Well for the past 2 weeks my trans has been rattlin and i thought the clutch basket was toast cause it would quiet up when i pullin the clutch. I tore it down to find the clutch basket looked like the day it was new and is tight. All the bearings are tight. Is anyone elses doing this? I realy dont want to dig into the trans again! Only thing i can figure is when my trans went the first time some of the debree got into a trans bearing and is on its way out. I was thinking bout letting itgo and hopefully it will be alright and replace the whole works when the 2002 trans gears are available but i dunno...... It does sound pretty sick.

 

Are you POSSITIVE that the rattling is even comming from the engine? Rattling noises have a way of transfering from one place to another and sometimes are hard to pinpoint. Of all the parts on a vehicle (anything with an engine), the part that I've found to transfer rattles the worst is the exhaust (check it first!). The engine/frame has a different natural frequency (mechanical engineering term) when the clutch is pulled in since less masses are turning. When the natural frequency of an object is reached, it will vibrate wildly.
With the engine running and the clutch released, try applying pressure to various parts of the bike. Try to find an area that muffles the noise when pressure is applied. If this fails and the motor seems to be the culprit, a mechanics stethiscope can sometimes narrow down the possible areas to dig into. If you drain the oil, run a magnet through it, and find no metal shavings, I wouldn't bother to open the trany. The transmission could still be your problem but the chances are slimmer.

 

This is probably stretching pretty far for a simple solution but remove the gas cap next time to see if the rattle goes away. The ball bearings can cause a pretty good rattle from time to time. The headlights can rattle a lot too.

Good luck, hopefully it isn't in the transmission again.

 

bummer i hope my raptor dont break anytime soon.