EXUP Worldwide

91' FZR 600 90,000kms

There is some sort of rattle that is apparent especially at idle. Engaging the clutch gets rid of the noise. Also on down shifts sometimes there is a huge cluck, like the chain is really loose and then clunking once all slack is taken up.

The clutch does not slip. Bike shop told me clutch is fine but I am sure something is amiss. Any pointers before i start pulling it down to check whats clunking and rattling?

Also the choke doesnt run smoothly, well it appears to move smoothly but the engine does not respond to it smoothly and at some points pulling the choke stalls the engine, start it again and its fine.

The tacho seems to be wandering sometimes too, reading about 2500rpm above what it should be and wobbles really poorly at idle. Not sure if this is connected to the choke issue?

Any help much appreciated.

Hello - my FZR started with some strange behaviour, and ditto sound, which I could not really pin down. After a few hundred miles, when pulling over at a gas station, it sounded like grinding teeth in the gear box. It ended up being a blown gear box bearing, which caused the main gear shaft, the oil pump, and while at it all the other bearings in the box, piston rings, and a few minor details as well.
Try and get the side casings off, and get acces to the clutch and the front sprocket, try and see if any odd play is showing up, if so you are in for a overhaul.

Regards -Lemmy

The same thing happened to my EXUP, same noise and symptoms, and it turned out to be the ball bearing on the shaft behind the clutch basket.

Second point, sounds like your engine is running rich, but if the engine is warm it will stall if you pull the choke on.

Third point, I would suspect a loose connection to your tacho, trace the wires to the connectors and check all connections are good with no corrosion.

chris