Gearbox noise "Whirring" in neutral

[Covboy]

Hello

I'm running in my GT240 / Cyclone 5 set up. I was very careful to shim correctly and torque everything properly.

When idling in neutral, there is a noise from the kickstart end of the casing that sounds a bit like the kick start is engaging - like a "whirring" though, not a fast clicking.

Pulling in the clutch in neutral has no affect on the whirring sound
But when I put the scooter into 1st, with the clutch pulled in, the noise stops.

I do not think it is the kick start, because i cannot feel any associated vibration when I touch the kick start, and I have to move the kick start about 3/4 of an inch before the shaft is engaged , which makes a different sound fast clicking sound, and I can also feel the teeth of the 1st gear. Ive also removed the kick start rubber as a test and this has no affect.

I know things like this are hard to diagnose on a forum, but just wondered if anyone else has encountered this or know what it could be.

[nastro azzurro]

Mine does the same.
Had never really noticed it but my friends commented on it whilst on the way to Italy last year.
Stripped it before we set off the next morning and couldn’t find anything wrong. No wear marks or anything.
Put it back together and carried on. Spoke to Dean at the rally and he was aware some gearboxes were noisy. He offered to change it if I wasn’t happy. I’ve left it and it’s still noisy but it doesn’t worry me now to be honest. Prob about 4000 miles on this one now.

[Covboy]

Thanks interesting - thank you -to confirm - does your noise stop when you select gear ? I m suspecting it’s the gear box shim making the noise, maybe loose under no load in neutral spinning/ vibrating, and when a gear is selected under a load it stops spinning/moving

[nastro azzurro]

Yes it does. I thought it was maybe the cogs spinning when in neutral and once under load (in gear) it stops.

[CHRIS in MARGATE]

Chain tension ?

[Covboy]

Hi Chris - I thought that might be it but the chain is quite well tensioned and the sound seems like its coming from further back...I tend to agree with Nastro ( and hope ) its just a noisy gearbox

& Nastro - just out of interest, are you using a standard side casing or a Casa one?

[nastro azzurro]

Standard side case.
It’s not the chain tension.
If I remember correctly, Dean said that the teeth were different on the latest version.
Like I said, he was completely aware of it (the noise) and offered (without prompting) to change the gearbox for the latest version.
It is noisy at rest but I’m not worried about it.

[ToBoldlyGo]

It's a lot of gears to fit in there. What are they up to now, space station grade metal?

[HxPaul]

It wont be the chain tensioner,the chain keeps moving wether its in gear or not.Its something to do with the gears or bearings,if the noise stops once a gear is selected.

[Covboy]

It was the kickstart - I took the casing off and noticed some witness marks on the kickstart teeth.
Adjusted and all ok now.