Was trying to chew my way out of a mudhole this evening, hitting it fairly hard, front end would launch in the air then come down kinda hard and be high centered. After a few tries, I started hearing a weird sort of "ratcheting" noise (best way I can describe it) from the front end. I thought I must have really blown something up, but the weird thing is, with the diff lock lever pulled, it still chews like mad and makes no noise.
Does this sound like anything familiar to anyone? I'm going to head back outside and have a look in thru the oil hole, can't really think of what else to check. Don't think its the actuator, still seems to shift in and out just like it should, diff lock still feels normal also, no more or less tension than before.
Any help will be greatly appreciated.

 

Update - just got in from checking it over, seems like either the diff clutch pack disintegrated or the right axle let go inside the diff. I'm guessing that it is the clutch, as the oil, new about 50 miles ago, is like coppery milk. I guess it could just as easily be the axle, don't want to take it apart myself tho, hopefully warranty will cover whatever it is.

 

589650- make sure your left axle is fully seated in the differential and make sure you can't pull it out easy. I would doubt that you clutch disintegrated because your diff lock would not work. If your axle poped out your front diff would fill with mud and water and would look like coppery milk. Just a thought.

 

Every time I have changed my front diff oil, there is a coppery color to it. It's normal. As for the ratcheting, I don't have a clue. If your diff is still locking, your clutch is still good. Are you sure the noise isn't the backlash in the straight cut gears in the tranny?

 

Hi dude, i was just asking these guys not long ago about a similar noise, its seems mine just started doing it recently,i have a 2003, it seems to do it more when i turn a sharp left and going over rough stuff. I was told it was cause of the straight cut gears and shouldnt worry. Whats strange though is that its never made those noises before lately,anyhow the bike works awesome,shifts good,i guess it could be normal.(I hope) Please let me know if you find out anything else.

Serge
27 inch dirt devils
Nyroc stock modded exaust![img]i/expressions/face-icon-small-cool.gif[/img]

 

This is definitely in the front end, with both front tires off the ground, if I turn one, the other one will start to turn then stop, and it makes a clicking kind of sound. Sometimes it will grab and the other tire will turn part way around. Both axles also feel loose in the diff now and half the time the ring gear is not turning when I turn the tire. I'm not going to touch it any more, just take it to the dealer and try for that elusive "warranty".

 

DOA just had that problem,it turned out to be a CV joint.

 

Turns out i blew up the side and spider gears, as well as some other goodies in the front end. Dealer is waiting on parts. The good news, they tell me for sure it is covered under the extended warranty.