2003-2006 Kawasaki KFX400 service manual, Page 304Get this manual
SERVICING INFORMATION
Complaint Engine is noisy
Symptom and possible causes Excessive valve chatter 1Excessive tappet clearance2Weak or broken valve spring3Worn camshaft4Worn or burnt camshaft journalNoise seems to come from the piston 1Worn piston2Worn cylinder3Carbon buildup in combustion chamber4Worn piston pin or piston pin bore5Worn piston ring or ring grooveNoise seems to come from the cam chain 1Stretched cam chain2Worn cam chain sprocket3Improperly working cam chain tensionerNoise seems to come from the clutch 1Worn countershaft spline2Worn clutch hub spline3Worn clutch plate teeth4Distorted clutch plate5Weak clutch damper6Weak clutch springNoise seems to come from the crankshaft 1Rattling bearing2Worn or burnt crank pin bearing3Worn or burnt journal bearing4Excessive thrust clearanceNoise seems to come from the transmission 1Worn or rubbing gear2Worn countershaft spline3Worn driveshaft spline4Worn or rubbing primary gear5Worn bearing1Clutch cable out of adjustment2Weak or broken clutch spring3Worn or distorted clutch pressure plate4Distorted clutch plate123412341234Clutch cable out of adjustmentSome clutch springs are weak, while others are notWorn or distorted clutch pressure plateDistorted clutch plateBroken gearshift camDistorted gearshift forkWorn gearshift pawlClutch cable out of adjustmentBroken gearshift shaft return springRubbing or stuck gearshift shaftWorn or distorted gearshift forkClutch cable out of adjustmentAdjustReplaceReplaceReplaceReplaceReplaceCleanReplaceReplace