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Old February 27th, 2016, 02:13 AM   #13
Mohawk
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Name: Chris
Location: Bristol, UK
Join Date: Feb 2016

Motorcycle(s): ZZR250, VFR800

Posts: 478
Check out the diagram you posted, the large driven gear of the clutch basket is held on by rivets inside which are plastic buffers that got hard, shrink & compress. When I bought my bike I was going to tear the engine down due to the big end knock. Then some research showed its the worn bushes, see here for full details.
http://faq.ninja250.org/wiki/What's_that_noise_coming_from_the_clutch%3F

On the pic link I posted, the gear has springs in it, which is how most other bikes clutches are. I've reviewed a load of videos on the net & no standard next gen has the knock, but most pre gen vids do.
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