1995 Z440 knocking at idle - ArcticChat.com - Arctic Cat Forum
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post #1 of 19 Old 12-24-2016, 05:48 PM Thread Starter
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1995 Z440 knocking at idle

My z440 fan cooled has started knocking after riding it today. This is my first time posting for help. [https://www.youtube.com/watch?v=sQxxMqZqc_s9] I made a video for it its really bad at lower rpms. I'm not sure if its the crank. Pistons looked really good for 6600 miles on it. Any help would be appreciated on what it could be.
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post #2 of 19 Old 12-24-2016, 08:40 PM
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I hate that don't you... those usually cost you big $$$. Can be some spectacular footage when it blows if caught on video though. Methanol motor explosions seem to provide the most breathtaking action for me... especially one of my own.

First thing I would suspect is something in the primary clutch has/is coming apart. But from here its not my call. Should be pretty easy to find though, with all that racket going on.

Have a great holiday regardless,

Last edited by SevenBlizzardsRoad; 12-24-2016 at 08:44 PM.
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post #3 of 19 Old 12-24-2016, 08:42 PM
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Sled: 2000 thundercat 1996 ZRT 800 AGLT/136"
10-11 Mileage: 1249
09-10 Mileage: 1200
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Originally Posted by SevenBlizzardsRoad View Post
Can be some spectacular footage when it blows if caught on video though. Methanol motor explosions seem to provide the most breathtaking action for me...



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post #4 of 19 Old 12-24-2016, 08:44 PM
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Sled: 2000 thundercat 1996 ZRT 800 AGLT/136"
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09-10 Mileage: 1200
07-08 Mileage: 650 - 2 thaws
06-07 Mileage: 1100
ATV: Arctic Cat 500/ SuzukiQuadzilla 500-sold
When you looked at pistons did you look at all of the piston or just the tops? That's a lot of miles for a piston in that motor I would think. You may have a cracked piston skirt. May also be a clutch. Turn it by hand and see if you can locate any noises.



Life is not a bowl of cherries, it's more like a jar of jalapenos, what you do today can burn your ass tomorrow !!!







https://www.arcticchat.com/forum/pinn...to-96-zrt.html
Crossfire skid into a 96 ZRT

https://www.arcticchat.com/forum/z-zl...t=zrt+800+aglt
ZRT 800 AGLT
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post #5 of 19 Old 12-24-2016, 11:25 PM Thread Starter
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Originally Posted by tcat446 View Post
When you looked at pistons did you look at all of the piston or just the tops? That's a lot of miles for a piston in that motor I would think. You may have a cracked piston skirt. May also be a clutch. Turn it by hand and see if you can locate any noises.
. I looked at tops. Lot of carbon other then that I didn't take off or look more then that. I did spin the clutch and there is play where It connect to crankshaft, also a metallic scratching noise. I looked on cylinder walls nothing wrong or anything I'll probably look closer soon in shop. Maybe a crankshaft bearing?
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post #6 of 19 Old 12-24-2016, 11:54 PM Thread Starter
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Originally Posted by SevenBlizzardsRoad View Post
I hate that don't you... those usually cost you big $$$. Can be some spectacular footage when it blows if caught on video though. Methanol motor explosions seem to provide the most breathtaking action for me... especially one of my own.

First thing I would suspect is something in the primary clutch has/is coming apart. But from here its not my call. Should be pretty easy to find though, with all that racket going on.

Have a great holiday regardless,
I hope it something simple but probably not. Never really replaced anything in an engine before. It might be the clitch. My secondary clutch came unbolted or more like broke off. But the is tight now. I don't know much about clutch either. It makes the noise as well when I pull start. Happy holidays as well.
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post #7 of 19 Old 12-25-2016, 12:10 AM
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With 6600 miles on the sled it probably needs a freshening of both of the clutches AND the motor. In other words, fixing a single knocking problem at this point isn't likely to get you very far.

Start at the top end on the motor... you can plan on a fresh honing, putting new pistons, rings, wrist pins, upper rod bearings, circlips and gaskets in it, at the minimum. The lower end may need new crank seals at a minimum. Bearings too, or possibly worse... but you gotta get down there before you'll know for sure.

Pull the heads and cylinders for upper end inspection and go from there.

As for the clutches, they will probably both need to be completely rebuilt unless they have been well maintained and/or recently freshened. Look for cracks developing on your primary sheaves and replace the clutch if you find any.

Let us know what you find,
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post #8 of 19 Old 12-25-2016, 12:33 AM
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Please don't take my comments above as doom and gloom. You can freshen your motor and clutches for a lot less money than you may be thinking... and the work is not very difficult.

Its fun to make things better than they were. When you get done you know what you got too, versus replacing it with an unknown used sled or buying an expensive new sled.

If you need help you can count on getting it, so hang in there.
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post #9 of 19 Old 12-25-2016, 01:11 AM
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Since I'm hogging your thread already tonight, here is another possible idea for the source of that racket. Supporting your fan shaft there are two sealed ball bearings, #5 in the parts fiche below, that may be shot. Pull the tin shroud off and yank on that bugger before going any further:



If one or both of them has come apart it can make an awful racket... just like yours is making and is cheap and easy to fix.

OK, time to run off and perform santa tasks... outta here.
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post #10 of 19 Old 12-25-2016, 11:39 PM Thread Starter
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Originally Posted by SevenBlizzardsRoad View Post
With 6600 miles on the sled it probably needs a freshening of both of the clutches AND the motor. In other words, fixing a single knocking problem at this point isn't likely to get you very far.

Start at the top end on the motor... you can plan on a fresh honing, putting new pistons, rings, wrist pins, upper rod bearings, circlips and gaskets in it, at the minimum. The lower end may need new crank seals at a minimum. Bearings too, or possibly worse... but you gotta get down there before you'll know for sure.

Pull the heads and cylinders for upper end inspection and go from there.

As for the clutches, they will probably both need to be completely rebuilt unless they have been well maintained and/or recently freshened. Look for cracks developing on your primary sheaves and replace the clutch if you find any.

Let us know what you find,
Well, I took the engine out after our holiday dinner and the pistons look great and so do the cylinders, Besides a lot of carbon build up which I can get rid of. Looked down into the crank and I saw that where the connecting rod connects to the shaft one side would move a whole inch before the rest of the crankshaft which would be 16 and 17 on the picture. I would have to say that is the issue. Which I am not sure if I would have to get a new rod or replace that single part or what would be better. I was looking at cranks and some are around 200 to 300. Other then that i notice my clutch seems to look like rust pit or chips in it where the belt runs. Is that common? seemed to happen this year too.
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