noise/rattle from the clutch area... [Archive]

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Grabber

05-07-2009, 06:08 PM

I have some noise comming from the clutch side of the engine, specially when the engine is cold. The noise almost dissapear with the engine hot though. Was thinking of the chain tightner that could cause it.

My question is can i remove the engine cover (clutch side) and start the engine with the cover removed without spreading oil everywhere ? I was thinking that with the bike on his stand ( leaning on the left side )that would avoid the oil from droping from the clutch side... Will be easier for me to verify exactly from where the noise is from. Would not want to buy the chain tightner without being sure that this will cure the problem.

thanks again,

zlMark

05-07-2009, 08:51 PM

Never heard o0f anyone trying to run the engine with the side cover off, so use your best judgement. The alt tensioners and chains are known to go bad. You might be able to take the cover off and see a broken rod on the tensioner

wuputt

05-07-2009, 09:49 PM

Sounds like a broken tensioner! Drain the oil and pull the cover. You can buy the parts first and return em if you don't need them. Don't forget the gasket! Let us know what you do and what you find.

Grabber

05-08-2009, 01:43 PM

went to kawasaki.com using the part finder (exploded view) to try to find that chain tensionner.... no luck. According to the following where should i look for the chain tensioner. ?

Search: Parts Manual
Model: ZL900-A1 (Eliminator) (1985)
Search For: ZL900-A1
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Jarney

05-08-2009, 07:38 PM

Look under Crankcase.

Also with that clutch cover off I found out the hard way that if you turn the motor over, it will shoot a stream of oil at you. So I don't think you can run the motor with it off unless you find a way to plug that hole - can't remember if it was a bolt hole or not or where it shot out from - somewhere in the upper right I think. Later.

jarhead

05-08-2009, 09:04 PM

Grabber

05-08-2009, 10:33 PM

paulfun

05-08-2009, 11:04 PM

Part number 39170-1053 found under crankcase

paulfun

05-08-2009, 11:09 PM

hope this works

horror1972

05-09-2009, 01:20 AM

Grabber

05-09-2009, 08:30 AM

Hi,

You can run the engine with the cover off;I did it.
I plugged the oil hole carefully with a 4 mm drill (not the drill side :no-no-no:)
Only a small amount of oil was dripping.

I saw the tensioner was doing it's job and didn't slam the clucth.
Also I measured the chain according to the manual, was within specs..

I also have this noise.
When I hold the clutch, I can move it a little, took it apart, but couldn't find any suspicious..I think it's just wear of the plates or so..
Has anyone a solution jet???

I suspect that could be carburator related.... have you ever synchronise your carbs ? I suspect that if all the carbs are not sync proprely, that will make the engine running not evenly making the chain and all the parts connected on the crank to be noisy, specially at lower RPM.
Will check that today on mine and will let you know.

jmac

05-09-2009, 11:38 PM

My 1000 does the same exact thing. Starts out loud and softens as it gets warmer. One guy told me it was wear on the clutch basket, but I've never had a problem with a clutch on any of my other bikes so I'm not that familiar with the clutch. Let us know what you find it might be a big help to me or some one else.

I have heard that too.Mine makes a little rattling noise from the clutch.If I pull the clutch in it goes away.Now you have to have your head down in that area to hear it,so its not real loud at all.If yours is loud enough to hear while sitting on the bike,you might want to have a look inside.

sharper

05-10-2009, 10:59 AM

Grabber

05-10-2009, 12:54 PM

My zl1 has the same noise. Loud when cold and pretty much goes away when warm. The noise on mine is coming from the front left side when sitting on the bike and you can definately hear it loud and clear.
I have had my carbs synch and my valves adj and the noise remains.
Sounds like this is a very common problem with the zl1, does anyone have a zl that doesn't make this noise?

i would verify the cam chain tensioner. They use to go bad. Mine as been changed with the Kawa Concour one. No more noise from left side, or maybe little when cold but quiet when hot.

golddrakul

05-14-2009, 03:12 PM

Have a similar problem on a ZL1000, noise on right side. Sounds like it's forward, but hard to tell. Pulled sidecover, tensioner looks original and intact [10k miles on bike] but marks on clutch. Think I saw the same marks in pictures on the site previously, but don't remember the thread. Previous owner had it to a mechanic that said it was starter clutch [which is why he parted with it] but starter engages and disengages fine. Doesn't slip or spin like it's not staying engaged. Anyone have a good idea of what this is??

