636 clutch explosion
 

My clutch basket exploded a couple weeks ago while in a wheelie. The engine immediately started knocking and I shut it down. Now, after dropping the pan and replacing the basket, I'm unable to shift into second gear and the knock continues. It sounds like a rod, but I really can't diagnose engine noise well. Is it possible there is an issue with the clutch install or the used basket I replaced it with? It looked fine. The replacement clutch is stock. I'm hoping that I didn't do more internal engine damage by just blowing this clutch, but I really have nowhere to begin. Any ideas or guidance please?

Re: 636 clutch explosion
 

It's gonna be bad(if your lucky)
I know you said you can't shift gears but does the clutch work normally in gear?
Also did you clean out all the shrapnel from your engine when You replaced the clutch?
Aaaaand did you check the bearings on the out put and crank shaft for any obvious play?


Hopefully you've just put something in ass up. If your unlucky you will need to drop your engine out and open her up to see all the the damage that the peices of clutch basket have caused while they bounced around your engine...

Good luck dude

Re: 636 clutch explosion
 

OK, it shifts through the gears just fine one rolling. Could the knock be from my
install of the oil pan? Maybe the oil Screen fell off or the hose was positioned inproperly. Could this cause a knock?

Re: 636 clutch explosion
 

You took off the oil pan to do your clutch? Usually you can just pull the cover off and It's all good.

It's probably good you did because it would have given you good opportunity to visually inspect the gears / shifting mechs not to mention cleaning out the pieces of clutch basket.

At this point I'd recommend taking her apart again.
Before you take her apart again, start her up and listen to her run. Use a screwdriver(preferably tang through style) hold the handle against your ear and place the Tip on different points on the engine(both sides, top end, crank, gear box etc). This will allow you to pin point where the noise is coming from.

Re: 636 clutch explosion
 

When you do take her apart, take your time and be critical. Look for damage, missing teeth, wear marks, bearing metal etc.
Then take photos and upload them if your unsure of what action to take.

Re: 636 clutch explosion
 

I'll get on that. I dropped the oil pan because there was a ton of basket pieces. The entire basket exploded. Everything seemed to be in great shape despite the explosion. I have not seen an instance where a clutch explosion caused more internal damage yet.

Re: 636 clutch explosion
 

Hopefully you just missed a peice of basket in the gear box and that was causing your problem.

Re: 636 clutch explosion
 

I'm still worried about that knock though

Re: 636 clutch explosion
 

I just remembered something! Kawasaki has a second gear lockout!!!!
It's to make it easier to get neutral when the bikes not moving. Your gear box has to be spinning fast enough to shift to second. It might be fine.

- the knock

Re: 636 clutch explosion
 

Yes, the lockout. I realized that last night. I didn't drop the oil pan again yet since it's 90+ today. if a piece was still in there I don't think it's causing a knock like this. it's sound connected to something like a rod.

Re: 636 clutch explosion
 

[QUOTE=Rhyno636;4436860]Yes, the lockout. I realized that last night. I didn't drop the oil pan again yet since it's 90+ today. if a piece was still in there I don't think it's causing a knock like this. it's sound connected to something like a rod.[/QUOTE]

Did you try using a screwdriver pressed against the engine and the handle against your ear? Checking in different spots it may help you determine where the noise is coming from