ZXR400 L2 Clutch Rattle maybe?

[MillaMeter]

Right, this rattle has been going on since I've owned the bike which has been since November 2007.

Basically I start the bike up, and there's this very horrible grinding sort of rattle coming from the engine on idle. As soon as the revs goes past 1500rpm the rattle stops. Now I know what you're all thinking, it could be the cam chain right? Yeah I thought so too untill I pulled in the clutch and the rattle disappears. Soon as I let the clutch out the rattle reappears.

It hasn't effected the bike in any way (As far as I know) in performance wise. Although when changing gear with the clutch it can sometimes be a bit loud and jerky?
tbh the bike changes gear better without the clutch.

What should I check first and whats the damage gonna be in my bank account?

Thanks in advice.
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Currently Own:
2010 Kawasaki ZX6R RAF Performance Edition / 2008 Kawasaki Ninja 250 K8F

[Ichy]

ummmm. Now clutch rattle is very common, I think Kawasaki build it into all their bikes . Mine sounds like its going to self destruct if I don't start it for a few days. Sounds fine at around 2k+ rpm. Usually its worth checking the carb balance first to see if this quietens it down. Try cleaning and lubing the clutch cable to see if the gear change is any better.

Occasionally the start clutch bolts can work a bit loose and rattle about. Goes quiet at above about 3k rpm.

Don't know if your engine is the same but some Kawasaki engines don't have a tensioner on the primary chain. This can flap about a bit at low revs. Not much you can do about that though.

Grinding noise? You sure? That's a bit more worrying.

[satans_BIG_helper]

General problem with kawasaki's everyone i have owned/ridden has done it, if it is a bit worrying for you i would get the cam chain checked and possibly changed, and maybe strip down the clutch buy a set of new plates and springs and fit them also a new cable at the same time, but the rattle was there on my 750 H2 and never affected its performance or caused any problems for me

[MillaMeter]

[MillaMeter]

Ok, the carbs are now balanced and the rattle still remains there. Now i would strip the clutch down but not knowing what the problem might be, it means buying new oil with money i don't really have. And not to mention not knowing how long it'll take to fix, i need the bike 4 work.

any ideas anyone? As the bike doesn't sound very pretty sitting at the lights
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Currently Own:
2010 Kawasaki ZX6R RAF Performance Edition / 2008 Kawasaki Ninja 250 K8F

[Ichy]

You could always drain the oil and put it back after?

The thing is that if you do find anything wrong are you going to have the money to repair it? Your may need to replace the clutch gasket for starters.

Remember its a common fault which in many cases is not likely to cause any problems. To attempt to resolve it your may be looking at replacing the plates, bearings,springs and the basket, I was told that normal wear in the basket causes most of the rattle, no idea how true this is, I chose to ignore it. It ain't cheap. If you take it all to bits and can't find anything obviously wrong what are you going to do?

Does it sound any better if you bump the tickover up by 100rpm?
If you think yours sounds bad at the lights then you should listen to a Ducati.

[Ichy]

Oh yeah, forgot to mention. If you take the oil filler plug out with the bike running you can pretty much confirm that its the clutch rattling.

[The Tot]

My ZXR250 was fitted with a new clutch when i purchased it and rattled like fuck when it was engaged. On the move, it disappeared. Unless you notice a profound difference in your performance, i shouldn't worry about it. It's a kwaka after all!
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The Tot 2019 Z1000SX - 2007 R1
Never argue with autism

[crphillips]

My mate tunes zxr400 engines and i've had two zxr400's.....i can tell you exactly what it is.........over time, especially on high mileage zxr400's the grooves in the clutch basket that locate the clutch plates wear.......the noise is the clutch plates rattling in the clutch basket.

Take your clutch cover off and undo the bolts retaining the clutch plates.......slide the plates out and run your finger down the groves that the plates were located in.....i bet you they're well worn...........there are two solutions.....1) new clutch basket 2) if you know someone who is handy with a welder and a file you could weld them back up......it's aluminium though. It shouldn't cause you too much trouble unless they're really bad.......it will tend to cause jerky clutch engagement and slipping when badly worn.

Same for you Titz..........they won't have replaced the clutch basket when they fitted a new clutch.....they'll have just fitted new friction plates......fit a new clutch basket and the rattle will disappear.

There is no need to drain the oil to do this either.........just rest your bike against something on the opposite side to the clutch.....you won't loose any oil that way.

It's only a 20min job if you have a tool to lock the crankshaft.
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CBR600RR8 Hannspree Colours, beautiful!

[ninja-man]

New to this guys and any help would be greatly appreciated, bought a zxr 400 l4 and problems seem to be like a flat battery although this is brand new and fully charged. she also make a humming/buzzing noise after i attempt to start her i dont want to fork out on expensive parts then them not being the problem lol, any help plz? :)

[andys675]

came across a couple of rattly ZXR400's years ago, they both had camchain tensioner guides that were cracked, the camchain wasn't loose enough to jump but it did slap around a lot inside the camchain tunnel