Grabber

05-14-2009, 03:22 PM

Engine is quiet like new now. Will explain what i did, and what was my problem. sorry for the long post. Please understand that English is not my best speaking/writing language, so i will do my best.

Had all kind of reason that it was making the engine to make more noise than normal from clutch side...

The first reason is my pickup coil that was misadjusted with the rotor. This was making two cylinder to have good spark and the other 2 to have weak spark. This was making the alternator chain to be bumpy/noisy

Once this problem was resolved, the sound of the engine was greatly a lot less noisy than before, but still had some noise.

My mirror was shaking from idling, image from it was fuzzy, this was not normal

So i decided to take a look at the calibration of my carbs. During the calibration, i noticed some funny things, mercury/reading was fluctuating a lot for Cyl 2, like it was stable for 20 sec, then it would get lower and stayed there for 20 sec then would jump back to the previous level and so on... I knew this was not normal, but didnt understand why it was fluctuating like this. Initially i thought my pickup cable could have been damaged, or even my spark box.

Just by the sound of the engine, and/or the way the engine was responding when revving from neutral... it was not as usual. I was mixed up bad, i knew something went wrong but couldnt figure what. Could a spark plug be bad ? Went to the local car part store and bought 4 plugs.
Same problem.
Engine was idling fine though, just between 1200 to 2200rpm it was not responding as fast as before.

Decided to remove the carbs to see if there was some crap/deposit that would have been loose from my previous Seafoam treatment i did couples of day ago. F?%K what a pain in the a$$ to remove and to put them back. Anyway, didnt see anything wrong in the carbs at all. I did clean them with carb cleaner hoping that all would be fine once they would be back.
Nope, the engine was still responding bad. Understand that the engine was not running that bad, but i know my bike like nobody. A friend of mine was once with me while working on the bike and he says that the problem was in my head. According to him the bike was revving ok, and the mirror shaking was normal to him. Nope man you are wrong. I know my bike.

The ****n reason was that one of my spark plug cable was not proprely connected to the coil. You know when you screw the cable in the coil, there is a little rubber thing that hold against the screw making the cable to get in the coil while you screw it in... (euh.... hard for me to explain) anyway the cable was not proprely insert into the coil making the fire to be poor/miss. So the spark was fluctuating because of this.
Once this issue was repaired, all was nice and quiet.

Sorry for the long post.

zlMark

05-14-2009, 03:51 PM

So all that noise from a rough running engine,,, go figure..thanks for letting us know the fix!!

SO CAL ZL

05-16-2009, 04:22 AM

Grabber....don't worry about the English...you're doing just fine!

I'm totally amazed at the solution to that crankcase noise problem. I too have had that identical noise since I bought my bike about 8 months ago. Up to this point, I was firmly convinced the noise had to be related to a failed mechanical part and was fully prepared to change-out every mechanical tensioner that I could find, until I cured the problem. That thrashing noise has irritated me to no end.....since day one of ownership.

I'll probably change-out the tensioners anyway, because they appear to be failure prone by improper design. However, I'll try your approach first, before the change-outs. I'll let everyone know the eventual results (It's going to be awhile).

vinny

05-16-2009, 02:14 PM

Really pleased that you got to the bottom of your trobles Grabber.

Its one more thing to try before tearing parts of the motor out!
Well done!
Your English is very good - don;t worry about it.