[Sethcfrider]

Hello everyone.

I was recently riding my 2022 zforce 800 trail, when riding I started hearing a heck of a knocking sound and when coming to a stop it stalled out.

When fired back up in park it ran but made a lot of noise from clutch side. When put in gear it would get louder or stall.

So Im thinking the wet clutch is not disengaging or something is wrong with the one way bearing. Looking for a little more professional help! Thanks for reading!

[NMKawierider]

It can be a couple of things but you will have to take the cover off and inspect...the bearing in the cover, the end bolt/nut and actually the rest of it. Then remove the belt and see how the primary spins and if there is any play in the shaft as it could be a bad bearing. Yes it could be that the wet clutch has lost a spring or the one-way has come apart...like some have. It can also be those other bearing causing misalignment or the cam plate stripped it's splines so..apart she comes.

In 2022 you have both wet and dry clutches on the 800s. Are you sure yours has a wet clutch? I guess you will know when you pull the cover.

[Sethcfrider]

Thank you
I got down to the wet clutch, and it is the earlier one so does have the wet clutch. Everything looks ok. While I was in there, I went ahead and replaced one-way and the primary clutch shaft bearing. and the there is still the noise, not as bad but still there. and doesn't want to disengage.

the Wet clutch spring appear to all be on there, but haven't taken off the machine. Just stumped at this point.

Note:The one-way was installed backwards first(only ran on jack stands, never drove), but now installed correctly.

[NMKawierider]

If the bearing in the cover is bad, it will allow the belt to pull on the shaft enough to cause it to make contact between the wet clutch shoes and the bell...so I would look at that..maybe even replace it just for good measure. CFM doesn't put much grease in their stuff.

[Sethcfrider]

I am going to try and attach a video so you can hear the sound. The wet clutch appears to be working correctly but is still making a racket.

Note: the one way bearing is not installed.

https://youtube.com/shorts/_YeW4FEudtY?si=2sbKGGPCiR-M-5gs

Thank you

[NMKawierider]

That is strange. Got any pics of the wet clutch and old drum's inside?

[Sethcfrider]

I do not right now but I can get some when I take it back apart.

Do you think that it could be the clutch making the noise or does it sound like the motor?

[NMKawierider]

Now that you mention it...and I took another few views, the ticking at the start and partly through isn't making the shaft move which any contact with the clutch should. How's the oil pressure? How long does it take for the light to go off? Hate to think its a rod bearing..and with that tick I wouldn't think so but how it sounds when you first hit the throttle says "spun bearing". 

[Sethcfrider]

Not sure if there's a way to check the actual pressure, but after I start it the light flashes for 2-3 seconds then shuts off.

I appreciate all the help!

[NMKawierider]

Between the two cylinders on the case is the oil pressure sensor. You can pull it and install a gauge long enough to test it. One with a bearing problem will have very low pressure...sometimes just enough..like 8psi..to just shut the light off. Remember the threads are metric..so don't screw anything NPT in there.

[Sethcfrider]

Okay I will dig more into it!

I just pulled the wet clutch out(so there is not drive train in) and the noise is still there.

so its gotta be a rod knock or spun bearing?

[NMKawierider]

Okay I will dig more into it!

I just pulled the wet clutch out(so there is not drive train in) and the noise is still there.

so its gotta be a rod knock or spun bearing?

Something...let's check the cam pier castings...some break. Just pop the caps off and look at each end. And check the chain tensioners and bars...they fall apart sometimes. That ticking sounds top end, that why I want to check these things.

[Sethcfrider]

I went under both valve covers and everything seamed to be in good condition, even fired it up for a second just to make sure and it looked good.

But I did pull the oil filter and there is a lot of copper colored flake.

Thanks again for the help!

[NMKawierider]

F'k.....well, don't run it anymore. She has a bearing problem looks like.

[Sethcfrider]

yeah, definitely a bummer.

Do you think I should flush oil cooler?