This has been a on going problem and has finally wore on my nerves. I just spent the last 3.5hrs tearing into the top-end of the engine to find anything wrong. Couldn't find anything. Adjuster is fine, timing is correct, and cam head bolt are proper torque. I believe the exhuast valve release is screwed up. It wobbles way too much for my liking. Tomorrow morning, I'm going to drive the KLX to the Kawi shop and see if they come up with anything.

Video sound clip.
http://s237.photobucket.com/albums/f...11-08_2157.flv

 

wow.... yea id take it in.... might be the ACR.... this is my bike, and this ended up being the timing chain itself.
http://s136.photobucket.com/albums/q...t=MVI_3884.flv

 

wow, first time I listened to that video Eric... That was pretty rough. Good thing it's fixed now!

 

Took the KLX to the Kawi Shop and talked with a tech. After a minutes, he came to the same conclusion as I did. He suggested to force the cam tensioner one click out to see if that helps. Did what he suggested and the clacking was almost gone for the most part. It does not clack at idle any more, just around 5K rpms. But at least it doesn't sound somethings gonna give. So I willmake a second trip back the Kawi Shop and order a few parts before I head off to work.

Did you know a Kawi Tech makes a flat rate of $80/hr. Good thing I'm my own mechanic.

 

kawi mechanics dont make that much, thats how much they charge..... see if your timing chain adjuster is out all the way, mine was... thats why it couldnt take up any more slack.

 

sounds good now.
http://s136.photobucket.com/albums/q...ersucks011.flv

 

Sometimes if you wait just a little longer, that adjuster will do its job, but it is nerve racking to say the least. However I did get a new camshaft with the ACR at around the 3000 mile mark. They said it could have made that noise forever, but my shop takes care of me and made Kawi put in a new one. I now have 10 miles shy of 7000 and the bike is as quiet as the day I brought her home, well minus the Muzzy noise. Speaking of the Muzzy, when the bike is idling in the driveway, from inside the house it sounds like a helicopter hanging over the house.[8D]

 

Nope, the adjuster was probably only a 1/4 out. I went ahead and ordered a new tensioner spring. Will be in Thursday. When I do get, I'll compare the old & new to see if the old is sagging. And if worse comes to worse, I'll replace the whole tensioner. Which will cost $69.

You're right, thats shop charge. Imagine, $80 bucks to fix a $4 part. I just saved myself $80. PRICELESS.

 

I got the spring a day early only to find, its the wrong one. The parts guy confirmed its the right one. After talking with the tech (same one I talked to a few day back), the springs belongs to the bottom tensioner. Which is just a bolt to hold the spring in. I went ahead replaced the spring, old & new were same length, and reset the cam adjuster. The clacking is back. Since I'm broke after paying for the KLX insurance for the next year, I decided to just manual adjust the cam adjuster. Forced it 2x clicks in and all is quite once again. I got right now 4,100 miles, I'm going to see how long it will hold until it needs adjusting again.

On a side note, this could be a common problem for the select few. Since already 2x members have already had this kind ofproblem before, me (LearjetMinako) and EMS. Hopefully, no more will have it.