No idea what you might find, but I know where I'd start looking.....
Early Gen II bikes had a problem with the drilling depth of the engine cover that supports the shaft for a starter gear. The side cover is drilled about 10 mm too deep, allowing the shaft to slide over far enough to be unsupported and cause wallowing and, eventually, nothing left to support the starter gear. The issue is limited to Gen II bikes with a VIN of 20739 and lower.
You may be hearing your starter gears rattling around in there.
Your timing chain tensioner may need to be reset. Its possible it didn't reset the last time the valves were adjusted / checked. There's also a timing chain guide system in there, that can come apart. KLR's don't have a bad rep for timing chain issues, yet anything is possible. On that note, while the balancer system idler lever has been replaced, some sources report that the replacement springs can and do break. Your noise could just as easily be an untensioned balancer chain.
Wish there were a better means of diagnosing, and a simpler prognosis. You are clever and comprehend well. I suspect you already know everything I mentioned. Hoping for a simple solution, keep us posted on your exploration.
ďmany a trip continues long after movement in time and space have ceasedĒ- Steinbeck, [I]"Travels with Charlie"
[FONT="Century Gothic"][I]Sometimes your only available transportation is a leap of faith[/I] [/FONT]
Last edited by vatrader; 05-12-2011 at 07:03 AM.