2009 FE 570 gear box noise

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mike1971

Joined May 2011

6 Posts | 0+

Discussion Starter
• Jul 31, 2011

• #1

Need some help.
I bought a new 2009 FE 570 last year, it now has about 25 hrs on it, did the break in oil changes as per the manual,
the last three or four rides the gear box has been getting noisier and noisier during riding, it seems to make the most noise when hot, sounds like a gear meshing noise.
When it`s hot and running in netral, I can pull the clutch in and the noise goes away.
When I first started to hear it, I drained the oil to check for metal, but it was clean, and the magnet was clean. I checked the oil again as the noise got louder, but the oil was still clean.
Pulled the clutch apart and had a look at it, and it looked good.

Any ideas ????
Thanks Mike.

 

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Duken4evr

Joined Mar 2011

46 Posts | 0+

Parker, CO

• Aug 1, 2011

• #2

Is the noise most prominent in the low gears? My '10 FE450 is a bit "agricultural and growly" sounding in 1st and 2nd. Coming from a Japanese bike it seemed noisy. I concluded it is normal.

 

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mike1971

Joined May 2011

6 Posts | 0+

Discussion Starter
• Aug 1, 2011

• #3

Doesn`t seem to mater what gear it`s in, it sounds the same.
Seem to hear it most under acceleration and deceleration.
Mike.

 

Taffy

Joined Nov 2001

17K Posts | 774+

Ely, England

• Aug 2, 2011

• #4

if the noise goes when you pull in the clutch then I suggest that it IS the clutch.

regards

Taffy

 

berger

Joined Apr 2002

3K Posts | 11+

Phoenix Arizona

• Aug 2, 2011

• #5

How does the magnet and oil screen look?

 

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GregUK

Joined Jul 2010

239 Posts | 1+

London, England

• Aug 2, 2011

• #6

Taffy said:

if the noise goes when you pull in the clutch then I suggest that it IS the clutch.

regards

Taffy

Click to expand...

When the clutch is disengaged, the gearbox shafts will stop rotating (at least to the extent that the gearbox drag is greater than the clutch drag).

If the noise is coming from, say, a failing g/box bearing, one would expect that the noise would stop or diminish as the clutch was disengaged.

You knew that really!!

Greg

 

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nick790

Joined Sep 2010

163 Posts | 1+

Kent, UK.

• Aug 2, 2011

• #7

Mine does this, gives a bit of grumble on over run, pull the clutch ant noise drops off. I say it's normal, my ktm's have done the same thing. Maybe try a different oil? Oil level correct?

 

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mike1971

Joined May 2011

6 Posts | 0+

Discussion Starter
• Aug 2, 2011

• #8

The oil, magnet, and screen are clean, no metal.
I generally would not be concerned with a little gear box noise, but it`s starting to get louder than the motor.
Going to pull the clutch and side cover off tomorrow and have a closer look at things.

Mike.

 

Facom

Joined Jul 2010

41 Posts | 0+

South East England

• Aug 14, 2011

• #9

i noticed the gearbox on my 450 was 'noisy' the last time i rode it, i can only put it down to the oil being old, i have no worries about this but will monitor it, i have a feeling that it may be a clutch issue(possibly slipping) as it only happens when the bike is hot

if it is the clutch, its the first clutch i will have changed in 10 years of riding 8O

 

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maKe

Joined Jun 2011

351 Posts | 24+

Finland

• Sep 5, 2011

• #10

My 570 made this rally car dog box whine once when my oil level was low that you couldn't see anything in the check window. 8O

 

Taffy

Joined Nov 2001

17K Posts | 774+

Ely, England

• Sep 6, 2011

• #11

GregUK said:

Taffy said:

if the noise goes when you pull in the clutch then I suggest that it IS the clutch.

regards

Taffy

Click to expand...

When the clutch is disengaged, the gearbox shafts will stop rotating (at least to the extent that the gearbox drag is greater than the clutch drag).

If the noise is coming from, say, a failing g/box bearing, one would expect that the noise would stop or diminish as the clutch was disengaged.

You knew that really!!

Greg

Click to expand...

I think that there are two areas here.

stood still and moving. load and no load. if you're stood still and pull the clutch, the noise disappears I would say that that was the clutch. If you're on the move, mmmm? possibly the box.

regards

Taffy

 

berglsmerg

Joined Aug 2009

1K Posts | 346+

Charters Towers, Australia

• Sep 6, 2011

• #12

Hey mike did you pull the side cover ? Cold it be a loose primary nut ? I recently came across a CRF 250 that had a heavy knock to the selector lever which had bent the shaft and caused gear dogs to slightly rub in neutral which made a horrible noise. My 09 570 exhibits a fair sort of clutch rattle in neutral. (100 hours)

 

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mike1971

Joined May 2011

6 Posts | 0+

Discussion Starter
• Sep 17, 2011

• #13

Sorry for the delay, I finally got to pulling the side cover off, (to much work and not enough play), Primary nut is tight and the main shaft nut is tight with the locking tabs still in place, I did notice the outer clutch basket whether on a bearing or bushing had a fair amount of play in it, could this be my noise.
I`m going to pull the inner clutch hub off and inspect the bushing/bearing tonite.

 

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mike1971

Joined May 2011

6 Posts | 0+

Discussion Starter
• Sep 20, 2011

• #14

Clutch basket bearing looks fine, no wear, there is about .025" in/out movement on the basket, this is factory set by the bearing sleve.( does this seem like to much play?) Main shaft bearings are good. Counter shaft bearings are good
Looked around on KTM talk a bit, 570 baskets are the same as most KTM EXC bikes, read a cuople of threads on clutch basket dampers going bad on the EXC`s. Some even breaking the damper rivets off.
Could this be the noise,?? Checked mine when it was off and it seems good.