Engine noise. - Kawasaki KLR 650 Forum
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post #1 of 9 Old 05-12-2011, 12:35 AM Thread Starter
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Engine noise.

So I'm getting this noise when I start the bike, especially on the sidestand which sounds like one of the chains is slapping against the case. The bike has 25,000 and the doo has been done.

When I pull the left cover off, what should I expect to find?

Also, when I shut her down, I'm getting a clunking gear like sound.
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post #2 of 9 Old 05-12-2011, 07:00 AM
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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.

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Last edited by vatrader; 05-12-2011 at 07:03 AM.
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post #3 of 9 Old 05-12-2011, 09:15 AM
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If you used a coil spring for the doo it's possible that it's run out of tension to adjust the chain. 25k is about what EM said it would go before the spring needed to be changed.
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post #4 of 9 Old 05-12-2011, 09:21 AM
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Quote:
Originally Posted by vatrader View Post
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.
Not to detract from the thread, but thanks for mentioning the VIN number of the KLR's possibly affected by that engine cover/starter shaft problem. That's a valuable piece of information folks should take note of.



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post #5 of 9 Old 05-12-2011, 09:36 PM Thread Starter
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Thanks for the head's up Vatrader. I DID have the 'deep hole' issue, you saved me from taking off both left covers. It was a quick fix, 3/8" nylon bushing cut 3/8" long.
Pretty much a half hour fix.

The very first time I started on the sidestand, it still cluncked weird, but every time after that, it behaved normally.

I had missed this issue, you saved me a bunch of work.
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post #6 of 9 Old 06-08-2011, 08:19 PM
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Quote:
Originally Posted by planalp View Post
Not to detract from the thread, but thanks for mentioning the VIN number of the KLR's possibly affected by that engine cover/starter shaft problem. That's a valuable piece of information folks should take note of.
The current data is that every 2008 is affected, and about a quarter of the 2009 models: we have seen deep holes on bikes up to and including 20738. The first bike we've seen that does NOT have the deep hole is 20803. So we've narrowed it to a 65-bike window where the fix was done... I quote 20802 and below as "problem" bikes until someone chimes in with one of those 65 bikes to further our study.

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post #7 of 9 Old 06-08-2011, 10:09 PM
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Uh oh. My vin is 19862.

Bill
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post #8 of 9 Old 06-08-2011, 10:21 PM
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I have a low serial # 08 and this was a concern to me as well, but when I looked at the set up, while doing the doo, it looked like a thrust washer between the gear and cover (housing) would not let the shaft move more than it should....? I must have not got the big picture.....

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post #9 of 9 Old 06-09-2011, 12:10 AM
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Quote:
Originally Posted by Matter View Post
I have a low serial # 08 and this was a concern to me as well, but when I looked at the set up, while doing the doo, it looked like a thrust washer between the gear and cover (housing) would not let the shaft move more than it should....? I must have not got the big picture.....
There are two gearsets in the starter gear reduction system.

One of the gearsets has a shaft that is fixed to the gears, so yes, on that one, the thrust washer keeps the gear from moving to the side, hence it keeps the shaft from moving to the side. However, the other shaft is not fixed to the gear, and the thrust washer (shown in red in my diagrams) is unable to restrict its motion.

Watt-man

'04 KLR650, 172,000 Miles
still on original piston, rings, entire top end. Just an Eagle doohickey, torsion spring and a Thermo-Bob, of course!

www.watt-man.com
Ride it like you own it!

Last edited by Watt-man; 06-09-2011 at 12:15 AM.
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