696 Engine Clunking Sound after 600 mi service and 14T sprocket - Any ideas?

[misterburns]

So I just dropped off my 696 for the 600 mile service at my local dealer.  Had a 14 tooth front put on, and some motovation frame sliders.  I get about 1/2 way home and feel/notice a clunk - clunk - clunk sound coming from the engine.   Its especially noticeable if I ride the clutch (could rally hear it in 2nd) not sure if its just more noticeable b/c of the low speed or less noise.

Has anyone heard of/had this issue?  Related to the sprocket or engine rod for the sliders ya think?  I've also noticed a black residue on the bottom of the engine now that wasn't there before the service.

Calling the shop tomorrow, but curious if anyone here has an opinion.  Thanks for any advice.

[Howie]

For the sake of safety, I would check that the sprocket is not loose before riding.  Then I would get it back to the dealer.  No noise before service, noise after, their problem.

[misterburns]

thanks for the response, and my concern is getting it back there (20 miles) without doing any damage to the bike (or myself <checking sprocket now>)

[Howie]

If the dealer is only 20 miles away I would express my safety concerns and ask them to pick up the bike.

[misterburns]

just talked to the shop, and the guy that worked on the bike (awesome guy and mechanic that I didnt get a chance to speak with yesterday when I picked it up) told me its just the new master link wearing in, and it will go away once that happens.  Said the bike was top top.  Seems reasonable to me... maybe I'll post the question on the 14t sprocket chain and see if others have had this issue.

[Bladecutter]

just talked to the shop, and the guy that worked on the bike (awesome guy and mechanic that I didnt get a chance to speak with yesterday when I picked it up) told me its just the new master link wearing in, and it will go away once that happens.  Said the bike was top top.  Seems reasonable to me... maybe I'll post the question on the 14t sprocket chain and see if others have had this issue.

Say WHAT?

Master links don't wear in.
Chains don't clunk.

Make sure your chain is set at the proper tension.
If it isn't, adjust it, and see if the noise goes away.
If not, pop off the front sprocket cover and make sure it is on tight.

Something is wrong with your bike.
Fix it before it fixes you.

BC.

[misterburns]

ugh... not what I was hoping to hear, but good to know.  Thanks for the advice fellas.    off to research

[JetTest]

Going down 1 tooth on the front sprocket should not require a new master link in the chain, and as stated above, master links do not "wear in", at least not if installed properly. If it is a riveted link, maybe they over-did it with the rivet tool and got it too tight, in which case I would insist that they install a new one correctly. If the chain is too tight it might be binding, and it can very quickly cream the countershaft bearing and seal (leading to an oil leak that would cause a mess on the bottom of the engine, among other bigger problems). I installed a 14t on the front of mine and did not have to break the chain, only removed the clutch slave and front sprocket cover. The wheel moves forward enough that you can slide the 15t off and the 14t on, no problem. Anyone who says you can't just didn't try. Takes about 20 minutes, start to finish.

[Slide Panda]

ugh... not what I was hoping to hear, but good to know.  Thanks for the advice fellas.    off to research

Nothing to research - JetTest and Bladecutter are right on about the master link theory - it's rubbish.  I've done a number of 14t conversions and there is Zero reason that your shop should have messed with the chain, beyond resetting the tension.  Besides the fact they shouldn't have messed with the chain (as said) a properly done master link isn't subject to any sort of wear/break in.  I'd be pretty suspect of the shop at this moment

All you need to do on a DSS monster is
-introduce as much slack in the chain as possible
-Remove the clutch slave
-Remove retainer for the sprocket
-Work the old on off the shaft.
- Reverse steps 2-5
- Retension the chain

As said this is a 15-20 min job.  I knocked out 3 in just under an hour with no clunking

[misterburns]

thanks for the info guys...

So upon further inspection, its def the master link causing the issue.  It sits slightly higher than the other links (like a little bump if you look at the chain from the side), and the sound is worse on deceleration (tension out of the chain I'm guessing).  Does this sound like something that can be fixed through tension adjustment, with a new master link, or do I need to get a new chain now?  Just want to be sure I'm informed going in.  Thanks again for helping me out.

[JetTest]

Sounds like they riveted the masterlink too tight. A new master might correct the problem, but I would not let the knucklehead that did the first one try again on my bike. Find a new mechanic, or better yet, buy some tools and learn how to do it yourself. Good help is hard to find.

[Slide Panda]

+1 to jetTest.  You need a new master - but not a new chain, and not to have that dude do it.

Basically he made it over tight and is causing a nasty kink in your chain.

I'd be taking a close look at your service bill, and be talking to someone higher up the food chain at that shop about cutting down the original fee and reimbursement for the costs of repairing the issue they created. 

[misterburns]

thanks guys... back to the shop today for a new master (on them of course).  Really appreciate the help.