I have a 2002 500ho sportsman, I have just developed a “clunk “ in the gear case when I take off. It’s not as soon as the clutch grabs, it’s more when you travel about a foot. One clunk and then it rolls fine.

I have put it up on jack stands and the ujoints are fine and no ripped boots or slop in the drive train. I can’t get it to make the noise up in the air only under load and in high gear.
This happens with it clunking three or four times in a row and then not doing it for a dozen time in a row.

I have recently changed the primary clutch about 50 miles ago and replaced the belt after doing this the machine shifts great with no noise and no creep at all.

I can turn the wheels back and forth in gear and get some play of about 1 to 2 inches of fore and back roll.

Was wondering if this is a sign that the chain or something is about to go and I have heard some horror stories of broken cases when it does let go.

 

Is it your chain slipping? see if the teeth on your sprocket are a lil rounded or if they are pointy.. make sure it is tight.. bout an inch of slack is all it needs

 

Make sure you drive line is in good condition(like it seemed you did)......and then for the tranny, check the oil dipstick and see if there is metal on it.....about the chain in there.....I doubt it is going bad already, but could be. I think the only way to know is to tear it apart, which isn't the easiest job, but do-able.

 

Changed oil and no metal ............I hate to tear it apart but I guess I will have too!

 

Sounds like the silent chain inside the tranny is bad

 

mine was doing the same thing..And it was the silent chain inside the tranny.$600 when all was said and done. "By..By tax return!"

 

Ouch!..........always seems that something comes up when you get that tax return check!!

I take it you took it to the shop; do you remember what else had to be replaced? gears?

Did the chain just stretch?

I realize that you never know till you get it apart. I have rebuilt lots of engine and motor cycle gearbox, so I guess I will add atv transmissions too the list.

I’m sure that there is that 50 dollar special tool I will have to buy also!

Thanks for the reply

 

I've tore a few apart. From what I can remember, you don't need any special tools. Its pretty strait forward on what you are doing, just take you time.....and if you need help remembering, take pics(or ask on here). You probably will need a clutch puller.....if you don't already have one. Its a good investment anyway.

 

yes, I took it to a shop. The parts are not that bad the silent chain {$40}rides on a shaft called the input shaft {$140}. the chain if and when it gets hot stretches and that is what makes the clunk noise. if you fix it in time you might only need the chain make sure you take a GOOD look at the teeth on the input shaft to decide if you need one..The LABOR is what kills a guy they hit me with 5.5 hours labor for the job.
PS: By the way the only reason this happend is because the $^%$% son of a ^%%%^ that I bought my machine from drained the gear oil and forgot to refill it!!

 

This is another klunk that the Sportsman is infamous for. Some machines have this starting off clunk and some do not. It is just the nature of the beast. The machine I am familiar with clunked for over 4000 miles and never did fail.