Several months ago my son shoved the bike into gear while revved up. At that time it didn't seem to hurt it, but there is a loud clunk sound that has gotten increasingly worse when riding in deep mud, up a steep embankment, or at top end speed. When the clunk happens I can feel it underneath me as well.

The sound is so loud that I can hear it inside my house (doors and windows closed) with the atv at least 100 feet away. It runs fine under normal conditions, but when stressed that when it happens.

I now have the bike completely apart, from the differential to removing and splitting the engine. I have not found one tooth broken or any sign of a problem in the tranny gears or the drive shaft or in the differential.

I am at a loss for where to check next, what to look for. Has anyone had this type of a problem or can offer some suggestions about what to do? I love the bike it's great ride and really need to fix it.

Thanks,

97 Prairie 400 4x4

 

I hate to be the bearer of bad news especially after all your work.

Sounds like your shifting linkage needed to be adjusted. the loud clanking sounds comes from you trann gears slipping by each other because of the linkage being out of adjustment or your motor mounts bolts became loose.

At least you know your gears are good, check your shifting fork while your in there, make sure it not bent.

Put in new rings when it goes back together and you have a new motor.

Just my opinion nothing more.

 

Thanks for the advice, I'll check it out. I'm surprised though that by it slipping by the teeth it didn't cause any damage to them. I'll let you know how things work out.

97 Prairie 400 4x4

 

mine was makeing the same noise and after two or three sled pulls it broke some gears and bent the fork.

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