Annoying lever rattle

MasterCylinder · August 4th, 2012, 11:22 PM

Well since I've had my bike I've had this annoying rattle once I got up passed 6k rpm that I just couldn't figure out where it was coming. It bothered me because I thought it was the engine and that there was some unforeseen damage...

Anyways, long story short I was riding yesterday and discovered that the rattle is my clutch lever that was rattling because of how close I like to keep my clutch pulls to the handle bars.

I need ideas on how to make the lever not rattle. Go!

Monkeytofu · August 4th, 2012, 11:56 PM

Quote:

Originally Posted by MasterCylinder

Well since I've had my bike I've had this annoying rattle once I got up passed 6k rpm that I just couldn't figure out where it was coming. It bothered me because I thought it was the engine and that there was some unforeseen damage...

Anyways, long story short I was riding yesterday and discovered that the rattle is my clutch lever that was rattling because of how close I like to keep my clutch pulls to the handle bars.

I need ideas on how to make the lever not rattle. Go!

What type of lever are you using? A lot of after market levers for the 250 aren't made as big as the original so you get some loose lever rattle. The easiest thing you can do here is replace them with OEM handles but that's going to run you 10 or 15 dollars on ebay.

you could also try putting a washer in between the lever and the housing that the main bolt goes through. Make sure it's thin enough that it doesn't cause your lever to stick. You may even want to JB weld/glue (the washer not the lever

) it in place if you find one that gives you the perfect fit.

OEM replacement: http://www.ebay.com/itm/1987-2007-Ka...250d77&vxp=mtr (not sure if the cheapest ones available online, do some research and save some money)

~17 dollars

MasterCylinder · August 4th, 2012, 11:58 PM

Well I just ordered some adjustable ones off ebay. Hope it fixes it.

Monkeytofu · August 5th, 2012, 12:01 AM

Quote:

Originally Posted by MasterCylinder

Well I just ordered some adjustable ones off ebay. Hope it fixes it.

They make them for the classic 250? I wouldn't see a reason for kawi to change the lever design from the classic to the current 08-12 "pregen" models but it could be different.

MasterCylinder · August 5th, 2012, 12:10 AM

Quote:

Originally Posted by Monkeytofu

They make them for the classic 250? I wouldn't see a reason for kawi to change the lever design from the classic to the current 08-12 "pregen" models but it could be different.

Well bollocks. Glad you mentioned that. I ordered the wrong ones =( stupid ebay.

*goes to cancel order*

Anyways, to answer your question I'm running stock levers.

Monkeytofu · August 5th, 2012, 12:32 AM

Quote:

Originally Posted by MasterCylinder

Well bollocks. Glad you mentioned that. I ordered the wrong ones =( stupid ebay.

*goes to cancel order*

Anyways, to answer your question I'm running stock levers.

Good thing we caught it :O

Strange. Maybe it just changed from year to year. I always hear about these rattle issues from people but it hasn't affected me. I'm going to assume your handle bars are straight and the rest of the bike is in normal condition.

Give the washer thing a try.

You could make your own as well: http://faq.ninja250.org/wiki/My_clut...rev_the_engine But I'd recommend against it unless you have the steady hand for it.

MasterCylinder · August 5th, 2012, 01:03 AM

Quote:

Originally Posted by Monkeytofu

Good thing we caught it :O

Strange. Maybe it just changed from year to year. I always hear about these rattle issues from people but it hasn't affected me. I'm going to assume your handle bars are straight and the rest of the bike is in normal condition.

Give the washer thing a try.

You could make your own as well: http://faq.ninja250.org/wiki/My_clut...rev_the_engine But I'd recommend against it unless you have the steady hand for it.

Indeed! Yeah I'm not sure how I didn't notice it wasn't for pre-gen.

Handlebars look pretty straight to me. The engine just naturally vibrates so much it doesn't help.

I'll look into the washer idea. I thought about the shim thing before but it doesn't look like it'll be something do able in a way I'd be comfortable with.

GeorgeRYoung · August 5th, 2012, 11:42 AM

Frugal shims - cut from coke cans

dirty nasty · August 5th, 2012, 06:10 PM

Mine rattles at 8k. Unless I am on the highway. In which case it doesn't rattle until about 80 MPH.

Lychee · August 7th, 2012, 05:10 PM

Strange. mine doesn't rattle at all, and I have a lot of free play. Perhaps add some grease to the points above and below the lever where the lever contacts the perch? Tighten the bolt and lock nut? Upgrade to EX500 perch and lever?

MasterCylinder · August 7th, 2012, 11:47 PM

Quote:

Originally Posted by Lychee

Upgrade to EX500 perch and lever?

Go on

Lychee · August 8th, 2012, 08:39 AM

Quote:

Originally Posted by MasterCylinder

Go on

http://faq.ninja250.org/wiki/I_want_...6_brake_levers

MasterCylinder · August 9th, 2012, 09:17 PM

Ordered! XD

August 4th, 2012, 11:22 PM	#1
MasterCylinder ninjette.org member Name: Bryan Location: TX Join Date: Apr 2012 Motorcycle(s): '90 ex250 Posts: 155	Annoying lever rattle Well since I've had my bike I've had this annoying rattle once I got up passed 6k rpm that I just couldn't figure out where it was coming. It bothered me because I thought it was the engine and that there was some unforeseen damage... Anyways, long story short I was riding yesterday and discovered that the rattle is my clutch lever that was rattling because of how close I like to keep my clutch pulls to the handle bars. I need ideas on how to make the lever not rattle. Go!

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August 4th, 2012, 11:58 PM	#3
MasterCylinder ninjette.org member Name: Bryan Location: TX Join Date: Apr 2012 Motorcycle(s): '90 ex250 Posts: 155	Well I just ordered some adjustable ones off ebay. Hope it fixes it.

August 5th, 2012, 11:42 AM	#8
GeorgeRYoung ninjette.org member Name: George Location: Ottawa, Canada Join Date: Jun 2011 Motorcycle(s): EX250, C10 Concours Posts: 109	Frugal shims - cut from coke cans

August 5th, 2012, 06:10 PM	#9
dirty nasty ninjette.org sage Name: Karl Location: MA Join Date: Jun 2012 Motorcycle(s): 2000 Kwak Ninja 250 and 1998 Yamaha YZ400F Posts: 534	Mine rattles at 8k. Unless I am on the highway. In which case it doesn't rattle until about 80 MPH.

August 7th, 2012, 05:10 PM	#10
Lychee sail away Name: Jon Location: San Jose Join Date: Jul 2012 Motorcycle(s): gixxer (sold), ninjette (upgrade!) Posts: 964 Blog Entries: 8	Strange. mine doesn't rattle at all, and I have a lot of free play. Perhaps add some grease to the points above and below the lever where the lever contacts the perch? Tighten the bolt and lock nut? Upgrade to EX500 perch and lever?

August 9th, 2012, 09:17 PM	#13
MasterCylinder ninjette.org member Name: Bryan Location: TX Join Date: Apr 2012 Motorcycle(s): '90 ex250 Posts: 155	Ordered! XD