Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech
Occasional clunk noise when letting out clutch in 1st gear? Occasional clunk noise when letting out clutch in 1st gear?
Register FAQ Calendar Today's Posts
Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by Alessio Corradini, on the Salar de Uyuni, Bolivia, of two locals

I haven't been everywhere...
but it's on my list!


Photo by Alessio Corradini,
on the Salar de Uyuni, Bolivia,
of two locals



Like Tree4Likes
  • 1 Post By Bones667
  • 1 Post By turboguzzi
  • 1 Post By turboguzzi
  • 1 Post By Doubleyoupee

Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 25 Jun 2019
ggr ggr is offline
Registered Users
New on the HUBB
  
Join Date: Mar 2019
Posts: 13
Occasional clunk noise when letting out clutch in 1st gear?
Hey all,

What seems to be the clutch/gearbox on my XT600 recently started making the occasional clunk sound when I'm in first gear with the clutch lever pulled in and start letting it out. It isn't accompanied by any judderiness but the noise is a bit disconcerting.

Any ideas on what could be the cause of this? The bike had some stuff done to it a day before I started noticing it happening:

- changed the exhaust
- changed the clutch and brake levers
- had the rear wheel and tyre changed (double checked the chain slack and it looks to be within the specs in the manual)
- drilled out a stripped allen bolt holding the tacho cable in the tacho drive while it was still attached to the engine

Likeliest culprit seems to be either the rear wheel change or the bad vibrations from drilling out the allen bolt borking something up.

Here's a short video to illustrate:

https://sendvid.com/e64v507i


Thanks!
Reply With Quote
  #2  
Old 26 Jun 2019
ggr ggr is offline
Registered Users
New on the HUBB
  
Join Date: Mar 2019
Posts: 13
I had a mechanic change the wheel and tyre and I'm hoping they would've checked for that sort of thing before fitting it.

Here's a video of me checking the play in the cush drive. Is this kind of play normal?

https://sendvid.com/4kvve0l3
Reply With Quote
  #3  
Old 27 Jun 2019
Registered Users
Veteran HUBBer
  
Join Date: Jun 2014
Location: Bristol UK
Posts: 104
Sounds like cush drive rubbers may need packing with some rubber (can use some old inner tube rubber)

Also check that the chain doesn't have a tight spot when you rotate the wheel. The mechanic may have adjusted the chain in a slack area rather than the tight spot so could be too tight?
Reply With Quote
  #4  
Old 28 Jun 2019
ggr ggr is offline
Registered Users
New on the HUBB
  
Join Date: Mar 2019
Posts: 13
Thanks for all the help!

It looks like it was the cush drive rubbers after all. I took it back to the mechanic that fitted the wheel and they confirmed that the cush drive rubbers are worn. Apparently the rear sprocket should only have 1-2 millimetres of play instead of the 7mm or so of play in the video. Would've assumed mechanics usually check for that sort of thing when fitting a new wheel. Also, I came across this example of a worn cush drive on a DL1000 and my bike has the same level of play:

https://www.youtube.com/watch?v=D03gRtDqZYs

I ordered some new cush drive rubbers so hopefully the problem with be resolved when they're fitted.

Is there a certain trick to adjusting the tightness of the chain on an XT? It has these notched adjustment plates on either side which aren't precise at all: one notch to the left and there's 25mm of slack at the tightest point, one notch to the right and there's 45mm, so it seems impossible to set it between 30-40mm as Yamaha recommends. 25mm was way too tight (bike struggled to shift into second), 45mm felt okay, and the first gear clunk happened regardless. Didn't have the clunk with the old wheel so the chain itself seems healthy.
Reply With Quote
  #5  
Old 8 Jul 2019
ggr ggr is offline
Registered Users
New on the HUBB
  
Join Date: Mar 2019
Posts: 13
Welp, I had the new cush drive rubbers put in and there's far less play in the rear sprocket, but the problem remains.

Any more ideas?
Reply With Quote
  #6  
Old 8 Jul 2019
Registered Users
Veteran HUBBer
  
Join Date: Feb 2012
Location: Milan, Italy
Posts: 607
With a dead motor, can you roll the bike fwd freely when pulling the clutch (in gear)?


if not clutch is not separating as it should, could be wrapped plates, grooves in the clutch hub or basket fingers, clutch hub nut not tight, etc.



do the test first....
Reply With Quote
  #7  
Old 9 Jul 2019
ggr ggr is offline
Registered Users
New on the HUBB
  
Join Date: Mar 2019
Posts: 13
Quote:
Originally Posted by Cholo View Post
the next obvious one is the chain, check it for wear (you can try and pull it away from the rear sprocker in the rearmost point, if there is alot of slack that might be it.
Adjust the clutch, sounds as if there is too much slack in the cable, 1cm freeplay at the end of the lever is enough. this is easy to do at a red traffic light, small adjustments till it feels right.
ALL BIKES THAT IVE MET CLUNK going into 1st gear WHEN THEY ARE COLD )
I've got it at 2mm at the gap which translates to about 1cm at the end of the lever. The chain is tight on the rear sprocket and doesn't pull away.

