When changing from reverse to forward my Sportsman makes a clunking noise. Sounds like a universal joint (I hope not), was wondering if anybody has changed universals on their's, and what kind of a job it is? If it isn't a universal, is there anything else that could make that noise? Any help would be appreciated!

 

It could be a bad universal or cv joint. What year is your quad?
Are you aware of the fact that most Sportsmans have a "clunking" noise by nature. This is due to all the gear mesh in the machine.
I am not saying what your problem is for sure because it could be a variety of things. I just wanted to make sure that you were aware of the classic Sportsman "clunk".
Where exactly is the noise coming from? Has it always been there or did it come on all at once?

 

Thanks for you input! It is a 1999 Sportsman 500 with about 1800 miles on it. NEVER HAD ANY PROBLEMS WITH IT! Put on first set of brakes at 1500 miles, that's it. Am not familiar with Polaris "clunk" What is it?

 

It is just the noise it makes when you put it in gear. Some people think it is gear mesh... slack between the gears in the tranny, part of it may be cause from slack in the chain.

 

gregsims, Don't want to appear stupid but what chain slack are you talking about? Is a chain drive of sort in the engine? Also has anyone ever changed universal joints on the Sportsman????

 

The classic Sportsman "clunk" is caused by gear lash or the drive chain in the tranny. Their are a couple of sets of gears and a chain that drive from the tranny to the rear wheels. Each set of gears that drive one another have a little bit of play in them so that they don't just bind up or possibly the drive chain play. The "cluck" I'm referring to is when these multiple sets of gears and chain all engage at once. When they get to the last gear that drives the rear wheels, it is not free and stops all those gears at once. It is at this point that you may here the "clunk". This is about the best I can do for an explanation by just typing it out. I would do better if I were talking to you instead.

As for what your problem may be, I think the 99'SP500 had cv joints instead of u joints. I could be wrong on this but I know I ordered two rear shafts for a guy that told me his were bad and I'm thinking he said they were for a 99'. I haven't seen the quad yet so I don't even know if they were bad. He just told me to order them and call him so he could bring his quad in to get them changed. I know the ones I ordered were cv joint type shafts.

If its not the classic "clunk", then you'll have to get the quad in the air and start turning wheels while looking for play in the shafts or joints. I'm sure if you jacked up the quad and started turning things you would probably be able to find it. If not, swallow your pride and take it to the dealer for diagnoses and repair. You don't want to break a shaft while riding because it may cause alot more damage to other components.

Let me know what you find.

 

Elroy..... Thank you, you have described the noise I'm talking about to a "T". I do have cv joints on it ,they are fine. What you said makes sense, since the only time I hear it is when I shift from reverse to forward. That could be the reason for causing the slack. Good input!!!!!!

 

My HO makes a noise after I stop and then take off again. I was told that it was the EBS releasing. The sound I am referring to is more of a popping sound than a clunk.

 

i ajusted my shift rods to get rid of my clunck,havn't heard since and that was about 700 miles ago!!