900GTS clutch area noise

francesque · Post by **francesque** » Sat May 28, 2011 8:26 am

Hi all, I have a 900GTS which I started up for the first time for a while today and there appears to be a noise which seems like a dry bearing rumbling type of noise, it seems to be coming from the left hand side of the engine around the clutch area. It does not come from within the engine, it seems more from the outer area, in fact if you feel the engine case you can actually feel it too. Any ideas as to what it could be? I have never worked on one of these engines, do I need and special tools or skills? its approx 1980 engine no. 8548**
many thanks
Frank

mizike77 · Post by **mizike77** » Sat May 28, 2011 3:05 pm

E start bike? Could be sprag bearing or related electric start components. Does the sound change at all when you pull in the clutch lever? Its very easy to take off the cover and look inside.

francesque · Post by **francesque** » Sun May 29, 2011 6:05 pm

Hi thanks for your reply, It is an electric start model, I have tried pulling the clutch in and it makes no difference, what is the sprag bearing? I have taken the upper cover off to reveal the two sprockets and chain drive from starter, all appears ok there. I then removed all the bolts holding the main cover on, It loosened but I ran out of time and didn't want to rush the job so I put it all back together, the noise seems to come from further back than the starter gear, more around the clutch area. thanks again for your help, I have never worked on a Ducati Bevel before and all the manuals I read make it sound so scary! Is it an easy job to remove the cover to expose the clutch?

rwhc80 · Post by **rwhc80** » Sun May 29, 2011 9:11 pm

Frank,
Whilst you say you are not familiar with the Bevel engine, it sounds like the perfect time to start tinkering. It's the only way to learn !

The clutch cover is not hard to take off, or put back on. Just be ready, as the area will have some residual oil when you take the complete clutch cover off. ( have a container and some old newspaper underneath ) Undo all retaining bolts, take off gear change lever, undo the starter chain behind the small upper cover and remove via the link. The starter motor "can" stay connected, but you may need a box to sit it on as the connected lead probably won't reach the floor. If it's a pain, remove starter. If the cover is stuck to the cases, just give a gentle tap with a soft face or timber mallet, You will then be able to carefully pull the cover forward and lift it over the starter sprocket. At this point you can inspect the clutch and even take the plates out, to inspect ( keep in order cause the first and last plates have tapered tangs ) Any further and you will need some specialist tools. The sprag is a one way bearing that fits in the back of the flywheel and is a bit prone to giving up the ghost. Do not run the bike until you know what the problem is, as a broken sprag can cause major engine problems if it collapses. (If your confident to go that far ?) Then let us know so we can give some direction. You may ultimatley need some mechanical assistance, but to this point easy to put back together. Keep us informed ? cheers Rick

francesque · Post by **francesque** » Mon May 30, 2011 2:13 am

Thank you again for your reply, The cover has been removed, I left the electrics attached and left it dangling, just out of the way, I have taken the clutch plates out, they seem fine, I have cabletied them in the correct order so they will go back as they came out, what next?
Frank

mizike77 · Post by **mizike77** » Mon May 30, 2011 5:12 am

The large nut in the center of the basket is tight? It should have a lock tab that is bent over to confirm that it hasnt come loose. (I must confess, its been a very long time since I have been in there). Give evrything that you can see a good look over. Grab the basket and associated parts with your hands and wiggle and jiggle them looking for anything that doesnt seem correct....

francesque · Post by **francesque** » Mon May 30, 2011 5:41 am

that big central nut is dead tight, with tab intact. there seems to be a bit of forward and backward play in the plate just in front of the ring gear the starter meshes into, there is about 2mm play forward and backward, could this be a problem?

bobnorton · Post by **bobnorton** » Thu Jun 02, 2011 10:37 am

I would rotate the motor and check that there is a little play between the primary gears all round, my crank was out and the gears overmeshed.

rwhc80 · Post by **rwhc80** » Fri Jun 03, 2011 4:48 pm

Frank,

reading your first post, it suggests the bike was fine until you started it after a lengthy lay-up ?????? If everything else looks fine, I can't help but think as mizike first suggested, that your sprag bearing maybe causing the problem. It may be that some of the teeth have jammed and are not letting go due to no oil from the time it sat idle, or it could be completley R.S. either way it looks like some deeper probing. A similar thing/sound happened to me a while ago whilst away for a weekend on the bike. after 3 or 4 successive starts it freed itself and hasn't happened since. Re : the 2mm movement, not sure on what plate you speak of ? do you mean the meshing onto the gear on the clutch drum ? Any sign of teeth damage from possible missaligned gears ?

francesque · Post by **francesque** » Tue Jun 07, 2011 2:57 pm

the play is in the flywheel, it moves backwards and forwards a good couple of millimeters, is this normal? or could this be the problem.
thanks for all you help by the way, it is most useful

bobnorton · Post by **bobnorton** » Wed Jun 08, 2011 1:07 pm

Loose flywheel sounds bad.Needs to come appart to check .

francesque · Post by **francesque** » Wed Jun 08, 2011 2:45 pm

Thanks, thats what I will do next, do I need the clutch holding tool to remove the big nuts or will a bar wedged in do the job without damaging anything?

Jon Pegler · Post by **Jon Pegler** » Wed Jun 08, 2011 11:31 pm

Do not use a bar wedged into the clutch basket.
They are very easily damaged.
Either get hold of the correct clutch holding tool, or make one out of an old clutch plate.
Haynes manuals were particularly at fault in advising owners to hold the clutch with a bar across the tangs of the basket. Don't do it or you may end up needing a replacement.

Jon

rwhc80 · Post by **rwhc80** » Thu Jun 09, 2011 4:38 pm

Frank,

some good advice from Jon above, and whilst your arranging a clutch holder you will be needing a puller as well to remove the flywheeel. have a good look at it first though, cause there's not a lot of room to get the claws over the flywheel. I bought a cheap one and had to grind the claws to get enough clearance between the flywheel and the engine case.

Good luck with it !

Rick

francesque · Post by **francesque** » Fri Jun 10, 2011 9:41 am

Thanks again gents, have come home from work tonight having borrowed a crowbar in readiness to attack it this weekend!
Will postpone work until I have the correct equipment,
P.S haynes manuals make good firestarters!
Have a good weekend everybody!!

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