My 04 sportman 400 makes a clicking noise mainly when I reverse and turn to the right. It does it ocassionally in forward too. It sounds like its coming from the joint at the right rear wheel. I just had to replace the boot on that side because it had a hole in it. I had it apart and cleaned it up and regreased it, and the bearings came out with little effort. Are they supposed to be press fit on this, or do they come
apart like that? It was clicking before i replaced the boot and still afterwards. Does anyone know about this?

 

It is the bearings for sure. My scrambler 500 does the same thing. I decided that i would just keep on riding because the ticking isnt constant and i cal live with it pluss my axle isnt loose or nothing so om goona keep on truckin. I wouldnt wory about it unless you get aloot of play in the axle, otherwise i would just keep on a roolin.

 

I found this in the search and it describes exactly the problem I'm having with my 03 sportsman. I can assure you that it isn't my bearings. Has anyone else had this problem that can help me?????

 

usually its the CV joint that makes the clicking sound.

 

mine does it and has always done it..

 

Maybe I'm too worried about it. I have been through everything and can't find anything wrong. I just have these visions of finding out whats wrong when it costs 1000 dollars!

 

thats the worst thing about these forums knowing to much
ignorance is bliss...lol...

 

The clicking is one of your CV joints on the right side, most likely the joint you replaced the boot on. If the axle bearing came apart when you did the disassembly it very likely doesn’t have long to live.

CV joints can click for a long time without breaking depending on the stress they’re under, and that big axle bearing can go for a while without destroying itself. When you replace either one of them is up to your comfort level with having a breakdown on the trail. You know they’re worn (marginal) and it’s only a matter of time before they fail. You can still ride home with a broken rear CV joint and it’s unlikely to take other parts to the graveyard with it. If that bearing gets bad enough to disintegrate you’ll ruin more than just the bearing if you ride it that way.