




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post #5 of 43 Old 07-14-2010, 02:43 PM Thread Starter
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Originally Posted by Lockjaw View Post
Huh. That's weird. You mean when it's already in gear and you let out the clutch it makes that noise, right?
Yup, the noise occurs as I'm riding away from a stop.

The cush drive seems OK.

The clutch doesn't slip, the lever feels normal, there's no binding in the cable.

Tom

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post #6 of 43 Old 07-14-2010, 03:36 PM
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Ok, I have no idea (big surprise). I have empathy, though! Sorry man. This is a weird one.




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-------------------
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post #7 of 43 Old 07-14-2010, 05:58 PM
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Tom, I am going out on a limb here and say there is nothing wrong with your bike. I have two 09 KLRs, mine and the wife's and both make what I call a chug, chug or a shuck, shuck when you are taking off from a dead stop. When I first got these bikes, after spending 30 years on touring bikes, I thought these things were coming apart. Actually mine shuck, shuck, shucks each time I take off. They sound like tractors until the rpms are up a little.

Greg
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post #8 of 43 Old 07-14-2010, 06:58 PM Thread Starter
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Originally Posted by Extrooper View Post
Tom, I am going out on a limb here and say there is nothing wrong with your bike. I have two 09 KLRs, mine and the wife's and both make what I call a chug, chug or a shuck, shuck when you are taking off from a dead stop. When I first got these bikes, after spending 30 years on touring bikes, I thought these things were coming apart. Actually mine shuck, shuck, shucks each time I take off. They sound like tractors until the rpms are up a little.

Greg
Hey Greg -

Yeah, it's not the 'KLR noise' - the chug-chug-chug thing. It's a soft clunk (sounds like a 'shuck', for lack of a better way to spell it) and there are only two of them.

Thanks,

Tom

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“The kid poured him another straight rye and I think he doctored it with water down behind the bar because when he came up with it he looked as guilty as if he'd kicked his grandmother.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

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post #9 of 43 Old 07-14-2010, 07:21 PM
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Countershaft spline looks ok? I'm grasping at straws here, just throwing it out there. Hope you get it sorted.

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Stew
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post #10 of 43 Old 07-14-2010, 08:07 PM
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Quote:
Originally Posted by Tom Schmitz View Post
the chug-chug-chug thing.


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