Project ‘89 FZR250r 3ln1

Generally, when it's noisy with no load - and quiet when the clutch is lifted - it's basket endfloat.
It's measured by exposing the clutch and removing the plates. Then a dial gauge onto the outer edge of the basket - in line with the shaft. Move the basket in and out and see what the endfloat is. Don't know what's in the manual but usually it should be no more than .002in.
There are ways of reducing it - but usually involving machining and possibly using a spacer shim. Some engines - early big Hondas for one - are more prone to it than others.

 

If it hasn't come off yet, it probably won't. The clutch cover's thick, I'd reckon all the bits will stay inside.
To generalise again, it's bigger bikes that usually have the retaining nut come loose.

 

That rattle is mostly the worn/hardened clutch basket rubbers - the quote I first encountered when signing up here is that they sound like a rattling bag of spanners, which is very true, mine did 35,000 kms sounding like that - the transmission never missed a beat, carbs well that's a whole other story now isn't it

 

actually removing that clutch cover is easy, BUT do yourself a favour and go and buy some gasket paper first, it will tear when you take the cover off, then you just trace out a new one and cut it - hole punches for the holes - two sizes, larger holes for where the locating dowels go

Then you can use a sharp craft knife to trim the inside contour

I use a very small amount of gasket goo onto the cover sealing edge, put the new gasket in place with the locating dowels, another very small amount on the gasket, put it back into place

There is a lock washer which holds that shaft retaining nut to prevent it from unscrewing, I would be surprised if it is loose

Also note that the clutch pressure plate with the 6 bolts is keyed and only goes on one way, screwing it down in the wrong position will break something

 

I swear permatex 85420 has kept me from replacing gaskets due to sticking to cases, would love for someone else to try it and confirm! main tips: thin and even on both sides of the gasket, let it 'cure' before assembly. per permatex themselves "enabling repeated assembly and disassembly of parts." I've even had luck gluing together a paper gasket with it.

 

I'd have to check what I've got, coordinated firing of neurons says it's permatex, small bottle, white plastic, red lid - non-hardening - just found one bottle - loctite, but I know I've got some permatex also - great stuff