Banging noise - Clutch?

[PJW]

2005 ZZR 250, it starts, idles, runs well but there is a terrible banging noise especially at idle. It gets quieter when the clutch is pulled in and when the engine revs, but at idle with the clutch out it is unpleasant

Video link:https://www.youtube.com/watch?v=JmmMDovN1GA

I think I need to replace the clutch but I am open to any ideas you might have.

Edit: OK, so it seems the clutch basket it the likely culprit and I have options like upgrading to a newer gen clutch basket, or finding a good used one. Opinions?

[SibSerge]

If the noise goes away when the clutch is under load then its likely the basket. Just upgrade to the new gen. I doubt you can find a “good used one” as they stopped using them in the new gen and oldest new gen is 13 years old. The problem in these baskets is the rubber bushings and finding a good rubber thats was sitting in an oil bath flr 13 years is nearly impossible. I have 6000km on my converted clutch and it runs great

[Mohawk]

Change the clutch to a new gen type. You will need the whole clutch, oil pump drive gear, inner & outer basket plus all plates, springs & bolts/washers, plus the central push rod.

You can use a 300 slipper clutch if you change the same parts & use the 300 clutch cover.

Have fun.

[PJW]

I have the clutch out of 2010 and it looks great except the big gear on the back of the old one isn't there on the new one? Is that the oil pump drive? And if so did the guy who sold it to me just forget to give it to me or do I need to transplant it from the old one?

Originally Posted by Mohawk

Change the clutch to a new gen type. You will need the whole clutch, oil pump drive gear, inner & outer basket plus all plates, springs & bolts/washers, plus the central push rod.

You can use a 300 slipper clutch if you change the same parts & use the 300 clutch cover.

Have fun.

[SibSerge]

Originally Posted by PJW

I have the clutch out of 2010 and it looks great except the big gear on the back of the old one isn't there on the new one? Is that the oil pump drive? And if so did the guy who sold it to me just forget to give it to me or do I need to transplant it from the old one?

Its a separate item, it slides over into place and then the basket will look just like the old one. They often sell them separately on ebay. Why would you package them if you can fetch few more $ for it

[PJW]

Thanks, that's what I was hoping. The guy I bought it from has it, so I'll get ahold of him and ask for it.

[Mohawk]

That gear ring is a very snug fit on the splines, it has to be aligned perfectly to slip on.

[PJW]

Originally Posted by Mohawk

That gear ring is a very snug fit on the splines, it has to be aligned perfectly to slip on.

So no hammer? But I need the one from the new clutch, right?

And do you mind if I ask another question? The rod that needs a 2mm washer assumes I am using the old rod, correct? If I use the new one I shouldn't need the spacer?

Edit: Great Success! Using the rod from the new clutch I didn't need a spacer. Once I got the order of the parts figured out from diagrams it slid in and voila. It started up, no awful thumping noise, and then I rode it around the block. It feels much nicer.