After removing the clutches to repair the transmission we put the clutches back on, everything works fine except when going down hills the primary clutch starts to make a loud metal on metal sound-cant figure it out-even took it apart and put it back together but still same sound. Any help appreciated. Thanks

 

A lot of people over look the plain bushings that may be worn. If the bushings show to be brass color,they're worn past the coating and need replacement. This can cause the clutch to wobble a little and counter shaft weights to work unevenly and clatter. Items#2 and 11. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

Thanks for your reply...but where on the clutch are the bushings located? Do I need to remove the clutch or can I leave it on to do this fix?
Thanks

 

Clutch has to be taken apart. Takes a clutch spider tool that about 90 bucks. If you're sure it's a front clutch problem,might be best just to remove it and let a dealer check it out. Plus you have to have a clutch remover tool or can get a bolt from a local hardware store to pop the clutch off.
http://i380.photobucket.com/albums/o...psd9423cac.jpg

 

I've got a rod and 3/4 16thread bolt to remove clutch. When I'm going fast then let up and coast it starts to make the usual whining sound but also now a metal on metal sound. I did notice the little chain sprocket coming out of tranny has lost a tooth so I got one on order and hopefully coming this week, I'm not sure this would cause the sound I'm hearing but replacing just because it needs to be...I'll check w a friend to see if he has the spider tool...thanks

 

What was the reason you tore into the tranny in your first post? Did you also replace the "silent chain" in there also? Plus yes,if you've lost a tooth on the front drive sprocket replace it. If the drive chain links themselves flex from side to side and when the rear end is jacked up and if you notice any stiff links or the chain tightens and loosens,the chain is worn and needs to be replace with a new o-ring chain also.

 

It ended up not being the clutch-it only sounded like it...while gassing it up the drive from stop I noticed the small drive sprocket slipping and making a similar noise so we pulled the tranny again and checked the silent chain-it ended up being "stretched" (this tranny is one I bought used of eBay) the old tranny had the 3 little teeth sticking out the side of the H gear sheared off-but the silent chain was still good so we swapped out chains (that was fun) so now all is good.
Thanks for your help

 

Kinda what I thought.. Anytime I tore into a transmission the "silent chain" was replaced whether it looked stretched or not. Nothing worse than to have to split a tranny again for a 35 dollar chain. Hope the used one you installed holds up.