Banshee0028

Here is a link to how it sounds: http://s121.photobucket.com/albums/o215/ba...=MVI_2311-0.flv

I put all new kicker springs, new washers and clips for the idler gears, and it sill does it! I think I know what it could be: There is a little bit of play between the clutch gears and the primary gear! I have a new basket so the cushions are perfectly tight. The play is between the gears themselves and along the shaft. With only the basket on the shaft, it has a little play from left, right, up and down even with the clutch nut on perfectly tight! Is it possible to replace the copper looking bushing in it? I think thats what I might need to fix this..

Well I got it to start! I think the kicker spring may have not seated all the way back? Plus I am starting it without oil since I am making sure it works before putting it all back together. Its still making the sound it was before which I think is the clutch basket bushing that needs replacement. The basket is new but when I try to manually turn the clutch basket the gears have play between them and the primary gear, just a little but enough to notice and make noise.

Thing is that I can kick it over fine with the ignition off and it seems to work great! I did put a new kicker spring in there but its installed just how it should be from what I can tell?

Well it was running fine the day before, timing should be ok from what I can see. I will check comp in both cyl's next. Any other ideas?

I opened the clutch cover to replace the kicker springs and primary gear. Now when I try to crank it, the kicker kicks back and it dies right away! It sounds like it started then immediately dies! The kicker seems to be going in the right direction and you can only put it on one way! It works fine with the ignition off. Everything should be installed perfectly! I even checked the flywheel nut and key and they are both seated perfectly and tight. I have an adj plate at +4 but did not mess with that at all, and its still at +4. It started just fine a few days ago before I took the clutch cover off to fix the noise it was having! Any ideas?

Thanks everyone...Ordered a new washer and clip. Will replace and see if that was the problem this weekend.!! :thumbsup:

Is it possible for the kick starter assembly to be installed wrong causing noise even though it seems to work? I will be taking everything apart this weekend, but I just want to have a better idea of what is causing these problems!

Thanks theshee...LOL But thats exactly what I just did after your recommendations. Put in a new basket and cushions and it does the same thing :: I think this is more of a metal on metal sound but not that bad like a grinding sound. Thats why I think its either the new primary gear OR the kicker gear and idler gear thingy .... Will post link soon...

Rebuilt motor and put in a new clutch and primary gear. The primary gear has a "91" etched into the side of it when my old one had a "90" on it. Not sure if that would cause a difference meshing with the original clutch gears or not. I used a mechanics stethoscope today and isolated the sounds right around the kicker area. So I am thinking the idler gear may be rubbing with the clutch gears. When I turned the clutch over manually it did sound like a small amount of occasional rubbing when spinning? The c clip was on there a week ago, but I am taking it apart this weekended to check again. The kick starter appears to work fine, but could it be possible for it to be installed wrong? I have the spring into the one groove in the case, and the other part on the top dowel on the side. I have a video with sound of how it sounds when running I will post soon..... Any suggestions so far?

I would think you mean between the seal and the impeller. So I tired this today with one washer and I was still able to push the impeller from the outside and caused it to rub. I went up to 5 washers and it still rubbed!! Then I figured out that my water pump seal and bearing could probably be hammered in about a washers diameter further into the cover!! Maybe this is whats causing it to rub. I think if I hammer down the water pump bearing flush with the inside clutch cover, then it should line up nice and never rub?

So just one washer closest to the impeller itself? I will have to add a washer this weekend!!

Well, there is still some free play even with the washer and clip on the back side of the gear. If I push it in towards the outside of the clutch cover ans spin it, it wont rub at all, but thats the problem, when its running will it be "pushed in" and not rubbing or will it be rubbing?

I dont think its really bad, but it looks like it has been rubbing the inside of the clutch cover for a while. I thought about sanding down that area, but unless we put something on the inside like a washer to hold it in place it might still rub even after sanding it?

Yep pro design for me too. I was thinking of using some kind of washer but not sure how that would help as there is nothing to hold it in place, or it might catch on the impeller fins?

I have a billet water impeller and it seems to be rubbing on the far inside of the clutch cover when i try to spin it unless I put pressure to push it out some. Not sure if this is normal or not. Maybe when the engine is running, its "properly" aligned and not an issue?

Definitely check for leaks: use some carb cleaner around the intakes and such and see if the idle changes. Also like Snop says, did you do a plug chop to tell if its really lean? I would think for your mods and temp, a 195 should be about perfect, if not then maybe a 180-190. But first need to check for leaks, plug chop, etc.

Hmm, so you really think its the cushions, huh?? I will also check the idler gear, but its definitely inside the clutch cover area. I seen the link, thats a great how to. I will use that if I finally get the Magnum basket! Oh, and it does it with or without the clutch pulled in. However once its in gear its a little quieter. Not sure if that helps....

Ok I just rebuilt my motor and just realized there is a little clutch chatter from the clutch side. Its not loud at all, and its not a high pitched sound. Its a pretty low deep sound and you can hear the clutch spinning, but not like its rubbing on something. kinda like a constant ggrrrrrrr sound.. (Its not easy describing sound in words I did some searching and it sounds like it might be my clutch cushions? Well the stock plate does have about 1/8 or 1/4" movement in it, but is otherwise pretty tight. It has Jeff's clutch kit in it and otherwise works Great! I would not mind installing the magnum basket if I had to, I would just feel better knowing that this was the cause and not something else. I don't mind taking the cover off and making sure everything is tight, but wanted to get some ideas of what it could be. It could be normal, but I don't think I remember this sound before now.... :shrug:

Yep, thats what i am planning on doing since I already have both, a 35 and a 38. Its going to take me a few weeks to dial each in but I will report back once I find out .

I was thinking of trying out a 38 also as I have both. Have you ever tried a 35 or just the 38? What mods do you have and what jetting if you dont mind... :cool:

Nice 450! Just out of curiosity, how does it compare to your shee??

Maybe its just me but this seems like NIGHT all over again

Any idea what your compression is?

Actually after reading this, yea you most likely do have engine damage, although I would still check the clutch first. But you most likely need to rebuild