Hi everyone, its my first post. I am new here so please go easy on me. I am stumped with this problem and need help to diagnose. I have searched and searched and can’t find a fix here or anywhere’s else. I have a Gen 2 ZX10R, a 2006 with 36000 KM. I am mechanically inclined or I guess I think I am :hello:
I can't get rid of idle gear / starter gear noise and I can’t figure out whats causing the noise. Original persisting problem since 2012 and the video by previous owner is here ----->https://www.youtube.com/watch?v=tA_KmD4Wly8
I replaced everything involved. Parts in picture below were from another motor with 11K on it and that didn’t fix the rattle.
Next step, I swapped the original parts back in. Shortened the sprag spring (see pic below) thinking it might be the loose thingies in the sprag but that didn't fix it.
Next step, Took the clutch sprag out of the starter clutch hub, reinstalled the hub on the bike. Reinstalled everything else back. Only the sprag was out. Push started, same noise and this eliminated the clutch sprag and the surfaces / gaps involved with the sprag as being the cause.
Video with just sprag out noise is still there -----> https://youtu.be/qq0lxYbanEA
Tested without the starter side idle gear (see pictures below). Noise remains and this eliminates the starter and that idle gear and its pin as being the culprits.
Also when tested without starter side idle gear the noise stays but when tested without both idle gears (the starter side and the starter clutch side), the noise goes away. Video of starter side idle gear removed ----> https://youtu.be/pO5RzmKIVTQ
Tested as above picture and also with that gear removed and with nothing but the starter clutch hub on the crank shaft, no sprag, no needle bearing, no starter clutch gear, no idle gears. Push started and she is perfect with no noise. This eliminates the timing chain or crank or other possibilities in the motor as being the culprits, video here -----> https://youtu.be/kPaFl43NA7g
Where do I go from here to fix this damn noise. What do I replace to fix this? I am now thinking it could be the needle bearing between starter clutch and starter clutch gear but just replacing the needle bearing don’t necessarily take care of the two surfaces involved and I replaced every thing involved already and that didn’t fix it and don’t know what to do next to fix this. Could it be the case cover that is warped in some way?
Starter clutch itself is the same for Gen 3. One option is to replace it including the needle bearing with a Gen3 starter clutch.
Starts perfect and works perfect minus that shitty noise. Any help and advice is much appreciated. Thank you in advance.
I can't get rid of idle gear / starter gear noise and I can’t figure out whats causing the noise. Original persisting problem since 2012 and the video by previous owner is here ----->https://www.youtube.com/watch?v=tA_KmD4Wly8
I replaced everything involved. Parts in picture below were from another motor with 11K on it and that didn’t fix the rattle.
Next step, I swapped the original parts back in. Shortened the sprag spring (see pic below) thinking it might be the loose thingies in the sprag but that didn't fix it.
Next step, Took the clutch sprag out of the starter clutch hub, reinstalled the hub on the bike. Reinstalled everything else back. Only the sprag was out. Push started, same noise and this eliminated the clutch sprag and the surfaces / gaps involved with the sprag as being the cause.
Video with just sprag out noise is still there -----> https://youtu.be/qq0lxYbanEA
Tested without the starter side idle gear (see pictures below). Noise remains and this eliminates the starter and that idle gear and its pin as being the culprits.
Also when tested without starter side idle gear the noise stays but when tested without both idle gears (the starter side and the starter clutch side), the noise goes away. Video of starter side idle gear removed ----> https://youtu.be/pO5RzmKIVTQ
Tested as above picture and also with that gear removed and with nothing but the starter clutch hub on the crank shaft, no sprag, no needle bearing, no starter clutch gear, no idle gears. Push started and she is perfect with no noise. This eliminates the timing chain or crank or other possibilities in the motor as being the culprits, video here -----> https://youtu.be/kPaFl43NA7g
Where do I go from here to fix this damn noise. What do I replace to fix this? I am now thinking it could be the needle bearing between starter clutch and starter clutch gear but just replacing the needle bearing don’t necessarily take care of the two surfaces involved and I replaced every thing involved already and that didn’t fix it and don’t know what to do next to fix this. Could it be the case cover that is warped in some way?
Starter clutch itself is the same for Gen 3. One option is to replace it including the needle bearing with a Gen3 starter clutch.
Starts perfect and works perfect minus that shitty noise. Any help and advice is much appreciated. Thank you in advance.