idle adjust

[kinger]

You should be able to set the idle up to say, ... 1800 Rs with no problem. If you cannot, then there is something else wrong. May be time to clean the carbs. After you clean them, sync them. Then set the idle to 1600-1800 RPMs. If you do this, the gear reducer rattle will go away.

The rattle with the gear reducer is a common noise. The best work around is to set the idle to 1600 to 1800 Rs. The rattle is coming from the large tolerance between the two gears. The tolerance was reduced in later models

I thought it was straight cut gears on the 03's vs angled gears on the 04+, thus the 03 gears are stronger but louder?

 

[Len Todd]

The clutch rattle typically comes from excessive tolerance in the Primary's sliders. It is more noticeable on a 3-holer or when the carbs are out of sync on the 4-holers. There is an O-ring kit to fix the excessive tolerance in the sliders. Or, ... you can shim them. Either way takes the rattle out of the primary.

The older (03) had excessive tolerance in the reducing gears. In 04' they decreased the tolerance. Later, they actually changed the gear ratio a bit. This rattle is most noticeable again when the carbs are out of sync or the idle is set below 1500 RPMs.

If ya don't believe it, try a search on "rattle" or "clutch." Just be prepared to read for a while cause there is a ton of info on these two noises.