Doo or Clutch noise??? - Kawasaki KLR 650 Forum
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post #1 of 17 Old 04-06-2012, 06:18 AM Thread Starter
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Doo or Clutch noise???

OK so i have an 01 with roughly 23k miles on it and on my last ride I noticed a grinding/crunching noise coming from lower left side of engine. Seems to only be in first and second gear while accelerating but i might just not be able to hear it after that from wind. My frist thought was an overtightened chain so i loosened and lubed it up. Seemed to help but once at operating temp noise quickly appeared and i shut her down. This noise is only during acceleration or while clutch is BEING let out and at operating temp. Any thoughts if this is the DOO or something else.

This bike still has the factory DOO in it and i know that they are prone to failure so that is my first guess. I dont want to blow 138$$ on the DOO upgrade from EagleMikes if i dont have to, but if that your recomendation I'll push ahead.

Any help in this matter would be greatly appreciated.
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post #2 of 17 Old 04-06-2012, 07:01 AM
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Long distance diagnosis, and I claim no expertise, but . . . don't think doohickey problems would be sensitive to specific gear engagements; rather--appear across the board.

You may have a problem in your transmission bearings, gears, or shifting mechanism.

Might take a look at the doohickey and spring; a possibility: Fragments from the idler shaft lever and/or spring fell off and became ground up in your transmission.

Sorry I can't be of more help, advise-wise.
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post #3 of 17 Old 04-06-2012, 07:08 AM Thread Starter
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Thanks for the reply.
Dont know if it is necessarily gear engagement, but 1st and 2nd is just when i can hear the noise. I honestly believe that noise is still there in gears 3-5 but im unable to hear due to wind or that at that "speed" the idle chain slack is taken out by engine revolutions or some other mechanical phenomenon. That being said, shifting is smooth and engine runs smooth. I would agree that doo fragments may have "floated" around and are causing unseen/unheard damage. Know of anyway to check tranny bearings or clutch assemply "easily"?
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post #4 of 17 Old 04-06-2012, 10:03 AM
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Quote:
Originally Posted by bcoiner View Post
Thanks for the reply.
Dont know if it is necessarily gear engagement, but 1st and 2nd is just when i can hear the noise. I honestly believe that noise is still there in gears 3-5 but im unable to hear due to wind or that at that "speed" the idle chain slack is taken out by engine revolutions or some other mechanical phenomenon. That being said, shifting is smooth and engine runs smooth. I would agree that doo fragments may have "floated" around and are causing unseen/unheard damage. Know of anyway to check tranny bearings or clutch assemply "easily"?
Welcome to the forum!

Yea the doo is the likely culprit. Filter the oil while you drain it and look for bits of spring or doo. Take off the side case and get a look also.

You should be able to borrow the tools from someone on this forum I know there's at least one set in circulation. Get the torsion spring and you won't have to go back in.

If it were me (and the doo had failed)... as long as the tranny was shifting good and I could account for most of the bits I would button it up and ride it. Maybe run a couple quick oil changes for piece of mind.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #5 of 17 Old 04-06-2012, 10:42 AM
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Do you hear the grinding when in idle?? What about if you put the bike up on a stand and have the rear wheel free and run through the gears??

Still there?

I did my Doo for $40 and $12 for a rotor bolt.. Although I wish I had the torsion spring, which wasn't available when I did mine 6 years ago.. The tools are out there for the borrowing..

It's your bike and your choice.. Do as you wish..

One other thing to check. Are there aluminum particles in the oil?

My 02' has 23K on it and it doesn't grind..
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post #6 of 17 Old 04-06-2012, 09:59 PM Thread Starter
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HEy guys thanks for the info...

No grinding at idle. The last time i changed my oil there were some small particles of what i believed to be alluminum, but i changed again after 100 miles to check again and there were no particles or shavings that i was able to see. Why do you ask about aluminum?
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post #7 of 17 Old 04-06-2012, 10:39 PM
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The typical grinding noise is the chain (that the doo tensions) grinding against the inside of the case.

As the engine speeds up, the chain takes a new route due to centrifical force and starts grinding against the inside of the engine.

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post #8 of 17 Old 04-07-2012, 12:11 AM Thread Starter
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Copy that. So once i have the outer and inner case off check engine side and casing side for abnormal wear and tear. If there is damage to either should I be concerned about replacing? Im sure that depends on level of damage, I guess a better question would be at what degree of damage should i consider replacing inner casing.. If damage is on engine side, am i totally SOL or is there some magical KLR fairy i can have fix it?
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post #9 of 17 Old 04-07-2012, 12:14 AM
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I'd be most concerned about seeing if the doo and spring are intact.. If not, replace.. Check the chain for damage.. As far as any grinding to the inside of the case, if it's minor I wouldn't worry about it..

Tough call without seeing the inside..

Good luck!! The good thing is that it's still running.. Several have been in your shoes and were able to fix and keep on riding..
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post #10 of 17 Old 04-07-2012, 12:22 AM Thread Starter
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Thanks for all the info. I really appreciate it. Ill post how things went while doing the DOO upgrade or when im sitting dead in the water needing advice.

Again thanks all
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