As some you might know, my 06' KLX250s has a Cam Chain issue with a clacking noise. I'm bound and determend to find and fix this problem. So I'm going on a repair mission to fix the issue. And I will be posting every step that I make to this Thread. Picutures and videos also will be included.

As my first step. I did what the Kawasaki mech suggested. And that was to replace the Cam Chain Tensioner. A simple job, but afterwards, the same problem. So its not the Cam Chain Tensioner.

New Cam Tensioner. FYI: It did not come with the O-ring seal. Kawi Part # 12048-1140


Location of Cam Tensioner on KLX engine. Its the center part. It has a 12mm bolt in the center and 2x 8mm bolts that hold the tensioner in.


Old and new Cam Tensioner spring lenght. The old one measured 2 1/2 inches while the new spring measured 2 9/16 inches. Just a 1/16 inch longer than the old one.


Natural, a video/sound clip of the work. Still same problem

 

i think mine clacks too. should i worry? i'm still under warr.

 

I dunno bro,

That certainly doesn't sound right. My '07 doesn't make that noise. Hopefully someone here can help you out. I'd hate to have you go to the 'stealership' to get the problem fixed.

Mike

 

I would do a search for adjusting the chain. Even though the adjuster is good, They seem to need a little bit of help via a manual tightening of the chain.

 

I have done manually adjusting the tensioner, but this is beyond just simple appiled pressure. Something is internally not working correct. That is why I'm going through this process as a write-up.

Also coming up in about 1-2 weeks. I have on order a new Cam Chain and the proper tools for the job. I already have on hand, new Cam Chain guides.
Cam Chain guides part #: 3 parts total
12053-1317, $5.15 (Top part)
12053-1391, $43.37 (Left part)
12053-1315, $27.93 (Right part)


On a later fix, Cam Valve seals. Part # 92049-1349, about $7 each seal


One of the tools needed for the Cam Chain removal is a flywheel holder. I got this tool for $205, Kawi dealer gave me a slight discount of almost $50. Part # 57001-1313. Other tools order is the Valve Spring compressor and adapter. Compressor # 57001-24, adapter 57001-1202.

On a side not, so any folks start asking about taking into the shop for warranty. My KLX never came with it, used bike. Also, I'm the 3rd owner since I bought it at 1,800miles. If your KLX has a problem and it still has a warranty, great, use the warranty. As for me, I'm a mechanic. So I love to do my own repairs.

 

What are the valve seals for? Is it starting to smoke?

 

Yeah i was gonna ask that too.

 

i'v had mine in the shop three times 09 klx. i thought it was valves they finally puled the valve cover off because of an oil leak coming from the gasket, they checked the valves they were in good shape. the told me the noise is normal that it is the cam chain tightener that it will make that noise at about 5500 rpms. i was told that is nothing to worry about. i still worry, driving the cr^p out of it we'll see what happens?

 

This is actually another problem that my KLX engine has had. If I don't start the engine up about once in a week, it would smoke a little during startup. Since it only does it when sitting for a week and only at startup, I suspect there maybe one or two worn seals. After 15 seconds of startup, the smoke clears and the engine runs good.

Since I will be tearing into the engine so much. It would also be a good time to replace the valve seals as well. More on this, is to come.

 

Well If your KLX needs those parts at such low mileage then It was either hammered beyond insanity or these KLX's are not the Tanks I thought they were. I really expect a chain & guides to last 10's of thousands of miles even if ridden hard. Same with valve seals. I do agree it is probably time to pull it apart & see what's going on. I'm gonna guess the noise is higher up in the engine, maybe cam or valves.