I have a 2004.5 sportsman 500 ho and it has a terrible noise in the front end. It sounds like rocks in the front gear case. I drained the front case and put new in. No help. No metal shavings. It sounds bad at around 20 miles per hour and higher. I have replaced the fan moter, rear wheel bearings due to bearings being out. I can grab my front axles and they move all around. My dealer said this is normal. I went to the dealer and sure enough 500 and 700's all moved like that. What could be causing the noise? It drives me crzy. You hear this noise mainly when on gravel or hard top roads. On the trails its hard to hear.

Noble

 

I have a similar noise coming from mine,noise coming from the right front.Let us know if u fine out what it is
rich

 

sounds like front wheel bearings to me

 

How hard would it be to repace the front wheel bearings? Could someone talk me thru it ????? Thanks. Ant special tools needed? Any other help would be appreciated.

Noble

 

No offence, but if you need someone to walk you through changing wheel brgs you should be taking it to the dealer.

Also what does your dealer say about the noise
Is it a vibration type rattle that is only audible under acceleration?

 

On mine its really only noticable when in high@ around 15mph,in low @ the same speed, it isnt as noticable. A while ago I was trying to locate the noise and it seams to be coming from the 4wd unit
only from the right side


I looked on polaris website,in the front gear case the is a bearing on the right side on the case,anyone ever change it? I doesnt look all that hard.

 

Noble.....this wouldn't be the rattle that the rack/front plastic makes is it? from the sound you are describing it should be noticeable if its mechanical.

the 04's and 05.5 are terrible for that rack/plastic rattle in the front.
When its making that noise, push or put pressure on the rack to see if it stops. If not, keep digging mechanicly

 

Kushman, no its not the rack or plactic. It sounds like its coming from the front gear case. Its super loud on hard top. It kind of sounds like rocks in the gear case popping around!!! I changed the oil in the case and there was no shavings in it. It bothers me so much, I can't stand to ride it. The engine is strong as can be. It made this noise when I purchased it new and the dealer said it was the nature of the beast but since it has gotten louder. I have 2100 miles on it now and hate to ride it. I have a 05 sp 500 too and it does not make this noise. Maybe I got a bad bike. If someone has a 2004.5 500 sp, wouls you take your down a road and go different mph and see if yours has a noise in the front end. Go up and down hill at least 20mph and then faster, l;et on and off the gas and see if it rattles like crazy. I would appreciate the help. If anyone is close to Paoli ,IN. and want to help me find the problem , I would buy your lunch!!!!!

Noble

 

Hey guys.
My 04\ 600 had similar noises and i always took it back to dealer to find out the problem but this time i found it.
Take both front wheels off and grap your a -arm pull front to backand check your tabs connecting your a-arms to the frame.
The back and forth motion will tell you if the tabs are slotted out. I had mine fixxed UNDER WARRENTY after 1 yr. i always heard a noise and felt a little shaking, Thought tires and gear box etc.
Welded up the front a- arm tabs and ok i guess. Let me know

 

Could you explain a little more on the tabs. Not sure what you are talking about. Did this over time wallow out or was it like that from the factory? Did you weld them or the polaris shop? Do you have a pic of this by any chance?

Noble