Now then all.

First post on a forum ever, so here goes.

I have a 2002 XT600E with 53000 miles on the clock and has started making an erratic knocking/chattering noise, it sounds like its coming from around the bottom end on the left hand side, but these things can be hard to pinpoint. You can almost feel it shuddering as it makes the noise, especially at low revs.

My logic suggests that it could be the cam chain. The adjuster has 4 clicks left on it, and I guess coming to the end of its life. I did try the trick of pushing it out a click to tension the chain a bit more, but it made no difference so I put it back to normal.

However, the noise seems very erratic, not entirely related to revs. Some rides it would be worse than others, and not present at times, then suddenly come back. No real change in power/acceleration.

It was doing this about 3 months ago for a few weeks and I tried to figure it out but had to use the bike for work still. I tried to get the left had side casing off, just to have a look, but it wouldn't budge as its probably never been off and then it stopped making the noise at all suddenly, as if magically fixed. now its comeback after maybe 2000 miles and me no likey.

Other suggestions have been flywheel and balance shaft nuts/woodruff keys, but I haven't had chance to check and it definitely seems to be from the left hand side, but I may be wrong.

Ive been through a lot of forum threads but cant find an answer to my problem exactly.

Hope someone can give some suggestions.

Thanks.

So im guessing you have read THIS POST?

Mezo.

Until you take the side covers off any answers are just guessing as to whats going on . There are several things that can cause a knocking sound, physical examination is the only road left to fixing it , plus continuing to ride it may end up costing a ton more from more extensive damage . Oil should show some particles or something by now , drain it in a clean container and look closely .

.

__________________
'86 XT600/3TB motor,,, '88 XT600, ,,'92 XT600e,,, '08 Husky TE510,,, '05 DRZ463,,, '95 KLX650 ,,,'96 KLX650

Turns out it was the balance shaft nut.

Thanks Mezo, that post is exactly what was wrong with mine, not quite as severe though. Dont know how I didnt see that post before in my hours of searching rather than spending the hour or so in diagnosing it properly.

The noise definitely sounded like it was coming from the left, but I guess not.

Oil looked fine, so probably no damage done hopefully, these engines seem to go on no matter what anyway.

Thanks

Glad we saved another motor, should really make that post a sticky. Mods?

Mezo.

the nut loosens because the woodruf key gets hammered, so the little back and forth play undoes it


dont just tighten the nut, replace the key too

Indeed, I have ordered a new key and locking washers, since they're so cheap and not worth the risk.

Yes this parts are cheap original, that goes for the seat check ball also. The complete set is more exspensive ordering from UK not original, so check prices before buying what you think is cheap. When parts have been on the bike for over 20years its no question original is good quality!