Whoa. The W thread was getting buried way too deep in the sea of threads!
Anyone been out riding? I took my new W out for about 100 miles. Wind was blowing like hell and only in the mid 40's. The low bars helped with the wind! New Race-Tech front and Koni rear shocks made a definite difference in ride quality!
After returning, I decided to do the bevel gear backlash adjustment mentioned in the following article and in the service manual. Has a neat cut-away drawing of the engine too.
My W is quiet for about the first 15-30 seconds at cold start up and the the backlash noise crops up pretty quickly and is significant. I have listened to a few idling on youtube and they don't seem as noisy (hard to tell though). I have read the cautionary tales about people messing with the bevel gear assembly. Usually that is if parts are removed though. The manual and article mention that 70° adjustment in either direction is a maximum limit. I found that I could make a significant reduction in clatter by moving around 10°. Only the lower joint needed a bit of adjustment. I still have backlash noise, but I figured I would error on the loose side rather than risk a binding situation at start-up. I also wonder if the splines in the bevel gear shaft aren't a little loose after 40K miles. Anyone else have a significant clatter from the bevel gear side?
BTW, didn't know if anyone else had found the online version of the Service Manual.