[Scooter_Maniac]

I've got some noise coming from the clutch assembly of my wife's '09 400 with around 11k miles. It sounds to me like a dry bearing. The inner clutch cover bearing (17) was frozen on the shaft when I removed the inner clutch cover so, replacing that was a no-brainer. However, the noise only occurs until the clutch fully engages (or, with the engine off I turn the rear wheel), I have concluded it must be either needle bearing (1) or, bearing (3) on the diagram since, once the clutch fully engages, the drive shaft and clutch assembly become stationary relative to each other and neither bearing would be "rolling". I replaced the needle bearing and the other one felt well greased and seemed to roll smoothly by hand (without having removed it from the fixed driven plate). I put it all back together and still get the noise. I've also noted with the wheel off the ground it wants to turn at idle, further indicating a bearing is dragging. So finally, my questions. Does someone more experienced concur that bearing (3) has to be the culprit? Can it be removed without totally breaking down the clutch assembly (the manual only shows its removal as part of the clutch disassembly)? Finally, even though it is brand new, since I will have to pull the needle bearing (1) in the process, is there a likelihood that would damage it, so I should plan on replacing it again, as well?

[attachment=0:1ysgak7h]Clutch Assembly.JPG[/attachment:1ysgak7h]

 

[Ralph M]

As long as you can stop the wheel turning at tick over with your foot then its normal,
if the noise is just as the clutch locks up when setting off then it's likely the clutch
shoes, chamfer off the leading edge a little and clean out any dust, that mileage is
low for bearings to go.

 

[Scooter_Maniac]

I don't think the noise is the clutch, as it occurs at normal idle before the clutch would even begin to engage. It is also present with the motor turned off, by spinning the rear wheel (or, pushing the bike). I also laid the clutch assembly on the ground with the clutch facing up and put the clutch bell on it. Even though there was no shaft to line things up perfectly, the bell could be easily spun without any interference from the shoes. No noise when the wheel is spun with the assembly off.

 

[Ralph M]

If it occurs at normal idle as you say it wont be the clutch and is likely one or more of the bearings.

 

[TwoWheelTim]

My rear brake were tight for thousands of miles. Make sure you don't have a dirty shoe or disc rubbing.

Good luck.

 

[cliffyk]

The inner needle bearing will make a ticking noise if it is damaged or dry, or if the output shaft (which is the inner race for the bearing) is damaged. I'd pull the clutch assembly again and "see what I could see". Spin it on the output shaft while the bell and belt are off and have a listen...

 

[Scooter_Maniac]

No ticking. Sound is similar to a dragging brake but, makes it only with clutch assembly on the shaft and, includes when the wheel is not turning hence, def not the brakes.

 

[Scooter_Maniac]

So, presuming bearing (3) on the original post is to be replaced, my other questions stand.

 

[cliffyk]

So, presuming bearing (3) on the original post is to be replaced, my other questions stand.

Without hearing it in person it's difficult to diagnose--are there any traces/markings suggesting something the clutch assembly might be rubbing on the case/etc?