I've got a 2006 KLX250. I bought it new. I broke it in according to the manual and changed my oil every 1000 miles and filter every 2000 miles. Even took it in for the 600 mile maintenance check. Since then the engine started to make a ticking sound. It is very noticeable between 5000 and 6000 RPMs. I brought it in to the dealer before my year warranty ended and they did not find any thing wrong. They checked the valves and everything checked out. They called the Kawi techs and they did not know what it could be and said to call back if the ticking hadn't gone away by the 7500 mi. check. It actually went away for about 700 miles between 4000 and 5000 miles then returned. It has since become very noticeable and doesn't sound good after sitting for the night. It sounds better after warming up but is still very noticeable between 5000 and 6000 RPMs. It is still there when the clutch is pulled in. Any ideas?

 

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Its the timing chain. I have exactly the same issue. One morning, it sound really bad and then click. It became all so quite running. The timing chain tensior is not a very fine adjuster and takes some time for it to adjust.

 

i wouldnt put money on it being the timing chain.... when the chain is loose it makes noise at idle, and when you let off the gas cause it gets slack in it, but when your on the gas it tightens up.... so it doesnt make any noise.

 

Yes Timeing chains make noise at Idle and when slowing down and the adjusters are made to stay in one position until the chain is loose and its moves out..... And it is very loud when its loose......I still think the compression release is making the noise on this bike I was wright about that last year when someone was having problems .....if you get a bad one it will make a ticking sound ......and valves have to be pretty loose to make a lot of noise at leats the shim ones do the tappet kind are a lot louder when loose....[]

 

Yep I got a new cam including the ACR since its part of the cam. It definitely was that, when I went to pick up the bike it was like new and is still quiet. I didn't keep a record of the mileage, but I would say I have the same or more miles on the new one and its flawless.

 

The timing chain on my KLX sounds something like a kid with a rock in a soda can, banging it around. And it was LOUD at idle. It would take a few minutes then it would soften and go away. But since the adjuster finally moved a tooth up, its been pretty good since then. And my valve clearance at the time were dead spot on.