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Transmission / Rear End
Chattering Clutch? Transmission Trouble?
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  #1  
Old 05-17-2007, 03:39 PM
telbdm telbdm is offline
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Clicking Noise

My bike started making a clicking noise about 2 weeks ago. It seems to be getting worse. One shop I took it to said they didn't know what it was but his 800 was doing the same thing. Not going there again. Another shop took a guess without getting too involved that it might be the camshaft tensioner needing adjusting. I have about 6000 miles on my 04 bike. The last 2500 are mine. Has anyone ran into this? Is this something I can adjust on my own or is it recommended to take it to someone?
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Old 05-17-2007, 03:47 PM
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Could be ACCT.........can ya be more specific on the noise and location?
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Old 05-17-2007, 05:08 PM
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its a loud clicking noise. sounds like its coming from behind the air filter box on the clutch side of the bike.
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Old 05-17-2007, 05:16 PM
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Originally Posted by telbdm View Post
its a loud clicking noise. sounds like its coming from behind the air filter box on the clutch side of the bike.
http://pages.tstar.net/~fergy/images...hain_noise.wav - Here's a link to what someone posted earlier related to cam chain tensioner noise. DOes it sound something like that? Your location is spot-on for the ACCT - but don't go to a dealer. There's lots of folks here who can walk you through the reloading process - if what's called the Grambo Trick doesn't work, we can get you going for $20 (new springs) and about an hour of your time.
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Last edited by Crobins365; 05-17-2007 at 05:17 PM. Reason: Wrong verb tense; dag - now wrong adjective
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Old 05-17-2007, 05:54 PM
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If you know what the automatic cam chain tensioners are, there's one on each jug, both facing the rear of the bike. On the left side you can see the front one under the carb. It will have a 10mm screw into the top of it. Remove that screw and take a small screwdriver or screwdriver bit and slip it in there, find the grove for the tensioner shaft and turn it clockwise about one turn and let it snap back. it's spring loaded. Replace the 10mm screw. On the right side of the bike, it's located behind the coolant overflow bottle. Remove the inset 10mm bolt holding the bottle in place, move it out of the way and remove the 10mm screw from the head of the tensioner, repeat the process by turning the shaft inside clockwise letting it snap back, install the screw, reinstall the overflow tank and start the bike. See if it still makes the noise. If not, one or both of the tensioners were just stuck, or the springs are getting weak.

This is the "Grambo" trick, and on mine it quieted it down for a few days, but my weak springs caused the noise to come back pretty quick so I replaced the springs in them. Hope this helps! Here's a diagram of the cam system. The tensioners are the part numbered 12048 which there of course are two of.
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Old 05-17-2007, 06:36 PM
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I don't think it was mentioned but the audio clip is a before and after repair demo. You'll notice the clicking in the first half disappears in the second half.
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Old 05-18-2007, 02:32 AM
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The way I first heard a bad tensioner described, and it sounds like it to me, was like shaking up a can of spray paint. Many times the noise is just from one side, but eventually they'll both need replaced.
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Old 05-29-2007, 10:27 AM
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I'm pretty sure this is the problem. went to two dealerships, one of which performed the Grambo trick while I was there. the noise went away for about 2 days. but its back now. Where can I get new springs for $20.00?
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Old 05-29-2007, 10:54 AM
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Originally Posted by telbdm View Post
I'm pretty sure this is the problem. went to two dealerships, one of which performed the Grambo trick while I was there. the noise went away for about 2 days. but its back now. Where can I get new springs for $20.00?
Go to the TOC Manufacturing website (www.tocmanufacturing.com, I think) and you'll find them there. If they're out, give a holler - I got extras the last time I ordered.
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Old 05-29-2007, 05:00 PM
telbdm telbdm is offline
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thanks, Cindy. I just ordered a replacement pair. Do you have detailed instructions for the rebuild or is it pretty self explanatory?
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