:We have two Sportsman's that have a cracking noise in the front end when they hit a rough spot in trail.One is a 2004 Sportsman 500 and theother is a 2004.5 Sportsman 400..It seems more noticable when hitting at an angle ..any ideas????

 

The bolts in the front a arms come loose all the time. Check that first.

 

Spray the front struts(up top where they bolt on) and suspension with wd40, this cured the cracking noise on my sportsman...