Hey guys,

I'm a bit worried about my savage girl.
Bought her at 800 mi have now put 700 mi on her to a total of 1500 mi
Year: 1998
Cleaned and treated gas tank
Raptor Petcock
White spacer mod
New jets matching RYCA specs
Removed airbox to direct conical air filter
New exhaust
(Few minor things like handlebars and other irrelevant stuff)

She has great power, idles fine, occasional thunderclap backfire on decel and seems to run a little bit lean. I drive moderately though on occasion aggressively. Basically cruise at 70mph on fwy and like the sound of my bike so some good revs are pretty standard.

Now here is the problem, When going from stop to start in 1st gear, releasing the clutch gradually and giving her gas, she begins to click/tick/cluck. Sounds like coming from bottom left of engine, like tranny. I haven't taken her apart down there because it was a recent development.

I am talking to Verslagen1 about getting a Verslavy and will do so ASAP but what the heck? Such low miles, fairly new, just adjusted the valves (quieted down but still funny).

Should I be concerned when riding? Is tensioner the issue here? Is clutch wearing out? (She gives normal power and torque on all gears and while shifting, just a nasty clicking/ticking/clucking sound when shifting.)

Any advice, thoughts or tips would be great. I've got most of my tools and can do most of the work on my own. My mechanic is great and teaches me how to do the work with his tools. So, gimme all you got.

Cheers,

SavageDan

Hey Serowbot, thanks for the reply. I did see your reply to another's request with the same message. I tried to find that front belt pulley but couldn't locate it... Do you have any reference for me to look at? (clymers, tech section) Otherwise some sort of image?

That's a good idea too, I will check for an imbedded object.

I did try touching the headlight, as well as the speedo, gas cap, petcock and a few others. Definitely sounds like near the tranny. I think the front belt pulley is a good idea. Again, any references would be very helpful

Thanks Serowbot. I removed the cover, checked the nut, had a friend depress the rear brake, I applied pressure and might have tightened it. I then tried my test to see if it handled the problem:

1. Turned her on in 1st
2. Applied the front brake while slowly releasing clutch.
3. Listened for noise...

Unfortunately, on #3 the noise was still there. I did the test while having the front belt pulley exposed and it was not wiggling or loose. So that cannot be the problem.

My buddy and I listened for where the noise was coming from and it sounded like in the block near the carb. However, my mechanic who was working on this with me thought it was near the transmission. This isn't a persistent noise. It happens upon releasing the clutch and at high revs.

Any other ideas?

P.S. To describe the noise: When releasing the clutch while the brake is depressed the revs slow. When the clutch is maybe half-way out, some component begins "clucking". It's rate is nearly twice per second. The sound can similarly be reproduced when going from a stop to a start at a stop sign or light. So whether giving her gas or not, the clucking happens. But, there is no noise at idle or on low revs while in motion.

How many miles on it? 1,500?

Look Closely at thatpulley &^ washer. Any sign that the washer isnt always covering the same spot? Any sign of shiny stuff peeking out from under that washer on one side or the other?>

If your going to change the cam tensioner, you will be in the clutch side anyways. If you have the means I would take the clutch disks apart and see if any of them are cracked or if anything is embedded in one.  The description you gave would make me suspect some clutch issues.

Its easy to take apart and isnt a ton of parts or time involved, but you will likely need access to the right size sockets and an impact wrench.  Replacing a clutch basket because of trying to get some leverage is expensive.

1500 miles on an engine? It better not be the cam chain,,
Id like to see that washer.

Getting it straightened up so a socket fits is a pain, start with a small chisel & get it moving, dont use the edge on the washer, just use it as a wedge, once youve got room, go up to a wider chisel, & when you can get a punch on the edge of the washer to drive it toward the engine, go for it,
Hitting things Hard to move them isnt a great idea, More Punches that move it a little are better than a few Great Big Slams, Once its going your way, you can put the socket on & use that.
You can get a whole set of 1/2" Deep Impact Sockets from Harbor Freight for cheap, about the same price as The Socket off of a Snap On Tool truck,.

A small compressor will do the job with a 1/2" impact.,Ive worked on things with a compressor I canj carry, with less than 3 gallons of air. Its slower, but it WILL crank out the torque required to get a nut on a shaft that would want to turn if you were using a ratchet.,& for that day when its time to do the cam chain, it makes working with the clutch SOOO much easier,being able to just squeeze a trigger & it spins the nut up so quick theres no need for a sp[ecial tool to hold the clutch.