[fz6rider04]

Hey all, long time since I have been on here but I have a question. I have an 04 with 36,000 miles. No prior problems except the TPS. New noise sounds like someone knocking on a plastic or steel door. Noise is inconsistent and not associated with RPM's I don't think. It does it every time but not at routine intervals like with a valve tap. It does not happen when just sitting still reving the motor in neutral. Only when taking off under load or moving under load. Does not happen when coasting. Coming from lower to lower left of motor. Oringinally thought it could be the chain but the more I listen I don't think so. I am sure it does it at higher speeds as well but difficult to hear over wind and engine noise. Anyone else with similar or higher mileage ever have this type of noise or anyone have any ideas as to what might be causing it? I thought posibilities could be something in the gears, or chain, or possibly clutch. I am going to try taking off the chain and put it on the center stand and try it to see if it does it with just the front sproket turning. Any other suggestions before I start tearing it apart to check it out? Also hope this isn't a repeat topic. I did some searching and couldn't find anything, but like I said it has been a while since I was last on here so I am sorry if this was brought up before. Thanks.
Mic

 

[Hewhois]

I'd double check all the screws and fasteners first. My FZ6 (39k miles) vibrates screws loose like a world champion.

Also, I know you said you don't think it's the chain, but...are you sure it is at the right tension, and did you check all along the chain for tight spots and/or kinking?

 

[silverbullet]

I too have heard this noise.

I usually hear it when miles from nowhere.

I know MotoGP riders hear it also - mostly when on the last lap of their maiden win.

A mate of mine would hear it after lending his bike to anybody else - even if they only sat on it.

Seriously though. Have you checked the fuel tank. Its the only part that really has a steel door as you described. There might be someone or something trapped in there trying to get out. Hey, don't laugh until you check. Gerbals are quite the petrol vapour fiend.

Seriously though... nah I got nothing.

 

[04Fizzer]

How's your chain look? Are some links getting bound up?

 

[jeepcoma]

Check your rear wheel bearing that carries the sprocket load.

 

[fz6rider04]

Thanks all for the suggestions. I am going to check the chain again. I was thinking it was not the chain due to it not doing it when coasting but only under load, then when you all describe the binding, that might only happen under load. So more investigation. Also I am pretty certain now that it does speed up with the RPM or or wheel RPM as I was listening very closely today. It is most prominant at low speeds in low gears under load. But I think what happens as I go through the gears, the load is lessened and the severity of the "clunk" is also lessened in the higher gears. Due to that and wind noise it is harder to hear but it is still definetly there. I am leaning toward the chain causing a problem or possibly the bearing at the front sproket. I can tell you that it is to the point where I can feel it through the footpegs now. Not sure if it is imagined because I am sad my bike is sick or if I really am feeling it. Anyway thanks again. I will keep updates if I find anything.

 

[RJN2112]

Usually when a chain reaches the end of it's usefull life, you'll start to feel shuddering and pulsing as you are riding. That's because the chain doesn't wear out evenly.... some links loosen up a lot more than others, and as each one 'gives' it yanks on the next one in line and causes it to start to loosen up as well. Sort of a domino effect.

The end result is that you can feel the different sections of chain pulling on the rear sprocket. The (still) 'tight' parts go thorugh, and then there's slack to be drawn up before the loose part pulls on the wheel.

 

[segue00]

You might get lucky that all you need is a chain tension adjustment.

 

[Phenix_Rider]

Cam chain tensioner?

 

[fz6rider04]

Ok, I found the noise problem. Silverbullet was right, there was a gerbel in the gas tank. Actually it was just the chain. When I rechecked the chain there were some links pretty loose and so I figured it was just binding as it came around and probably hitting on the front sproket cover. Now for the chain change from hell. I got a new chain and a tool that was suppose to be for breaking the old chain, pressing the new chain and it would be a quick easy job. Well, as you all know it never goes as planned.
First off I was told not to use the tool to break the old chain because it would break the tool. Just grind off the pins flush with the sideplate and use a screwdriver. Ok that was easy enough. Done. Now to put on the new chain. They sold me the wrong one and it had 2 extra links. Had to remove those first. Used same technigue as above. Then I get the new chain on the bike, get the pins in and go to press the side plate and don't ya know the tool they sold me was for a 520 or 525 chain but not a 530. So the pins holes don't line up. Worthless. So I improvised and took vice grips and pressed the side plate up to the point of being even with the pins. Then I had to take two very small box end wrenches and center them over the pins and use the vice grips alternating each side until the plate was on. So far so good, just a little aggrevation. Now to finish the job. The pins of course are the rivet type where you have to mushroom the end to hold the side plate on. Does my handy new tool provide this feature at least. Hell no! So I am back to improvising. I tried using a dolley from my auto kit and a punch but that didn't work real well. Too hard to hold it all and get enough force. I tired a c-clamp and a ball bearing against the end of the pin, and that didn't work very well. C-clamp keeps slipping. So I am wondering now, does anyone have a good way to rivet the pins without having to wait to get a riveting tool? Shop closed today. I am glad that all I needed was a new chain but damn it has been frustrating trying to change the thing.

 

[RJN2112]

Ok, I found the noise problem. Silverbullet was right, there was a gerbel in the gas tank. Actually it was just the chain. When I rechecked the chain there were some links pretty loose and so I figured it was just binding as it came around and probably hitting on the front sproket cover. Now for the chain change from hell. I got a new chain and a tool that was suppose to be for breaking the old chain, pressing the new chain and it would be a quick easy job. Well, as you all know it never goes as planned.
First off I was told not to use the tool to break the old chain because it would break the tool. Just grind off the pins flush with the sideplate and use a screwdriver. Ok that was easy enough. Done. Now to put on the new chain. They sold me the wrong one and it had 2 extra links. Had to remove those first. Used same technigue as above. Then I get the new chain on the bike, get the pins in and go to press the side plate and don't ya know the tool they sold me was for a 520 or 525 chain but not a 530. So the pins holes don't line up. Worthless. So I improvised and took vice grips and pressed the side plate up to the point of being even with the pins. Then I had to take two very small box end wrenches and center them over the pins and use the vice grips alternating each side until the plate was on. So far so good, just a little aggrevation. Now to finish the job. The pins of course are the rivet type where you have to mushroom the end to hold the side plate on. Does my handy new tool provide this feature at least. Hell no! So I am back to improvising. I tried using a dolley from my auto kit and a punch but that didn't work real well. Too hard to hold it all and get enough force. I tired a c-clamp and a ball bearing against the end of the pin, and that didn't work very well. C-clamp keeps slipping. So I am wondering now, does anyone have a good way to rivet the pins without having to wait to get a riveting tool? Shop closed today. I am glad that all I needed was a new chain but damn it has been frustrating trying to change the thing.

If you have a sledgehammer, or other really heavy tool, place that behind the link you want to 'peen'. That's your anvil. Use a light hammer (tack hammer is perfect) and rap the end of the pin you want to mushroom repeatedly. The end of the pin will spread on the 3 or 4th hit...