'05 450: crunch/buzz taking off in 1st

tourist · Jan 13, 2014

A friend got a reasonably good looking 2005-model 450 last summer for a pittance. 235 hrs on the clock though so not unexpected that it may need maintenance. Runs really strong though and functions well.

There's an uncomfortable noise though when slipping the clutch and giving a little gas to take off in 1st. Crunchy "bgrwoorp" like noise from the engine. It's not apparent in other gears, and if you take off smoother then it's fine - that is, it only makes the noise if you rev it a bit higher and the clutch-in starts to pull down the engine speed.

Before we open it up, can you tell what we might find? Thanks!

rsarroyo · Jan 13, 2014

Look at the clutch for a broken friction disk...I have had this with a orangeberg 450. It also caused the bike to jump out of gear.....which I blamed on a worn shift drum...

rsarroyo · Jan 13, 2014

Also check the rear hub....KTM wheel bearing go fast. Moose has a nice repair kit. A bad bearing will cause the chain to run from tight to slack if really bad, but it makes a grunchy noise....finally the rear hubs hairline crack and it hard to see this with the sprocket and brake rotor in place. The stock hubs polish up nicely if you are replacing rims. Free bling

tourist · Jan 13, 2014

Aha! Thanks!! We know that most of the rear-end bearings are shot. It's comforting to know that it could possibly be that simple. We should try get that motor open soon though.

jimmythehat · Jan 14, 2014

The rear hub theory sounds dodgy to me. I had a grinding noise from my clutch for a long time taking off quickly. But not all the time. I put it down to vibrating clutch plates. Sometimes caused by grooves?? Not sure but I overlooked the issue and it never gave me trouble. Still pulled strong!! Happened more with new oil than with old. Other people seemed to have similar problems when I researched it.

bushmechanic · Jan 14, 2014

if you search a bit you will find a post by Orangeberg about the clutch shriek

there are 2 parts that should be checked

7 (59032007000)

9 (59032009000)

the stepped washer 9 can end up too close to the main clutch basket 1

make sure the half washers 7 are not mangled and if needed shave down the stepped washer to provide more clearence between it and the main clutch basket

ned37 · Jan 14, 2014

...or live with it as the rest of us did.

bushmechanic · Jan 14, 2014

ned37 said:
...or live with it as the rest of us did.

yes .. mine does it and im not fussed at all

nice to know where it comes from though.. being a very odd noise and all

Taffy · Jan 15, 2014

the clutch drum was changed twice after this. something else to consider. all else stayed the same through to 2008.

Taffy

ned37 · Jan 17, 2014

nice to know where it comes from though

i think it was engineered that way to discourage us from abusing the clutch :lol:

tourist · Jan 17, 2014

thanks all!!

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'05 450: crunch/buzz taking off in 1st

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