Roughness and muffled noise most at idle

Mihalis fjr · Nov 10, 2015

I noticed the last months,''perhaps was there for a long time'' but i didn't noticed it,a roughness and a heavy muffled noise where probably comes from the clutch housing or gearbox.You can feel it most on the handlebars.When i pull the clutch the roughness and the noise disappears and the engine runs smooth.The same thing happens and when i open a bit the throttle,again i pull the clutch and everything is smooth again without roughness and noise.The roughness and noise are not bad and not very noticeable but it is there.If i remember right i noticed the same thing in the past in some other four cylinder bikes.

Are these symptoms normal for the fjr?Has someone noticed that in his fjr?

I am pretty sure that these symptoms wasn't there the previous years,or when the bike was brand new.

On the road the bike runs perfect..

I wonder what cause these symptoms and when i pull the clutch everything disappears..?!

RaYzerman19 · Nov 10, 2015

How many miles/kms. on the bike? Have you had to adjust the clutch lever in the recent past to get sufficient travel for clutch disengagement? Has the issue arisen suddenly, or has been gradually getting worse over a long period of time?

The only thing that is cured by pulling the clutch is putting pressure on the clutch internals.. if it's noisy when clutch lever at rest, then I suspect there is some play somewhere...... I'd pull the clutch side off and inspect the entire clutch. First before you unbolt it, check for in-out play. If you find some, start disassembling the clutch plates, inspect, measure. Two things come to mind first, worn plates below limits may be enough to have little/no tension on the outer clutch spring. Then there's the spring itself...... total cumulative effect..... If the plates are worn too thin, replace them with OEM or aftermarket, including a new spring.

The other think to check is the actuation rod and the ball bearing 'spacer' in there.... are they in good shape?

Once you've had a look at all that, let us know.

Mihalis fjr · Nov 10, 2015

RaYzerman19 said:
How many miles/kms. on the bike? Have you had to adjust the clutch lever in the recent past to get sufficient travel for clutch disengagement? Has the issue arisen suddenly, or has been gradually getting worse over a long period of time?
The only thing that is cured by pulling the clutch is putting pressure on the clutch internals.. if it's noisy when clutch lever at rest, then I suspect there is some play somewhere...... I'd pull the clutch side off and inspect the entire clutch. First before you unbolt it, check for in-out play. If you find some, start disassembling the clutch plates, inspect, measure. Two things come to mind first, worn plates below limits may be enough to have little/no tension on the outer clutch spring. Then there's the spring itself...... total cumulative effect..... If the plates are worn too thin, replace them with OEM or aftermarket, including a new spring.

The other think to check is the actuation rod and the ball bearing 'spacer' in there.... are they in good shape?

Once you've had a look at all that, let us know.

I have 60 kms,not many..I don't remember how or when started the issue.Simple a day i noticed that.I have replace the plates some months ago but i didn't noticed something wrong or some play somewhere inside there.Everything was normal from what i remember.The issue was there before the replacement of the plates.Sounds like that there is some play somewhere,but where..?This muffled noise with the roughness,i can't explain it well,you feel it like a hit gear to gear,like a smooth krrrrrrr noticeable on the handlebars and in your ears.As i said all this isn't too bad but is there.Also on the road the bike runs perfect.This issue is noticeable only at idle,and when i open a bit the throttle.When i pull the clutch this dissapears and the engine sounds smooth and perfect..You can feel it on the handlebars.

You feel that thing more as smooth hit,smooth vibration more than a noise..

RaYzerman19 · Nov 10, 2015

I'm not there to hear the noise, so will try to guess..... Since the clutch plates have all been replaced, the noise may be from play or wear in the actuation system, and I will guess you are feeling/hearing the noise/vibration because the engine/clutch is spinning against the ball and push rod (items 25 & 24 in the parts diagram), and perhaps the dowel item 29. There should be very little or no load on these parts and they should not be worn. Remove the clutch slave and see if all is good on that end. To inspect the ball, you may need a skinny magnet or have to remove the right engine cover again. The ball should be replaced if damaged, and should be greased, as it is the wear item.

These components should last a very long time and rarely need replacement, except perhaps the ball....

YummYam · Nov 10, 2015

When I come to a stop changing down eventually to first, depending on the situation I'll often be listening to how the bike sounds and feels as it's idling in gear.

If I flick her into neutral, there is a subtle but noticeable change in the general mechanical sounds I'm aware of,as well as in the vibrations felt through the bars and seat.

Strange, but it seems quite normal to me,components no longer under compression I guess, and quickly becomes the 'normal' sound.

As RayZerman states, it's likely caused by free play in the clutch mechanism somewhere.

Less than 21k miles!

Mihalis fjr · Nov 11, 2015

I pulled out the rod with the ball and everything is in great condition there.

I feel i think the same thing as ''YummYam'' describes.

When i come to a stop and flick her into neutral,pull the clutch and the roughness and the general mechanical sound especially from the gearbox and from the clutch housing disappears.I leave the clutch and appears again,pull the clutch disappears,etc,etc...It is more a roughness feeling through the bars and seat,more than a muffled noise.

For one thing i am pretty sure,that this thing wasn't there before some years or when the bike was brand new..

Seems like something there gets some free play or wear after some time.

I would like to hear and from other guys if they feel the same thing,or and if this worsen by the time an kmiles..

RossKean · Nov 11, 2015

My FJR doesn't do this but I had Yamaha Venture that did. At idle in neutral with the clutch pulled it was quiet. Let the clutch out and I would get a noise like you describe. Never got worse and never went away. Never any problems. I mentioned the Venture because the clutch is similar.

Mihalis fjr · Nov 11, 2015

RossKean said:
My FJR doesn't do this but I had Yamaha Venture that did. At idle in neutral with the clutch pulled it was quiet. Let the clutch out and I would get a noise like you describe. Never got worse and never went away. Never any problems. I mentioned the Venture because the clutch is similar.

I have noticed this thing in some other bikes in the past,but those bikes was 80s,90s old school bikes.

Even my XTZ 750 Super Tenere 1990 model with 160 kmiles doesn't do it.Pull or leave the clutch without any difference.

I wonder what cause this issue and from where this roughness,noticeable at the bars and seat with the muffled noise comes and why disappears when i pull the clutch..?!Perhaps there is a problem in the gearbox..Gears or bearings..But the bike has only 40kmiles.Ι don't know.

On the road the bike runs smooth and perfect!

Roughness and muffled noise most at idle

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