I know it's normal to clunk while going into first gear, but the clunking while slipping the clutch in first gear is what I find strange.

Quote:
Originally Posted by turboguzzi View Post
With a dead motor, can you roll the bike fwd freely when pulling the clutch (in gear)?


if not clutch is not separating as it should, could be wrapped plates, grooves in the clutch hub or basket fingers, clutch hub nut not tight, etc.



do the test first....
Yep, the bike rolls forward freely in gear with the engine off and clutch pulled in.

What I did notice is that if I move the bike back and forth, there's a quieter clunk which seems to be coming from the gearbox or clutch. Is this sort of thing normal?

Video to illustrate:

https://sendvid.com/87uug5xi
Reply With Quote
  #8  
Old 9 Jul 2019
Registered Users
Veteran HUBBer
  
Join Date: Feb 2012
Location: Milan, Italy
Posts: 607
now that i managed to see your first video, is the plastic chain slider over and under the swingarm pivot intact? to me it sounds now like the chain hitting the swingarm metal.


part 14 here


https://www.cmsnl.com/yamaha-xt600e-...l#.XSTryFZS9zk



youd be hearing that too when pushing back and forth.
Reply With Quote
  #9  
Old 10 Jul 2019
Registered Users
Veteran HUBBer
  
Join Date: Jun 2017
Posts: 145
I'd get the bike up on a stand so the rear wheel is off the ground. Might be easier to see where the sound is coming from. You might also get the chain from the front sprocket and turn the front sprocket manually to see if you can get the sound. That way you can narrow it down / whether it's rear wheel/chain related or clutch/outputshaft/gearbox related
Reply With Quote
  #10  
Old 12 Jul 2019
ggr ggr is offline
Registered Users
New on the HUBB
  
Join Date: Mar 2019
Posts: 13
Quote:
Originally Posted by turboguzzi View Post
now that i managed to see your first video, is the plastic chain slider over and under the swingarm pivot intact? to me it sounds now like the chain hitting the swingarm metal.


part 14 here


https://www.cmsnl.com/yamaha-xt600e-...l#.XSTryFZS9zk



youd be hearing that too when pushing back and forth.
Checked it out and the chain slider is intact.



Quote:
Originally Posted by Doubleyoupee View Post
I'd get the bike up on a stand so the rear wheel is off the ground. Might be easier to see where the sound is coming from. You might also get the chain from the front sprocket and turn the front sprocket manually to see if you can get the sound. That way you can narrow it down / whether it's rear wheel/chain related or clutch/outputshaft/gearbox related
Good idea, now I just need to get some sort of stand!
Reply With Quote
Reply

« Previous Thread | Next Thread »

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
89' Yamaha XT600 Oil pump drive gear play normal? (Noise) tinkerer Yamaha Tech 4 4 Feb 2017 00:21
Wanted XT 600 crankshaft, cam chain, 1st gear cog simonetti Yamaha Tech 1 13 Jun 2016 13:56
Help - Kle noise in 6th gear sadn3ss Kawasaki Tech 1 1 Dec 2014 10:01
KTM 690 Enduro 2009 - 2013 Auto Clutch (Rekluse Type Clutch) Harty TRAVEL Equipment for Sale / Wanted 0 13 Nov 2014 21:05
F800 GS clutch noise carussell BMW Tech 2 17 Feb 2014 23:16

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now, and add your information if we didn't find you.

Next HU Eventscalendar

ALL Dates subject to change.

2025 Confirmed Events:

  • Virginia: April 24-27 2025
  • Queensland is back! May 2-4 2025
  • Germany Summer: May 29-June 1 2025
  • CanWest: July 10-13 2025
  • Switzerland: Date TBC
  • Ecuador: Date TBC
  • Romania: Date TBC
  • Austria: Sept. 11-15
  • California: September 18-21
  • France: September 19-21 2025
  • Germany Autumn: Oct 30-Nov 2 2025

Add yourself to the Updates List for each event!

Questions about an event? Ask here

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

Adventurous Bikers – We've got all your Hygiene & Protection needs SORTED! Powdered Hair & Body Wash, Moisturising Cream Insect Repellent, and Moisturising Cream Sunscreen SPF50. ESSENTIAL | CONVENIENT | FUNCTIONAL.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

Your ad could be here, on EVERY page of the HUBB, or the whole website, or as many as you like!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.



All times are GMT +1. The time now is 08:02.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top