[Hank68]

 Hello all, I purchased my ATV @ 8 months ago, it has less than 400 miles on it right now. I have had it in the shop for a knocking sound which the dealer determined was a bolt/nut that came loose in the clutch. It is now making a noise that sounds more like piston slap and is worse at idle. Once I slightly throttle up the noise goes away and will only return at idle? I did take it back to the dealer and they said it was some loose screws on the Right side clutch cover? They charged me $86 because they said they didn't have to order any parts and the warranty would not cover. The noise is still there and it definitely does not sound right, several friends that I rode with today made mention of it and they also agree that it doesn't sound healthy.  Has anyone experienced this with their machine? Any suggestions would be appreciated.

Thanks and safe riding.

[Wheels]

Sounds like the larger hat bolt backed off, this would have caused the hat washer to release from octegonical  match with clutch hat and washer
When this happens it messes the clutch hat up, and will need to be changed along with washer and nut.
the 15/16 yr models had a lot of problems about this as the bolt was under torqued and left hand thread.
They changed to right hand thread and increase the torgue and added blue lock tight, problem  solved

[Hank68]

Thanks Wheels, I guess it's back to the dealer I go. You all were very helpful the last time I took it in, I was much more prepared to explain my predicament. I'll let you know how it turns out but my local dealer is very slow on getting things done! I'll have the first service done as well. Thanks again.

[Wheels]

Here is what I believe happened to cause the noise at idle
You see the corners are not sharp anymore, this always the hat to move and knock.

[Hank68]

Much thanks for the pic Wheels. This sure seems like it may be the problem. I did check the oil for level and any signs of metal and both checked out ok. Would this fix for the hat be extremely difficult? Just asking in case I don't get the support from the dealership.

[Wheels]

Easy, about 2 out f 5
As you need to make sure the washer sits on the splines, or else I'd give it a 1 out of 5

[Hank68]

I might just take it myself tomorrow, I don't feel like dealing with the shop and waiting 2 to 3 weeks for my machine. Thank you Wheels for taking the time to share your knowledge, it is much appreciated.

[Wheels]

No worries, let me know if you need any help

[Hank68]

Just as you explained Wheels, the hat was the problem. My picture doesn't do it justice but it is almost stripped out. I will definitely need a new one. I did re-set the washer and tightened it all back up and it's quite! 😃  Now making the dealer understand without putting myself in a bad way for opening it up? Who cares at this point...just happy it is resolved and no engine damage. Thank you Wheels.

[Wheels]

No worries, Happy trails

[Srkennedy]

Does anyone have a part number for a new hat, not a complete clutch assy.?

[NMKawierider]

Does anyone have a part number for a new hat, not a complete clutch assy.?

Look it up on Alpha-Sports..see if you can just get that part.

[Workhardplayhard]

Hay guys. Mine started giving the same symptoms on my last ride. It did at about the last 10 miles. It's got 506 miles on it now. Of course the first thing I did was check the oil lol. Couldn't figure out what it was but no trouble codes and no power loss so I kept going. Found this post after getting home and took it apart. Sure enough the bolt had backed off a tiny bit. It didn't look as bad as the pictures here. Looked similar to the pic wheels posted. So I put it back together with lock tight on everything. Fired it up with the cover off and it makes a very light sound. I assume it's the weights rattling a little. As it's reved up a little it goes quite. Of course I don't have a replacement hat on hand so I put the cover back on anyway. With the cover on it's as quite as it was new. So I'm wondering how much noise is normal with the cover off? Should I worry about replacing the hat? Or should the lock tight have me fixed up?
Thanks for all the help! This forum is awesome!

[NMKawierider]

I think as long as it's tight to the shaft it should be OK.

[Skogsvarelse]

if you tighten it up properly with lock tight you should be fine but youst in vase ceep an eye on it andd listen if you start to hear the noise again