Honda 200s Clutch Noise??

[mike84bigred]

There is a knocking sound, kind of like something's loose on the clutch side of my motor. Sounds like its coming from the centrifugal clutch and only does it at idle. Clutch seems to be working fine though. I did have it apart a couple months ago to replace the clutch plates, but only started doing it recently. Any ideas what it could be??

[El Camexican]

There is a knocking sound, kind of like something's loose on the clutch side of my motor. Sounds like its coming from the centrifugal clutch and only does it at idle. Clutch seems to be working fine though. I did have it apart a couple months ago to replace the clutch plates, but only started doing it recently. Any ideas what it could be??

I'm no Honda guy, but I believe the centrifugal clutch is the one directly connected to the crankshaft and usually has pads that look like brake shoes held in place with springs. The secondary clutch has flat steel and fiber plates and is driven by the centrifugal clutch. Is that the one you worked on? Let me know and if it is I may be able to explain the noise.

[mike84bigred]

Yes, that is the primary/ centrifugal clutch. I replaced the disc on the secondary, but I had to remove the primary clutch to get to the secondary, so it was indeed off the machine.

[mike84bigred]

Could it possibly be the clutch sprag? Its not so much a knocking noise, more of a grinding noise

[mike84bigred]

https://www.youtube.com/watch?v=Z0JqCpmKZxg

Shared a video. Now its not the regular engine noise you can mostly hear, it's in the background and kind of intermittent. A deeper, grinding noise.

[El Camexican]

I would open it back up and make sure that no nuts have backed off. I don't know your engine, but usually clutches have lock washers, or use Loctite, or have very high torque values. If a nut has backed off and you keep using it you'll screw something up pretty quick.

[mike84bigred]

Ill get on it

[mike84bigred]

Well, I removed the right crankcase cover, ripping my new gasket of course, and didn't find the source of the noise. Bolts were tight. I removed the primary clutch just to see if anything got put in wrong and check the sprag. All looked good. The only thing I noticed is that both clutches, just the drum on the primary, had a little play in and out. I'm guessing that's normal. I will put it back together I guess, and see what happens.

[El Camexican]

Did you take any photos? Did you make sure all gears are lined up correctly from clutch to oil pump, crankshaft etc? http://www.ronniesmailorder.com/fiche_section_detail.asp?section=2555659&category=ATVs&make=Honda&year=1986&fveh=132728 There are 2 washer #12's in that image of the clutch. If either was missing that would make a lot of noise.

Your primary clutch gear should be riveted between the hub and a steel plate that holds a few springs in plate that are mean to absorb shock and keep things from wearing out or cracking. Over time the springs lose free length and the gear starts to beat on the rivets. I've seen a few get real loud, but the grinding noise you described makes sense only if your worn gear sets are no longer lined up the way they were all these years after you put it back together. A loose clutch basket makes more of a rattling, or whirling sound.

[mike84bigred]

The link is to the secondary clutch, not the primary. I think the noise is coming from the primary but I could be wrong. Might as well take a look anyway.

[El Camexican]

Yes, I meant to say secondary, that's the one with the springs that makes noise when it's worn. Sorry.

[mike84bigred]

Well, I figured out what the noise was. I put the clutches all back in and started it up and the noise was 10× worse than before. I thought the crank was bout to throw a bearing when all of a sudden there was a ticking noise coming form my pull cord. I took the cover off and realized the flywheel came loose and was flopping around. Tightened it up, noise gone. Ugh, wish I knew that before.

[El Camexican]

We've all been there. Next time you want to find a noise grab a wood broom handle, or hockey stick and place one end against the running engine and the other against your ear, or the side of your head. It is a great way to find the source of a noise. Works great on cars too, just watch out for fans and pulleys.

[mike84bigred]

Ya I know the old broom stick trick and did it, but apparently not very good at it.

[Scootertrash]

Mike,
I heard this here I think, I have done it myself but haven't had to disassemble the parts yet:
Grease both sides of your gasket before you put stuff together, supposedly the gasket won't stick to the metal parts you are disassembling.

ETA: I take that back. I have a recoil off of a Polaris expedition up on my bench that I told the guy to grease the gasket. It appears to have separated nicely with the loss of only one ear on the gasket that goes around a bolt hole. I wasn't there for the assembly or disassembly so I'm not sure how much grease or what kind of grease he used, nor how he manhandled taking the recoil off, but it appears to work not too bad. :wondering

[El Camexican]

Ya I know the old broom stick trick and did it, but apparently not very good at it.

You have to put it in your EAR, not your REAR!:)