2002 CR80 Squeal

[Chuck Frozina]

 https://vimeo.com/121853547 Hi all, Luke was out blasting on his 2002 CR80RB and the bike started making a squealing noise. I have linked a video highlighting the noise and thought one of you could steer me in the proper direction to fix it. Take a listen to the video, the bike is in neutral with the plug out when I recorded the noise.  Thanks

[Donn Nay]

sorry, can't hear anything besides the kick/ratchet. Does it do it when in gear? Clutch in or out? does it vary with engine speed or bike speed?

[Chuck Frozina]

https://vimeo.com/122046289 Try this video instead. I crank it and the sound is not there then it shows up. I ran the motor today and did not hear the noise.  I drained the oil yesterday and refilled it today and now it won't go into gear. the gear shifter moves up and down and the shifter rod is moving with it but doesn't seem to be doing anything inside. There is no resistance when moving the shifter.

[Donn Nay]

still don't hear anything. Did you pull the clutch cover? When you move the shifter the linkage should turn the shifting drum, if it turns the drum and it doesn't go into gear then there's an issue with the shift forks or gears, split the cases. If when you move the shift lever the linkage doesn't engage the drum, or move it correctly then it's probably worn out and needs replacement, easy fix. Try turning the shifting drum by hand and see if it goes into gear.

do you have a service manual? If not, stop and get one before proceeding.

you can download one here:

https://www.tradebit.com/filesharing.php/search/0/cr80r

for $5.00 but search around I got lucky and found the original factory service manual for Kyle's KLX450R on line for free. I downloaded it and printed it out and put it in a binder.

[Charlie & Darlene Barney - Life Members, 2015 President]

Donn is sending you in a good direction.

The Pres 

[Donn Nay]

Donn is sending you in a good direction.

The Pres

That's what we're here for right?

[Chuck Frozina]

OK the problem of not shifting into gear was caused by the new oil drain plug I put in the bike.  The original one was a little chewed up so I had a spare for my bike and it was a little longer than the other one and was not letting the shift lever complete its travel.  After figuring out that I ran the bike for about 20 - 30 minutes and could not get the noise to duplicate itself.  So if/when it returns we will deal with it then.  Thanks for the info and I had already bought the manual from that exact site that you posted Uncle Donn.

[Dave Springer]

Well that was far easier than having t split the cases.  Good catch.

[Donn Nay]

Very cool!

[Charlie & Darlene Barney - Life Members, 2015 President]

Looks like we have Chuck competing for James nick name Drain Plug. What is it about Rosamont and drain plugs?

The Pres

[Chuck Frozina]

Thank CB, but I think I'll stick with "Cousin Chuckie."

[Donn Nay]

Thank CB, but I think I'll stick with "Cousin Chuckie."

Not sure really, might like "Drain Plug" better. Your physical profile fits that nickname better.