My 2009 has started making a terrible grinding noise. It is intermittent. But it sounds like it's coming from the clutch or maybe the waterpump. I'm hoping someone here recognizes the noise and can help id what's going on.

One thing of note, a week ago the bike died when I dropped it into first at a light that just changed to green. When I tried to restart it, it wouldn't start until I put it back in neutral. It was not the battery (I know battery trouble), when I hit the starter, it just like "clunked" and then nothing. Every time I hit the starter button, clunk, clunk, like it was hitting something solid and could not spin at all. Then, in neutral it started right up and when I dropped it into first it was fine and it hasn't happened since.

Here's a video of the sound at idle....
https://www.youtube.com/watch?v=3v0alvsmpjo

Thanks for listening!

* Last updated by: pjgeorgejr on 11/20/2018 @ 6:32 AM *

My first guess/thought was the starter (sprag) clutch?

* Last updated by: piken on 11/20/2018 @ 7:39 AM *

Don't run it anymore. Sounds like:
1. Tensioner failure.
2. Slipper broken.

So best thing to do is pull the right engine cover off so you can see the cam chain and slipper blade. Take a screwdriver and get the flat blade in between the slipper and chain. Is the chain loose? Then it's the tensioner. But you'd hear that noise on startup before the oil pressure takes over and quiets the tension on the chain.

Say the chain is tight. It might be a loose balancer bolt, slipped balancer with a tight bolt? Bottom line, it does not sound good. Any more damage is going to take out [more] parts if you keep running it.

Next thing is to remove the tank, pull both service doors, WOT the throttle, ratchet the subthrottle open by hand, look down each port and look for piston degradation of aluminum in the ports.

No tensioner loss, no piston eaten up, pull engine out and start looking. Drop sump pan first. We see chunks of any metal in the pan... go to the fridge, pull a few ice cubes, dunk them in a glass, open the hard stuff, pour some, sit down and relax... it's only parts.

Thanks for the leads! I'm am going to pull both side covers tonight and see what's up. Hopefully it is not in the engine...

Did the noise start after the stall and restart where the starter just clunked twice before it started back up? Starter gear didn't kick back after the restart and is now stuck engaged rattling. Something to check anyway.
Good luck

Talking to my local shop owner at RnR Cycles in Sterling, VA, he said it sounded like the stator had come lose. Damn if he wasn't right on the money! Just by watching the YT vid I posted!

I have a pic but can't upload here at work (they block everything). But suffice it to say it wasn't pretty. Two screws had backed out far enough to contact the cover. One was simply grinding itself down, the other had made a more sudden contact and literally bent over. The stator itself was still fine and the cover is still good (if not a little scraped. I replaced the screws, retighted with red locktite! And it's running perfect again.

If anyone lives in the Northern VA area, I highly recommend Rick Beggs over at RnR Cycles. Dude's a motorcycle whisperer.

Wow.

I think that's about the best that could of gone wrong.

Thanks for posting the final issue.

Pls tell us you changed the oil and filer too?

I didn't but now that you mention it.... :P

There were no particles inside the stator case but yeah, the top of the one screw ground away to somewhere... Guess I'll do that today. :} Thanks for the reality check.

Glad that worked out.Good call Crude;)

While the oil is out put in a magnetic drain plug if you don't already have one.

@1wheelpeel, it already has one in there. :) I imagine it'll be chock full of gunk right now.

RnR has that empirical ear. Or maybe hearing it live. Learned something so now I hear that nose, I'll hold the tensioner in hand or dyno cover with both hands. Cold of course. Loose parts make noise hot or cold. If it was my bike, I'd change its diaper and drop the sump cover. Last thing I want is material that does not crush going thru the engine. Damage begins at the oil pump blades. Travels to the conrod inserts and crushes that layer of aluminum. Or up the top end and causes cam tower cuts in a half circle. Finally drops down in the sump, doesn't hit bottom yet and takes a ride with crank spin splash and is caught between the wall and piston skirt and there is one long line on the thrust side of both parts when it changes direction.

Piken had it. If I reread the complaint, it mentions the starter locking.

* Last updated by: Hub on 11/21/2018 @ 9:45 AM *

Na, I wouldn't have got it. I've been away from the service end of it too long. It's more the building of it [now] and that's a whole new round of skillsets attending to those cans of worms; building from the ground up.

"Why couldn't I think like that?"... every time I'm stuck on something and check in with the boss.

wait til you hear the pesky cam sprocket loose bolt noise