Low speed clunking? How much brake play is too much?

J

jwhalen123

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Jan 8, 2013
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Age
45
Location
VT
My sled clunks fairly rapidly when going slow. As soon as I get up to trail speed it seems to go away or I just can't hear it. everything in the chain case checks out. It doesn't look like the heat exchanger cover is in the way. The only thing I can really see is the brake rotor may be loose. What is the amount of acceptable free play? It moves side to side about an 1/8" and front to back quite a bit, maybe 10 degrees or more??
 
My brake rotors have always had free play, I never measured it but likely similar to your numbers.

If your bearings checked out a-ok in the chaincase, check 'em on the opposite side of the tunnel, one bearing behind the secondary clutch, and one bearing on the axle behind the speed pick-up. They do go bad and can make a clunking or thumping noise that can go away with higher speed.
 
Thanks guys. I'll change the belt today since it's the easiest and if that doesn't work I'll look into the bearings more.
 
I had same problem with my 99 Vmax 700. I replaced all the bearings and still goes clunk at low speed. Gonna try the belt next. Chaincase bearings need replacement as the round magnet apparently came off the dipstick and had gotten chewed up. Magnet chunks all over in the chain case!
 
Hopefully the belt takes care of it. I just went through this on my Viper. Checked track tension, belt and then decided to tear into the bearings. No way to tell if they're bad unless they are totally shot and you're getting movement on the end of the shaft. My lower drive bearing in my chaincase was toast! Once I had it out, I could basically feel every ball in the bearing. Other bearings were good but changed em' anyways. Not too bad of a job. Good to go now and no bad noises. As far as the brake rotor, mine is the same way. I ordered an extra key for the shaft just incase but tolerances were good. I only notice it when I'm on the brakes hard.
 
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The belt took care of the clunking but something must have got bound up in the secondary clutch when I depressed it to change belt because it got stuck open and now there is a high pitched squeeling noise coming from under the hood. It also seems like i have to rev high to engage now... Maybe 5k or so? Although that would sound more like a problem with the primary as well or am I wrong. One key piece of information was that this sled was completely underwater from a flood and I've just finished rebuilding it and getting it running good.
 
most likely need to take washers off them 3 8mm bolts on the backside of your secondary. When belts wear, you can add washers to extend their lives. Inversely a new belt will be wider and require the washers to be removed.
 
Definitely belt .. if you've burned it (Stuck, Brakes on, Ran over back flap etc) you've got a worn spot that jumps every rotation until up to speed and no load
 
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