Looking for some ideas on the clacky noise coming frome the front of my 500 motor. I did replace the outside brass bushing on starter bendix.valves have been recently adjusted correctly. The noise is more pronounced when i start the atv when cold. Can hear it most when i stick my head in front wheelwell on clutch side. Sounds rattly,marbley kindoff. Can't find any loose parts,exhaust etc. Timing chain? Maybe a stretched spot? Clutch? Clutch buttons are good. Rollers seem ok. Weights. It is ebs clutch.Wondering if mabe the noise is resonating up from clutch housing and up through the. Primary intake under the tank. Hard 2 pinpoint! Driving me crazy! Any ideas!!!!!

 

Easiest way to check is to just pull the clutch cover. Check if you have side to side play on the spider even if the buttons are ok. Could be the rattling noise. To eliminate the clutch entirely just pull it if you have the tool handy and then see if that was the noise.

 

Thanks OPT will do. I did make a tool to pull primary so i'll probably just pull the clutch and start it up. Hoping thats what it is. I have a feeling it may be. The atv has just over 2k on it so i asume the primary could use a few parts. Recently had it off and notice the one way bearing had some side to side play maybe the fiber style washer is worn down or do they have some side to side motion?

 

In new clutches there's very little side to side play on the one way. If you can insert a .020 feeler gauge or larger between the one way and inner sheath then probably time to replace the fiber washer and the brass washer beneath the cup. Here's some posts on this about exchanging the soft brass washer that wears quickly for a steel washer. Clutch belt creeping - ATVConnection.com ATV Enthusiast Community

 

Yes pretty sure i had more than .020 clearance. Wonder if thats some of the noise from clutch with it hitting side to side on the sheeves. Will check. Thx

 

So i took primary clutch off today started the atv and the noise is still the same. Def. Can hear it most towards the front off motor more so on clutchside. Rattling like something is loose or bouncing around in motor? Did a piston and rings months ago. The head gasket never took so i had to replace it again w oem polaris one. When i had it off everyth. Looked fine piston,clips etc. Put all back together redid valve clearances etc. Timing done right. Been running good but just recently after quite a few rides making this clanking rattling noise. Hard to hear unless your right beside machine or up toward wheelwell

 

This can be anything.. If it's smoking then you could say it broke a ring. If it's more of a rattle,could be something like an oil pump or gear driven off the counter balancer. Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse I'm just guessing on this..

 

No smoking or any oil loss. Coulld be the oil pump i suppose. I did crimp the line for the hell of it and got some air release a couple times. No change though. Guess i will just stop worrying about all the dang noises that come up on these things and run them till something goes!

 

Someone once said that if a Polaris isn't making any noise there's something wrong with it. I'd still worry about some noises.

 

True to that! But it seems like theres to much tinkering and not enough riding on this one!