2002 Trail Boss
It has a popping (slapping) sound comming from either the gear box or clutch housing area. I have removed the gear box and it turns smoothly and makes no noise when I turn it by hand. I can take the clutch and press it in and when I release it it makes a popping noise. This problem has worsend and seems to happen more with heavier loads. Thanks

 

wiggle ur clutch weights and see how much side to side clearance they have, if they have a lot, then u should replace them, also check your primary buttons in between the outer clutch sheave and the spider, they wear out over time and if u don't replace them in time, then you get to buy and new clutch which isn't cheap, also, you might as well check your clutch spring free length as well, if u can compare it to another spring the same size and color

 

alos check the brass bushings in the primary to see if there totaly worn out so when they slide they fetch up. weights and pins can have grooves worn in them as well. just an idear.

 

My '02 Trailboss had a clicking/tapping sound that appeared from that area but only when running forward and underload (was easiest to hear when accelerating from a stop on a hill). I was fearing the worst but it turned out to be a worn chain and sprockets making the noise. Its an easy check.

 

<div class="FTQUOTE"><begin quote>Originally posted by: Thoratv

My '02 Trailboss had a clicking/tapping sound that appeared from that area but only when running forward and underload (was easiest to hear when accelerating from a stop on a hill). I was fearing the worst but it turned out to be a worn chain and sprockets making the noise. Its an easy check.</end quote></div>

good point. the chain would sound like that ifd it was completely worn out and almost skipping on the teeth.