Kawi2strokes.com Forum

As long as you have to take it apart, you might as well have a couple reasons.

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If it surges, that's normal, upshift.

That long strip of shrapnel looks like part of a ball bearing.

Thanks for that comment. I've been wondering where to start looking once I get the cases split. I'll attach a few more pics in the event that it's helpful for potentially identifying the root cause. All of the metal is ferrous. The small bits have axial scoring marks and are roughly .010" thick. The large metal strip is roughly .050' thick so I am assuming that we are looking at bits from two different objects. Additionally, the small bits also seem to have the same radius on one surface area that might be from manufacture. As stated earlier in the thread, the transmission is not properly upshifting so that's an area that will be getting close attention. Any additional comments are welcome!

This shows what might be a manufactured radius

One last pic

I think it's going to be a lot easier to figure out what they are once you open the case. There's not that much stuff inside, so finding out what's missing some metal won't be hard.

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If it surges, that's normal, upshift.

Thanks Jim,

I'll post up some pictures when I get the cases split.

So here is the source of the metal debris. The clutch shaft bearing is completely broken up and missing some balls. I can move the shaft back and forth a good quarter of an inch. I guess I also know why the clutch was slipping

Interesting, but I'm not sure how that would make the clutch slip. Unless maybe the whole shaft was allowed to move toward the clutch side. I would have thought that something else would prevent that, but maybe not.

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If it surges, that's normal, upshift.

Check that the shaft play hasn't destroyed the primary drive gears as well. A quarter inch out of mesh will have taken its toll on them, also the internal box gears.

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1974 Kawasaki H2B 750, 1981 Yamaha XV750 Cafe, 1986 Kawasaki KDX200, 2003 Honda XR100, 2004 SDG140. 2006 Ninja 500R Turbo intercooled fuel injected.