American Voyager Association

Hi Guys, I have an 89 vouager 1200, about 45000 miles, last friday it was fine 10 hours later I have develpoed a noise, the noise almost sounds like knocking,but only when bike under power like at take off, It resembles a spark knock like on a car but this is not coming from the engine, it appears to be from the middle around starter/alternater housing? or in clutch, noise goes away after you let off ,
I will changes the oil but never knew about the second drain plug in all th years I have owned this thing!? I just put 20/50 in I will try 10/40 and see, but I really do not think it is the engine?
So can some please give their input!! I realy hope this is an easy fix
Thakns for time in advance Scott form NH

Scott,

Have you checked the drive shaft universal joint? That may be worn and what is doing the knocking. Although you don't have that many miles on your bike yet, it still might be the problem. You may be able to check that by sliding the rubber boot back or forward near the drive side of your swing arm. Have the bike on the center stand and turn the rear wheel back and forth, and see if you can see slop in the universal joint as you do this. If so, you will need to replace the whole drive shaft (it comes as a unit from Kawasaki), unless you have a drive shaft shop handy who can remove the old one, which is pressed in, and replace it with a new one. Sorry I couldn't answer before this, just got back from the AVA Rally.

the bolt that holds the coupling onto the alternator shaft can get loose, and you'll SWEAR it's gas knock - kind of irregular, not there on decels, etc. But what's different from gas knock is that it will also do it at idle. To see if that's the issue, remove the chrome cover over the alternator and lay your hand on the alternator while the engine is running in neutral. If you feel the little little knocks, that's the culprit. Easy fix too - just pull the alternator, re- locktite and tighten the 6mm bolt that holds the coupler. steve

Thanks guys ok the U joint seem fine, and the alternator nut seems fine, so took starter back out to check starter motor clutch, the chain only moves in one direction like it should but the drive gear has play from side to side about 1/8 inch or more and might be the sound I am hearing, the manual does not cover anything about this, any more ideas? I will call Leo tomm but the more input I have the better, again thanks for all your time Scott

well after talking with Leo it might be the carbs out of synch, I also have never adjusted the pilot screws, made an appt to get done, this way if they f somthing up they can fix it, I will repost when bike is back next week
Scott

well just some info, just pilot screws done and carb resynched and still making noise, mechanis said it was deff, chain noise, or ajduster, anyone had a similar problem?

I too have this noise that you describe. Have talked to Carl about this also. I did sync the carbs as he suggested and it made no difference. Will be checking some other things as time permits and will post if cure is found. Sorry I can't help you more at this time.

If you are hearing what sounds like a definite chain rattle, It isn't!!!! I had the same problem and swore it was a cam chain and when I talked to Carl he convinced me it was the carbs so I synced them and still rattled & even bought a cam chain adjuster and then I tried this procedure and what I found was astonishing!!!!! Add the proper amount of Seafoam to gas and run for a few miles, then might be a good idea to let it sit overnite. Drain each carb separately while engine is running, as it is draining rev engine back and forth from 0 rpms to 3 to 5 to 6 000rpm for about 10 seconds on each carb as each is draining. Make sure when you drain each carb that there is gas coming out of that carb, some of the little carb drain hoses can get a little kink in them and they are not draining, that is why if you do it with one person opening the drain screw and one making sure that it is draining then you know you did it right. Apparently the reving creates a turbulence and breaks loose and cleans the jets and bowls because when I got done it ran perfect and absolutely got rid of the chain rattle noise and I found some weird yellow and red crap in my drain cup and it looked like a by product of ethanol. This 97 XII sits in my garage for long period's at a time and always worked perfect when I rode it. 125m miles If that does not do it perhaps you have one that is really plugged and you need to send it to carl to have them done by a professional. Let us know if this works for you..

I took bike out today after getting carbs synched, I added seafoam to gas also, the bike runs awsome now, but still has rattle, I will talk with Leo tomm, and give update, Thanks guys! Scott

I recently had that rattle noise and as it turned out my universal joint on my drive shaft was just about ready to come apart. Got it fixed just in time.

OK another update, I did add seafoam and drain the carbs as in last post, but still has noise? I have been away so I will try Leo today

ok another update still not looking good!! I switched to 10/40 synth last time and rode a little, now seems to getting louder? so drained it to tyry 20/50 again I have had several people listen to this and everyone says it is coming from starter, tenioner area, or poss, clutch area, next step will be pull clutch out and look , please any onfo at all !!!!!!!!!!!!!!!! summer is passsing fast and i NEED TO RIDE Thanks Scott

Where is the oil level on the site glass? Can you see the top of the oil between the marks when the bike is on the centerstand on a level surface? If the oil is past the site glass that is bad! Any chance that there is bubbles in the oil? If the bike has too much oil than maybe it is the hydraulic lifters you are hearing. A search in this forum under "lifters" should tell more of the story.

Thanks Mike, nope been through all that also, was on phone with Carl yest too, I got him stumped on this one ! I have adjusted the counter ballancers also, re adjusted the pilot screws that the dealer just did, checked cam tentioner too,

Scott, I'll try to do the procedure that you pm'd me about this weekend. Supposed to be nice here today but rain tomorrow. So looks like if I get it done it will be Sunday. Will let you know.

update, I put on 70 miles yesterday, and am truely thinking it might have something to do with clutch? If I let clutch out slowly on first take off and be real easy on gas I can almost get bike not make the noise? does not get louder or quieter if bike get warmer or colder? any other ideas?? thanks again Scott

Does anything odd appear in your drain oil, have you been draining it thru a paint filter for signs of any wear metal's ?. And what did the spark plug colors show between them, ..Also ;what I do to get a rough idea of float level is to drain them in a baby food jar. with a scale penciled in on a peice of tape, to get a rough idea of fuel in each bowl. How long have you owned the bike? When it started to make the noise did you just gas up, or miss a gear, anything out of the usuall. Or did it just start making the noise without any other symptoms. Have you had the oil pan down? Maybe removing the clutch cover will show somthing, Keep us posted Gene

Hi Gene, The noise just started on morning after riding the night before? it was almost on empty though,when I drained iol last time I did not look at drain pan to close but thought I saw a touch of filings maybe? the plugs are new this year, I have not pulled them since the problem started though,
I have a gasket coming from Carl this week and will pull clutch hopefully this weekend to check that, I will update as soon as I can, Thanks for responding Scott

OK NEW UPDATE I pulled clutch out this weekend and this what I found or DIDN"T find
Behing the clutch housing there is is smaller gears, one is the oil pump gear and the other one connects to the back of the housing with gear, there is supposed to be a washer and shims between gear and case! well there is washer or shim ?? so the last gear has just been riding against the case!? now I bought this bike with 11.000 mile on it from first owner, it now has around 45.000, the clutch plates looke almost prefect, I honestly do this anyone has ever had this apart, so how could this washer not have been put in from factory and never had a problem till recently??? mayby it was just wearing enough to start making noise? I have another used gear and washer coming from Carl, He pulled two cluches apart today and both had washer behind gear? I will update again this week when I put it back together

installed new spacer and gear from Carl today and no change is sound !!!!!!!!!!!!!!!!!! I simply can not beleive this !!!!!!!!!!!!!!!! the old gear is so worn I though for sure this was the fix !! not sure what to do next but put more insurance in it drive it off the road??