800 Drivetrain noise

[Wildhorse800]

My friend has an '07 SP 800. He basically was plowing with it until he met me about 2 months ago.(He's the one whose '06 burned up, literally).

Under load, it is making a light, but noticeable, clunking. Free wheeling it is quiet.

CV joints are all ok as are the u-joints.

I have had to replace the cluth buttons before in a 500 SP. This was a a while ago, but I could swear it is the same noise.

This thing only has @ 120 miles, 21 hrs.

Looking for your expertise and ideas.

[MrBill]

Buttons in the clutch would have a much higher frequency and not a clunking sound. (like a sticky tappet and go up with RPM)
I would look again at the CV’s and may be front wheel bearings.
Is the sound up front or out of the clutck cover?

[Wildhorse800]

Definitely towards the rear. I'd say either transmission or in the secondary clutching. They still have chains in the trannys?

[roon101]

with that low of hours and miles i would take to the dealer and see if they can check it under warnty if it is free why hassle sounds like could be some sirours

[MrBill]

Definitely towards the rear. I'd say either transmission or in the secondary clutching. They still have chains in the trannys?

No chain on the big boys, just the 500's have chain.
Pull the fill plug for the rear diff and check to see if the rear diff is full.
Also check the drive shaft that runs from the trans to the rear diff.

[popotim]

You should check all your fluids even if its straight from the factory. My buds RZR tranny was nearly bone dry, and my dealer caught my 800 was very low in the rear diff. Also remember that if you have ADC (newer models only) it takes "LT" front diff. fluid, and not the older stuff like my 04 500. If you put the older front diff fluid in the ADC models, the front wheel drive won't engage, it's too thick. This is in addition to the ADC fluid, that you fill from the top. Even some dealers don't know this, and put the wrong stuff in. Read you owner's manuel VERY CAREFULLY and buy the exact stuff they say.

[Wildhorse800]

Now my new one is making the same noise as was the guy who also bought one while I was there. It is that driveline/clutch "clanking" when you first hit the throttle. Also does it on rough terrain at light throttle. That makes three that do the same thing. Is this a normal noise? Are they all that noisy?

Dealer said that is just the way they are. Maybe they are putting something together wrong. I dunno.

I will try and get video with sound if needed.

[Kendo]

So it makes the noise with throttle input?

If so, it sounds like the tell tale "Polaris 800 engine rattle" that MANY have complained of but is 'normal' according to Poo.

[Wildhorse800]

Well, sitting still not running, if you rock it back and forth you can hear it real good. It is in the gearcase. I think it is just under really light throttle over rough terrain that the noise is coming from the gearcase, but traveling through the shafts as it gets backlash.

A good comparison would be like in car. Too much play in the rear gives you the "clunk" when you leave off the gas then another when you hit the gas.

I am just trying to acertain if it is just the nature of the beast. I don't trust dealers as they still look to cover their asses first and the customer second.(Not all, but most)

[Ken]

Well...you will hear a clunk from the Active Control Descent. If you gas, and let off...you'll hear it clunk.

[Wildhorse800]

It does it in any range-4x2,4x4,4x4ADC.

Mainly when first starting out and anytime the engine brake engages.

[popotim]

Sportsmans all make this noise. The ADC only works on the front wheels. The engine brake is the same as in non ADC models and can't be turned off, and works in all drive modes. The engine brake makes a clunking noise. Nothing to worry about. Sounds weird, but just get used to it.