I did a search and found some threads on clanking, but wanted some more input. I got a '03 Prairie and was just rearranging the garage. I was pushing the ATV forward and backwards in neutral in 2wd and could hear a click that sounded like it was coming from the left front area. So I put it up on jack stands front and back. I spun the front tires and it didn't do it. Odd, it did it on the ground with weight but not off the ground with no weight.
Next, I started it up and left it in 2wd and gave it some gas. You could hear the clanking that people are talking about. Must be the gear backlash people talk about. Ok so that is normal. Now I put it in 4wd and give it some gas. I hear the same sort of noise from the front drive shaft area, or that is where it sounds like it is coming from. Almost like the front driveshaft has some slop maybe. Not sure exactly. I will screw around some more and maybe even try to record some of the sound when I bring my laptop home tomorrow. Anyone else noticed this in the front?

 

the noise on my 03 is noticeable from the rear only at slow speeds. my buddies Grizzlies have a similar noise only much worse, plus they can't wheelie at will!!

 

Yes, same here it is only at slow speeds you can hear it. I think I will pull my CVT cover to check things out to be safe. Sounds a little loud in there, but I never stuck my head next to it either. I may just be paranoid due to the clicking sound I heard with it in neutral on the ground moving it around in the garage. I hope I am just being paranoid, but am going to check things out to be safe.

 

Hmmm, so I went back out and pulled the cover but left the wires hooked up. Fired it up and started listening. What I hear is some clanking that sounds like it is coming from the tranny but also sounds like the gear meshing people talk about. I notice it alot more if I get on and off the gas alot. High, low, 4wd or 2wd makes no difference I get the same sound. Everything in the clutch looks fine but it sure sounds like the secondary making the noise but..... I can hear it all the time as well even when doing 20 on the jack stands, just you can hear it more when you get on and off the gas.

Anyone hear this on theirs... Tell me I am being paranoid.

 

Dude i heard that you not suppose to turn ur key on once the cover is off. You know that engine brake switch thing on top of the belt cover, well when you turn ur key on it makes that thing kick in and when it kicks in it has nothen to stop that spring thingy and it can screw it up. My buddy did this to his. I have did the same thing you did and i never had no problems but i think i got lucky. I heard of this happening to alot of 650's. Good luck!

 

I hear you. I will check that out as I put it back together. Hopefully it will be fine. [img]i/expressions/face-icon-small-confused.gif[/img]

 

All this clanging could be the gears, I recall reading an article stating that Kawasaki cut the gears differently to save weight and cost. I read it a while back so I cannot quote directly from the article, but it did mention louder gear noise......hope this helps

 

I have a clank sound coming from the front of mine, but mostly when im turning at lower speeds and getting on and off the gas. Done it since new, its worse in reverse too. I think its just one of thoose mechanical sounds, cant find anything wrong. And it only makes one clank then quits, so probably not CV joints. Four year warranty will ease my mind about it for three more years, then I will try to find it.

 

same with my '03 650, does it at low speeds. I asked the dealer and he said that he hasn't had one yet that didn't "clank" at low speeds. says everything is normal, just doing its thing

 

Yeh mine does the same thing as all you describe, so I'm thinking it's gonna be totally normal and acceptable or we'd have a really big recall coming our way if something was wrong with it.

I really notice the sound a whole lot when I was riding on the railroad tracks the other day, going over all those ties really makes it loud.

I think it is slipping in and out of gear, is what it sounds like.. But it goes fine, so I'm not sure. Oh well, what I got a warranty for.