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Discussion Starter #1
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.
 

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Discussion Starter #3
Is it possible that you stater is not disengaging
Hey thanks for that suggestion. I have already ruled out the starter. Look at the pictures where I have removed the starter side idle gear. this results in disconnecting the starter from the rest of it. I push started the bike after removing the starter side idle gear and same noise. I took the first cover off on the running bike and I can see the starter not moving at all with and without the gear connected and the noise is still there.
 

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Discussion Starter #4
Could this be the cause of the noise --> https://youtu.be/0hvviZwAios

That is the starter clutch side idle gear in the case cover off my bike complete with the bolt and pin to replicate the gap when installed on the bike. This gear only turns when the starter is engaged. It is idle when the motor is running. I tried a 1 mm washer but its too think. I am going to get a thinner .5mm washer and try that to see if I can eliminate that play but still leave enough gap for the gear to turn normal.
 

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It could be the play in the bearings allowing the gear to rub up against the casing.

As little as it sounds is everything tourqed up?

Isn't there a gasket or some sort of seal around that area ?
 

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Thats probably a bent crank, noise being the slightly opening and closing of teeth gaps on the idle gear. Need to check run out.
 
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