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I have an 04 with about 16000 miles on it, and I'm having some problems that I would greatly appreciate advice on. This morning I took her out for the first time in a month (yes I know... shame on me). She's been out in the Oregon rain, and she took about 15 sec of turning her over before she got going. And when running in neutral she was a bit sporadic and I'm wondering if water didn't condense in the gas line/tank or something.

I let her idle for a couple of minutes till it seems all is well and then with the clutch pulled in and I shift from neutral to first and she dies. I did this quite a few times making sure the kickstand was up, etc. I managed to keep the rpm's up while shifting to first and successfully got her moving and down the street, I shift to second and at some point, I believe when I had the rpm's up ready to go to third, I hear a loud sound like something is wrong with the chain (sound of grating metal that definitely is not normal) and I downshift, move to the side of the road and she's still running but not feeling well. I put her in neutral and look the bike over and can't see anything from the outside. But I do notice a lot of mechanical noise coming from the doohickey area which I am pretty damn sure I've never heard before. So I get ready to go back home but she again dies upon shifting into first (again she dies immediately upon shifting, I don't even get a chance to let out the clutch). This time I have no success getting her moving so I walk the bike home three blocks with my tail between my legs. (A guy in a wheelchair on the sidewalk even said "Takin her for a walk?"... it was quite depressing)

I am suspecting it is the doohickey. BUT, in February I replaced the doohickey with the upgrade part (just for peace of mind) and successfully rode all summer in New Mexico. About a month ago I unscrewed the adjustment bolt and screwed it back in exactly as recommended in the Clymers.

I don't have a whole lot of experience with mechanics so I thought I would see if anyone had any advice before I opened her up. It would be much appreciated.
 

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the noise

pop the covers off..place a pan under to catch any parts...KLRs are nice to work on..if its the doo send a photo like to see...
 
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