Has anyone had this rattling problem..?

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I have a rattling noise that audibly seems to be emininating from within the clutch area. As the clutch lever is pulled in, the rattling noise significantly decreases, but it clearly does not go away. In general, the rattle does lessen as the motor warms up, but it is still very audibly present even when the engine is fully warmed to operating temperature.

Has anyone had this clutch rattling symptom, if so, what's the fix? Thanks for the help in solving this thing.
 
Could be a couple of things. Do a search, there are a couple of things people find in there that give way. There are these "finger" things in there that break and then there is the tensioner for the starter chain that has been known to break. Don't think any of it is real common but possibilities. Just something to check out. I'm looking into mine tomorrow as I thought I heard something rattling in mine last trip to the drag strip. Hope that helps. Later.
 
Jarney said:
Could be a couple of things. Do a search, there are a couple of things people find in there that give way. There are these "finger" things in there that break and then there is the tensioner for the starter chain that has been known to break. Don't think any of it is real common but possibilities. Just something to check out. I'm looking into mine tomorrow as I thought I heard something rattling in mine last trip to the drag strip. Hope that helps. Later.
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Jarney,

You know....you may very well have something there regarding the starter chain tensionor possibly being the rattle's source.

Try this conjecture. As I've never removed the clutch cover, I'd presume the chain routes around the clutch basket assembly during it's path of travel. That being the case, is it reasonable to believe that any noise transmitted directly to the chain would also be carried along it's entire length of travel, which would then include being transmitted to the clutch basket. Compression and de-compression of the clutch assembly, via the clutch lever, changes it's density and therefore could change the pitch of the rattle.

Does any of that make sense to you? Just a wild a$$ guess here...??
 
The tensioner is broke and grinding against the basket? We have seen the video on here before wher the clutch is scored all the way around from the tensioner, seen one in person last week on gremlins
 
zlMark said:
The tensioner is broke and grinding against the basket? We have seen the video on here before wher the clutch is scored all the way around from the tensioner, seen one in person last week on gremlins
Click to expand...

ALRIGHT.....now were getting somewhere. The best I could do was to reason it out and guess at the problem. If memory serves me correctly, the best tensioner choice is to upgrade to the one that fits the Connie....is that correct?

Thanks to both of you guys...Jarney and Mark, you guys were a huge help; that rattle has been driving me absolutely nutsooo....!!
 
The chain does not run around the basket but if like Mark says, it's broke and hitting the basket, that might have the same effect. The concourse upgrade is for the Cam chain tensioner, not the starter chain tensioner. Cam chain tensioner is on the opposite side of the bike. There have been some guys that have modded their own starter chain tensioner, but I don't know of an actual, better upgrade. Below are some links:

One of the tensioner mods, I think there is another posted, but didn't jump out at me while searching:
http://www.zl-oa.com/forums/showthread.php?t=9871&highlight=starter+chain+tensioner

This link has videos on page 6 that let you see what's in the clutch area:
http://www.zl-oa.com/forums/showthread.php?t=8649

Hope that helps. Later.
 
Since mine will be apart in a bit, and after reading on this a bit, I think I may look into doing the adding a spring and washer trick/mod. That seems to be the easiest for now until there's time to do or someone comes up with a good mod or replacement that definitely works. Later.
 
Jarney said:
The chain does not run around the basket but if like Mark says, it's broke and hitting the basket, that might have the same effect. The concourse upgrade is for the Cam chain tensioner, not the starter chain tensioner. Cam chain tensioner is on the opposite side of the bike. There have been some guys that have modded their own starter chain tensioner, but I don't know of an actual, better upgrade. Below are some links:

One of the tensioner mods, I think there is another posted, but didn't jump out at me while searching:
http://www.zl-oa.com/forums/showthread.php?t=9871&highlight=starter+chain+tensioner

This link has videos on page 6 that let you see what's in the clutch area:
http://www.zl-oa.com/forums/showthread.php?t=8649

Hope that helps. Later.
Click to expand...

Jarney said:
Here's another link to another forum where they have the same problem:
http://zrxoa.org/forums/showthread.php?t=192915
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Jarney,

A boat load of THANKS for taking the time to come up with the tech links for the source and fix to this rattling problem. All muchooo appreciated. - PM following.
 
