Ever since Ive had my P650 on the right side down by where the belt cover is, theres a funny or strange sound when its idling. Sound like air making a low baffeled knock sound.Dons't sound mechanical at all. Its very noticeable when I first start it when its cold outside. Once the motor is warmed up or its warm outside the sound is still there but not as loud. I'm going to take the cover off and see what I can see. The sound is hard to explain ,but if anyone has experienced anything similar give me a shout. thanks

 

This is natural and will not hurt anything or now.It is the bushings.There is one in the outer cover and one on the moveable sheave.I just recently replaced mine and it quieted it down.If you take the cover off grab the primary pulley assembly and shake it.It will have some movement but if it has alot the bushings are most likely out of spec.
Some will tell you it's the shoes but I don't know anyone that has replaced them.Mine were still ok.I do know people that have replaced the bushings.
02 650 camo

 

Yup, it's the bushings. Mine are toast and it's time to do them. Gotta make a tool to get the clutch apart first. I'm gonna make a set out of oillite brass and check my shoes while I'm in there.

 

where are the shoes, how do you inspect and service them, and what do they do. thanks for the reply in advance.

 

I first went ot the dealer and let them crack it open.Then I replaced the bushings and took it back to then to tighten it up.They twisted the fixed shaft that goes thru the inner sheave.I bought a new inner sheave ($220.00) and THEN I asked the dealer if I could borrow the holder to do it myself.He let me (I gave him a deposit) and tightend the new one myself.Kaw says to torque it to 205 ft lbs but thats how mine got twisted.I "only" torqued mine to 160 ft lbs.It's a left handed thread so I don't think it can come loose.I just did about 140 miles at H/M with no problems.
The outer bushing is only serviced with the cover ($60.00) and there are three diff ones.The inner is sold by Kaw and is cheap.I was going to have them made but decided at the last minute not to.
The shoes are the parts that transfere the power while aloowing the sheave to move.They are small black round looking shoes.Mine were ok at 1400 miles.If you look at a manual you will see them.
02 650 camo

 

BTW...you need the puller to get the primary off...I got mine from EPI.
02 650 camo