Ieat4strokes Posted July 10, 2009 Report Posted July 10, 2009 (edited) Dave mentioned I should pull clutch cover and check for broken plates etc, well this is what i found, seems something is rubbing the direct drive cover, basket maybe? and something else is rubbing the rivets on the basket itself....I didnt remove idler gear and i think thats the only thing that could do this.....BUT i did put kickstarter assembly in wrong, the spring tab on the back of the gear, i didnt put it in the recessed area in the case, maybe it was coming in contact with the idler gear while running? Heres the pics? what you guys thinkk???? The nick in the cover itself is actually a nice gouge....damn camera phone wouldnt pic it up well.... but its close to side that mounts to case maybe the gear on back of basket? Edited July 10, 2009 by Ieat4strokes Quote
Drewski Posted July 10, 2009 Report Posted July 10, 2009 how much play does the idler gear have in it? i just fixed mine it had to much play then broke a tooth off and made a big mess of my basket and seals. it also sounded like a knock Quote
dajogejr Posted July 10, 2009 Report Posted July 10, 2009 I've got two ideas... Once, you're missing a washer, spacer, something....or put one in the wrong place, etc. Even though it's a stock basket, even worn cushions won't cause it to rub. Get your clymers, go by piece by piece the installation, spin it over and check for rubbing. Quote
LiftdT4R Posted July 10, 2009 Report Posted July 10, 2009 Hmm, how now is the direct drive cover? Ive had a knocking type noise ever since I put mine on last year, but I know for sure its not the engine, I may have to pull the cover and take a look. Quote
Ieat4strokes Posted July 10, 2009 Author Report Posted July 10, 2009 i mean i can wiggle it back and forth but it dont look excessive.....but that idler gear does look real close to the back of the basket.. Quote
dajogejr Posted July 10, 2009 Report Posted July 10, 2009 Pull the window. Put the cover back on with 2-3 bolts to hold it tight to the motor. Kill the ignition and remove both spark plugs, turn off the fuel valve and turn it over by hand and try to isolate the noise. Quote
Ieat4strokes Posted July 10, 2009 Author Report Posted July 10, 2009 (edited) I got the cover from "arfountains" off here, not sure how new it is but im tempted to take lockout off, throw stock cover back on and see if it goes away.....it seems everything is on right according to manual Dave - as far as the book goes, im not missing no pieces.....im going to try your advice and see if i can hear anything, also on my fibers, somethings rubbing the outside fiber by the pressure plate..... i dont even see what it could be..... its on the tabs facing outward....the shiny grey on the tab is the scuff marks im talking about Edited July 10, 2009 by Ieat4strokes Quote
blowit Posted July 10, 2009 Report Posted July 10, 2009 I got the cover from "arfountains" off here, not sure how new it is but im tempted to take lockout off, throw stock cover back on and see if it goes away.....it seems everything is on right according to manual Dave - as far as the book goes, im not missing no pieces.....im going to reassemble everything and see what happens Why don'y you just pull the guts out of the clutch entirely and fire it with just the basket in place? At least get the lock up hub, plates, and trans out of the equation. B Quote
Ieat4strokes Posted July 10, 2009 Author Report Posted July 10, 2009 FIRED it up without cover on and no knocking at all.....put cover back on filled it with tranny fluid because i thought it was fixed and when i first started it NO knocking and then the knocking gradually came back..... then if you put it in gear let out on clutch it quits again, like the noise comes and goes or fades in and out........do all direct drive covers not have a vent hose? mine doesnt......and the sound sounds like its coming through the T5's like a hollow ping through the pipes, it dont sound like its coming from motor..... Quote
dajogejr Posted July 10, 2009 Report Posted July 10, 2009 Did you follow the clymers manual and put parts back one at a time and in order? Newer direct drive covers have the vents removed.... Quote
Ieat4strokes Posted July 11, 2009 Author Report Posted July 11, 2009 (edited) I mean yea. I put on thrust washer then the spacer clutch basket 2nd thrust washer innerhub lockwasher then tightened it down. Put in fibers and steels then pressure plate and lockup fire it up no knocking. Put on cover filled it with tranny fluid and fired it up and the knocking gradually came back but it fades it and out. Knocks for the most part but sometimes stops. It's coming through pipes like a hollow knock sound. It seems to be coming from top end. If I get underneath it with a screwdriver to case by crank I can't hear it. It's up by cylders head exhaust area. Edited July 11, 2009 by Ieat4strokes Quote
kubitza123 Posted July 11, 2009 Report Posted July 11, 2009 Well atleast things are sounding better and most likely like its nothing major which i'm glad to hear. Makes me feel better beens i knew everything you got from me should have been in ex shape. Let me know when you get it cured for sure and how you like the power. Quote
Ieat4strokes Posted July 11, 2009 Author Report Posted July 11, 2009 im about to throw the damn thing in a lake......i dont know what it is and im tired of fooling with it to be honest, i bet ive tore this motor down 8 times......im sending it off. Quote
Darthwall Posted July 11, 2009 Report Posted July 11, 2009 keep us informed on what it turns out to be I have been down the same road you are going down right now I got fed up with the same thing and since then have replaced everything except the crank! did you ever replace the wrist pin bearings when doing the top end? Quote
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