No problem, let us know if you find anything. I opened mine up, and there was nothing broke - thank goodness - so evidently I was just hearing things - old age is creeping up on me fast - hahaha. Later.
 
zlMark said:
Tony, what did you find??
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Mark,

I haven't tackled it yet, as I'm in the process of gathering up all parts needed for a range of repairs, etc., that I need/want to do. The plan being to nail down everything at one time. I'm in the construction business (general contractor) and I have to make effective use of whatever available time can be carved out of life right now. I'm beginning to feel like I need 27 pairs of hands in order to get all done that needs doing everywhere.....Ha ha. GEEEZZ, what a rat race..!!

Be assured when completed, I'll report back on the blood and the gore of the task, etc.,....Ha ha.
 
May I jump in on this Clutch noise thread? Sure I can....
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Last Wednesday I rode 86 ZL900 home late. A nice ride. When I got into my neighborhood I started hearing a rattle noise.
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This Friday I started diagnosis. I took my wife’s stethoscope and starting to listen around the engine. The noise could best heard when I placed the stethoscope on top of the clutch area.
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I tore off the cover looking obvious problems. The chain tensioner looked good. The chain is good.
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I twisted the clutch assembly and the clutch plates rattle. Is this normal?
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I removed each of the clutch plates looking for a broke plate. Visual inspection appears to look good.
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When I twist the sprocket that the clutch plates ride I hear a noise with a knocking sound when I twist it hard. Is this normal?
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Is there a bearing that has gone bad in the back of the clutch?
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I am lost at this point and need a some direction. What do I do next?<o:p></o:p>
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rattling - Streched Chain?

I found these marks on the clutch plate. I think my problem is a streched chain.
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Does any one agree?
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Could these mistry marks appear when with chain is flying and pushing the tensioner out where it touches the clutch plate?
 

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I own 3 ZL600 and they all have a rattle. I agree you should check if nothing is broken. On the other hand, the standard rattle that's less when clutch is pulled in, I believe it's a characteristic of these bikes. All the GPZseries (same engine) have it too. You can improve on the rattle by renewing some parts in the clutch area but about 1Ok miles later, it will be back. Oil (NO, NOT another oil discussion) has an influence too. So does carb sync.
So, apart from the few that actually have a problem, this rattle is what makes these bikes what they are: 20 to 25 years old with a specific sound and a bit of a rattle included.
I'm making this statement because we should be aware of making people, especially new owners, nervous and spoked about a problem that in most cases isn't one.
 
Peter - you are right to point out that there are some noises that are normal to the bike and its "family" (GPZ. ZZR, ZRX, GTR etc) and that new owners can be spooked by tales of doom and gloom related to possible problems.
However, I would not feel very happy with myself if I had come across a potentially catastrophic failure that can happen and did not warn other people about it.
I have seen pictures on ZZR / ZRX forums showing a completely destroyed clutch - all the debris lying in the sump pan. This may have been preventable? On the ZRX the clutch casing is different to ours and has the oil filler cap on it. A quick visual check for marks on the pressure plate can be made by pulling the filler.
The tensioner push rod is not strong enough and some have sheared off ( I believe someone on here has had this happen?).

If you are familiar with a bike or its siblings, then you have a good chance of recognizing what noises are Ok and which need investigating!
For new owners this is obviously more difficult.
 
Yes, of course, Vinny. Better be safe than sorry. That's why I said that it should be checked. But I see this question being asked over and over again and especially new owners can be alarmed by that.
But again, if in doubt, always check. I have to admit, the 3 bikes I own all have been opened: 2 were fine and 1 had an actual problem with the star washer but she had a slippery clutch too, so it wasn't just a rattle.
 
Re: rattling - Streched Chain?

SandstoneSmitty said:
I found these marks on the clutch plate. I think my problem is a streched chain.
.
Does any one agree?
.
Could these mistry marks appear when with chain is flying and pushing the tensioner out where it touches the clutch plate?
Click to expand...
That is coming from the tensioner itself. look at the metal part of the tensioner and you will see the correspnding marks. If the rod is broken or slightly disfigured then it won't lock like it supposed to, it is a one-way tensioner. Rough idle is what causes it to slap the clutch.
 
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