Vmax 600XT -96 clunking at start.

D

Diversion

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Mar 3, 2009
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sweden
It started at the end of last season. When starting from standstill it's a clunking noice but once in motion everything works fine and it shifts as it should. If I'm in motion and give full throttle it's not there, only from standstill.

I tightened the chain as per instructions in the manual but it didn't help. If I grip the secondary clutch and twist, it feels tight, it's not moving coaxially like when a bearing is worn. However in radial there's a huge slack. If I turn it and look on the side where the chain housing is, the brake disc can rotate almost 10 degrees before I meet any resistance, should it be like this? Even if the chain and sprockets are worn i can't imagine it would be such a gigantic slack. It''s 3000 miles since brand new so the sled hasn't been used much.
 

Belts make noise when there is a flat spot, also there is a key that is in the brake that could wear. II would lean toward belt, as I dont see how the play you mention could be more than one clunk right at engagement then the slack would be gone. If that makes sense.
 
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At first I would think it was too much chain slack too but I would check your primary clutch.....worn ramps or a broken spring in your primary would cause it too...I would start it with the hood open...rev it up slowly with your hand on the brake and see if the primary clutch engages smoothly or all at once...another thing to check is your drive shaft bearing opposite of the chaincase...they take a lot of abuse and can fail...... and like captnviper said a worn belt could be the culprit
 
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X3 - likely the belt. Common by-product of off-trail riding and trying to power out of stucks. If it isn't the belt check your chain, gears and shafts. Especially the drive shaft. Finding the issue now before carnage might save you some buck.
 
if you grab the brake does it do it, basically the opposite of when you take off

Have you tried doing it on a stand to see if you can isolate the noise, maybe even with parking brake on and see if the noise occurs possibly indicating issues is in the clutches (since chain track etc. are not moving).
 
super1c said:
Sounds like break rotor key wear to me.
Click to expand...

Don't know how it could be I've almost never use the break, this happens even if you feather the throttle to make a slow smooth start. Reason I mantioned the brake disc is that I used it as a reference for how much I could rotate the sceondary before it met resistance . I'm not sure what you mean by "key" since I'm not US. Don't have the sled in the yard but will check later.
 
It is a keyed shaft - a small insert that goes into a cutout in the jackshaft and the brake rotor hub cutout to keep the rotor from spinning on the shaft. Similar to a Woodruff key if you know what that is or look at a picture on the web.
 
If you hear noise from clutch side ,,,,,,,, do not lock up your break (as in a skid) your bearing is probley failing,,,,,,,,, (New belt,& both springs,,,,,,,,,,,,, cheapest place to start........................
 
Since you are seeing a large amount of movement in the secondary shaft before you feel any resistance, The slack is in the chaincase or the track drive cogs.
Rotate the secondary shaft back and forth and watch/feel the drive axle for movement, if loose its in the chain case. If tight , see if the drive cogs are loose on the front drive axle.


super1c said:
Sounds like break rotor key wear to me.
Click to expand...
The brake rotor is splined on.
Rustman said:
If it's a two piece jackshaft i would be looking at the place where it connects.
Click to expand...
Starting in 95 the shafts are one piece.
s-l1000.jpg
 
I checked and as caravanman says the rotor is splined on and the shaft in one piece. I posted some videos of the clutch working:



https://www.youtube.com/channel/UC6rmtUlfdmz5CtAzEc5oU7Q

As you can see in two of them I don't really notice any slack in the chain since when I turn the secondary by hand, the track follows without delay. It's strange, it felt much more the first time I checked.
 
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The speedo side axle bearing I have lost caused a ROAR sound when the sled was up to speed. The speedo also stopped due to the short link breaking.

Diversion, does your speedo work?
 
Just ordered a new belt, I'm also going to check the track tension and see if it improves. Would you say from the other video that the clutch seems to be working as it should?
 
Please, try tightening your track. I can see it sagging in the video. Your clutches seem to be working perfectly. I don't care for the belt. Yamaha belts are much better.

Good luck.
 
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