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post #1 of 4 (permalink) Old 05-12-2011, 07:35 PM Thread Starter
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weird rattling sound

Hi guys,

Today my bike started making a weird little rattling sound like a loose nut bouncing around the engine I guess.

The rattling happens once I rev over about 4K and , only when I am in gear. If I pull the clutch while rolling, it goes away.

It seems to come from the left side (starter cover) but not sure since I can't really listen to it when not moving.

I already opened up the head and everything looks good in there.

My carbs are synched, but I did notice this morning like a sneezing sound coming from the cylinder #1 when I started her up this morning.

After the rattling started, I made a 180 degree back home driving like a gandma to avoid damaging anything.

The bike is a 91 bandit 400, I would appreciate any guidance on this.
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post #2 of 4 (permalink) Old 05-12-2011, 10:11 PM
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I had one of those about 20 years ago. The only thing I remember is it was too damn fast for me.
I can't even find a parts fiche... So I'll do some guessing;

Clutch retaining nut backing off?
Loose motor mount?
Shift linkage falling apart?
Loose drive chain?

Tap things with a rubber hammer. Grab pieces and wiggle / push-pull, etc.
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post #3 of 4 (permalink) Old 05-13-2011, 08:26 AM Thread Starter
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Indeed, quite a fast bike for such a small engine

I do have the service manual for it. I will tear into it this weekend and hopefully find the offending noise.

Thank you
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post #4 of 4 (permalink) Old 05-22-2011, 01:38 PM Thread Starter
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Arghhhh!!!

I spent countless hours (in between days of raining sessions) tearing every bit of engine I could get to without dropping it out of the frame.

Nada.... When I started, I found and cleaned out a bunch of pebbles stuck around the exhaust pipes (4 in 1 are good at collecting crap in between the pipes) but still felt I needed to go in there to check.

Now, no more rattle...wasted hours, but at least I have a sense of confidence now that everything I went over looked good.
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