So today i finaly got a day to myself and was able to take my scrambler on a ride. Before I left i wanted to change the hub fluid to see if it would fix my 4x4, so i started to doing it and to my surprise not a drip of fluid in either hub. So I topped them off and went on my way. Everything was going good engine running very strong and seems like a very fun machine. So after prolly a hour of riden I started to here this clunk noise when I would get on the gas. Its not a consitent clunk just a single clunk when i get on the gas a bit. I looked it over and everything seemed fine chain and sprocket looked good loobed up the chain real good before I left. This sound definatly doesn't sound like anything good, any ideas on what it is guys? Ive wanted one of these four wheeler for years and finaly come around to getting one and not having the best of luck. I baught it from a chevrolet dealer so i think they are gonna pay for it to be fixed. Any input on what noises your machine makes is greatly appreciated. Mine is a pretty loud clunk, hear it pretty well over the loud *** exhaust.

 

Also since i havn't recieved my service manual from the dealer im not quite sure on how tight the chain is spose to be. It was the first thing i though of hearing the clunk. It has a little play in it I can move it up and down a bit, so should it be like that or should it be tight to were there is no play but its not pulling on the chain?

 

PGT,

First of all, the Chevy dealer is not likely to pay for anything regarding your ATV. Now to your problems, where is the sound coming from? Front, midway, or rear of the ATV?

The chain should not be tight. Without having a manual or any other experience with this particular ATV, I would say that 1 inch of vertical play (total range of movement) at the mid point of the chain should be okay until you find out the exact specs on it. If the chain is too loose and if the sprokets are worn, the chain could jump sprocket teeth under heavy load.

Good luck.

 

Ya thats what i thought till I called them and i think they are kinda doing out of generosty, plus they advertised it as perfect condition without a single flaw. I can't realy pinpoint the clunk whether its from the transmission or suspension/frame. Its only when i give a good amount of throttle quickley. I sure do hope the dealership calls me soon and says my manual is in. I mean im just trying to think of what this clunk could be, i mean its gotta be either the transmission, or the suspension, or atleast i would think.

 

Alright check the sprocket and change the chain! The chain will almost fold up on the loaded side of the spocket. I had what seemed like the same problem and it took me riding my buddies quad and him on mine, with me telling him to gas it for me, when i saw the chain doing this. good luck.

Jay

 

WOOOP WOOOP Chevrolet dealership called me today, im dropin it off at there dealership monday morning and there bringing to there local polaris dealer to have it all fixed. Hopefully they can solve the problems in a decent time and manor but for some odd reason i have a feeling this might be a pretty long process but who knows. The 4x4 system doesn't look that complicated but then again I have no idea what im talking about lol, and hopfully i can explain and get them to here the clunk it is making.

 

Check for broken teeth on the front sprocket.

If the teeth are hooked you need a new sprocket.

I had three of those older Polaris "3 chain drive" atv's talk about a nightmare. If you don't tighten the chains in the proper order you will always have a clunk. Down load an owners manual from the Polaris web site if you don't have one. Follow the directions to the letter or you will have this problem after the dealer gets your atv fixed.

One other thing I learned the hard way is there is a grease zerk hidden behind the engine main jackshaft sprocket. DO NOT forget to grease this one.

The other thing you will notice is when your chains need lube the floorboards will vibrate. I always carried a can of chainwax on the trail along with a master link and a chain breaker to fix the chains.

After driving 20 miles in front wheel drive you will never leave the house with out making sure a master link is in the tool kit.

 

I couldn't find anywere on the polaris sight that lets you download the service manual. Only thing i could find was the little 2 page manual that gives all the specs on the four wheeler. Mabye im looking in the wrong part of the sight, let me now. Thanks for the input.

 

I just checked your signature... You have the concentric drive system with one rear chain.

I had two Explorers with that drive train.

Your still going to need to carry a master link. I busted one of those too. When your doing the chain adjustment have somebody sit on the machine when checking the slack. The adjustment is very easy to do and takes little time. I always had my tools at the camp site to set the chain. Mud, water and Iron dust where very hard on chain drive machines doesn't matter what brand they are.

I'll check the Polaris site and see if I can find where the manuals are.

 

Thanks for the help