Sat we went riding since the weather is getting better here, after we had rode all day we were heading back to the trucks, about 10 miles away, when we would stop for a quick BS break i noticed the 650 felt like it was vibrating a little more than usual, it acted the same way in neutral, we took back off, the funny thing is when the vibration started, I swear this thing started running better, i mean better clutch response than it ever has, got back home and ate before I unloaded the quad, so between coming home and being unloaded it sat and cooled down about 2 hours, when I unloaded it I found the vibration, The Front drive clutch was vibrating pretty bad, you could feel it through the clutch housing, it also was making a fairly loud knocking roaring noise that I have never heard before, I said I better put this thing in the shed, when I put it in gear, and pulled out, it started making a squeling sound like the belt's do when they are loose but this is coming from my clutch, almost like something in the clutch is dry, maybe the torque bolt has backed off a little i dont know, Someone posted here once that some bushing or bearing or something to do with the clutch was supposed to be greased from the factory and some of the earlier model's(mine) were not and left dry, and Kaw had to replace some of the clutch's, What does everyone thing before I haul it to the dealer? something is definitely not right in there, but i can't figure out why it ran better when this started? It sound like like the clutch is about to vibrate off inside that housing at idle. any idea's You guys with service manual's.......

 

I had the same problem,it was one of the earlier models and at 1700 km had to take it to the dealer and get some bearings and bushings replaced lack of lubrication,dealer repalced at no charge except for the new belt.Then the bike worked great for 300km,then a new noise come from the clutch,this time the dealer charged me for a new belt deflection and another new belt $300 later i had my bike fixed,I finally heard about the black and red springs evryone is putting in their machines and ordered them and put them in myself and have not had a problem since.The only thing i am going to do now is check belt deflection ,because i think the belt is a little loose.Good luck and get the black spring!!!![img]i/expressions/face-icon-small-smile.gif[/img]

 

Some SECONDARY (back) clutches had been left dry from the factory. Get the cover off; the bolt may have just backed off on the primary.

 

The clacking could indicate the wear shoes are making contact at the wrong moment in the shift weight progression. Sound like the clutch is stuck and not releasing position possibly due to lack of lubrication. This would explain the vibration as well because it would put the clutch out of balance if the shift weights were in the wrong position. Hope this helps and check your sheave to see if it has grooved or burned if the absence of lubrication is the problem.

 

Stakk,

Is it dry where you live, most people who have problems with the front clutch live in dry areas. Does sound like your weights are not disengaging properly, if you have a dead blow hammer with the hard plastic ends give the front sheave a little tap while it is idling. If this helps then you know that the weights are not lubed properly. Also try taking off the belt to see if the vibration is in the back or the front this will help to narrow down the problem.

 

thanks guy's, I'll let everyone know what it was.......