[Chrisg73]

Hey everyone,

Was out for a ride today and noticed I had a clunking sound coming from what I believe is the clutch. When sitting in the garage I tap the throttle to bring up the rpm but not move and I hear it every time. Don't remember hearing it before but now with the windshield and roof on I think it is making it more noticeable. I would assume this is weights in the clutch but just want to make sure it not something serious.

Thanks

[NMKawierider]

If you can make a video of it and post it we can tell better. On the 800s, the wet clutches make some noise on engagement.

[Chrisg73]

It sounds exactly like someone is taping on the case with a plastic ended mallet or a screwdriver handle. Kinda hollow sounding. Not a metallic sound.

[NMKawierider]

It sounds exactly like someone is taping on the case with a plastic ended mallet or a screwdriver handle. Kinda hollow sounding. Not a metallic sound.

And this is in-gear..not neutral?

[MarianT]

When the engine is cold, its louder?
These cvts are noisy and normal on a 800.
I did a thread of a wet clutch and one way bearing problem on my 800 ex with 7 kms.

[Chrisg73]

Hey MarianT. Just watched your videos and my noise is nothing like the one you have. I have no noise whatsoever under idle and no noise while driving. When I tap the throttle in neutral or in gear it sounds light weights flying out at a certain rpm then returning when rpm slows down. I can understand this is probably weights starting to activate the clutch but like I mentioned I don't remember this being so noticible before I put the windshield and roof on which is just probably making the sound more intense. Anyone have a breakdown of the clutch and related components?

[emersonsc]

Hey MarianT. Just watched your videos and my noise is nothing like the one you have. I have no noise whatsoever under idle and no noise while driving. When I tap the throttle in neutral or in gear it sounds light weights flying out at a certain rpm then returning when rpm slows down. I can understand this is probably weights starting to activate the clutch but like I mentioned I don't remember this being so noticible before I put the windshield and roof on which is just probably making the sound more intense. Anyone have a breakdown of the clutch and related components?

Hope these help you find what youre looking for

[Cosmosdan]

When I went with lighter weights I did start to hear them more. Sounds like a hard plastic mallet on something hollow.

[Chrisg73]

When I went with lighter weights I did start to hear them more. Sounds like a hard plastic mallet on something hollow.

That's exactly what it sounds like.

[Chrisg73]

Hey MarianT. Just watched your videos and my noise is nothing like the one you have. I have no noise whatsoever under idle and no noise while driving. When I tap the throttle in neutral or in gear it sounds light weights flying out at a certain rpm then returning when rpm slows down. I can understand this is probably weights starting to activate the clutch but like I mentioned I don't remember this being so noticible before I put the windshield and roof on which is just probably making the sound more intense. Anyone have a breakdown of the clutch and related components?

Hope these help you find what youre looking for

Thanks for the breakdown. Now I can understand what's happening down there.

[NMKawierider]

Mine makes this dull knock when cold just off idle and quits when it starts moving. I changes the rollers to lighter sliders when I did the clutch work but that made no difference in the noise. It goes away when warm so I figure its the shoes on the wet clutch. Its done it sense the day I bought and it hasn't gotten any worse...and I do hear it better with the windshield in oddly. I'll try and do a sound clip next chance I get.

Here's a pic of the all the components system:

[emersonsc]

The noise is from the wet clutch shoes releasing and retracting. I should be getting my unit back from STM within the next week or two, and it will have the wet clutch removed. Ill let you guys know if that got rid of the noise.

[MarianT]

I hate the wet clutch, engine brake is too strong. Keep us informed.

[NMKawierider]

I hate the wet clutch, engine brake is too strong. Keep us informed.

And I think the engine braking on these isn't strong enough...lol  although much improved with the secondary set harder. Anyway with any CVT system you will have engine braking as long as it back-shifts on deceleration and prior to the primary or wet clutch completely releasing the belt or CVT system. Without the wet clutch, the primary will have to be able to release the belt. This type of system is used in many Kawasaki's and several others. Although it does offer a better initial hit, it does shorten belt life as it causes a spinning primary to close on a stopped belt. Others such as the Yamaha, Suzuki and the newer Kawie Teryx use a wet clutch system and enjoy many many thousands of belt trouble-free miles. I have already been several situations that if I hadn't had a wet clutch, I would have been replacing a belt. I think the key here is having a wet clutch large & designed well enough and tune-able for one's needs. JMO