Rhythmic clunking, vibrations hard to explain.

How often have you been cleaning and oiling the chain. I found a good grunge brush at my local offroad shop and clean and lube the chain religiously. If it's kinking now, though, forget it and start fresh. You don't ever, at any speed, want the chain to break.

Ok, I've made sure the the chain is spotless and lubed. I've checked the rear sprocket and the teeth seem fine. I tried pulling the chain of the rear sprocket as suggested but I could only see about a quarter of the teeth so I'm assuming the chain isn't stretched too much. I've checked the tension and it seems fine. I don't think there are kinks in the chain, as i put it on the center stand and rotated the wheel, but frankly im not sure how obvious a kink would be to spot. The only other thing i haven't done (because i have no idea how) is removed the front sprocket cover to check the front sprocket. Can someone offer some suggestions o how to do this and what to avoid?

Ok second thing, im going to change the rear brake pads to make sure this isn't the issue, i don't think it is, but they are looking a little worn and i should get it done anyways. Im assuming i don't need to remove the rear wheel, and that i can just remove the caliper? I cant find any info or pics on how to do this though. Can anyone offer any pics or links that could help me out?

To access the front or engine sprocket(sometimes called the countershaft sprocket) usually requires removing the shifting lever from the shaft,sometimes removing the left footpeg assembly,a cover for the starter motor(usually 2 bolts) and then usually 4 bolts holding the sprocket cover.

While the sprocket cover is off, check the wiring going from the alternator for corrosion in the bullet connectors and good operation of the clutch throw out mechanism(it might need some grease on the moving parts.

The clutch pushrod should be checked for chain lube build up, I've found paint thinner on a rag or paper towel the best way to remove excess grease or chain lube.

Maybe I missed it but have you gone over engine mounting bolts and swing arm pivot bolt torqued to spec?

Exhaust mounts tight?

Just a thought...

TeK9iNe wrote:

Something rhythmic that increases/decreases speed regardless of gear and engine speed is attributed only to the chain and front/rear wheels.

Rarely, but sometimes, there can be a problem with the transmission/output shaft assembly.

There is a number of easy things to check:
Start with brake discs since you felt it there first - Disc warp/wear/damage Pads - wear, damage, stuck debris.
If drum in the rear - dissasemble and spec for wear/damage.

Wheels - Tire pressure, wear/damage/ balance/trueness.
Bearings - Spec, wear/damage, maintenence.

A chain is basically considered worn when it exceeds its origional length by 2% Your service limit is 323mm over a 20 link pin2pin length. Measure in several spots.
Check alignment too. It should ride on the center of the sprocket, not hard to one side or another, a little off is ok.

The manual is the best source for maintenence and ideas as to where the problem is.

GL.

You might want to check a few things before throwing the cash at it. All bikes can always use a new chain and sprockets, but a little sluthing can save you $$$.
Use the manual.

Changing the brake pads is very easy. Pull off caliper, squeeze piston in slightly, throw in new pads, replace caliper, squeeze the brakes a few times.
The technical info is in the manual

Good Luck.

This link should enable downloading Owners Manual.

kzrider.com/index.php?option=com_docman&...d&gid=410&Itemid=108

There's probably a downloadable KZ650 Factory Service Manual somewhere around here.

Ebay is often a good source for an FSM.

Good Fortune!

Thanks for the info on how to get the sprocket cover off. Could someone offer some pointers on how to get the rear caliper off? The rest seems simple enough.

Patton wrote:

Ebay is often a good source for an FSM.

Good Fortune!

Her is the manual that covers the KZ650-C2. As an owner of a 30 year old bike, you really need this book. Good luck, Ed

Kawasaki Factory Service Manual